Lead Smelting Recycling Plant Suppliers and Manufacturers

1. Lead smelting A.Mini blast furnace B.Rotary furnace 2. Refining pots for refining and alloying. 3. Ball mills for lead oxide. 4. Fugitive emission control system. 5. Continous casting machines with ingot and jumbo ingot moulds 6. Battery cutting machines 7. Battery crushing and hydro sepration. 8. Sewage and effluent treatment plant

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.

Sewage and its Treatment Sewage is the spent water stream generated after use of fresh water in various activities of domestic, non-industrial nature, such as washing water, food preparation waste, laundry waste, and other waste products of normal living including sanitary Waste water. This sewage, if discharged untreated into water bodies, leads to their pollution and degradation of the most valuable resource of all – water. Sewage hence needs to be treated before its discharge and after that, can also be reused for some applications such as toilet flushing and gardening etc. Sewage Treatment Plant and its Process A Sewage Treatment Plant, commonly called as STP, is domestic waste water treatment plant used to achieve the end of making spent water pollution free before its disposal or re-use. It mainly consists of 3 stages: Preliminary, Biological and Tertiary: Depending upon the intended end use of treated water, a fourth stage of advanced treatment may also be considered. Preliminary Treatment Consists of screening and removal of oil and grease (if applicable) for which mostly physic mechanical processes are used. The purpose of this stage is to remove external large solid/ floating material as well as floating oils in the stream so as to make it suitable for biological treatment stage. Biological Treatment Is the stage where organic impurities in the waste stream are treated by the use of microbial organisms. These organisms metabolize the pollutants as their food either in presence or absence of air, called aerobic or anaerobic processes respectively. The sludge so generated is settled and ultimately flushed out from the system. It is thus, the Biological Reactor which is the HEART of any Sewage Treatment Plant and it is on the basis of the same, that all processes are classified into different groups. Other than this, different stages of all processes are similar. Tertiary Stage consists of disinfection and filtration. Disinfection is required for the purpose of removal of any residual harmful bacteria in the water stream. Filtration is used to remove any TSS in the stream and also for polishing the treated water clean. Sewage Treatment Plant & Process: 1 Resistant to shock loads 2 Widely used and accepted 3 Properly digested sludge 4 Low maintenance cost 5 Recycling of Sludge into the reactor 6 Low retention times of 12-16 hrs. 7 No External Media 8 Easy to operate and maintain.

Lead Ore

About Mini Blast Furnace A Mini Blast Furnace (commonly known as Mandir Bhatti or Shahi Bhatti) is a simple, time-tested and widely used system to produce secondary lead in India and many other countries. It is the most basic of all furnaces and a production system based on this technology has certain distinct characteristics such as: Low Project Capital Cost Low Energy Cost ( wooden coke fired) Easy to install Easy to operate & maintain Production of low Antimony Lead (soft lead) at low temperature Generates high pollution Description of Mini Blast Furnace The Furnace itself is a modified blast furnace which consists of a brick lined structure with fire brick oven in the midst and a metal Exo skeletal structure outside. Raw material & fuel (coke) is charged manually through the side metal doors fitted in the brick structure and air is provided from the FD fans provided at the back of the brick structure. Molten metal & slag is tapped at the pits made in front of the brick structure and flue gases are sucked from the top of the brick structure which is provided with a metallic hood. A typical Double Oven Mini Blast Furnace has the following standard sizes & specifications: Outside Dimensions of Brick Structure 2400mm L x 1900mm W x 2400mm H No. of Ovens 2 Nos. Oven Size Top Dia 600mm Bottom Dia 250mm Depth 650mm No. of FD Fans 2 Nos. (1 for each oven) FD Fan Capacity 300cmh at 250mm of WG No. of Charging Doors 2 Nos. (1 for each oven) Charging Door Dimensions 1100mm H x 650mm W Manufacturing Process Lead to be manufactured from Mini Blast Furnace is usually obtained from scrapped batteries. They are cut open or broken to segregate lead scrap, plastic and other materials from it. Lead scrap in the form of lead powder and plates etc. is charged in the furnace along with a proportionate charge of wooden coke. Thereafter the furnace is manually fired with the help of rags. FD Fan provides the necessary air required for combustion from the back of the furnace. Coke in the oven performs the functions of both, the fuel as well as a reducing agent for obtaining lead from its oxides charged in the form of lead plates & powder. Temperature of the furnace is maintained at the desired level for approximately 30 minutes, after which molten lead along with slag flows out from the bottom of the oven into the outlet pit. Here slag is separated and molten lead is poured into Ingot Moulds. To maintain this, continuous charge of raw material and coke is maintained in the furnace. This process leads to generation of flue gases which are toxic in nature and need appropriate and adequate Air Pollution Control System for their treatment. Process Details for a typical Double Mini Blast Furnace Raw Material Charged 700-800 kg hr. Fuel used Wooden Coke Calorific Value of Fuel used 4000-5000 kCal kg Fuel Consumed 70-75 kg hr. Air provided for process 300 cmh Lead Produced (1st Charge) 300-350 kg hr. Flue Gas generation 8000-9000 cmh Advantages and Disadvantages of Mini Blast Furnace Advantages No consumables used other than Wooden Coke which is also used as Fuel Low Power Consumption Produces low Antimony Lead suitable for soft lead purposes Pollution can be controlled with minimum fugitive emissions Easy to install, operate & maintain Disadvantages Cannot recover 100% lead in the first operation Subsequent recovery of lead after first recovery consumes higher coke & manpower. Equipment cannot be scaled up for higher production capacities. Various types of lead present in used batteries, plates and paste of lead oxide are charged in the furnace. In addition to these, certain compounds of sulphur are also present in the batteries. When this material is heated in the presence of carbon, lead oxide is converted to lead. This conversion along with burning of fuel generates flue gases and fumes containing dust, dirt, oxides of lead, lead particles and other impurities etc. Hence, to meet various goals of maintaining employees' health, for factory environments as well as regulatory requirements, it becomes imperative to get high end Air Pollution Control Systems to be installed with the Mini Blast Furnaces. At the time of Delivery

