DEMAND SUPPLY FOR LEAD LEAD ACID BATTERIES AND

DEMAND & SUPPLY FOR LEAD & LEAD ACID BATTERIES, AND PROSPECTS FOR LEAD RECYCLING INDUSTRY BY: V. K. AGGARWAL SUPREME BATTERIES [P] LTD HYDERABAD AT CONFERENCE PROGRAMME IBRX INDIA 2015 MARCH 3 -5, MARRIOTT HOTEL, GOA SUPREME BATTERIES PVT LTD, HYD. 1

INTRODUCTION IN THE PART I OF THIS PRESENTATION : THE DEMAND SUPPLY OF LEAD ACID BATTERIES FOR THE YEAR 2014 AN ESTIMATE OF THE LIKELY DEMAND & SUPPLY FOR THE SAME BY 2020. THE DEMAND SUPPLY OF LEAD FOR THE YEAR 2014. AN ESTIMATE OF THE LIKELY DEMAND & SUPPLY FOR THE SAME BY 2020 THE PRESENTATION ALSO HIGHIGHTS INDIA’S POSITION IN GLOBAL OUT LOOK FOR LEAD ACID BATTERIES AND LEAD. IN THE PART II OF THIS PRESENTATION: THE PRESENT SCENARIO OF INDIAN LEAD RECYCLING INDUSTRY. SUITABILITY OF VARIOUS LEAD SMELTING TECHNOLOGIES FOR SECONDARY LEAD SMELTING. CHALLENGES DUE TO CHANGE IN THE RAW MATERIAL AND REQUIRED FINISHED GOODS.

PART- I

SHARE OF LEAD ACID BATTERIES OUT OF THE TOTAL LEAD CONSUMED YEAR 1960 YEAR 2014 60% 85% 40% 15% YEAR 2025 90% 10% BLUE COLOUR REPRESENTS LEAD USED FOR BATTERIES. MAROON COLOUR REPRESENTS OTHER USES OF LEAD. 4

DEMAND & SUPPLY FOR LEAD ACID BATTERIES 2014 SUPREME BATTERIES PVT LTD, HYD. 5

TOTAL MARKET FOR LEAD ACID BATTERIES IN INDIA (year 2014) APPROXIMATELY Rs. 25, 000 TO 27, 000 Crores [USD 4 BILLION] BATTERY TYPE MARKET SHARE REPLACEMENT/OE RATIO AUTOMOTIVE 55 to 60% 80/20 INVERTER & UPS 15 to 20% 70/30 TRACTION & TELECOM 15 to 20% 70/30 SOLAR, E-VEHICLES, WIND POWER & BIO GAS 4 to 5% 20/80 EXPORTS * 3 to 4 % * Actual Export year 2012 -13 ------* Actual Exports Apr-2013 to Sep-2013 ------- Rs. 686 Crores Rs. 297 Crores SUPREME BATTERIES PVT LTD, HYD. 6

SUPPLY SIDE OF LEAD ACID BATTERIES (year 2014) APPROXIMATELY Rs. 25, 000 to 27, 000 Crores [USD 4 BILLION] SECTOR NUMBER MARKET SHARE % LARGE SCALE UNITS 3 to 4 45 MEDIUM SCALE UNITS 20 to 25 25 SMALL SCALE UNITS & OTHER SMALL BATTERY MANUFACTURERS > 2000 25 ROAD SIDE ASSEMBLES ? ? IMPORTS* 2 to 4 * Actual Import year 2012 -13 ------* Actual Imports Apr-2013 to Sep-2013 ------- Rs. 382 Crores Rs. 321 Crores SUPREME BATTERIES PVT LTD, HYD. 7

