ilzda conference 28 sep delhi presentation

8/11/2019 ILZDA Conference 28 Sep Delhi Presentation

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Eco-Friendly Recycling

We Recycle to Save Environment

Presented By:


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LEAD ACID BATTERY RECYCLING

ABOUT GRAVITA

Established in the year 1992 Dedicated to Secondary Lead Metal since past 18 years

Over 500 plus Lead Professionals placed globally

The company is head quartered at Jaipur (India) with presently, 9 recyclingfacilities spread over the four continents

INDIA


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OUR MAJOR BUSINESS VERTICALS

International BusinessImport & Mercantile export of Lead Raw Materials &

finished Products

Turnkey ProjectsLead Recycling, Smelting and Refining Plants: End to End Solutions

Process & Pollution control Technology

Technical Consultancy to establish Lead Battery Recycling Projects

Manufacturing Operations

Lead Smelting, Refining, Alloying, Oxides (LSO,Red Lead & Litharge)

Cont inuous R & D w i th

Operat ion al Excel lence c reates

di f ference


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OUR NETWORK

LOCATION MAP

H.O.- JaipurINDIA

Mirigama

SRI LANKA

Addis Ababa, ETHIOPIA

Tema

GHANA

Maputo, MOZAMBIQUE

Antananarivo, MADAGASCAR

Dakar

SENEGAL

Lusaka

ZAMBIA

San Pedro Sula

HONDURAS

Tiblisi

GEORGIA

Gravita Group Operations

Turnkey Projects Implementation

*

*Under Construction


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We Recycle to Save EnvironmentWe Recycle to Save Environment


POLLUTION PREVENTION HIERARCHY

Decreasin

gPreference


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WHY LEAD RECYCLING

Secondary Production of Lead (Recycling) from Scrap results in less Solid

Wastes, uses less energy & reduces the consumption of minerals resources

compared to the Lead Production from Ores.

Lead Battery Scrap is a Hazardous waste

and unsafe disposal creates

Environmental / Health problems.

Careful Recycling is essential, beneficial &

cost effective in comparison to its safe

disposal cost.


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LEAD

OXIDES

BATTERY RECYCLING CYCLE

Lead is the 5th

most widely usedMetal on earth

Lead has highest rate of recyclingamong all Ferrous & Non-FerrousMetals

Lead is only metal on earth whichretains its 100% Chemical &Physical properties, irrespective ofany number of recycling

Worldwide production of secondaryLead has increased substantially inthe past decade.

NEW

BATTERY

END USER USEDBATTERY

PLASTIC LEAD

METAL IN

GRIDS

ACID FOR

NEUTRALIZATI

SODIUM

SULPHATE

CRYSTALS

GLASS, TEXTILES

DETERGENTS

LEAD

INGOTSPLASTIC

PELLETSNEW

COVERS &

CASES

NEW

GRIDS


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2000

2500

3000

3500

4000

4500

5000

2003 2004 2005 2006 2007 2008

P RIM ARY S ECONDA RY

GLOBAL TRENDS OF LEAD METAL PRODUCTION

Gap between the Production from Primary & Secondary sources has

increased in the last 2 Decades

World Lead Production Trend

T

housand

Tons

Increase in demand o f Lead and

Concern for the Environment :

Increase in Secon dary Produc t ion


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GLOBAL LEAD METAL MARKET

Metal Consumption and Yearly Average LME price, 2004-2009

Source : Metalworld 2009

6500

7000

7500

8000

8500

9000

2004 2005 2006 2007 2008

0

500

1000

1500

2000

2500

3000

Consumption LME Yearly Average

PricesUSD

The total Lead m etal consumpt ion has

increased by appro x 17% in the past f ive

years

00

0

Tons


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GLOBAL LEAD INDUSTRY OVERVIEW



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BATTERIES

Emerging demand of UPS

Invertors

Power systems in Telecomm,Automobile & Other fields

ROLLED AND EXTRUDED PRODUCTS

PIGMENTS & CHEMICALS

AMMUNITION & SHOTS

MISCELLANEOUS

ALLOYS

CABLE SHEATHING

CONSUMPTION SEGMENTATION

The total Lead metal consumption inbatteries has increased in the pastdecade whereas the use in paints hasdecreased



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BACKYARD SMELTERS ARE MUSHROOMING

High Demand of Lead Metal - Leading to birth of Backyard

Smelters.

