Industrial Training Report on Lead(Pb) Industry

LEEKHA CHEMICALS PVT. LTD.20,M.I.E. PART-A, BAHADURGARH, DIST. JHAJJARHARYANA

Factory training & Major report(from 27-June-2015 to 20-July-2015)

Submitted to.MEERUT INSTITUTE OF ENGG. & TECHNOLOGYMeerut, Uttar Pradesh

In partial fulfillment of requirements

For B-Tech in CHEMICAL ENGG.DEEPAK CHOUDHARY Roll No-1306851901MIET, Meerut

ACKNOWLEDGEMENT

The success of the training course, I had undergone at the prestigious LEEKHA CHEMICALS PVT. LTD. plant of Bahadurgarh, Haryana owes its debt to many.First, I express me deep sense of gratitude and personal regards to Mr. Ravi Leekha ( M.D.), Who permitted me to undergone as a trainee.At last but not least, thanks to all the officers and staff workers of Leekha Chemicals Pvt. Ltd. plant and our Director General Mr. J. M. Garga, college staff, T.P.O. Mrs. Akansha Mam and H.O.D. Mrs. Girish Tyagi sir and also to God for their cooperation extended to me without which it would not have been possible to get practical knowledge to work at such a reputed and prestigious organisation.

DEEPAK CHOUDHARY

IndexPage No. a. Introduction of Leekha Chemicals Pvt. Ltd. (4) b. Raw material (5-6) c. Manufacturing Products (7-8) d. Chemical & Physical Properties of Products (9-12) e. Applications of Products (13-14) f. Processing using Flow-chart (15-19) g. Equipments & Specifications used in Industry (20-34) h. Environmental issues & Treatment (35-37) i. Risks & Precautions (38) j. Conclusion (39)

Introduction of Leekha Chemicals Pvt. Ltd.

Leekha Chemicals Pvt Ltd was founded by Mr. Ravi Leekha (Managing Director) in 1981. Ravi Leekha is a B.Sc. in Chemistry. Since his graduation, Mr. Ravi Leekha has worked with various reputed organizations. In 1981, Mr. Ravi Leekha established Leekha Chemicals Pvt. Ltd. and started manufacturing Stearates of various metals such as TBLS, DBLS, DBLP etc to a score of PVC pipe manufacturers in India.

Besides PVC pipe industry, They are also supplying chemicals to Cable Industry, Paint Industry, PVC/PP Compounding Industry etc. Many of their clients are ISO certified too. The company has well-established manufacturing facilities, supported by the laboratory and technical staff.

Leekha Chemicals Pvt. Ltd., the first fully integrated PVC stabilizers manufacturing plant in Northern India has been providing support to plastic industry for nearly three decades. Leekha Chemicals Pvt. Ltd. is the manufacturer & supplier of various Lead Chemicals suh as Litharge (PbO), TBLS (Tribasic Lead Sulphate), DBLS (Dibasic Lead Stearate), DBLP (Dibasic Lead Phthalate), Calcium stearate, Lead stearate. And produce chemicals as 1500 tonns per annum.

The company has its factories located at Bahadurgarh, Dist. Jhajjar, (Haryana). Well-trained staff and workforce manage the factory. The current strength is about 50 persons.

Under the capable guidance of Mr. Ravi Leekha , the Leekha Chemicals Pvt. Ltd. is ready to take up any challenge in the field of manufacturing and services.