ESTIMATE OF DEMAND SUPPLY FOR LEAD ACID BATTERIES BY THE YEAR 2020 WE HAVE MADE A MODEST EFFORT IN FORECASTING THE DEMAND FOR LEAD ACID BATTERIES BY 2020. (AS THE ECONOMY IS AGAIN PICKING UP, THE PROJECTIONS ARE MADE ACCORDINGLY. ) PROJECTIONS FOR GROWTH: - • BATTERIES FOR AUTOMOBILES • BATTERIES FOR UPS (IT SECTOR) • BATTERIES FOR INVERTERS (HOME SECTOR) • BATTERIES FOR TELECOM • OTHER INDUSTRIAL BATTERIES I. RAILWAY TRACTION AND SIGNALING II. FORKLIFTS III. ETC. @ 10 TO 15% @ 00 TO 05% @ 05 TO 10% • • @ 20 TO 25% @ 30 TO 35% BATTERIES FOR SOLAR E- VEHICLES SUPREME BATTERIES PVT LTD, HYD. 8

FORECAST FOR 2020 FOR LEAD ACID BATTERIES FOR INDIA THE TOTAL ESTIMATED MARKET FOR LEAD ACID BATTERIES FOR INDIA WILL BE BETWEEN USD 8 BILLION TO USD 9 BILLION (RS. 50, 000 TO 55, 000 CRORES) BY 2020. (AT TODAY’S PRICE) COUNTRY INDIA 2010 2014 2020 USD 3. 2 BILLION USD 4 BILLION USD 8 TO 9 BILLION (RS. 50, 000 TO 55, 000 CRORES @ TODAY’S PRICE) SECTORWISE CHANGES AUTOMOBILE INDUSTRIAL OTHERS [NEW THRUST AREAS] 2014 60 % 35 % 5% 2020 50 % 30 % 20 % SUPREME BATTERIES PVT LTD, HYD 9

SUPPLY SIDE OF THE LEAD ACID BATTERIES IN INDIA BY 2020. 1. MOST OF THE MANUFACTURERS, HAVE PLANNED MAJOR EXPANSION IN THEIR CAPACITIES. 2. MANY NEW PLAYERS ARE ALREADY IN THE PROCESS OF PUTTING UP PLANTS EITHER IN JOINT VENTURE, COLLABRATION OR EVEN NEW GREEN FIELD PROJECTS. THE NEW VENTURES ARE: a) PANASONIC JAPAN b) AMARAJA BATTERIES c) LUMINIOUS d) BASE COROPORATION 3. SMALL SCALE UNITS AND OTHER SMALL MANUFACTURERS WILL CONTINUE TO EXIST BUT WITH A REDUCED SHARE OF THE MARKET. 4. SOME IMPORT MAY CONTINUE. BUT MOST OF THE DEMAND WILL BE MET BY DOMESTIC PRODUCTION. SUPREME BATTERIES PVT LTD, HYD 10

DEMAND & SUPPLY FOR LEAD 2014 SUPREME BATTERIES PVT LTD, HYD 11

SECTORWISE DEMAND OF LEAD IN INDIA BASED ON THE FACT THAT THE ESTIMATED VALUE OF THE LEAD ACID BATTERIES PRODUCED IN INDIA IS 4 BILLION DOLLARS, ESTIMATED DEMAND FOR LEAD ACID BATTERIES, IS 1. 1 MILLION TONS PER YEAR. [11 LAC TONS] ( year 2014 ) SECTOR LAC TONES SHARE BATTERIES 11. 00 85 % ALLOYS & CHEMICALS 01. 70 13 % CABLE SHEATING 00. 30 02% TOTAL 13. 00 100 % EXPORTS * 01. 50 TOTAL 14. 50 HENCE TOTAL DEMAND FOR LEAD 1. 45 MILLION TONES OR 14. 5 LAC TONES. * EXPORT FOR THE YEAR 2012 -13 * EXPORT FOR THE YEAR 2013 -14 - 01. 599 LAC MT TONES 00. 322 LAC MT TONES [UPTO SEP 2013] SUPREME BATTERIES PVT LTD, HYD 12

THE DEMAND FOR THIS LEAD IS BEING MET AS FOLLOWS YEAR 2014 FROM LAC TONES QUALITY HINDUSTAN ZINC LTD 1. 30 PRIMARY LEAD IMPORTS 3. 00 TO 3. 50 MIXED LEAD LOCAL LEAD PRODUCTION 9. 50 TO 10. 00 RECLAIMED TOTAL 14. 5 SUPREME BATTERIES PVT LTD, HYD 13

