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Eco Friendly Recycling 2 PROPRIETARY & CONFIDENTIAL LOCATION…  Strategic position at north India  Jaipur is the capital of state of Rajasthan  Ours.

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Presentation on theme: "Eco Friendly Recycling 2 PROPRIETARY & CONFIDENTIAL LOCATION…  Strategic position at north India  Jaipur is the capital of state of Rajasthan  Ours."— Presentation transcript:

1

2 Eco Friendly Recycling

3 2 PROPRIETARY & CONFIDENTIAL LOCATION…  Strategic position at north India  Jaipur is the capital of state of Rajasthan  Ours is the nearest big city from New Delhi  3.2 mil inhabitants in total  Industrial tradition: 14 Industrial areas around Jaipur  Our city is an important Tourism destination 1202 kmsBombay 1730 kms 2019 kms Calcutta Chennai 259 kmsDelhi Distance to other cities INDIA

4 3 PROPRIETARY & CONFIDENTIAL OUR BACKGROUND…  Professionally managed company  Exclusively dealing in Lead Metal for the last 12 years  Rich experience in Lead Smelting, Refining, Alloying & Lead Oxide manufacturing  ISO-9001:2000 Certified  We own plants at:  Jaipur : Lead Smelting & Lead Oxide Manufacturing  Sri Lanka : Lead Smelting.

5 4 PROPRIETARY & CONFIDENTIAL WHAT WE OFFER…  Lead Battery Scrap Recycling : An Environment Friendly Technology.  Lead Refining & Lead Alloying : An Proven Technology.  Lead Oxide Manufacturing : An Efficient Process & Plant for Litharge, Red Lead & Lead Sub-Oxide (Grey Oxide).  Training of Personal for Smelting, Lead Refining / Alloying Techniques & Processes.

6 5 PROPRIETARY & CONFIDENTIAL OUR INVOLVEMENT…  Market survey to perceive Battery Recycling Project with correct capacity  Plant Layout  Structural Designing  Electrical Drawing  Supply of complete Plant  Erection supervision at your site  Commissioning of plant with training of your personal (1 month)

7 6 PROPRIETARY & CONFIDENTIAL OUR INVOLVEMENT (Supplement)…  We help to prepare documents for submission to Government Department.  Environment Impact Assessment (EIA) study : help to local agency for creating such report.  Help in recruiting experienced man-power for Project.

8 7 PROPRIETARY & CONFIDENTIAL A TYPICAL TURNKEY PROJECT ENGAGEMENT… Feasibility Study Detailed Project Report Plant and Project Design Supply of complete Plant Erection, commissioning and start-up Training of Technical Personal / Engineers

9 8 PROPRIETARY & CONFIDENTIAL RESEARCH AND DEVELOPMENT (R & D)…  Gravita’s in-house R&D effort is geared to continuous improvement in plant and furnace designs for greater efficiencies.  Special attention is paid to integrate emerging technologies in our solutions.  Our aim is to provide our customers with solutions which have the optimum blend of proven and state–of-the-art technologies.

10 9 PROPRIETARY & CONFIDENTIAL INNOVATIONS IN TECHNOLOGY…  Our technology deployments make Lead Recycling Operations as  Environment-friendliness  Low Capital Cost  Economical viability  Our integrated turnkey plant installations comprising of  Secondary Lead Smelting  Lead Refining & Lead Alloying  Lead Oxide Manufacturing Our Pollution Control Plant meet the complete needs of medium sized Lead Recycling units Our plants are with guaranteed design performance Our plants are with guaranteed design performance. “ ”

11 10 PROPRIETARY & CONFIDENTIAL OUR EXPERTISE COVERS…  Special Blast Furnace  Low Capital Cost  Low Maintenance Cost  Usage of only Charcoal  NO- Furnace Oil Usage  10 MT per day production  Lead Refining  Do not operate with Caustic-Nitrate  Special Flux- reduces operating cost  Low Drossing  High temperature band-width Retrofitting of operational plants including Battery Manufacturing units for optimizing production, meeting of environmental and occupational health standards & concerns “ ”

12 11 PROPRIETARY & CONFIDENTIAL OUR FABRICATION FACILITY…  All engineering designs & drawings are made on CAD / CAM soft wares  We have tie-up with 4 more Engineering Fabrication Shops for speedy jobs  Ability to handle 10’ dia & 30’ length for machining job  Strict fabrication quality checks  These fabrication shops are all multi-discipline shops including all phases of testing  Our shops are ISO approved, insuring you the best quality available  Our Engineers have rich experience in total ‘Quality Check’

13 12 PROPRIETARY & CONFIDENTIAL OUR PLANT & SERVICES…  Supply of equipment for ‘Lead Recycling Plant’  Battery Breaking / Cutting Unit  P.P. Crusher  Plastic Granulator  Smelting Furnaces: Blast/Rotary Furnace  Integrated set of pollution control equipments, which covers  Dust Collector  Cyclone  Cooling-Tower  Bag-House  Induced Draft Fans  Wet-Scrubber  Chimney (Stack)

