Lead Recycling

Smelting of Battery Scrap and Extraction of 99.98% Refined Lead Ingots & Various Lead Alloys. First of its kind in the entire ‘Sultanate of Oman’.

OUTLINE SCOPE OF EXECUTIVE SUMMARY:

• Collection Units: Collection and transportation of solid hazardous waste from generating units(Government Entities / Oilfield Companies / Telecom & Automobile Companies / Private Companies / Local Vendors etc.
• Carrying out Segregation, Recycling / Recovery, Treatment, Storage, and Disposal of hazardous waste residues.
• On Site Monitoring including emergency preparedness.
• Reporting to regulatory authorities as needed.
• Undertaking closure and post-closure measures on exhaustion of the site capacity.
• Compliance with existing regulations and amendments made from time to time.

LEAD INGOTS MANUFACTURING PROCESS:

• Pre-treatment: The first step involves collecting and sorting used lead-acid batteries, which are typically sourced from automotive, industrial, and stationary applications. The batteries are sorted based on their type, size, and condition. Damaged batteries with potential acid leakage are neutralized using sodium bicarbonate or other suitable chemicals before proceeding to the next stage.

• Breaking and Separation: Batteries are fed into a mechanical crusher or hammer mill, which breaks them into smaller pieces. This process helps in the separation of the different components, such as lead grids, lead oxide paste, separators, and electrolytes (sulfuric acid solution). A series of vibrating screens, hydro-separators, and sink-float tanks are used to separate these components based on their specific gravities. The lead grids and lead oxide paste, which is heavier, settle at the bottom, while lighter materials such as separators and plastic casing float to the top. The electrolyte is drained and treated separately for neutralization and water recovery, a process that is even more enhanced in our latest Battery Breaker launch called Gravity Breaker which leverages massively on the usage of natural forces such as Gravity and/or Inertial Mass.

• Smelting: The lead-bearing materials, including the lead grids and lead oxide paste, are transferred to a smelting furnace. The furnace can be a rotary kiln, short rotary furnace, or blast furnace, depending on the plant’s capacity. Our process lies on fixed rotary furnace technology engineered by our R&D and improved over the years on the field to reduce at minimum the NG consumption/cycle while improving the time to smelt.

• Refining: The lead bullion obtained from the smelting process usually contains impurities such as copper, tin, antimony, arsenic, and other trace elements. To obtain pure lead, the bullion undergoes refining using one or a combination of the following methods:
• Pyrometallurgical Refining : This method involves the controlled oxidation of impurities in a refining kettle or furnace. By adjusting the temperature and introducing air, the impurities are oxidized and form a slag, which is skimmed off the surface of the molten lead. Based on this technology, in GME we’ve been developing a vertical kettle leveraging on Gravity force to reduce at ZERO the oxidation production during pouring step.

• Ingot Production: The fifth step of the lead ingot process involves casting the refined lead into ingots. This stage is crucial for preparing lead in a form suitable for storage, transportation, and further processing or sale.

Infrastructure:

• Land Area: 20000Sqmts.
• Covered Area: 60% of the Total Land Area.
• Plant Facilities: Fixed infrastructure like Covered Factory Sheds, Storage Sheds, Offices, Recreation & Other Facilities.

• Production Capacity:

Al Thail Metal Recycling LLC(ATMER) has the following production capacity @

• 18000 TPA used lead acid batteries breaking & separation.
• 10000 TPA smelting to produce lead bullion.
• 15000 TPA refining to produce Pure Lead & Lead Alloyed

Equipment & Machinery:

• Section 1 :
• Battery Breaking & Segregation Unit Capacity (500-Kg/Hr) SS – 304, Waste Water Treatment & Recycling System & Air Control Pollution System (01 Unit).
• Battery Cutting Machines, 8.0TpH(SS-304,2Units)
• Acid Neutralization cum Batch ETP Plant 5.0KL/Batch(1Unit)

• Section 2 :
• Rotary Furnace 6.0 TpB (Dual Fired) (02 Nos.)

(a.1) Jumbo Ingot Moulds and Track & Trolley 6.0TpB (15Molds + 1Set x 2Nos.)

• Primary APC System (02 Sets)

Flue Gas Chamber, Air Pollution Control System, Electrical Control Panel, Compressor, Wet Scrubber Capacity (20,000cmh)

• Secondary APC System (02Sets)

Rotary Covering Chamber, Air Pollution Control System, Electrical Control Panel, Compressor, Capacity 24,000cmh.

• Common Stack for Primary & Secondary APC System (02 Sets)

• Section 3 :
• Refining Pot 50.0 Ton. Dual Fired (2 Nos.)
  Refining Pot 20.0 Ton. Dual Fired ( I No.)
  Common Platform for Pot ( 1 No.)
• Ingot Casting Machine Capacity.15.0 Tpl I ( I Set )
  Lead Metal Transfer Pump. 15.0 TpFI (2 Nos.)
  Ingot Stacking Machine. 15.0 Tpl 1 ( I No.)
• Fugitive Emission Control System, capacity 60000cmh(01Set)
  Electrical Control Panel, Air Compressor.

• Section  4 :
  Assembly, Installation & Commissioning – 1 Set

Operations Support Systems:

ATMER has numerous systems setups where the urgency of a problem is addressed and arrival of accepted potential solution i.e.., It’s not only important to evaluate whether a system can work but also evaluate whether the system will work Viz.,

• Performance – To ensure the mode of operation is executing adequate number of units that can be produced by a production process within a certain period of response time.
• Information – To ensure the mode of operation is providing end users with timely, accurate and useful information.
• Economy – To ensure the mode of operation is providing cost-effective information services to the business ie., possibility in reduction costs and increase in benefits.
• Control – To ensure the mode of operation is offering effective controls to protect against fraud and to guarantee accuracy and security of data and information.
• Efficiency – To ensure the mode of operation is making maximum use of available resources, including people & time
• Services – To ensure the mode of operation is providing reliable service which is both flexible and expandable.

National Advantages / Salient Benefits:

• FDI by expat stake holders to boost local economy.
• Generation of Employment.                                       
• Production of Omani National Product.
• Escalating Domestic Market Growth with the supply of end product catering to the demand of other manufacturing units in the Sultanate of Oman.
• Major contribution of Foreign Exchange Reserves with ‘International Exports’.

The Used Lead Acid battery Recycling Plant (ccollection, transportation, reception, treatment, storage, re-use, recycle, blending and disposal of industrial hazardous battery scrap waste) is very unique and in fact will be a giant step in the drive towards environment protection in ‘Sultanate of Oman’.