IMPORTS (in , 000 MT’S) * S no item 2009 -10 2010 -11 2011 -12 2012 -13 1 Unwrought lead 215. 06 246. 11 214. 10 222. 00 2 Lead waste and scrap 037. 64 057. 33 068. 63 051. 90 3 Lead plate , etc 004. 82 002. 89 002. 53 004. 00 4 Lead oxides 000. 94 001. 66 000. 95 001. 90 TOTAL 258. 46 307. 99 000. 35 001. 22 - 001. 22 286. 21 005. 58 003. 47 279. 80 002. 60 008. 60 026. 23 039. 66 021. 37 077. 40 5 Battery plate scrap 6 Drained batteries 7 Lead conc. etc 1. In future imports of finished products like pure lead and alloys of lead should go down. 2. Import of item no 5, 6, 7 should go up substantially. 3. * data obtained from import / export data bank of Govt. of India converted to Quantity from Value by suitable rate. SUPREME BATTERIES PVT LTD, HYD 14

EXPORTS [in , 000 MT’S] * S no item 1 Unwrought lead 060. 94 054. 11 092. 53 060. 90 2 Lead plates etc 002. 24 001. 78 001. 79 001. 60 3 Articles of lead 001. 06 001. 33 001. 05 000. 80 4 Oxides of lead 001. 76 000. 78 004. 20 004. 40 066. 00 058. 00 099. 57 066. 80 TOTAL 5 1. 2. 3. 4. 2009 -10 2010 -11 2011 -12 2012 -13 Lead conc. 028. 59 043. 22 014. 63 Exports from India are mostly of pure lead or alloys of lead Exports from India are expected to go up due to a) value addition possible above the imported scrap, drained scrap batteries , lead conc. etc. b) due to cyclical nature of demand for lead in India There may also be exports of other products of lead. * data obtained from import / export data bank of Govt. of India converted to Quantity from Value by suitable rate. SUPREME BATTERIES PVT LTD, HYD 15

NET INPUT OF LEAD FOR RECYCLING FOR THE PAST 4 YEARS [IN , 000 MT’s] 2009 -10 IMPORT - FINISHED & SEMIFINISHED PRODUCTS 258. 46 2010 -11 307. 99 IMPORT – RAWMATERIAL 2011 -12 2012 -13 TOTAL 286. 21 279. 80 30. 00 88. 00 124. 82 HINDUSTAN ZINC 71. 62 63. 19 98. 72 TOTAL 330. 08 371. 18 414. 93 492. 62 1608. 81 TOTAL EXPORTS 066. 00 058. 00 099. 57 066. 80 0290. 37 NET INPUT 1318. 44 LESS LEAD CONSUMED IN NON RECOVERABLE PRODUCTS [APPROX] 0300. 00 BALANCE 1018. 44 SUPREME BATTERIES PVT LTD, HYD 16

ESTIMATED DEMAND OF LEAD 97 -98, 13 -14 & 20 -21 3000 2000 for exports 1000 Column 1 for batteries 0 1997 -98 2013 -14 2020 -21 [in , 000 MT’s] NIL 150 400 FOR EXPORTS 040 200 300 FOR OTHER USES 1100 1800 FOR BATTERIES 150 1450 2500 TOTAL We have estimated the demand supply for lead for the year 2013 -2014 and projected for the year 2020 -2021. this is an ongoing exercise at our end , for both lead as well as lead acid batteries , and have been presented at various seminars. Here we are presenting only the final estimates and projections , that also for lead only. Your suggestions are always welcome since these are estimates only. SUPREME BATTERIES PVT LTD, HYD 17

ESTIMATED SUPPLY OF LEAD 97 -98, 13 -14 & 20 -21 2500 2000 1500 1000 500 0 imported reclaimed hzl 1997 -98 2013 -14 2020 -21 1997 -98 2012 -13 2020 -21 [in , 000 MT’s] 035 320 850 FROM IMPORTS** 1000 1400 FROM RECLAIMED 015 130* 250 FROM HZL (*124. 84 actual) 150 1450 2500 TOTAL ** Imports do include raw material and semi finished products. As per the ministry of mines ( ninth 5 year plan working group report of 1998) the projected figures for demand for lead for the lead acid batteries was: year 2006 -07 -1. 35 lac MT, year 2011 -12 – 1. 89 lac MT SUPREME BATTERIES PVT LTD, HYD 18

“ 353” LEAD RECYCLERS REGISTERED WITH MOEF/CPCB AS ON 2010 Allowed Quantity (MTA) No. of Units 40, 000 - 65, 000 3 20, 000 - 40, 000 5 10, 000 - 20, 000 17 5, 000 – 10, 000 49 <5, 000 279 *Source: MOEF/CPCB SUPREME BATTERIES PVT LTD, HYD 19

SMELTING & REFINING CAPACITY OF LEAD – INDIA 1. INDIA HAS SUFFICIENT CAPACITY OF LEAD SMELTING AND REFINING AS INDICATED IN THE LAST SLIDE. THERE WERE 353 UNITS IN 2010 REGISTERED WITH MOEF. HAVING AN INSTALLED CAPACITY OF AROUND 10 LAC TONES. HOWEVER THE PRESENT INSTALLED CAPACITY IS MUCH HIGHER AROUND 20 LAC TONES. 2. THESE UNITS WILL HAVE TO HEAVILY DEPEND ON IMPORT OF BATTERY SCRAP TO MEET THERE DEMAND FOR SCRAP OR ELSE THEY WILL HAVE TO MODIFY THEIR PLANTS TO PROCESS LEAD CONCENTRATES AND AS WELL AS LEAD BATTERY SCRAP TO MEET THE GROWING DEMAND OF 2. 4 MILLION TONS BY 2020. SUPREME BATTERIES PVT LTD, HYD 20

THE GLOBAL MARKET FOR LEAD ACID BATTERIES AND LEAD SUPREME BATTERIES PVT LTD, HYD 21

LEAD ACID BATTERIES 2013(US $) TOTAL MARKET 38 -40 BILLION CHINA 18 -19 BILLION INDIA 4 BILLION REFINED LEAD 2013 TOTAL LEAD(LAKH 2013 METRIC TONNES) LEAD FROM CONCENTRATES TOATAL MARKET 112. 24 53. 86 CHINA 51. 00 31. 58 INDIA 14. 50 01. 30 SUPREME BATTERIES PVT LTD, HYD 22

TOTAL LEAD= RECYCLED LEAD + VIRGIN LEAD • IN FUTURE MORE AND MORE QUANTITIES OF RECYCLED LEAD WILL BE AVAILABLE AS THE USE GOES UP AND DUE TO THE FACT THAT ALMOST 99% OF THE LEAD FROM SCRAP BATTERIES IS RECOVERABLE. • HOWEVER VIRGIN LEAD IS BY PRODUCT OF ORE GELENA MAIN PRODUCTS BEING ZINC, SILVER, AND SMALL QUANTITIES OF GOLD ETC. HENCE, IRRESPEVTIVE OF THE ECONOMICS OF THE DEMAND SUPPLY OF RECYCLED LEAD CONSIDERABLE QUANTITY OF VIRGIN LEAD WILL CONTINUE TO COME TO THE MARKET. • IT IS DIFFICULT TO FORECAST THE OVERALL PRICE FLUCTUATIONS DUE TO THE MISMATCH IN THE DEMAND SUPPLY.

TO SUM UP 1. LEAD ACID BATTERY MARKET IN INDIA WILL GO UP @ AROUND 10 TO 12 % BETWEEN 2014 - 2020. SHARE OF THE NEW EMERGING USES OF BATTERIES LIKE FOR SOLAR, E-BYCYCLES, E-BIKES, E- THREE WHEELERS WILL BE SUBSTANTIAL. IT IS LIKELY THAT INCREASED DEMAND FOR THE BATTERIES WILL BE MET BY THE DOMESTIC PRODUCTION. 2. IN LINE WITH LEAD ACID BATTERY, THE DEMAND FOR LEAD WILL ALSO GO UP AT THE RATE 10 – 12%. THERE WILL BE ENOUGH INSTALLED CAPACITY TO MEET THIS DEMAND INDIGINOUSLY HOWEVER SHORTAGE OF SCRAP MAY REQUIRE IMPORT OF SCRAP OR LEAD CONCENTRATES. SUPREME BATTERIES PVT LTD, HYD 24