14 13 PROPRIETARY & CONFIDENTIAL PLANT LAYOUT OF ROTARY FURNACE… BlowerRotary FurnaceDust CollectorCyclone Cooling TowerBag HouseI D Blower Wet Scrubber

15 14 PROPRIETARY & CONFIDENTIAL OUR PLANT & SERVICES…  Refining Furnaces  Cattle: 5-50 Mt per charge capacity  F.O. / Gas Burner with Pre-heater  Steering System  Hood with Pollution Control Equipment  Automatic Ingot Casting Machine (10 MT/hr)  Plant Erection supervision, commissioning & start-up services. Our Plant comes with all required Electrical Motors & Electrical Control Panel with Temperature Indicators “ ”

16 15 PROPRIETARY & CONFIDENTIAL POLLOUTION CONTROL EQUIPMENT…  Pollution control plays an important part in the used Lead-Acid Battery Recycling and new battery manufacturing industries.  Filter Bag House with Pulse Jet cleaning arrangement is a key equipment to control Lead and other particulate matters / pollutants.  The permeability of Bag-Filters are about 3-5 microns, which results in achieving relevant mandatory environmental standards.

17 16 PROPRIETARY & CONFIDENTIAL BATTERY RECYCLING CYCLE…  Lead is the 4 th most widely used Metal on earth  Lead has highest rate of recycling among all Ferrous & Non-Ferrous Metals  Lead is only metal on earth which retains its 100% Chemical & Physical properties, irrespective of any number of recycling  Worldwide production of recycled Lead is now about 3 times then production Prime Lead…

18 17 PROPRIETARY & CONFIDENTIAL TYPICAL COMPOSITION OF LEAD-ACID BATTERY SCRAP… Component by weightPercent Metallic Lead35 Lead sulphates/oxides40 Plastic7 Acid15 Residuals3 TOTAL100 Grid plate Positive plate Micro porous separator Negative Plate Positive plate pack Positive cell connection Electrolyte-tight seaing ring Negative pole Negative cell connection Negative plate pack Valve adapter and valve

19 18 PROPRIETARY & CONFIDENTIAL LEAD SMELTING… Flow Diagram of a Secondary Lead Smelter A Lead Scrap Material B Furnace Metal C Slag (Discard) D Finished Metal E Dross F Filter Dust 1.Rotary Furnace 2.After Chamber 3.Gas Cooler 4.Filter Plants 5.Blending/Refining Pots 6.Ingot Casting Machine 7.Exhaust Fans 8.Chimney 9.Scrap Loading Bay

20 19 PROPRIETARY & CONFIDENTIAL LEAD SMELTING…  Battery Scrap composition may vary somewhat across countries/regions.  Normally 55-64% of Lead Metal recovered in terms of Drained Battery Scrap through Lead Smelting produces.  This impure Lead is converted in Pure Lead (99.97%) and Lead Alloys through Refinery / Alloying Pot.  Lead Compounds are being reduced in Blast Furnace / Rotary Furnace with help of Carbon / Charcoal.  These Furnaces operate in 900 o C to 1250 o C temperature range.

21 20 PROPRIETARY & CONFIDENTIAL ROTARY FURNACE…  We offers-  Tilting Type R.F.  Stationery type R.F.  Our Rotary Furnace is Robust in design & structure.  Designed for maximum fuel efficiency  Salient Features  Crome-Meagnisite Refractory  Insulation & refractory withstand for 2500 charges (Min.)  Variable rotating speed  Reverse rotation- time delay mechanism

22 21 PROPRIETARY & CONFIDENTIAL LEAD REFINING…  We use Pyro-Metallurgical process in Lead Refining.  We produce Lead Ingots with a minimum purity level of 99.97%.  We supply refining kettle furnaces of…  Various capacities ranging from 5-50 MT per batch  Accompanied by high efficiency natural gas burners/ furnace oil burners  Equipped with preheating arrangements  We control emissions by…  A flexible kettle hood  Venting into a Venturi Wet Scrubber  Attached to an Induced Draft Fan along with a chimney/ stack arrangement.

23 22 PROPRIETARY & CONFIDENTIAL ADDITIONAL EQUIPMENTS…  We provide additional equipment for automatic dross removal.  Automatic Lead Ingot-Casting Machine (with Lead- Pump) having a production capacity of up to tones/hr may also provided along with Refining Unit.  Lead Alloying Pot to produce Lead Calcium Alloy.  Our refining unit package is optimally configured for high throughput with good emission control, as proven by the existing installations in operation.

