Lead Recycling Plant
Owing to our rich industrial expertise and skills, we are renowned as one of the most profound manufacturers, and exporters of Lead Recycling Plant. These are devised in our well equipped manufacturing unit by using quality tested raw materials and advanced technology. Manufactured according to the international and national norms & standards, our range is offered at very economical prices. The offered range of Lead Recycling Plant is widely acknowledged for its robust construction, high operational fluency and corrosion & rust proof surface finish.
18.A bout 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.
"Re-Melting" for removal of slag,
"Refining" for attaining required purity levels and
"Alloying" for producing various alloys of lead.
The equipment used is the same, the consumables and the processes, however, differ.
Refining Pot Details
The Refining Pot (or Refining Kettle 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 anoil fired/ Diesel burner& sometimes by Wood burning 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 3.0 Tons per Batch to20.0 Tons per Batch. Higher capacity pots are also manufactured as required by any particular establishment.
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.
Melting Processes have been grouped as
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.
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 oflead.
Lead is melted in the pot; additives such as Sulphur, Wooden Powder & Coke Breeze are added and mixed gently followed bydross removal. Thereafter, Tin & Antimony are added to the liquid metal to get the desired grade of Lead.
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.
Characteristics of Air Pollution generated in Melting Pot
Dust : 500-600 mg/Nm3
Temperature : 60-80oC
Gases: Fumes and Dust
Discharge Characteristics required as per Norms
Dust : Less than 50 mg/Nm3
Lead ( Pb) : Less than 10 mg/Nm3
Temperature : 50-60oC
Gases : Not Detectable
Selection & Details on 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 is Pulse Jet based Bag House Filtration System
SUCTION HOOD: -
Aerodynamically designed suction hoods are provided to capture flue gases generated at source itself.
DUCTS & 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.
ID FAN: -
ID Fan provides necessary driving force to convey flue gases from top of furnace to top of the chimney. The volume sucked overcomes the total resistance offered by equipment and duct with the help of fluid horse power provided by ID Fan driven bysuitable motor.
STACK (CHIMNEY): -
The generated gases are passed into atmosphere after treatment through chimney of suitable height and diameter.