PART- II

Part-II lead recycle in India[present scenario] • India, being an emerging economy, is already producing and recycling more than 10 Lakh (1 million )MT of lead from scrap batteries. • India is a second largest recycler after China. • As already pointed out, with the new sectors like solar energy, wind energy and e-bikes requiring lead acid batteries in large quantities, demand for lead is going to go up substantially. • India does not have large stocks of lead ore or concentrates and it has to depend largely on locally recycled lead and imports. • More than six hundred registered recyclers having capacities varying from few hundred tonnes to almost one lac tonnes. SUPREME BATTERIES [P] LTD. , HYD, INDIA 26

Part-II lead recycle in India [present scenario] cont. . . • Additionally there are unknown number of unregistered back yard smelters. • Industry is highly scattered through out the length and the breath of the country. Similar is the case with the user industry i. e. lead acid batteries. • The raw material i. e. the scrap batteries are also available distributed all over the country. • Local taxation laws, transport cost , subsidies given in couple of states, play a major roll in deciding the location, capacity and technology. • Even if there is a plan to put up a large size unit, there is no guarantee of availability of scrap, import or otherwise. SUPREME BATTERIES [P] LTD. , HYD, INDIA 27

Part – II lead recycle in India [present scenario]. cont. . . • The industry is highly susceptible to local self government i. e. local politicians, NGOS, police, media etc. • Government rules and regulations continue to change frequently. • New pollution norms: As per the rules: - All the stake holders, like manufacturer, importer, reconditioner, assembler, dealer, recycler, auctioneer, consumer (individual & bulk) to register and to file returns to respective pollution control boards as defined in the battery management & handling rules 2001. SUPREME BATTERIES [P] LTD. , HYD, INDIA 28

lead smelting technologies a comparison introduction • For the last 10 -15 years, many new processes for primary as well as secondary lead smelting are challenging the age old systems & processes of lead smelting like – sinter / blast furnace, reverberatory furnace and to some extent rotary furnace. • The intensification of the metallurgical reaction by applying oxygen enriched fuel or pure oxygen to bath or to flash smelting principles resulted in cost savings and a higher flexibility with respect to raw materials and additives usage. • This has resulted in producing a virtually waste free product and lowemission mode of operation with nearly optimum energy use, meeting stringent govt. regulations. SUPREME BATTERIES [P] LTD. , HYD, INDIA 29

Introduction -Continued India, which is predominantly dependent on recycled lead, has remained immune to these developments. It continues to use age old methods of smelting by mini blast furnace and rotary furnace. Hindustan zinc limited, which is the only producer of primary lead in the country, has successfully installed one of these new processes called AUSMELT. SUPREME BATTERIES [P] LTD. , HYD, INDIA 30

Various Lead Smelting Technologies contd… In this part, we will discuss the following: 1. The sulphur cycle 2. Removal of sulphur a) Draining of the batteries b) Before smelting c) During smelting 3. Old and new technologies 4. A comparison of Ausmelt and Mini blast furnaces, the so called mandir bhatti SUPREME BATTERIES [P] LTD. , HYD, INDIA 31

various lead smelting technologies • There is a saying : Sulphur is the smelter’s great friend. Without sulphur no one would need the smelter, because anyone could melt down the battery. • To which it was replied, “with friends like sulfur, who needs enemies? ” SUPREME BATTERIES [P] LTD. , HYD, INDIA 32

various lead smelting technologies the sulphur cycle From sulphated plates, free acid in plates, separators and the container From copper dross while refining lead From fuel and additives Hard rubber containers etc. Process of Recycling of Scrap Batteries Before smelting operations By removing free acid During smelting operations By soda-iron systems By de-sulphurizing the paste (na 2 so 4) By so 2 removal from the stack (na 2 so 4) SUPREME BATTERIES [P] LTD. , HYD, INDIA 33

