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Eco Friendly Recycling
2PROPRIETARY & CONFIDENTIAL
LOCATION…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
3PROPRIETARY & CONFIDENTIAL
OUR BACKGROUND…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.
4PROPRIETARY & CONFIDENTIAL
WHAT WE OFFER… 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.
5PROPRIETARY & CONFIDENTIAL
OUR INVOLVEMENT…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)
6PROPRIETARY & CONFIDENTIAL
OUR INVOLVEMENT (Supplement)…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.
7PROPRIETARY & CONFIDENTIAL
A TYPICAL TURNKEY PROJECT ENGAGEMENT…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
8PROPRIETARY & CONFIDENTIAL
RESEARCH AND DEVELOPMENT (R & D)…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.
9PROPRIETARY & CONFIDENTIAL
INNOVATIONS IN TECHNOLOGY…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 performanceOur plants are with guaranteed design performance.
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10PROPRIETARY & CONFIDENTIAL
OUR EXPERTISE COVERS…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 Retrofitting of operational plants including Battery Manufacturing units for
optimizing production, meeting of environmental and occupational health optimizing production, meeting of environmental and occupational health
standards & concernsstandards & concerns
““””
11PROPRIETARY & CONFIDENTIAL
OUR FABRICATION FACILITY…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’
12PROPRIETARY & CONFIDENTIAL
OUR PLANT & SERVICES…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)
13PROPRIETARY & CONFIDENTIAL
PLANT LAYOUT OF ROTARY FURNACE…PLANT LAYOUT OF ROTARY FURNACE…
Blower Rotary Furnace Dust Collector Cyclone Cooling Tower Bag House I D Blower
Wet Scrubber
14PROPRIETARY & CONFIDENTIAL
OUR PLANT & SERVICES…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 Our Plant comes with all required
Electrical Motors & Electrical Control Electrical Motors & Electrical Control
Panel with Temperature IndicatorsPanel with Temperature Indicators
“”
15PROPRIETARY & CONFIDENTIAL
POLLOUTION CONTROL EQUIPMENT…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.
16PROPRIETARY & CONFIDENTIAL
BATTERY RECYCLING CYCLE…BATTERY RECYCLING CYCLE…
Lead is the 4th 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…
17PROPRIETARY & CONFIDENTIAL
TYPICAL COMPOSITION OF LEAD-ACID BATTERY SCRAP…TYPICAL COMPOSITION OF LEAD-ACID BATTERY SCRAP…
Component by weight
Percent
Metallic Lead 35
Lead sulphates/oxides 40
Plastic 7
Acid 15
Residuals 3
TOTAL 100
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
18PROPRIETARY & CONFIDENTIAL
LEAD SMELTING…LEAD SMELTING…
Flow Diagram of a Secondary Lead Smelter
A Lead Scrap MaterialB Furnace MetalC Slag (Discard)D Finished MetalE DrossF Filter Dust
1. Rotary Furnace2. After Chamber3. Gas Cooler4. Filter Plants5. Blending/Refining Pots6. Ingot Casting Machine7. Exhaust Fans8. Chimney9. Scrap Loading Bay
19PROPRIETARY & CONFIDENTIAL
LEAD SMELTING…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 900oC to
1250oC temperature range.
20PROPRIETARY & CONFIDENTIAL
ROTARY FURNACE…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
21PROPRIETARY & CONFIDENTIAL
LEAD REFINING…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.
22PROPRIETARY & CONFIDENTIAL
ADDITIONAL EQUIPMENTS…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 10-25 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.
23PROPRIETARY & CONFIDENTIAL
REFINED LEAD / PURE LEAD…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
24PROPRIETARY & CONFIDENTIAL
LEAD ALLOYING…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.
25PROPRIETARY & CONFIDENTIAL
AIR POLLOUTION CONTROL…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.
26PROPRIETARY & CONFIDENTIAL
ENVIRONMENT…ENVIRONMENT…
Most critical part of ‘Lead Recycling Operation’ is of Air Pollution Control
Our Plants are specifically designed to meet specific norms of yourcountry’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
27PROPRIETARY & CONFIDENTIAL
AMBIENT AIR LIMIT AMBIENT AIR LIMIT (WHO Recommendations)(WHO Recommendations)
Pollutant Averaging
TimeLimit 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. 1.0-2.0 mg/Nm3
28PROPRIETARY & CONFIDENTIAL
STACK EMISSIONS STANDARDS…STACK EMISSIONS STANDARDS…
PollutantStandard/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
29PROPRIETARY & CONFIDENTIAL
EFFLUENT DISCHARGE STANDARDS…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 6.0-8.5 6.0-9.0 5.5-9.0 5.5-10.0
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.
30PROPRIETARY & CONFIDENTIAL
LEAD CONTENT LIMITSLEAD CONTENT LIMITS(Solid Waste Disposal on Land)(Solid Waste Disposal on Land)
Cumulative Limit
Annual Limit
Soil Concentration
1000 Kg/Ha 33 Kg/Ha 550 mg/Kg limit
MAXIMUM PERMISSIBLE NOISE LEVELS MAXIMUM PERMISSIBLE NOISE LEVELS (At Plant Perimeter)(At Plant Perimeter)
Day Time (0600-1800 hrs)
Night Time (1800-0600 hrs)
65db 55db
31PROPRIETARY & CONFIDENTIAL
EFFLUENTS AND SOLID WASTE MANAGEMENT…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
32PROPRIETARY & CONFIDENTIAL
OCCUPATIONAL SAFETY & HEALTH SOLUTIONS…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
33PROPRIETARY & CONFIDENTIAL
OCCUPATIONAL SAFETY & HEALTH SOLUTIONS…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”
CONTACT
501, Rajputana Tower, A-27 B, Shanti Path, Tilak NagarJAIPUR-302004 (Rajasthan) INDIAPhone:+91-141-2623266, 2622697, 2621037Fax: +91-141-2621491Website : www.gravitaexim.com E-mail : [email protected] [email protected]
