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1 Products availableWe offer a complete product range of PARTS SEPARATION MACHINE, Acid Draining Machine, Rotary Chamber, Rotary Chamber Machines and DISCHARGE CHARACTERISTICS
The Lid part is completely crushed and sent to Lead-Plastic separating Machine: i.e., Metal Classifier; with this process plastic parts are separated from the Lead parts. Such plastic parts are sent to thePlastic Crusher& are cut into smaller pieces. The Rest of the battery is moved on conveyor to thePART SEPARATOR MACHINE& all the parts are separated totally and sent to their separate respective storage tanks with the help of Conveyor systems. This separation machine is enclosed & no dust particles come out of the plant this increases plants recovery & reduces wastages of material. For dust collection BAG HOUSE is attached so that the oxide dust is stored in a filter bag. In this machine, on the First stage, the Battery Casings are taken out & sent to their separate section through its connecting conveyor. Later on, these Casings are sent to the same earlier Plastic Crusher, or a separate crusher can be placed as per customer's choice at additional cost which depends upon the Production capacity of the plant.
After this step, the Plates & Separators are sent to the second level, in this section using a particular stage of vibration resonance at certain level we have taken out maximum quantity of Lead parts from the Plates & Shredded oxide material on the Third stage for Collection in its particular storage tank. In this stage, we took out the impregnated material from the plates on Grid. The rest material on plates are taken out with Battery Separators are sent to the Part Separation Machine on which the Plates are separated on one stage i.e., on one side & Separators are stored on other side. The Plate Parts & Separator Parts are separated and here we are collecting the rest of the shredded oxide material. The Grid parts & separators are separated by using the Grid-Separator Separation Machine. In this machine, Both Grids parts & separator parts are dropped through conveyor. Heavy air & water pressure is given simultaneously in the machine and by using floatation method we are separating the Separators & Grid Parts. These shredded Plates are sent to the FURNACE FOR SMELTING [Recycling]. And the Separators are sent through conveyors to A Separator Washing Machine. This separator washing machine is added to the system as per the customer's on demand or as per the plant production capacity. The machine is completely enclosed and environment friendly. Getting back on Parts Separation Machine, in the third layer of separation, Broken Separator Parts, Broken Grid Parts & Oxide Dust is taken out & sent to the other Metal Classifier & Floatation Tank is attached on that. In this section, Separator parts floats in water tank. The Lead Parts & the Oxide dust is settled down on the bottom side of the tank due to its weight & taken out with the help of rotary valve. And, the same water can be used again & again. The transferring of Lead Parts & Oxide Dust material can be sent to their respective Refining Pots & Smelting Units through Fork Lifts/ automatically with the help of automated mechanized system that will be on customer's demand at additional cost.
The shaved lid which is separated from under the welded straps is sent through conveyor to Lid Crusher Machine. Plastic parts are separated from the Lead parts. Such plastic parts are sent to the Plastic Crusher & are cut into smaller pieces. This machine is used to crush Battery Container made of Plastic Material. It crushes to small Pieces up to size of 1" square in one go and Washes Lead accumulated on it. It is shearing & hammering action increases its Power versus Output Ratio. Lead is precipitate on another conveyor. This conveyor conveys Lead Particles/ Pieces to one side. Plastic which can float on water will be filtered on another Conveyor. Plastic is fed to Plastic Washing Machine. This Plastic Washing Machine washes Plastic with Soap Solution. Plastic is filtered and collected. Water is used again after purification.
Acid stored in a tank, the precipitated oxide slurry is taken out with the valve & the acid is sending for Recycling: Neutralization. It can be handled in two ways: First way, the acid is neutralized with an industrial compound similar to household baking soda. Neutralization turns the acid into water. The water is then treated; cleaned, tested in a waste water treatment plant to be sure it meets clean water standards. Second way, the acid is processed and converted to sodium sulfate, an odorless white powder that's used in laundry detergent, glass, and textile manufacturing.
Like copper, lead has also been a familiar metal used by human beings since ancient times. Lead, a highly malleable and easy to melt metal, is widely used in various industries even today. However, due to its highly toxic nature, the use of lead has been facing pressure from environmentalists in recent years.
The pressure to end manufacture of lead-based paints is an example of the growing concern on the potential health hazards caused by lead. Plastics, aluminum, tin, and iron are replacing the use of lead in construction materials, containers, packaging, etc. Tin and other metals are being used to replace lead as a solder in some applications where lead could poison people, such as in drinking water systems.
Lead is a very corrosion-resistant, dense, ductile, and malleable blue-gray metal that has been used for at least 5, 000 years. Early uses of lead included building materials, pigments for glazing ceramics, and pipes for transporting water. The castles and cathedrals of Europe contain considerable quantities of lead in decorative fixtures, roofs, pipes, and windows.
