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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. 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% depending upon 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 but in separate batches only.
 

3. What is the electricity requirement for the standard plant?
Electricity requirement depends upon size of plant. For Example a typical plant of about 300MT Lead production per month consumes apporx 120kwhr/MT.


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.

• About 600 MT per month Lead production plant & so on based on the customer requirement.
We also 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?
Though we also provide Acid Neutralization plant, still for small size plants, acid neutralization is done using chemicals in Neutralization Tanks. This Leads to the formation of salts like calcium sulphate as by-products which settles at the bottom of tank. 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 include not only the price for machines & equipments but also for our services & associated technology. Hence providing price break up is not feasible for us, for all equipments.


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


10. In which countries (companies & capacities) did Gravita supply the system of Lead Recycling?
We have supplied / installed 38 plants in 26 countries in Africa, Gulf area, Asia, Europe and Central America. We do have our own plants in India, Sri Lanka, parts of Africa and Central America. We are also in process of forming joint ventures in Saudi Arabia and South Africa.


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?
Our Standard Terms are:

40% Advance through T.T. Balance 60% through irrevocable confirmed letter of credit at sight against submission of export documents.


15. What are the warranty terms?
All the Plant machinery & equipment is warranted for a period of 1 year calculated from the date of its Installation or 18 months from the date of last shipment whichever is earlier.


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:


: Environmental standards for Ambient Air :
Pollutant Averaging Time Limit values    (µg/m3)
Carbon Monoxide (CO) 8 hr.  10000
1 hr. 30000

Sulphur Dioxide (SO2)
Annual 50
24 hr. 125
Nitrogen Dioxide (NO2) Annual 40
1 hr. 200
Total Particulate Matter (TPM) 24 hr. 120
Lead (Pb) Annual/24 hr. 0.5-1.0
 

: Standard/Maximum Stack Emission (Stationery Source) :
Pollutant Standard/Maximum Emission Level
Soot & Dust 150 mg/Nm3
Smoke Ringlemann 2
Lead (Pb) & it’s Compounds 10 mg/Nm3 as Pb
Particulates (SPM)–Blast & Reverberatory Furnaces 50 mg/Nm3
Particulates (SPM)-Pot Furnaces 10 mg/Nm3


19. 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.

 

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