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 FD Fan capacity : 1250 cmh at 1000mm 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 Manufacturing Process Lead to be manufactured from Rotary Furnace can be obtained directly from scrapped batteries or as slag from Mini Blast Furnace. In case of former, batteries are cut open or broken to segregate lead scrap, plastic and other materials from them; lead scrap in the form of lead powder/ plates etc. is charged in the furnace along with a proportionate charge of additives. In the case of latter, slag produced from Mini Blast Furnaces is charged into the Rotary Furnace, again with proportionate additives. This process is a batch type process. After filling the required quantity of raw material (either manually or mechanically), the lid of the furnace at the front is closed. The burner attached to the moving door is then fired. Complete mass of lead raw. Material along with additive chemicals is heated at high temperature inside the furnace. After some time, molten lead is collected at the bottom of the furnace by puncturing the central opening of the Rotary Furnace. Lead is collected either directly into Jumbo Ingot Moulds or in receiving channels from which they are poured into Jumbo Ingot Moulds. After draining the Furnace of the first batch, production of next batch is undertaken and the Furnace is again charged with raw material. After three such batches, one batch of slag collected in Rotary Furnace is executed. This process leads to generation of flue gases which are toxic in nature and need appropriate and adequate Air Pollution Control System for their treatment. The steps of Charging and Tapping of Rotary Furnace also lead to generation of Fugitive Emissions which need to be captured at source and treated to maintain ambient air standards at workplace. Process Details of a typical 3.0 TpB Rotary Furnace Raw Material Charged3000 kgs/ Batch Total additive chemicals charged:400-500 kgs/ Batch Rotational speed1-2 RPM Fuel usedFurnace Oil Calorific value of fuel used8600 kCal/ kg. Fuel consumed30-40 lt/ hr. Air provided for process1250 cmh Lead produced9000-10000 kg/day (for Raw Material feed of 12-15 T raw material being lead powder and plates) Flue gas generation15000 cmh Section View of Rotary Furnace Advantages and Disadvantages of Rotary Furnace 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. Air Pollution Control Device for Rotary Furnace Apart from plates and paste of lead oxide from scrap batteries, slag from Mini Blast Furnace is charged in the Rotary Furnace. In addition to these, certain compounds of sulphur are also present in the batteries. When this material is heated in the presence of carbon, lead oxide is converted to lead. This conversion along with burning of fuel generates flue gases and fumes containing dust, dirt, oxides of lead, lead particles and such other impurities etc. Hence, to meet various goals of maintaining employees' health and factory environments as well as regulatory requirements, it becomes imperative to get high end Air Pollution Control Systems to be installed with the Rotary Furnaces. Characteristics of Air Pollution generated in Rotary Furnace Selection of Technology for Air Pollution Control System Based on the parameters and the standards mentioned, the following technology is adopted for Air Pollution Control System in Rotary Furnace: Rotary Chamber Gravity Chamber Involute Cyclone Pulse Jet based Bag House Filtration System Details of Equipments allow with Functions Rotary Chamber Rotary Chamber receives very hot gases from Rotary Furnace while cold gases from atmosphere are induced into chamber via specially designed profile. Thus chamber works as an equalizing chamber to reduce the temperature of gases and also where sedimentation of dust particulate matter takes place. Duct & Bends Ducts and Bends are required to convey flue gases from point of suction to final top of the chimney and connect various equipments like gravity chamber, cyclone, bag house, ID Fan and chimney. All bends and reducers are aerodynamically designed and have provision of manhole cleaning mechanism. Gravity Chamber It is a low pressure drop device which: Allows large size particles to settle down Cools down temperature of flue gases Used as spark arrestor to entrap live or red hot particles. Involute Cyclone Cyclone is used to remove medium size particles from flue gases stream. The treated flue gases are discharged from top and dust is collected at bottom. Bag Filtration System It is used for final filtration of flue gases to remove fine dust particulate matter using Pulse Jet Technology. Treated gases from all the bags are collected at top of bag house and passed through ID Fan to exhaust the same through chimney. The dust is collected at bottom of hopper and is discharged through Rotary Air Lock Valve. ID Fan ID Fan provides necessary driving force to convey flue gases from top of furnace to top of the chimney. The volume sucked overcome the total resistance offered by equipment and duct with the help of fluid horse power provided by ID Fan driven by suitable motor. Stack (Chimney) The generated gases are passed into atmosphere after treatment through chimney of suitable height and diameter. At the time of Delivery

