Detailed Project Report on recycling of lead

RECYCLING OF LEAD
(CODE NO. 2084]  


Lead is a highly corrosion resistant, dense, ductile, and malleable blue-grey metal, which has been used for at least 5000 years. In some countries, however, environmental or health consequences have eliminated or reduced its use in cable sheating, petrol additives. Solder, shot, and pigments.


Lead has the highest rate of recycling of all the metals. Due to its corrosion resistance, lead scrap is available for recycling, decades or even centuries after it is manufactured. New environmental regulations in several countries has greatly reduced the dissipative uses for lead, including paint, pigments, leaded gasoline, stabilizers, solder, and ammunition.

Currently, just about half of the total world lead production of 4.7 million tons comes from the recycling of lead scrap. In recent years, the amount of recycled lead has been increasing and this rate of lead production is expected to increase in the future.

Most of the lead produced comes from secondary sources. Lead scrap includes lead acetate batteries, cable coverings, pipes, sheets and lead coated, or terne bearing, metals. Solder, product waste and dross may also be recovered for its small lead content. Most secondary lead is used in batteries.

To recover lead from a battery, the battery is broken and the components are classified. The lead containing components are processed in blast furnaces for hard lead or rotary reverberatory furnaces for fine particles. The blast furnace is similar in structure to a cupola furnace used in iron foundries. The furnace is charged with slag, scrap iron, limestone, coke, oxides, dross, and reverberatory slag. The coke is used to melt and reduce the lead. Limestone reacts with impurities and floats to the top. This process also keeps the lead from oxidizing. The molten lead flows from the blast furnace into holding pots. Lead may be mixed with alloys, including antimony, tin, arsenic, copper and nickel. It is then cast into ingots.


COST ESTIMATION

Plant Capacity                                               12.00 MT./day
Land & Building (5000 Sq.Mtr)                   Rs. 4.78    Cr
Plant & Machinery                                         Rs. 1.31   Cr
W.C. for 2 Months                                          Rs. 11.45  Cr
Total Capital Investment                              Rs.  17.90  Cr
Rate of Return                                                32%
Break Even Point                                           44%


INTRODUCTION    
PROPERTIES OF LEAD    
TYPES / GRADES    
SPECIFICATIONS OF RECYCLED LEAD    
USES AND APPLICATIONS    
TYPICAL USES    
B.I.S. SPECIFICATION    
MARKET POSITION    
DEMAND & SUPPLY RELATIONSHIP    
ANALYSIS OF IMPORTS OF LEAD INGOTS ANTIMONY    
ANALYSIS OF IMPORTS OF LEAD INGOTS ANTIMONY    
PRESENT MANUFACTURERS    
MANUFACTURING PROCESS    
INDUSTRIAL BATTERY BREAKING    
HANDLING AND TRANSPORT    
SMELTING PROCESS (LEAD REDUCTION)    
POLLUTION CONTROL PROCESS    
PLANT AND MACHINERY    
PROCESS FLOW CHART    
PLANT LAYOUT    
SUPPLIERS OF PLANT AND MACHINERY    
SUPPLIERS OF RAW MATERIALS    


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