PROCESS FLOW
The Alloy production process comprises of two major steps including the preparation of Mother Alloy and preparation of KL-Alloy. The Antimony and Arsenic are used as additives in the alloy production process. The sources of incoming raw material used for KL-Alloy Production are as follows.
• External Source:
Reclaimed Lead procured from local vendors and suppliers.
• Internal Sources:
Melting of Washed grids obtained from pasting shop. Melting of Rejected negative plates obtained from process.
Method For Preparation of Mother Alloy
The procedure used for preparation of Mother Alloy. The steps followed are as given below.
• Load furnace with 2500 kg of Reclaimed Lead.
• Set temperature of furnace temperature controller 500 o C to 550 o C.
• Remove dross from the furnace.
• Put 50 kg Arsenic pack & hang the pack in the Molten Lead.
• Hangout the pack after 60 min from furnace.
• Mixing of the alloy is done.
• Switch off the burner and pour molten alloy into the mould.
• Moulds are emptied in the form of ingots.
• Put red line mark on ingots.
Method For Preparation of KL-Alloy in Manual Furnace
The procedure used for preparation of KL-Alloy in Manual Furnace. The steps followed are as given below.
• Load furnace with 2500 kg of Reclaimed Lead and set the furnace temperature to 500-550 o C.
• Remove dross from the molten lead in furnace.
• Check Antimony from the quality inspector and complete antimony as per given standards and procedure of checking is described in article 3..
• Weigh and mix the required amount of Antimony.
• Add 5 ingots of Mother Alloy.
• Remove dross from the furnace.
• Quality inspector checks alloy quality.
• Pour Alloy into the moulds.
• Spray water for rapid cooling of mould and to increase heat transfer rate.
• Moulds are emptied in the form of ingots.
• 24 ingots are stacked in one group.
Method For Preparation of KL-Alloy in Automatic Furnace
The procedure used for preparation of KL-Alloy in Automatic Furnace. The steps followed are as given below.
• The crane is used to Load furnace with 3500 kg Reclaimed Lead and set the furnace temperature to 500 – 550 o C.
• Remove dross from the molten lead in furnace.
• Check Antimony from the quality inspector and complete antimony as per given standards and procedure of checking is described in article 3.
• Add 7 ingots of Mother Alloy.
• Remove dross from the furnace.
• Insert Lead Pump into the furnace and flame its burners.
• After 10 minutes, Switch on the conveyor machine.
• Quality inspector checks alloy quality.
• KL-Alloy is automatically poured into the moulds by the lead pipe nozzle.
• Water is sprayed for rapid cooling of mould and to increase heat transfer rate.
• Moulds are emptied in the form of ingots.
• 24 ingots are stacked in one group.
Procedure For Checking Antimony In Furnace
Quantity of antimony present and required to add is determined by the following procedure.
• Take a sample of molten lead from furnace by the help of a spoon.
• Insert thermometer probe into the molten lead and wait for its temp to lower down.
• The moment the molten lead starts to change phase then temperature become stable.
• Note down that temperature and use chart against that temperature to add suitable amount of Antimony into the furnace. The range of temperatures for antimony addition is 304 to 322 o C.
• External Source:
Reclaimed Lead procured from local vendors and suppliers.
• Internal Sources:
Melting of Washed grids obtained from pasting shop. Melting of Rejected negative plates obtained from process.
Method For Preparation of Mother Alloy
The procedure used for preparation of Mother Alloy. The steps followed are as given below.
• Load furnace with 2500 kg of Reclaimed Lead.
• Set temperature of furnace temperature controller 500 o C to 550 o C.
• Remove dross from the furnace.
• Put 50 kg Arsenic pack & hang the pack in the Molten Lead.
• Hangout the pack after 60 min from furnace.
• Mixing of the alloy is done.
• Switch off the burner and pour molten alloy into the mould.
• Moulds are emptied in the form of ingots.
• Put red line mark on ingots.
Method For Preparation of KL-Alloy in Manual Furnace
The procedure used for preparation of KL-Alloy in Manual Furnace. The steps followed are as given below.
• Load furnace with 2500 kg of Reclaimed Lead and set the furnace temperature to 500-550 o C.
• Remove dross from the molten lead in furnace.
• Check Antimony from the quality inspector and complete antimony as per given standards and procedure of checking is described in article 3..
• Weigh and mix the required amount of Antimony.
• Add 5 ingots of Mother Alloy.
• Remove dross from the furnace.
• Quality inspector checks alloy quality.
• Pour Alloy into the moulds.
• Spray water for rapid cooling of mould and to increase heat transfer rate.
• Moulds are emptied in the form of ingots.
• 24 ingots are stacked in one group.
Method For Preparation of KL-Alloy in Automatic Furnace
The procedure used for preparation of KL-Alloy in Automatic Furnace. The steps followed are as given below.
• The crane is used to Load furnace with 3500 kg Reclaimed Lead and set the furnace temperature to 500 – 550 o C.
• Remove dross from the molten lead in furnace.
• Check Antimony from the quality inspector and complete antimony as per given standards and procedure of checking is described in article 3.
• Add 7 ingots of Mother Alloy.
• Remove dross from the furnace.
• Insert Lead Pump into the furnace and flame its burners.
• After 10 minutes, Switch on the conveyor machine.
• Quality inspector checks alloy quality.
• KL-Alloy is automatically poured into the moulds by the lead pipe nozzle.
• Water is sprayed for rapid cooling of mould and to increase heat transfer rate.
• Moulds are emptied in the form of ingots.
• 24 ingots are stacked in one group.
Procedure For Checking Antimony In Furnace
Quantity of antimony present and required to add is determined by the following procedure.
• Take a sample of molten lead from furnace by the help of a spoon.
• Insert thermometer probe into the molten lead and wait for its temp to lower down.
• The moment the molten lead starts to change phase then temperature become stable.
• Note down that temperature and use chart against that temperature to add suitable amount of Antimony into the furnace. The range of temperatures for antimony addition is 304 to 322 o C.