various Lead Smelting Technologies Draining of the Batteries • It is essential that the scrap batteries are drained at the recycling facility or at the dump yard, having facility for acid storage and neutralization. • Sometimes it is forgotten, when buying old scrap discarded batteries that there is a considerable difference between fresh scrap batteries which have been drained and those old scrap batteries which have not been drained and are more sulphated. • Old un-drained sulphated scrap batteries will give lower yield then the fresh scrap batteries which are drained. • We should drain the batteries as soon as possible • VRLA batteries with AGM separators, contain acid in the absorbed form and cannot be drained. The acid conc. is also high. Therefore, these batteries should be the first priority for breaking. SUPREME BATTERIES [P] LTD. , HYD, INDIA 34

Part-II Various Lead Smelting Technologies Desulphurization of the paste • Desulphurization is the conversion of lead sulphate to lead carbonate using soda ash. • As there is always sulphuric acid present in the paste after the batteries have been broken in the Battery Breaker, even if the paste is dewatered, excess of soda is required in solution to take care of the extra sulphuric acid present. • An alternative to the use of soda ash would be to use 50% sodium hydroxide (Na. OH) solution. • The desulphurized paste is normally filtered in a press and stored prior to drying and charging to the furnace. SUPREME BATTERIES [P] LTD. , HYD, INDIA 35

various lead smelting technologies Removal of sulphur during smelting operations • If sulphur is not removed in a pre-treatment process described above, then the most appropriate technology for the removal of sulfur dioxide depends on the degree of fixation of the sulfur in the slag and the subsequent formation and the concentration of SO 2 produced. • For very low strength SO 2 off-gases, such as, those produced in a secondary rotary furnace, a wet scrubber is required. One can also go for a venturi scrubber. • Some of the sulphur present in the raw material can be fixed into the slag by the addition of iron, soda ash. • However it is unlikely that sufficient sulfur will be fixed in the slag to meet SO 2 discharge limits. Hence there is a need for a “scrubber”. SUPREME BATTERIES [P] LTD. , HYD, INDIA 36

various lead smelting technologies • Old processes are : - 1. Blast furnace 2. Reverbaratory furnace 3. Rotary furnace 4. Mini furnace or mandir bhatti • New Processes are 1. Kivcet process 2. QSL process 3. Kaldo technology 4. Ausmelt process or isasmelt process [siro smelt] 5. SKS bottom blown technology (especially in China) SUPREME BATTERIES [P] LTD. , HYD, INDIA 37

Part-II Contd… The new processes: • The new processes are based on the principle of flash smelting by oxygen enriched fuel to the bath or direct flash smelting. • These methods do not require any pre -treatment like sintering/ roasting of the raw materials. • Considerable amount of smelting is possible in the first cycle it self. • Pollution issues are minimum. • It is possible to process various types of raw material , although they were initially designed for primary smelting. • A number of such furnaces are in operation. • Present operations are comparatively very large. • It is not clear , whether, all of them can be suitable for smaller operations. • Theoretically , it should be possible to process any material including scrap lead acid batteries in these furnaces. SUPREME BATTERIES [P] LTD. , HYD, INDIA 38

PART-II CONTD. . Other processes: There are some hydrometallurgical and bio-leaching methods under investigations for quite some time. Some of them have reached the trial stage and may be commercially viable. Bio-methods include use of bacteria / elgi in converting lead sulfides and lead sulphates to lead. Subsequent to hydrometallurgy where lead and oxides/ sulphates are separated, there are efforts to directly convert oxides/ sulphates to oxides of lead like red lead or letharge. SUPREME BATTERIES [P] LTD. , HYD, INDIA 39

BLAST FURNACE SUPREME BATTERIES [P] LTD. , HYD, INDIA 40

REVERBARATORY FURNACE SUPREME BATTERIES [P] LTD. , HYD, INDIA 41

ROTARY FURNACE SUPREME BATTERIES [P] LTD. , HYD, INDIA 42

MINI BLAST FURNACE LINE DIAGRAM SUPREME BATTERIES [P] LTD. , HYD, INDIA 43

KIVCET FURNACE 1. It is a continues flash smeltin process developed by Vniitsvetmet in Russia. 2. It can treat a vide variety of lead building raw material. 3. The raw material should be dry to less than 1% moisture content and must also be grinded to less than 1 mm size. SUPREME BATTERIES [P] LTD. , HYD, INDIA 44

