Detailed Project Report on lead extraction from scrap battery

 LEAD EXTRACTION FROM SCRAP BATTERIES
[CODE NO. 5827


Lead  is  an essential commodity in  the  modern  industrial world, ranking  fifth  in  tonnage consumed  after  iron,  copper, aluminium ,and zinc.  In 1978, the world's consumption of refined lead was 4.4 * 106 metric tons of  which  the  United  States consumed 22% .

Its  outstanding properties are: Low melting point, ease  of casting  , high density, low strength, case of  fabrication,  acid resistance, electrochemical reaction with sulfuric acid,  chemical stability  in  air, water, and earth, and the unique  ability  of lead tetraethyl and tetramethyl to suppress knocking in  gasoline engines.   The  principal  uses of lead  and  its  compounds  in descending order are storage batteries(about half of total U.S. consumption,   tetraethyllead,  pigments,  ammunition,   solders, plumping,  cable covering, bearings and caulking.  In addition, the use of lead to attenuate sound waves, atomic radiation, and mechanical vibration shows promise for growth.  Because of its softness and high density,lead is used as an  alloy  in  these applications.

Lead, copper, silver, and gold were the metals first used by ancient  humans to meet some practical and esthetic  needs.   The Egyptians probably  used  lead as early as 5000  B.C.   Lead was widely used by the Greeks and Romans.  Segments of the fluted columns common to Greek architecture and pinned together by iron rods fitted into sockets which were filled with molten lead.  The well-publicized lead water pipes discovered in the ruins of Rome and Pompeli confirm the importance of lead to antiquity.  Some pipes of this period still function in Britain today.
      
Although  simplicity  of reduction from  ores,  low  melting point,  and ease of fabrication favored its use in  a  primitive technology,  its unique physical and chemical  properties  have assured its place in modern industrial society.  By the middle of the 19th century , world production of lead had risen to  100,000 metric  tons  per  year, passed 1 * 10 6 t early  in  the  20  th century  , reached 1.5 * 106 t by mid-century , and is  estimated to exceed 9 * 10 6t by the year 2000.

Lead and its compounds are cumulative poisons and should be handled  with recommended precautions.  They should not be used in contact with food and other substances that may be ingested.


COST ESTIMATION

Plant capacity                                     6.00 MT/day      
Land & Building (714 Sq.Mtr)             Rs.19.45 Lacs
Plant & Machinery                              Rs. 19.50 Lacs
W.C. for 3 Months                              Rs. 1.55  Cr
Total Capital Investment                     Rs. 2.00  Cr
Rate of Return                                   48%
Break Even Point                               37%


 1.  INTRODUCTION                                      
 2.  PROPERTIES                                        
 3.  USES AND APPLICATIONS                           
 4.  REPRESENTATIVES LEAD ALLOYS                      
 5.  MARKET SURVEY                                    
 6.  PRESENT CONSUMERS LEAD FOR LEAD-ACID
     STORAGE BATTERIES                                     
 7.  MANUFACTURING PROCESS                            
 8.  PROCESS FLOW DIAGRAM                             
 9.  PLANT LAY OUT                                    

 
APPENDIX – A :

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET