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About Rotary Furnace The Rotary Melting Furnace is a very flexible and universal equipment used for recycling many non-ferrous metals. It is the major lead production technology used in India and many other countries for Secondary Lead Production. A lead production system based on this technology has certain distinct characteristics such as: •Equipment scalable for installing higher capacities •Recovers all lead in one production cycle •Plates & powder from scrap battery as well as slag from Mini Blast Furnace can be used as raw material •Requires addition of certain consumables •Can be fired with various fuels •Generates high Pollution both as Flue Gases & Fugitive Emissions Description of Rotary Furnace It is a Rotary kiln in the form of a metallic cylinder with conical sides on both ends. Mild steel plate is used for construction of this shell and its thickness varies depending upon the capacity of the equipment. This shell is rotated on its own axis at 1-2 rpm. For this purposes tyres (also called riding rings) are fitted on the shell. These are fabricated from MS squares or flats, machined for a smooth finish. These tyres ride on steel rollers which are again machined finely. These rollers are fitted on a robust MS structural frame and driven by a gear & motor arrangement. The shell is lined inside with insulation and fire bricks of suitable Alumina content. Conical ends of the furnace are open on both sides. The furnace is charged with Raw material along with additives from the front end. This side is provided with a movable door on which a burner is mounted. The burner can be a conventional one or a fully automatic one depending upon the fuel used. At the other end, an exhaust block lined with refractory bricks is provided. A tapping hole is provided in the center of the shell from where molten metal & slag are discharged. Flue gases generated are sucked from the exhaust block side of the furnace. A typical 3.0 TpB Rotary Furnace has the following standard sizes & specifications : •Outside dimensions of the Rotary •Shell dia : 2075mm •Shell length : 2500mm •Total length : 4500mm •Charging dia : 450mm •Exhaust side dia : 450mm •Refractory thickness : 200mm •Fuel : Furnace Oil •Burner : Model 4 A Make: Wesman with complete assembly •FD Fan capacity : 550 cmh at 44mm of WG •Gear Box in drive : 8”, 1:40 Ratio •Motor in drive : 15.0 HP x 960 RPM •Structure used for base : ISMC 250 x 80 Advantages •Recovers 100% lead in the first operation. •Slag produced is lead free. •Equipment can be scaled up for higher production capacities. Disadvantages •Many chemicals are required for operation. •High power consumption. •Difficult to produce low Antimony lead suitable for soft lead purposes. •Fugitive Emissions need to be captured in addition to flue gases. •Need skilled operators and careful maintenance.
UNIVERSAL TILTING ROTARY FURNACE (UTRF) for Lead recycling the above mentioned photograph under production capacity 10 ton/batch. Universal Tilting Rotary Furnace is designed like a rotary closed well furnace. It has advantages of rotary furnace, rebvetory furnace and dry hearth furnace in a single equipment. Main advantage of UTRF is that it can be rotated as well as tilted. Firstly lead scrap is loaded in furnace with smelting flux and furnace locked. The material is heated with the help of oil/gas burner which is mounted on the door, until it reaches melting point. Heating is immensely faster because of horse shoe flame design. Due to the quick heating, consumption of oil and melt loss is very less as compared to the conventional tube furnace. Merits of Universal Tilting Rotary Furnace: 1. Less amount of flux is required for melting. 2. Efficient working condition. 3. All non-ferrous scrap can be recycled in a single unit. 4. Homogenous charge resulting in high quality of material. 5. Self-cleaning of lining. 6. Recurring cost is approximately 30% less as compared to horizontal rotary furnace. 7. Ensures faster melting rate. 8. Better yield. Comparison between UTRF and Horizontal fixed axis Rotary Furnace: The traditional furnace (fixed axis rotary furnace) is primarily a rotating tube with burner on one end and flue at the other. The furnace functions under negative pressure and gets cold air from outside making it virtually impossible to control the atmosphere in the furnace, which is nearly always oxidizing (air rich). It view of it, large amount of flux is required to protect the charge. Consumption of oil is also high because travel length of flue gas is less. On the other hand, UTRF furnace is designed with a single entrance and exist point. The door carries burner and flue. The furnace operates under positive pressure and during firing of the burner there is complete absence of cold air from outside resulting in reduced amount of flux required during operation. In addition the furnace operates at an angle, the charge is mixed with similar action that of a concrete mixing machine. This improves homogeneity heat transfer resulting in high thermal efficiency. Salient Features of Universal Tilting Rotary Furnace: 1. Tap to tap cycle time 4- 5 Hrs. 2. Energy consumption 600 Kw/MT 3. Robust steel structure with proven drum 4. Life of refractory lining is long 5. Oversize driving system and bearings. 6. Tilting, door opening and closing is hydraulically operated. 7. Sturdy interlocks for safety of the equipment. 8. Less manpower required. Only two persons per shift can operate the furnace.
About Lead Refining Lead recycled from used lead acid batteries or other sources (Secondary Smelting) via the Mini Blast Furnace or Rotary Furnace route, contains lot of contamination and undesired components. On the other hand, Lead required for battery manufacturing is either soft Lead with 99.97% purity or hard Lead of varying Antimony compositions. In order to make quality of lead suitable for its different uses, different variations of pot melting processes are employed. These include – “Re-Melting” for removal of slag, “Refining” for attaining required purity levels and “Alloying” for producing various alloys of lead. The equipments used are the same, the consumables and the processes, however, differ. Description of Melting Pot The Melting Pot (or Refining Pot or Alloying Pot, as it is variously called), is a mechanical mixing device with a pot and a heating arrangement. The inner pot is made of heavy MS plate with dish end bottom. It is placed within a jacket of refractory bricks, which in turn, are protected by an outer cover of MS plate with reinforcements. The pot is covered at the top with opening for feeding lead ingots and is provided with an electro-mechanical mixer. At the bottom, a heating source, usually an oil fired burner, is provided to heat the pot and to melt the lead. Once lead melts, impurities are skimmed and removed and any consumables required are added. Lead is then drained from the pot through an outlet pipe and valve. Capacity of such pots depends upon the requirements of particular units. Standard pot capacities made are from 4.0 TpB to 20.0 TpB. Higher capacity pots are also manufactured as required by any particular establishment. A typical 10.0 TpB Refining Pot has the following standard sizes and specifications: •Diameter (ID) : 1150mm •Height : 1250mm (+Dish Depth of 200mm) •Flange Width : 350mm •Outer Shell Diameter : 1900mm •Stirrer MoC & Dia : SS-304 & 75mm •Stirrer Motor : 5.0 HP x 960 RPM •Outlet Valve Size : 40mm •Burner : Diesel Fired •Fuel Consumption Range : 8-18kg/ltr Melting pots are installed both with and without accessories which may include Ingot Casting Machine, Ball Making Machine (where Ball Mills are installed down the line), Air Pollution Control Systems, Jib Cranes etc.
This ingot casting conveyor will operate in conjunction with a suitable capacity of refining pots. Your require ingot casting machine to produce 25~26 kg lead ingots with a production capacity of 10 tons per hour. The final system will be composed of the following machines and equipments Technical specifications of auto ingot casting machine This ingot casting conveyor will operate in conjunction with a suitable capacity of refining pots. Your require ingot casting machine to produce 25~26 kg lead ingots with a production capacity of 10 tons per hour. The final system will be composed of the following machines and equipments 1. Flow control box (tundish) 2. Tilting launder: - 3. Distributor wheel: 4. Ingot casting conveyor: The conveyor will be complete when assembled with: 4.1. Ingot mould: - 4.2. Conveyor chain: 4.3. Idler- end assembly: 4.4. Drive end assembly: 4.5. Ingot knockout arrangement: 4.6. Ingot retaining mechanism: 5. Mould cooling arrangement: 6. Pre-heating arrangement: 7. Control system:
Battery cutting machine (semi-automatic) Main parts: Conveyor: Guide rail: Cutter house: Cutter platform: Control panel: Additional features: •curtains at outlet to contain debris •height marker to adjust height of cutter wheels •modular panels of cutter house for easy maintenance
Lead acid batteries contain lead bearing raw material inside the pvc or rubber containers. For recycling, pvc and other material need to be segregated from lead bearing raw material. For this purpose processes of battery cutting or crushing are adopted.
Ball mill for lead oxide is a basic device in the modern world of metallurgy and is extensively used in a variety of applications. Among others, it's applications in the processing of non-ferrous metals is one of the most important. In the field of lead processing, dry type ball mills are used for conversion of lead pellets into fine lead oxide powder (lead oxide free lead), also commonly called grey oxide due to its appearance. The ball mill with its preparatory and collecting equipments is therefore also called a grey oxide plant. Description of process: Lead is melt in a melting pot and cast into pellets (hemispherical or cylindrical shape) at a ball making machine and fed into the ball mill. The ball mill is rotated on its own axis at low speeds. The rotation of the mill imparts tumbling & cascading action to the balls fed (in this case the lead pellets). The rotation is adjusted so that the raw material inside does not reach critical speed. Below the critical speed (at around 65 - 75%), the balls which are carried along the walls of the mill fall back to the center. This continuous action leads to friction and generation of heat which induces the reaction of lead (pb) with oxygen (o2) present in air and generation of lead oxide (2pbo). This reaction is an exothermic reaction which leads to generation of heat and this sets of a chain reaction of heat generation and accelerated oxidation process. Draft of air through the mill carries small sized or light particles outside the mill to the collection system. Temperature within the mill is controlled with the help of water spray outside the barrel of the mill. Several crucial characteristics of this produce such as free lead percentage, retention percentage, apparent density are set as per requirements of the client.
Jumbo ingot mould Jumbo ingot moulds are collection trolleys used for collecting molten lead from rotary furnaces. They can be of varying capacities, ranging from 500 kg. , 750 kg. And 1000 kg. The most prevalent of the same is 500 kg. Ingot mould. Due to higher weight of the cast, it is called a jumbo ingot mould. These moulds have trolley type structure with two unidirectional wheels at the back and one free spin wheel at the front. It is provided with a handle to pull it. They are moved manually or on rails electro-mechanically, varying from unit to unit. They are smoothened on the inside and do not have any sharp folds or edges. They are usually constructed in sg cast iron for longer life and increased strength. We also provide basket type of jumbo ingot moulds for handling with material handling device i.E. Eot crane. Typical parameters for a 500 kg jumbo ingot are Shapepyramidical hopper type Size – top500mm x 500mm (inside) Size – bottom350mm x 350mm (inside) Height500mm Mocsg iron Thk40mm Back wheels200mm dia x 50mm wd Front wheel150mm dia x 50mm wd.
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Bio gas plant
Heat exchanger Made from ferrous & non ferrous metal
1. Converised dip pretreatment plants 2.Spray pretreatment plants. Sea
liquid coating converised automatic plants
Tandem insulating line Used for generating insulated wire at a line speed of 2200 mpm and consisting of the following - Pay-off stand - Intermediate wire drawing machine - In-line annealer cum preheater - 80mm extruder with hopper loader & color doser - Hot water/cooling troughs with multi-capstan - Diameter controller - Capacitance monitor - Spark tester - Fully automatic dual take-up for 500 dia reel - Automated line control system
Group twinning machine Used for forming pairs of insulated wires and consisting of the following: - Pay-off stand (10 pairs) - In-line spark tester - Oscillator (s-z strander) - High speed tape binder - Non-slip feed back unit - Self traversing take-up for 1600 dia. Drums - Automated line control system
Roller Burnishing Tools - Used for superfinishing and sizing of precision engineering components Packing: Robust decorative light weight plastic