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. Production Process Melting Processes have been grouped as Re-Melting Process Refining Process Alloying Process Re-Melting Process This process is undertaken for value addition to the recycled lead from furnaces. Lead is melted in the pot and major impurities are skimmed from it to make it saleable in the market. Refining Process Lead is melted in the pot, additives such as Sulphur, Wooden Powder and Coke Breeze are added and mixed gently followed by dross removal. Thereafter, Tin is added to remove Copper and temperature is increased to 550-6000C. Further, additives such as Sodium Nitrate & Caustic Soda are added to remove Antimony. This process is repeated to get the desired purity of lead. Alloying Process Lead is melted in the pot, additives such as Sulphur, Wooden Powder & Coke Breeze are added and mixed gently followed by dross removal. Thereafter, Tin & Antimony are added to the liquid metal to get the desired grade of Lead. Air Pollution Control Device for Refining Pot Melting processes lead to generation of air pollution at the following stages Initial heating and melting generates fumes Drossing with sulphur, wooden powder and coke breeze generates lot of smoke and dust particles Further heating for Refining and Alloying with different chemicals generates fumes and dust particles. Hence, to meet various goals of maintaining employees' health, factory environments as well as regulatory requirements, it becomes imperative to get high end Air Pollution Control Systems to be installed with the Melting Pots. Air Pollution Control Device for Refining Pot Dust : 500-600 mg/Nm Temperature : 60-80C G Gases : Fumes and Dust Discharge Characteristics required as per Norms Dust : Less than 50 mg/Nm Lead ( Pb) : Less than 10 mg/Nm Temperature : 50-60 C Gases : Not Detectable Selection of Technology for Air Pollution Control Based on the Parameters and the Standards mentioned, the following technology is adopted for Air Pollution Control System in Melting Pot: Pulse Jet based Bag House Filtration System Details of Air Pollution Control Device with functions Aerodynamically designed suction hoods are provided to capture flue gases generated at source itself. Duct & Bends Ducts and bends are required to convey flue gases from point of suction to final top of the chimney and connect various equipments like suction hood, bag house, ID fan and chimney. All bends and reducers are aerodynamically designed and have provision of manhole cleaning mechanism. Bag Filtration System: It is used for final filtration of flue gases to remove fine dust particulate matter using Pulse Jet Technology. Treated gases from all the bags are collected at top of bag house and passed through ID Fan to exhaust the same to chimney. The dust is collected at bottom of hopper and is discharged through Rotary Air Lock Valve. Bag Filtration System It is used for final filtration of flue gases to remove fine dust particulate matter using Pulse Jet Technology. Treated gases from all the bags are collected at top of bag house and passed through the ID Fan to exhaust the same through chimney. The dust is collected at bottom of hopper and is discharged through Rotary Air Lock Valve. ID Fan ID Fan provides necessary driving force to convey flue gases from top of furnace to top of the chimney. The volume sucked overcome the total resistance offered by equipment and duct with the help of fluid horse power provided by ID Fan driven by suitable motor. Stack (Chimney) The generated gases are passed to atmosphere after treatment through chimney of suitable height and diameter. At the time of Delivery

Ingot casting machine An ingot casting machine (continuous ingot caster) is a chain conveyor based mechanical arrangement which is used for easier handling of molten lead from melting pots. It leads to hassle-free casting of lead into ingots with minimum human contact and keeps this process safe, clean and fast. It is a custom made device suited for particular capacity required by user. The size of ingot to be casted can also be varied. Further, in special cases, even subdivision of ingots into smaller shapes is possible for suitability of usage. The output of a melting pot needs to be synchronized with the speed of the conveyor. A rotary distributor drum continuously receives the molten metal and pours it into ingot moulds below it. The ingot moulds are fastened on a chain conveyor that continuously moves in a loop. A robust frame of ms is provided for fitting of this conveyor alongwith sprockets, shafts and geared motor based drive. There is a water jet based cooling arrangement mounted on the frame itself which helps cooling down of the metal in the mould. It is provided with a mechanical knocking arrangement at the end of line for 100% knocking of ingot from the mould. These can be further supplemented with provision of multiple cooling lines, water re-circulation system, gas burners for drying up moulds, fumes collection hoods and discharge end conveyors. Note: due to continuous up-gradation in technology, specified & projected values may differ in actual products

Non ferrous metal recycling plant, secondary lead recycling plant, lead smelting plant, secondary aluminum recycling plant, secondary copper recycling plant, secondary zinc recycling plant, secondary brass recycling plant, secondary tin recycling plant, air pollution control device, sewage treatment plant.Turnkey projects, manufacturing of lead recycling plant, metal recycling plant, lead smelting plant, metal smelting plant