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Apart from plates and paste of lead oxide from scrap batteries, slag from Mini Blast Furnace is charged in the Rotary Furnace.

In addition to these, certain compounds of sulphur are also present in the batteries. When this material is heated in thePresence of carbon, lead oxide is converted to lead. This conversion along with burning of fuel generates flue gases and fumescontaining dust, dirt, oxides of lead, lead particles and such other impurities etc.

Hence, to meet various goals of maintaining employees' health and factory environments as well as regulatory requirements,it becomes imperative to get high end Air Pollution Control Systems to be installed with the Rotary Furnaces.

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.

Recovers 100% lead in the first operation.
Slag produced is lead free.
Equipment can be scaled up for higher production capacities.
Many chemicals are required for operation.
High power consumption.

Difficult to produce low Antimony lead suitable for soft lead purposes.
Fugitive Emissions need to be captured in addition to flue gases.
Need skilled operators and careful maintenance.

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

PM (size < 2.5 micron) < 40 microgm/ Nm3 Annual Basis
PM (size < 10 micron) < 60 microgm/ Nm3 Annual Basis
Lead < 0.5 microgm/ Nm3 Annual Basis
SO2 < 50 microgm/ Nm3 Annual Basis
NO2 < 40 microgm/ Nm3 Annual Basis

Allows large size particles to settle down
Cools down temperature of flue gases
Used as spark arrestor to entrap live or red hot particles.

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.

It is used for final filtration of flue gases to remove fine dust particulate matter using Pulse Jet Technology. Treated gases fromall the bags are collected at top of bag house and passed through ID Fan to exhaust the same through chimney. The dust iscollected at bottom of hopper and is discharged.

All bends and reducers are aerodynamicallydesigned and have provision of manhole cleaning mechanism.

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.

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.

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.

[Note: Due to continuous up-gradation in technology, specified & projected values may differ in actual products.]

AIR POLLUTION CONTROL SYSTEMS, GAS NEUTRALISING SYSTEM & GAS STACKING UNIT REFINING POTS/KETTLE