Raw MaterialsThe major raw materials which are used in the industry are as follows:- Lead :- Lead is a chemical element in the carbon group with symbolPb and atomic number82. Lead is a soft, malleable and heavy post-transition metal. Metallic lead has a bluish-white color after being freshly cut, but it soon tarnishes to a dull grayish color when exposed to air. Lead has a shiny chrome-silver luster when it is melted into a liquid. It is also the heaviest non-radioactive element (some radioactive elements, like technetium, are lighter). Lead is used in building construction, lead-acid batteries, bullets and shot, weights, as part of solders, pewters, fusible alloys, and as a radiation shield. Sulphuric acid (H2SO4) :- Sulphuric acid is a highly corrosive strong mineral acid with the molecular formula H2SO4 and molecular weight 98.079 g/mol. It is a pungent-ethereal, colorless to slightly yellow viscous liquid which is soluble in water at all concentrations. Sometimes, it is dyed dark brown during production to alert people to its hazards Sulfuric acid has a wide range of applications including domestic acidic drain cleaner, electrolyte in lead-acid batteries and various cleaning agents. It is also a central substance in the chemical industry. Principal uses include mineral processing, fertilizer manufacturing, oil refining, wastewater processing, and chemical synthesis. It is widely produced with different methods, such as contact process, wet sulfuric acid process and some other methods.

Acetic acid (CH3COOH) :- Acetic acid systematically named ethanoic acid is an organic compound with the chemical formula CH3COOH. It is a colourless liquid that when undiluted is also called glacial acetic acid. Vinegar is roughly 39% acetic acid by volume, making acetic acid the main component of vinegar apart from water. Acetic acid has a distinctive sour taste and pungent smell. Besides its production as household vinegar, it is mainly produced as a precursor to polyvinylacetate and cellulose acetate. Although it is classified as a weak acid, concentrated acetic acid is corrosive and can attack the skin.

HCl :- Hydrochloric acid is a clear, colorless, highly pungent solution of hydrogen chloride (HCl) in water. It is a highly corrosive, strong mineral acid with many industrial uses. Hydrochloric acid is found naturally in gastric acid. Hydrochloric acid is used in the chemical industry as a chemical reagent in the large-scale production of vinyl chloride for PVC plastic, and MDI/TDI for polyurethane. It has numerous smaller-scale applications, including household cleaning, production of gelatin and other food additives, descaling, and leather processing.

Phthalic acid :- Phthalic acid is an aromatic dicarboxylic acid, with formula C6H4(CO2H)2. It is an isomer of isophthalic acid and terephthalic acid. Although phthalic acid is of modest commercial importance, the closely related derivative phthalic anhydride is a commodity chemical produced on a large scale.

Stearic acid :- Stearic acid is a saturated fatty acid with an 18-carbon chain and has the IUPAC name octadecanoic acid. It is a waxy solid and its chemical formula is C17H35CO2H. The salts and esters of stearic acid are called stearates. As its ester, stearic acid is one of the most common saturated fatty acids found in nature following palmitic acid.[9] The triglyceride derived from three molecules of stearic acid is called stearin.

Sodium meta bi sulfite :- Sodium metabisulfite or sodium pyrosulfite (IUPAC spelling; Br. E. sodium metabisulphite or sodium pyrosulphite) is an inorganic compound of chemical formula Na2S2O5. The substance is sometimes referred to as disodium (metabisulfite). It is used as a disinfectant, antioxidant and preservative agent.

Manufacturing Products

Litharge:-

Litharge is one of the natural mineral forms of lead(II) oxide, PbO. Litharge is a secondary mineral which forms from the oxidation of galena ores. It forms as coatings and encrustations with internal tetragonal crystal structure. It is dimorphous with the orthorhombic form massicot. It forms soft (Mohs hardness of 2), red, greasy-appearing crusts with a very high specific gravity of 9.149.35. PbO may be prepared by heating lead metal in air at approx. 600C (lead melts at only 300C). At this temperature it is also the end product of oxidation of other lead oxides in air.

Tribasic Lead Sulphate (TBLS):-

Tribasic Lead Sulphate (PbSO4) is a colourless solid, which appears white in microcrystalline form. It is also known as fast white, milk white, sulfuric acid lead salt or anglesite. It is often seen in the plates/electrodes of car batteries, as it is formed when the battery is discharged (when the battery is recharged, then the lead sulfate is transformed back to metallic lead and sulfuric acid on the negative terminal or lead dioxide and sulfuric acid on the positive terminal). Lead sulfate is poorly soluble in water.