Shortage of Supply - Way towards Small Unconventional /

Backyard recycling Practices

Price Hikes in Lead Metal

Poor Implementation of Laws


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Short-term Lead exposure of high doses can result in serious

illness

Long-term overexposure can cause numerous health problems

and can also prove fatal

Lead is hazardous to mankind & living organisms, if NOT

handled properly

Occupational hazards also needs attention

EFFECTS OF UNORAGANIZED LEAD PRACTICES

Let us come together and Join hands

to save our Mother Earth and be

more environmentally aware and

organized


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TIME TO AWAKE!

CONCERN ABOUT ENVIORNMENT

GREEN RECYCLING SYSTEM


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STEPS INVOLVED IN ECO-FRIENDLYLEAD RECYCLING PROCESS

Collection of whole wet BATTERIES

Safe Storage of Batteries

Drainage & Collection of Acid/Electrolyte

Neutralization of Acid/Electrolyte

Crushing & Separation of Lead bearing material & other component of battery

Smelting in Closed compact Furnace

with Effective Pollution Control

Equipments

Highly Efficient Refining Process

Effective control of the fumes & gases

generated during operation of furnaces

Proper treatment of wet & solid

effluents generated while pollution

control


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GLOBAL GOVERNMENT POLICIES

With time most of the Government along with local representative bodies have emerged in order to

curb the ill-effects of Unconventional Recycling System & to promote Eco Friendly Recycling

Policies:

USA Battery Council International

EUROPE - Best Available Techniques (BAT), EU Directives Policies

IRELAND RETURNBATT country wide collection scheme

SWEDEN - RETURNBATT Scrap collector organization

GERMANY Revised form of EU Directives

ITALY COBAT Organization for Scrap Collection

JAPAN Battery Association of Japan (BAJ) promotes recycling activates

with Environmental Guidelines

INDIA Indian Lead & Zinc Development Association (ILZDA)


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17 LEAD ACID BATTERY RECYCLING

HIGHLIGHTS ON BATTERY COLLECTION

Collection Containers

Mobile Lead Recycling Vans/ Trucks

Battery Recycling Stations

For shopping centers, service stations, amenity areas and local authorities

Battery Recycling Center -

For All types of batteries

Lead Acid Battery Recycling Crates -

For All types of Lead Acid batteries

Battery Boxes

For domestic Batteries

BatteryR

ecyclingStations

Battery Recycling

ContainersLead Acid Battery Crates

Battery Boxes


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COMPONENTS OF ORGANISED LEAD RECYCLING

Battery Crushing & Hydro separation Unit

Acid Draining & Acid Neutralization System

Rotary Type Smelting Furnace

Complete Pollution Control Equipments

Refining / Alloying Furnace

Fugitive Emission Control System

Ingot Casting Machine

PLC based Control Mechanism & Equipments



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BATTERY CRUSHING & HYDROSEPARATION

Acid Draining & Neutralization System

Batteries with Acid are drained separately

to collect acid for further processing

Whole system is enclosed with fumigation

Hood to collect fumes.

Collected Acid will either reprocessed to

convert electrolyte or neutralized formaking by products.

Battery Breaking & Hydro separation

Drained Batteries are crushed with

Battery Breaker

PP, Metallic Lead & Lead Compounds (inPaste form) Separation is done by

Hydro-Separation method

Grid & Paste processed separately


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LEAD SMELTING

Battery Scrap composition may vary somewhat across

countries/regions.

Rotary Type of Smelting Furnaces are the common Furnaces

used for Smelting operation world wise.

Versatile for using Lead Battery Scrap, Concentrates and

other Lead Scrap material

Lead Compounds are being reduced in with help ofCarbon / Charcoal.

These Furnaces operate in 900oC to 1250

oC

temperature range.

Rotary furnaces are much more efficient than Reverbfurnaces since they transfer heat both via radiationand direct contact between the melt and therefractory as it passes beneath the charge.