Prior to the early 1900's, uses of lead in the United States were primarily for ammunition, brass, burial vault liners, ceramic glazes, leaded glass and crystal, paints or other protective coatings, pewter, and water lines and pipes.
The advent of the electrical age and communications, which were accelerated by technological developments in World War I, resulted in the addition of bearing metals, cable covering, caulking lead, solders, and type metal to the list of lead uses. With the growth in production of public and private motorized vehicles and the associated use of starting-lighting-ignition (SLI) lead-acid storage batteries and terne metal for gas tanks after World War I, demand for lead increased.
Most of these uses for lead continued to increase with the growth in population and the national economy. Contributing to the increase in demand for lead was the use of lead as radiation shielding in medical analysis and video display equipment and as an additive in gasoline. By the mid-1980's, a significant shift in lead end-use patterns had taken place. Much of this shift was a result of the U.S. lead consumers compliance with environmental regulations that significantly reduced or eliminated the use of lead in nonbattery products, including gasoline, paints, solders, and water systems.
More recently, as the use of lead in non-battery products has continued to decline, the demand for lead in SLI-type batteries has continued to grow. In addition, the demand for lead in non-SLI battery applications also has continued to grow. Lead is processed & refined from lead scrap batteries. Non-SLI battery applications include motive sources of power for industrial forklifts, airport ground equipment, mining equipment, and a variety of nonroad utility vehicles, as well as stationary sources of power in uninterruptible electric power systems for hospitals, computer and telecommunications networks, and load-leveling equipment for electric utility companies. By the early 2000's, the total demand for lead in all types of lead-acid storage batteries represented 88% of apparent U.S. lead consumption.
Other significant uses included ammunition (3%), oxides in glass and ceramics (3%), casting metals (2%), and sheet lead (1%). The remainder was consumed in solders, bearing metals, brass and bronze billets, covering for cable, caulking lead, and extruded products. Lead is mined in the United States, Canada, Mexico, Australia, and Peru. More than 1 million tons of lead is recovered in recycling annually, the majority of which is from the recycling of batteries. Australia and China are the leading suppliers of lead in the world. China, India, Japan, US and European Union are the main consumers of lead in the world. Lead is traded mostly as soft lead, animated lead, lead alloys and copper-based lead scrap.
India imports nearly 50 percent of its lead requirement every year. Lead production in India is estimated to be around 82, 000 ton, mostly from secondary sources. Lack of any major lead ore deposit is the main constraint for enhancing domestic lead production. The domestic industry is characterized by the presence of only a few players in the primary segment. The primary lead industry in India is divided between the following main players: Binani Industries Limited and Sterlite Industries (India) Ltd. (Hndustan Zinc Ltd.). Due to increasing use of lead in domestic market both players are expanding their smelting capacities for lead. Lead in the global market is traded as soft lead, animated lead, lead alloys and copper-base scrap.
Pure Lead Ingot is being produced from Raw Lead Bullion / Remelted and Secondary Lead Ingots / Lead Scraps though Pyro-metallurgical process. Refining Process, producing Pure Lead Ingots with a minimum purity level of 99.97% by weight but achieves purity level of 99.985% in most of cases.
| Elements | Symbol | 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) |
| Selenium | Se | 0.0005 (max) |
| Cadmium | Cd | 0.0005 (max) |
| Tellurium | Te | 0.0010 (max) |
| Lead | Pb | 99.970 (min) |
Rotary Chamber receives very hot gases from Rotary Furnace while cold gases from atmosphere are induced into chambervia specially designed profile. Thus chamber works as an equalizing chamber to reduce the temperature of gases and alsowhere sedimentation of dust particulate matter takes place.
Rotary Chamber Advantages
Rotary Chamber Disadvantages
Application :-This machine checks pin hole, separator missing and splash of lead in cells, etc. It also checks that all the cells are connected to each other with the help of high voltage. If there is any fault then it gives visual indication as well as audio alarm.
Application :-This machine connects cells through the partition of container.
Operation :-This Machine forges L- connecter of cells through the hole of partition together and passes heavy current at low voltage so portion of these connecter through hole of partition melts, taking advantage of resistance of lead, and become single entity. This machine does mass production and running cost comes to minimum, hence cost per battery is reduced to minimum.
Application :-This machine seals Lid to Container. For every size of container you require Separate sealing fixture.
Operation :-Battery has to be pushed to other machine manually. Battery has to be placed from Front & pulled to get battery out from machine. Hot Plate has two different temperatures to melt cover & container respectively. Fixture is required to hold top cover for melting & sealing. This machine is having heavy structure to suit faster production and longer life.