QSL FURNACE 1. It is a continues bath smelting process developed by 2 Americans professor Queneau and Prof. Schuhmann. And was patent by German Company Lurgi AG. 2. It is slitely inclined 0. 5% closed, klin-like furnace and can be tilted by 90 degree. 3. It can smelt secondary material also along with the primary. SUPREME BATTERIES [P] LTD. , HYD, INDIA 45

KALDO PROCESS 1. Boiliden Metal AB developed the Kaldo Process and the operation in Ronnskar /Sweden. 2. The process based on flash smelting principal operates on batch wise basis and consist of top blowing rotary converter. 3. The furnace is very flexible and can treat a vide range of secondary materials including battery scrap residues etc. 4. The feed has to be totally dry with less than 1% moisture. SUPREME BATTERIES [P] LTD. , HYD, INDIA 46

ISA SMELT FURNACE SUPREME BATTERIES [P] LTD. , HYD, INDIA 47

Conclusions From The New Technologies • Environmental pressure have strongly influenced many of the most significant and recent developments in the lead industry, either directly or indirectly. • It is inevitable that environmental concerns will remain at the top of the agenda. • With the majority of lead used in batteries close to 85% of all lead bearing products are recyclable. One direct consequence is the steadily increasing recycling rate of lead bearing scrap. It is probable that most, if not all, growth in lead demand can be met without increasing mine production SUPREME BATTERIES [P] LTD. , HYD, INDIA 48

Conclusions From The New Technologies • This requires that the lead smelters must accommodate more and more secondary material in their feed material. • The traditional sinter machine / blast furnace operation is not only challenged by direct smelting processes but after over coming initial problems these new technologies are now more than major competitors. • It seems that Kivcet & QSL processes are well established and mature technologies introduces new era of a lead smelting. They are economically and particularly environmentally viable technologies and offer several advantages. But are more suitable for primary smelting of course with addition of some lead scrap from secondary sources. • Jksldfkjsld SUPREME BATTERIES [P] LTD. , HYD, INDIA 49

Conclusions from The New Technologies • The Ausmelt or the similar Isamelt technology as well as Kaldo furnace offer additional and alternatives for economical lead smelting complying with the increasingly stringent environmental regulations. • The most important aspects of the above two mentioned processes are that they are suitable for secondary lead production and can be scaled down to even for a production of 10, 000 MT of per year. Infact Isasmelt technology and Ausmelt have already got a couple of plants running for secondary lead production. Kaldo furance al though sutiable for small secondary recycling, require raw material to be moisture free and to be very fine. Therefore out of the new techologies only ausmelt seem to be most suitable for secondary recycling. • The ongoing introduction of more stringent regulations of pollution control in many countries will be most likely the prime motive for further modernization in the future. SUPREME BATTERIES [P] LTD. , HYD, INDIA 50

An old proverb “before removing a fence, I always try to find out why the fence was put in there” SUPREME BATTERIES [P] LTD. , HYD, INDIA 51

comparison of ausmelt furance with mini blast furnace SUPREME BATTERIES [P] LTD. , HYD, INDIA 52

S. No 1 Criteria Suitability Ausmelt Mini Blast Furnace/Mandir Bhatt Primary as well as secondary Only secondary Large as well as small operations Only small operations 2 Recovery 70 to 75% in the first smelt balance In the second campaign 60 to 65% the first smelt balance in the second campaign 3 Raw Material Any material Any secondary material 4 Sulphur Removal By scrubber reactions More or less similar to mini blast furnace. Almost complete oxidation of all the other elements except lead By scrubber Roasting of sulphates by charcoal Pbso 4 + 4 pb =4 pbo +pbs 2 pbo +pbs =3 pb +so 2 2 pbo+c + 2 pb +co 2 And partially Pbso 4 +c =pb +co 2 +so 2 Partial oxidation of other elements 5 Pollution Aspects Totally closed but level of temperature very high Many openings but level of temperature low MINI BLAST FURNACE OR MANDIR BHATTI CAN BE IMPROVED SUPREME BATERIES [P] LTD. , HYD, INDIA CONSIDERABLY 53

