FREQUENTLY ASKED QUESTIONS

1. What is the recovery rate of Lead Recycling plant?

2. Can Lead Ore & Battery Scrap be operated in the same system?

3. What is the electricity requirement for the standard plant?

4. What are the standard sizes of Lead Recycling Plant you offer?

5. What types of raw materials can we process in Lead Recycling Plant?

6. How is the capacity defined for Lead Recycling Plant?

7. Is there any process for Acid Neutralization in your system?

8. What is the price for each stage of the process?

9. What is the capacity of each stage of a standard Lead Recycling process (breakdown)?

10. In which countries (companies & capacities) did Gravita supply the system of Lead Recycling?

11. What is the land area, covered area required for the Lead recycling plant?

12. What is the manpower required to run the plant?

13. What is the estimated time for supplying the machineries and equipment?

14. What are the payment terms?

15. What are the warranty terms?

16. What is the expected cost of utilities to produce 1 ton of refined Lead?

17. What is the expected time for installing the plant?

18. Please mention the details of effluents and emissions from the plant during its regular course of operations?

19. What are the annual maintenance costs?

20. Please provide us a complete comparison of the two types of furnaces especially in the areas such as technical performance, capital costs and operational costs?

1. What is the recovery rate of Lead Recycling plant?

The Recovery rate of Lead recycling Plant is defined in two ways – Recovery from the complete weight of Battery Scrap     (including plastic, acid) is about 55-62% based on the size & grade of Batteries available at the location.
However the recovery/efficiency in terms of Lead metal content which is feed inside the Furnace is about 98%. The above percentages will vary slightly in case of Blast Furnace in comparison to Rotary Type of Furnace.
 

2. Can Lead Ore & Battery Scrap be operated in the same system?
Yes in our system the Lead Ore & the Battery Scrap can be processed in separate batches only.
 

3. What is the electricity requirement for the standard plant?
The Electricity consumption for a standard plant of about 300MT Lead production plant per month is about 300KVA including administrative & other utilities.

4. What are the standard sizes of Lead Recycling Plant you offer?
The standard sizes of Lead Recycling/Smelting Plant are:
• About 150MT per month Lead production Plant
• About 300MT per month Lead production plant
• About 450MT per month Lead production plant & so on based on the customer requirement.
We provide Tailor made comprehensive turnkey projects for Lead Recycling/Smelting Plant.

5. What types of raw materials can we process in Lead Recycling Plant?
The types of Lead Scrap that can be process are as follows:
• Lead Acid Battery Scrap
• Lead Sheaths/Cables Scraps
• Others

6. How is the capacity defined for Lead Recycling Plant?
The capacity of plant can be defined either in terms of Lead production capacity per day or per month or it can be expressed as raw material (Lead Scrap) processing capacities per day or per month.
 

7. Is there any process for Acid Neutralization in your system?
Yes in our process the Acid neutralization is done using chemicals & make up water. This Leads to the formation of some salts as by-products which are again feed into Rotary Furnaces. However the neutralized water is re-circulated with in the system hence no drop of water is made to move out of the process zone.

8. What is the price for each stage of the process?
The price offered in the Quotation does not include only the price for machines & equipments but also include our services & other features. Thus it will not be feasible to justify the price break-up for each & every equipments.

9. What is the capacity of each stage of a standard Lead Recycling process (breakdown)?
The capacity of complete Lead Recycling/Smelting Plant is mentioned below:
• Battery Cutting System : 2.0-2.5 MT/Hr.
• Battery Breaking & Hydro separation system – 3-5MT/Hr.
• Rotary Furnace : 10 MT/Hr.
• Lead Refining Furnace : 20MT Holding capacity
• Lead Alloying Furnace : 10MT Holding capacity
• Lead Ingot Casting Machines : 10MT/Hr.
• Plastic Crusher : 100-150Kg/Hr.

10. In which countries (companies & capacities) did Gravita supply the system of Lead Recycling?
We have given our plants at overseas Africa, Gulf area, Asia & currently we are in the process of supplying our new projects in parts of Europe, USA etc. We do have our own plants at India, Sri Lanka & parts of Africa (5 plants), some joint ventures in UAE & Saudi Arabia.
However we will not be able to disclose our reference list at this initial stage of Business. It will be done after some mutual commitments only.

11. What is the land area, covered area required for the Lead recycling plant?
For a standard plant of about 300MT per month Lead production:
• Land Area : minimum about 8000 square meters.
• Shed Area : about 2200-2500 square meters.

12. What is the manpower required to run the plant?
It is about 20 per shift for Lead Recycling Plant.

13. What is the estimated time for supplying the machineries and equipment?
Normally we take about 135 days but can be shortened on some request & extra cost.

14. What are the payment terms?
The payment terms are as per the details mentioned in the Quotation where 40% of the total value will be in advance & rest of the value by 60% in terms of Letter of Credit.

15. What are the warranty terms?
We can give warranty of about 1 year on our machines & equipments.

16. What is the expected cost of utilities to produce 1 ton of refined Lead?
It is approx about US$ 80.00

17. What is the expected time for installing the plant?
It is about 30-45 days with full support from the Erection team at the Buyer site along with availability of Tools & Tackles on time.

18. Please mention the details of effluents and emissions from the plant during its regular course of operations?
The Environmental guidelines which our plant & machineries are meeting out are mentioned below:

19. What are the annual maintenance costs?

It depends upon the regular schedule maintenance to be done. Normally wear & tear is only because of maintenance. It is approx 1-1.5 Lacs INR per month.

20. Please provide us a complete comparison of the two types of furnaces especially in the areas such as technical performance, capital costs and operational costs?
Yes, Rotary furnace is quite feasible, efficient & versatile to use as compare to Blast Furnace.
The salient features for both the Furnaces are as follows. :
• Blast Furnace is Coal-fired which combines the features of low set-up and operating costs, high process efficiency, low maintenance requirements due to no moving parts and user-friendly features. Blast Furnace can be run in shifts since starting and shut down of furnace is not much costly. This process must require wood charcoal of good quality since charcoal acts as heating media as well as reducing agent for charge material.
• Rotary Furnace is oil fired and display good operating/efficiency characteristics. The fuel required for burner to heat furnace is F.O. / L.D.O. or any other equivalent burning media / oil. Since charcoal or coal is required only as reducing agent hence lower grade of charcoal / coal can also be used. Rotary furnace will be used for continuous production in Batch process. For setting up this type of plant one has to ensure availability of raw material in plenty on regular basis.