Once Battery is cut and now only Plates with separator are there in Plastic container. There may be acid in the Battery Container still. Battery will drop in upside position, manually assisted. Container can be picked up and placed at a side or drop in Plastic Crusher. Battery Plates and Separator can be dropped in Plate Crushing Machine. Acid will drop in tank. Acid Proof Tank is in-built in the attachment. Lead Oxide Dust and small grid parts will precipitate. Acid can be pumped out, if connected to another tank. Lead Sludge can be charged in furnace.
Jumbo Ingot Moulds are collection trolleys used for collecting molten lead from Rotary Furnaces. They can be of varyingcapacities, ranging from 300 Kg. to 800 Kg. The most prevalent of the same is 500 Kg. Ingot Mould. Due to higher weight of thecast, it is called a These moulds have trolley type structure with two unidirectional wheels at the back and one free spin wheel at the front. It isprovided with a handle to pull it. They are moved manually or on rails electro-mechanically, varying from unit to unit. They aresmoothened on the inside and do not have any sharp folds or edges. They are usually constructed in SG cast iron for longer life and increased strength.
Tapping of Rotary Furnace also lead to generation of Fugitive Emissions which need to be captured at source and treated to maintain ambient air standards at workplace. Air Pollution Control Device for Rotary Furnace
Operation :-Fingers has to put manually across connection so it is able to apply Force on one connection against other this force can be varied depending on connection size or size of battery, if that connection is hollow it will break. The time to apply force is determined by Digital Timer so force as well time to apply force is precisely preset hence result become accurate.
Application :-This machine checks pin hole, separator missing and splash of lead in cells, etc. It also checks that all the cells are connected to each other with the help of high voltage. If there is any fault then it gives visual indication as well as audio alarm.
Operation :-Operator has to place the Battery underneath the machine and press the button on its Probe, which initiates machine that does its job for One cell in one go.
Cut Strap & Plastic Container strip held together will separated by this machine. This machine is pneumatically operated and initiated by Pedal Valve. Cut Container Strip with Intercell connections is placed on machine, Partition will be placed on centerline and fork arm will be across it. It is operated by pressing foot on valve. One fork will press against another and connection will break. This can be seen in the video. Now, Cut Container Strip will be with-out Lead parts.
Application :-This will check strength of welded connections torsion strength by applying mechanical force across connections.
Operation :-Fingers has to put manually across connection so it is able to apply Force on one connection against other this force can be varied depending on connection size or size of battery, if that connection is hollow it will break. The time to apply force is determined by Digital Timer so force as well time to apply force is precisely preset hence result become accurate.
A Wet Scrubber in the Air Pollution Control System is mandatory in India and many parts of the world. Wet Scrubber uses water to scrub clean the flue gases of any pollutant gases or particles that may remain after Bag Filtration System. The Scrubber therefore requires a pump, pipeline and a retention tank.The size of the Scrubber depends upon the capacity of the system being installed. Flue gases are introduced in the body of theScrubber from side and as they move up towards the top of the Scrubber which has the outlet,
they pass through a spray of fine water droplets provided by a spray shower provided in the body. This fine spray leads to scrubbing of any pollutant in the flue gases. Cleaned gases escape through the top opening after passing through a mist eliminator whereas water with pollutants moves to the bottom of the Scrubber from where it is passed into the tank. One or more chambers of the tank allow for settling of pollutants which are then periodically cleaned and fresh water is added to make up any loss in quantity of water.It is then recalculated to the Scrubber.
Smelting of lead in furnaces involve stages or parts where though pollution is generated, it is not handled by the main AirPollution Control System, like charging of Rotary Furnace when it is red hot or tapping of lead from Rotary Furnace which leadto generation of fumes.
Systems put in place to capture and treat these fugitive emissions as and when they arise are called Fugitive Emission ControlSystem. Fugitive Emissions generally lead to pollution of work atmosphere and jeopardize the maintenance of ambient airstandards at the workplace. Hence, to safeguard employee health, these systems are becoming mandatory world over.
Norms of Ambient Air which the Fugitive Emissions Control System helps to meet are Parameter Approved Range Time Period
Cyclone is used to remove medium size particles from flue gases stream. The treated flue gases are discharged from topand dust is collected at bottom.
Ducts and Bends are required to convey flue gases from point of suction to final top of the chimney and connect with various pollution control equipment like gravity chamber, cyclone, bag house, ID Fan and chimney.
Once Lid is cut from battery, there is Lead casted Pole/Post molded in Lid. This Pole can be extracted from Lid. Pole Extraction Machine will be used for this purpose.
This machine is fitted with interchangeable die. This die can changed by pick & place technique. This machine is pneumatically operated and initiated by Pedal Valve. Cut Lid is placed on die and machine is operated by pressing foot on valve. Top punch presses Pole out of Lid. This can be seen in the video. Now, Lid will be with-out Lead parts. Of course, Lead parts will be having bit of Plastic in which it is molded. This Plastic can be ignored.
Sector 62, Noida, Uttar Pradesh 