CHANGES IN THE RAW MATRIAL AND REQUIRED FINISHED PRODUCTS • BATETRIES IN HARD RUBBER CONTAINERS <5% (REST ALL PLASTIC CONTAINERS) • ALMOST NIL HARD RUBBER, SLIGHT DECREASE IN RECOVERY BECAUSE OF THE LEAD IN CONNECTORS. • PLASTIC SCRAP FULLY RECOVERABLE, HENCE BETTER VALUE FOR SCRAP BATTERIES. • PVC SEPARATORS USED 10 -20% LIKELY TO GO DOWN FURTHER. • • PE SEPARATORS 50 -60% LIKELY TO DOWN GLASS WOOL AGM SEPARATORS 20 -30% AND LIKELY TO GO UP. • • • SCRAP PVC SEPARATORS ARE RECYCLABLE AND FETCH REVENUE. SO FAR THERE IS NO MARKET FOR PE AND GLASS WOOL RETAINS FULL ACID HENCE, LESS TRANSPORTATION PROBLEMS BUT DIFFICULT TO DRAIN THEM.

CHANGES IN THE RAW MATRIAL AND REQUIRED FINISHED PRODUCTS • PERCENTAGE OF ANTIMONY GOING DOWN AND OF TIN GOING UP. • PERCENTAGE OF OXIDE PER PLATE GOING UP, MORE SULPHATION. HIGHER GRAVITY OF ACID, MORE SULPHATION. • • SEGREGATING RAW MATERIALS IS BECOMING MORE RELEVANT BASED ON THE REQUIRED FINISHED PRODUCT. • LOWER RECOVERY , BETTER MANAGEMENT OF SULPHUR REMOVAL. •

CHANGES IN THE RAW MATRIAL AND REQUIRED FINISHED PRODUCTS • FOR VRLA BATTERIES THE REQUIRED LEAD MUST CONTAIN CERTAIN ELEMENTS LIKE NICKEL AND COBALT AT VERY LOW LEVEL. • VERY ACCURATE TESTING AND IMPROVED METHODS OF CONTROLLING THESE ELEMENTS. • LOW ANTIMONY REQUIREMENT HENCE SURPLUS OF ANTIMONY IS ANTICIPATED. • • INCREASED PERCENTAGE TIN AND SILVER IN LEAD ALLOYS • DEVELOP TECHNIQUES/ PROCESSES TO CONCENTRATE ANTIMONY IN LEAD TO BE USED ELSEWHERE. DEVELOP TECHNIQUES/ PROCESSES TO CONCENTRATE TIN AND SILVER IN LEAD TO BE USED AS ADDITIVE.

TO SUM UP 1. THERE A NUMBER OF NEW LEAD SMELTING TECHNOLOGIES, BUT ARE AT PRESENT MORE SUITABLE FOR PRIMARY LEAD PRODUCTION. 2. IN INDIA THE TOTAL SCRAP GENERATION OF LEAD ACID BATTERIES IS HIGHLY SCATTERED, RESULTING IN LOCAL SCATTERED SMELTING MORE ECONOMICAL. 3. LARGE SCALE RECYCLING IS EITHER POSSIBLE FOR LARGE BATTERY MANUFACTURERS WHO HAVE BY BACK ARRANGEMENT FOR SCRAP BATTERIES OR ELSE THROUGH IMPORTED SCRAP BATTERIES IF IT IS ECONOMICAL. 4. IT IS LIKELY THAT SOME INCREASE IN CAPACITY BY THESE NEW SMELTING TECHNOLOGIES MAY TAKE PLACE IN INDIA TO PROCESS IMPORTED LEAD CONCENTRATES.

THANKS SUPREME BATTERIES [P] LTD. , HYD, INDIA 58