The secondary production of Lead begins with the recovery of old scrap from worn-out, damaged, or obsolete products and with new scrap. The chief source of old scrap is Lead-acid batteries; other sources include cable coverings, pipe, sheet, and other Lead-bearing metals. Solder, a tin-based Lead alloy, may be recovered from the processing of circuit boards for use as Lead charge.

The smelting of Lead involves several elements that are required to reduce the various forms of Lead (mainly Lead oxide and Lead sulphates) into metallic Lead. mostly this includes;
1. a source of carbon, usually in the form of metallurgical , petroleum coke, charcoal and
2. energy, mostly available from natural gas, oil or electricity and
3. neutralizing agents used to capture Sulphur such as caustic, soda ash, or lime and
4. fluxing agents also used to capture Sulphur and improve Lead recovery. Frequently this includes various forms of iron and slag enhancing materials.

Our Company exclusively engaged in establishing Lead Smelting Plant by providing Technology, Plant & Machinery, Training of personals etc.

Our unique smelting technology has allowed the facility & opportunity to process a much wider range of industrial wastes and by-products than a traditional Lead recycling facility.

Our secondary recovery plants use Lead paste desulfurization to reduce sulfur dioxide emissions and generation of waste sludge during smelting.

Our smelting Plant are fully integrated with pollution control modules and can be configured for a wide range of Battery Recycling Capacities.

SMELTING PLANT ELEMENTS

Battery Storage/Stock Yard : The first element is a properly designed battery storage yard, which ensures proper material throughput. We have developed efficient designs for Battery Storage Yards for a wide range of capacities. There are many customisable options available, employing various degrees of automation.

Battery Cutting & Processing Section : In this section, Batteries are segmented into Lead bearing material and outer shells. We provide the option of either using the hydraulic shearing machine or the continuous roller conveyor blade saw cutting machine. We design, fabricate and install shearing and cutting machines which can continuously operate at capacities of 1 tonne/ hr. to 5 tonnes/ hr, with low downtime and maintenance requirements

Plastic Recovery Section : The outer Battery Shells are received and processed in this section into polypropylene chips/granules. The shells are crushed in a polypropylene crusher and the resulting polypropylene chips are either washed and stored, or further processed into polypropylene granules using an extruder machine. We design, fabricate, supply and commission crushers with crushing capacities up to 0.5 tonne/hr. For further conversion of polypropylene chips to granules/pellets, we provide and install continuous hot caustic washing systems, plastic batch mixers, dryers and extruders with capacities of up to 0.5 tonne/hr along with granule cutter machines.

Smelting Section : The Lead bearing material from Batteries, along with appropriate fluxes, reductants, Slag and other scrap & process wastes, is smelted in a Blast/ Rotary Furnace or a combination of the two, depending on the product mix required e.g. hard Antimonial Lead, soft crude Lead etc. The furnaces operate in a temperature range of 900-1250 degrees centigrade. We supply both tilting/ non tilting type Rotary and Blast Furnaces designed as per the capacity requirement along with a customised complement of accessories and equipment. The blast and/ or rotary furnace(s) configuration is decided after taking into account factors like, the smelting, refining and pollution control plant configuration, designed battery processing capacity, expected capacity utilisation range, desired degree of flexibility in product mix, composition of locally available raw material, consumables etc.

All our furnaces are designed to minimise Sulphur-dioxide emissions in flue gases by conversion into non-reachable solid compounds to the maximum possible extent. The flue gases released are treated by the air pollution control plant, of our proprietary design, in which a typical configuration comprises of dust collectors, cyclones, cooling towers, spark arrestors, bag-house filtration units, induced draft fans (ID Fan), wet scrubbers and a chimney/stack. We provide detailed process fine-tuning and training inputs in the commissioning phase to ensure optimum functioning of our Secondary Lead Smelting Plant.

For an overview of our entire range of available services from, feasibility studies to turnkey Plant, retrofitting and modernisation of existing units for capacity expansion to pollution control reengineering; see our services & turnkey projects section. Contact Us with your requirements for a customised equipment, solutions and services package.