Detailed Project Report on RECYCLE OF LEAD ACID BATTERY (CAP: 24 TONS/DAY PROCESSING)

Battery recycling is a recycling activity that aims to reduce the number of batteries being disposed as municipal solid waste. Batteries contain a number of heavy metals and toxic chemicals and disposing of them by the same process as regular household waste has raised concerns over soil contamination and water pollution.

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ENGINEERS INDIA RESEARCH INSTITUTE
4/54, Roop Nagar, Delhi-110007 (India)
Phone: [phone]
E-mail: [email protected]
Website: www.eiriindia.org



RECYCLE OF LEAD ACID BATTERY (CAP: 24
TONS/DAY PROCESSING)
[EIRI/EDPR/4723] J.C.: 2943XL



Battery recycling is a recycling activity that aims to reduce the number of batteries
being disposed as municipal solid waste. Batteries contain a number of heavy
metals and toxic chemicals and disposing of them by the same process as regular
household waste has raised concerns over soil contamination and water pollution.

Lead-acid batteries include but are not limited to: car batteries, golf cart batteries,
UPS batteries, industrial fork-lift batteries, motorcycle batteries, and commercial
batteries. These can be regular lead–acid, sealed lead–acid, gel type, or absorbent
glass mat batteries. These are recycled by grinding them, neutralizing the acid,
and separating the polymers from the lead. The recovered materials are used in a
variety of applications, including new batteries. The lead in a lead–acid battery can
be recycled. Elemental lead is toxic and should therefore be kept out of the waste
stream.

Lead–acid batteries collected by an auto parts retailer for recycling. The casing of a
Lead–acid battery is often made of either polypropylene or ABS, which can also be
recycled, although there are significant limitations on recycling plastics. Many
cities offer battery recycling services for lead–acid batteries. A battery-industry
promotional group, the Battery Council, says that about 99% of lead from used
batteries is reclaimed.

Car battery recycling represents one of the most exciting recycling processes due
to the possibility to recover important quantities of lead and plastics. The recycling
process is easy and cost-effective as lead is easy to extract and can be reused
multiple numbers of times. This led to many profitable businesses and the
recycling of other batteries.

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The battery contains around 70 % lead, 20% acid and 10% plastic case. In
recycling process batteries are broken cover of batteries is removed and acid is
drained out for neutralization. Top portion is hammered for shredding of plastic
and the lead posts fixed in the top are released. Furnace smelting is done for
approximately 5 hours at over 1000ᵒ C lead and slag is tapped separately. Refining
is done by lowering the temperature thereby decreasing the solubility of
impurities. Once the lead is purified it is cast into ingots and reused for further
purposes.

It is estimated that at least 85% of lead consumed could potentially be recycled.
However, in practice the amount that is recovered is lower. Car battery recycling
represents one of the most exciting recycling process due to the possibility to
recover important quantities of lead and plastics. The recycling process is easy
and cost-effective as lead is easy to extract and can be reused multiple numbers of
times. This led to many profitable businesses and the recycling of other batteries.

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CONTENTS

INTRODUCTION

USES & APPLICATIONS

LEAD INGOTS

BATTERY

ROLLED EXTRUSIONS

PIGMENTS

CABLE SHEATHING

LEAD INGOTS FOR CAST LEAD BULLETS

LEAD ALLOYS

LEAD BATTERY – TOUCHES OUR LIVES

GOVERNMENT INITIATIVE AND OPPORTUNITIES IN BATTERY RECLING

THE PROCESS OF RECYCLING BATTERIES

COLLECTION AND SORTING OF USED BATTERIES

BREAKING DOWN AND SEPARATION OF COMPONENTS

PURIFICATION AND PREPARATION FOR REUSE

THE NEED FOR RECYCLING BATTERIES

ENVIRONMENTAL IMPACT OF IMPROPER BATTERY DISPOSAL

ECONOMIC BENEFITS OF BATTERY RECYCLING

INDIAN GOVERNMENT’S POLICY ON BATTERY RECYCLING

OVERVIEW OF THE BATTERY WASTE MANAGEMENT RULES 2022

ROLE OF EXTENDED PRODUCER RESPONSIBILITY (EPR)