24 23 PROPRIETARY & CONFIDENTIAL REFINED LEAD / PURE LEAD… * Elements Composition in % Antimony (Sb)0.001% (max) Arsenic (As)0.001% (max) Tin (Sn)0.001% (max) Copper (Cu)0.001% (max) Bismuth (Bi)0.025% (max) Iron (Fe)0.001% (max) Nickel (Ni)0.001% (max) Silver (Ag)0.003% (max) Zinc (Zn)0.001% (max) Calcium (Ca)0.0005% (max) Sulphur (S)0.0005% (max) Aluminum (Al)0.0005% (max) Lead (Pb)99.970% (min) * Typical composition of

25 24 PROPRIETARY & CONFIDENTIAL LEAD ALLOYING…  Our Alloying plants use the pyrometallurgical refining process.  We supply kettle pots of various capacities ranging from 5-35 tones per batch accompanied by high efficiency natural gas / furnace oil burners equipped with preheating arrangements.  Emissions control is achieved by a flexible kettle hood venting into a Venturi scrubber.  Attached to an Induction Draft Fan (IDF) along with a chimney/stack arrangement. We configure the total alloying plant package(s) as required.

26 25 PROPRIETARY & CONFIDENTIAL AIR POLLOUTION CONTROL… We provide the following services for controlling the air pollution Consulting services Plant engineering and design Assembly and testing System integration Commissioning Operations & maintenance Manpower training.. We also undertake turnkey assignments for Lead Acid Battery Recycling and manufacturing units. Diagnostic studies for identifying fugitive emissions Air pollution control plant deficiencies.

27 26 PROPRIETARY & CONFIDENTIAL ENVIRONMENT…  Most critical part of ‘Lead Recycling Operation’ is of Air Pollution Control  Our Plants are specifically designed to meet specific norms of your country’s guide-line  We follow all Environmental Standards,  Which has serious concern in Lead  Smelting Operations:  Ambient Air Standard  Stack Emission Standard  Effluent Discharge Standard  Solid Waste Disposal Limits  Noise Levels  Occupational Exposure

28 27 PROPRIETARY & CONFIDENTIAL AMBIENT AIR LIMIT (WHO Recommendations) Pollutant Averaging Time Limit values (µg/m 3 ) Carbon Monoxide (CO) 8 hr hr Sulphur Dioxide (SO 2 ) Annual50 24 hr.125 Nitrogen Dioxide (NO 2 ) Annual40 1 hr.200 Total Particulate Matter (TPM) 24 hr.120 Lead (Pb)Annual/24 hr mg/Nm 3

29 28 PROPRIETARY & CONFIDENTIAL STACK EMISSIONS STANDARDS… Pollutant Standard/Maximum Emission Level Soot & Dust150 mg/Nm 3 SmokeRinglemann 2 Lead (Pb) & it’s Compounds10 mg/Nm 3 as Pb Particulates (SPM)–Blast & Reverberatory Furnaces. 50 mg/Nm 3 Particulates (SPM)-Pot Furnaces 10 mg/Nm 3

30 29 PROPRIETARY & CONFIDENTIAL EFFLUENT DISCHARGE STANDARDS… Parameter/ Substance Tolerance Limit Values Discharge into inland waters Discharge into coastal waters Discharge into public sewers Sensitive waters General waters pH Total Suspended Solids 20 mg/l max. 50 mg/l max. 150 mg/l max. 500 mg/l max. Lead (Pb) 0.1 mg/l max. 0.5 mg/l max. 1.0 mg/l max. 5.0 mg/l max.

31 30 PROPRIETARY & CONFIDENTIAL LEAD CONTENT LIMITS (Solid Waste Disposal on Land) Cumulative Limit Annual Limit Soil Concentration 1000 Kg/Ha33 Kg/Ha550 mg/Kg limit MAXIMUM PERMISSIBLE NOISE LEVELS (At Plant Perimeter) Day Time ( hrs) Night Time ( hrs) 65db55db

32 31 PROPRIETARY & CONFIDENTIAL EFFLUENTS AND SOLID WASTE MANAGEMENT…  Our solid waste management solutions include  Consulting services for solid waste treatment  Conversion of the discard Slag and other process wastes to marketable\ safely disposable forms  Selection and design of in-plant hazardous material storage facilities and disposal landfill sites.  Our comprehensive services include  Plant layout, design  Process selection  Effluent treatment plants  safely disposable /marketable forms

33 32 PROPRIETARY & CONFIDENTIAL OCCUPATIONAL SAFETY & HEALTH SOLUTIONS…  Proper plant design and engineering controls in order to protect workers from occupational exposure to Lead, including by control of process and fugitive emissions.  Appropriate codes of practice/policies/plant hygiene practices for the workforce and relevant management personnel  Required education & training to workforce about facilities and protective equipment

34 33 PROPRIETARY & CONFIDENTIAL OCCUPATIONAL SAFETY & HEALTH SOLUTIONS…  Regular monitoring procedures including in-plant/perimeter environmental monitoring of Air Lead Levels  Screening of workforce Blood Lead Levels at 6 months interval  Advance planning of steps to be taken in case of crossing of prescribed action levels.  Remedial actions, which may include engineering and process corrections, job rotation of workers with High Blood Lead Levels to no-exposure work areas “Reduction of Lead Blood Level by Chelation Therapy, if required”

35 CONTACT 501, Rajputana Tower, A-27 B, Shanti Path, Tilak Nagar JAIPUR (Rajasthan) INDIA Phone: , , Fax: Website :


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