The constant mixing and motion of the chargematerial maximizes the heat transfer within the scrap


LEAD REFINING / ALLOYING


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LEAD REFINING / ALLOYING

REFINING SECTION

Pyro-metallurgical process is mostly used in Lead

Refining Process using the Refining kettles

A temperature governed Chemical process

Need to be carried out with proper Fugitive Control

Hoods

REFINED LEAD

INGOT CASTING MACHINE

REMELTED LEAD


OXY FUEL BURNERS


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OXY FUEL BURNERS

A great support to Furnaces

Increased capacity since possible to heat a fully

charged Furnace

Powerful, yet small dimensions

Reduced Fuel consumption and lowered emissions

Provides longer Flame length

Allows to use different Flame geometries reducing

energy consumption and dross formation


SOME MORE TECHNIQUES


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SOME MORE TECHNIQUES

HYDROMETALLURGICAL PROCESS

Alternate of Pyro-metallurgical process

Electro-refining using formations of Cathodes/Anodes

Efficient process for removing Bismuth from 200 ppm to

20 ppm

ELECTRO-WINNING PROCESS

Lead Paste from the Batteries consist of oxides/sulphates

Desulphurised using Alkali solution

By Electrochemical deposition Lead is obtained

Costly Process

Suitable for big units


PLC BASED CONTROL & MONITOR SYSTEM


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24 LEAD ACID BATTERY RECYCLING

PLC BASED CONTROL & MONITOR SYSTEM

ENVIRONMENT


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ENVIRONMENT

Most critical part of LeadRecycling Operation is

of Air Pollution Control

Lead Recycling Plants should be specifically

designed to meet Environmentally sound guide-

lines.

Environmental Standards, Which has serious

concern in Lead Smelting Operations are:

Ambient Air Standard

Stack Emission Standard

Effluent Discharge Standard

Solid Waste Disposal Limits

Noise Levels

Occupational Exposure of work force


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TREATMENT SYSTEMS


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TREATMENT SYSTEMS

The effective Pollution Control Equipments consist of the following :

Acid Draining & Neutralization System

Battery Breaking & Hydro separation System

Dust Collector with Cyclone

Cooling Tower

Filter Bag-House

Wet-Scrubber System

TREATMENT SYSTEMS



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TREATMENT SYSTEMS

Dust Collector

A sort of Gravity Settling

Chamber with baffles

Gas velocity is reduced to

enable dust to settle down.

Cyclone

In Cyclone centrifugal force separates

suspended particles from the Flue gases.

Gas is introduced tangentially producing

a spiral motion which directs the solid

particles downward (for exiting) and

clean gases flown ahead in the system.

TREATMENT SYSTEMS


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TREATMENT SYSTEMS

Cooling Tower

Flue gases are allowed to cool down

up to 120C - 130C

Designed as per the ambient air

temperature where Plant is

operating

Filter Bag House

Important part of Pollution Control Process

Contains filter bags through which dust

laden gases are made to pass.

Filter bags are Anti adhesive for water

repellence & Easy dust release

Automatic Pulse jet cleaning system for

periodic cleaning

Implementation of EffectiveSystem leads to Long Innings


TREATMENT SYSTEMS (Continue)


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TREATMENT SYSTEMS (Continue)

Scrubber System

Packed Bed Type Wet Scrubber is most widely used

scrubbers for gas dissolution.

Dissolves pollutant gases using reverse current method

where spray of water ensuring maximum contact of Liquid

in MIST FORM & unwanted gases.

Filled material produces maximum surface area for liquid

droplets and make distribution for efficient scrubbing of

gases /particulates / contaminants.

Water absorbs SO2gas & the acidic water passes through

Water Treatment Plant and get neutralized. Neutralized

water is re-circulated in the system using P.P. pump.

At other End MIST Eliminator is employed to remove water

content from the Gases coming-out.

OCCUPATIONAL SAFETY & HEALTH SOLUTIONS


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OCCUPATIONAL SAFETY & HEALTH SOLUTIONS

Proper plant design and engineering controls

are essential in order to protect workers from

occupational exposure to Lead, including by

control of process and fugitive emissions.

Lead Blood level is main indicating parameter for Lead

Exposures of workforce

Appropriate codes of practice/ policies /plant hygiene

practices for the workforce and relevant management

personnel is important.

Required Chelation therapy under qualified Medical

supervision to workforce reduces Lead Blood Levels.

SUMMARY..


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SUMMARY..

Lead Acid Battery Scrap Recycling is essential for mankind as well as for

Industry survival.

Recent technological deployments made Lead Battery Scrap RecyclingOperations as Environment-friendly.

An Environment Friendly Lead Battery Recycling will prove a conscious stepforward to the conservation of the Environment

Increasing Environmental

Awareness makes th is op erat ion

more profession al & techn ical,

wh ich f inal ly leads to high

econom ic v iabi l i ty



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We Recycle to Save EnvironmentInitiating Eco-Friendly Lead Recycling World Wide

Website : www.gravitagroup.comwww.gravitaexim.comwww.gravitaindia.com

E-mail : [email protected]


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