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THE BUSINESS OF BATTERY RECYCLING IN INDIA

CURRENT STATE OF BATTERY RECYCLING INDUSTRY IN INDIA

MAJOR COMPANIES INVOLVED IN RECYCLING BATTERIES

OPPORTUNITIES AND CHALLENGES IN THE BATTERY RECYCLING BUSINESS

MARKET OVERVIEW

GREEN RECYCLING

GLOBAL PICTURE

KEY MARKET PLAYERS

SUPPLY-DEMAND OF LEAD SCRAP IN INDIA

TRADE IN LEAD

CONSUMPTION OF LEAD

LEAD-ACID BATTERIES

COMPOSITION OF AN AVERAGE LEAD-ACID BATTERY

APPLICATIONS OF LEAD AND LEAD-ACID BATTERIES

INDIAN SCENARIO

BATTERY COLLECTION

SPECIFICATIONS

BENEFITS OF BATTERY RECYCLING

REDUCTION IN WASTE SENT TO LANDFILLS AND TURNING THEM INTO

NEW PRODUCTS

LEAD ACID BATTERY – A VIEW

THE CHEMICAL REACTION IN A LEAD- ACID BATTERY:-

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BATTERY LIFE

RAW MATERIAL

DESIGN OF A STARTER BATTERY

MINIMUM REQD FACILITY AND STANDARD OFSECONDARY LEAD FACILITY

TYPE OF FURNACE INSTALLED (ROTARY/MANDIR BHATTI)

SPCBS/PCCS MAY PRESCRIBE THE FOLLOWING STANDARDS FOR

EMISSION/DISCHARGE FOR LEAD

STEPS TO MINIMIZE FUGITIVE EMISSIONS OF LEAD

LEAD RECYCLING PROCESS

LEAD RECYCLING PROCESS INCLUDES THESE FOLLOWING STEPS:

1. LEAD BATTERY BREAKING AND SEPARATION

2. DESULPHURIZATION SYSTEM

3. LEAD SMELTING

4. LEAD REFINING AND ALLOYING

5. LEAD CASTING

PROCESS FLOW SHEET OF RECYCLING SCRAP BATTERY

SEQUENCES IN LEAD ACID BATTERY RECYCLING

LEAD RECYCLING PROCESS INCLUDES THESE FOLLOWING STEPS:

LEAD BATTERY BREAKING AND SEPARATION

DESULPHURIZATION SYSTEM

LEAD SMELTING

LEAD REFINING AND ALLOYING

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LEAD CASTING

GAS CLEANING SYSTEM

LEAD ACID BATTERY RECYCLING EQUIPMENTS

SMELTING

REFINING

INGOT STACKING MACHINE:-

BATTERY BREAKING AND SEPARATION

REFRACTORY

POLLUTION CONTROL EQUIPMENT & MATERIAL HANDLING

THE AIR POLLUTION CONTROL SYSTEM CONSISTS OF:

LEGISLATION ON BATTERY SCRAP

THE SALIENT FEATURES OF THE RULES ARE AS FOLLOWS:

SUPPLIERS PLANT & MACHINERY / CONSULTANT

ACS LEAD TECH

PLANT LOCATION FACTORS

RAW-MATERIAL SUPPLY:

MARKETS:

POWER AND FUEL SUPPLY:

WATER SUPPLY:

WASTE DISPOSAL:

LABOR:

SITE CHARACTERISTICS:

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WASTE EFFLUENT/FLUE GAS EMISSION

SOLID WASTE MANAGEMENT

HEALTH SAFETY & ENVIRONMENT

SAFETY & OCCUPATIONAL MEASURE FOR STORAGE/HANDLING OF RAW
MATERIAL & PRODUCT

ENVIRONMENTAL/SAFETY LIABILITY & ENVIRONMENT CLEARANCE PROCESS

ANTICIPATED ENVIRONMENTAL IMPACTS

CONSTRUCTION PHASE

OPERATION PHASE

MITIGATION MEASURES (PROPOSED)

PROPOSED IMPLEMENTATION SCHEDULE

PROJECT FINANCIALS

BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)


APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

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09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)

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COST ESTIMATION

Plant Capacity 24 MT/Day

Land & Building (5000 sq.mt.) Rs. 2.95 Cr

Plant & Machinery Rs. 3.10 Cr

Working Capital for 1 Month Rs. 6.28 Cr

Total Capital Investment Rs. 12.58 Cr

Rate of Return 40%

Break Even Point 42%