Dibasic Lead Stearate (DBLS):-

Di Basic Lead Stearate (DBLS) is a white powder which finds extensive use in the field of lubricant and stabilizer at high temperatures during PVC processing. This is because Di Basic Lead Stearate has free lead oxide and free fatty acid content. The free lead oxide contributes towards the stability, whereas the free fatty acid helps in lubrication, both working well at high temperatures. Di Basic Lead Stearate finds application in cable manufacturing, PVC processing, calandering operations and extrusions. Due to toxicity, Di Basic Lead Stearate is not used in articles that are likely to come in contact with foodstuff. Normally, Di Basic Lead Stearate is used along with Lead Stearate and Tri Basic Lead Sulphate.

Lead Stearate (LS):-

Stearic acid is a saturated fatty acid with an 18-carbon chain and has the IUPAC name octadecanoic acid. It is a waxy solid and its chemical formula is C17H35CO2H. The salts and esters of stearic acid are called stearates. As its ester, stearic acid is one of the most common saturated fatty acids found in nature following palmitic acid. The triglyceride derived from three molecules of stearic acid is called stearin.

Dibasic Lead Phthalate(DBLP):-Dibasic Lead Phthalate, 2PbO-PbC6H4(COO)2 1/2H20, is an excellent heat stabiliser, particularly at high temperatures, besides being also effective as a light stabiliser.

It confers excellent long-term protection on phthalate plasticised PVC compound which is to be subjected to ageing at elevated temperatures, due to its low reactivity with plasticisers, particularly the polyester type. This is of particular advantage in cable sheathing. It is treated with special organic coating to ensure ready dispersion in PVC. Calcium Zinc:-These materials are generally based on metal carboxylates and will sometimes incorporate other elements to boost performance such as aluminium or magnesium. Because the heat stability in some applications may require some enhancement when using calcium/zinc, organic co-stabilisers will also often be added to this type of formulation. These materials include polyols, epoxydised soya bean oil, antioxidants and organic phosphites.

Calcium Stearate:-Calcium stearate is carboxylate of calcium that is found in some lubricants and surfactants. It is a white waxy powder. Calcium stearate is produced by heating stearic acid, a fatty acid, and calcium oxide:2 C17H35COOH + CaO (C17H35COO)2Ca + H2OIt is also the main component of soap scum, a white solid that forms when soap is mixed with hard water.[2] Unlike soaps containing sodium and potassium, calcium stearate is insoluble in water and does not lather well. Commercially it is sold as a 50% dispersion in water or as a spray dried powder. As a food additive it is known by the generic E number E470.

Chemical & Physical Properties of Products

Tri Basic Lead Sulphate (TBLS):- Product Data Sheet Molecular Formula 3PbO.PbSO4.H2O

Appearance White Powder

Molecular Weight990.74

Specific Gravity2.66

Moisture , %1.0 Max.

Melting Point900*C

Particle Size-200 Mesh

Lead Content(as PbO ), % Purity, % 87-89 99.0 Min.

Free Fatty Acid , %Not Applicable

Packing25 Kg. HDPE bags with LDPE liners

Di Basic Lead Stearate (DBLS) :- Product Data SheetMolecular Formula 2PbO.Pb (C17H35COO)2

AppearanceWhite Powder



Moisture , %1.0 Max.

Melting Point115 - 117*C

Particle Size -200 Mesh

Lead Content(as PbO ), % Purity, % 54-55 99 Min.

Free Fatty Acid , %2.0 Max.


Calcium Stearate :-

Product Data SheetMolecular Formula Ca (C17H35COO)2




Moisture, % 1.0 Max.

Melting Point150 (+/- 5)* C

Bulk Density Gm/CC0.2 (+/- 0.03)

Particle Size -200 Mesh

Calcium Content (as CaO), %9.5 (+/- 0.5)

Free Fatty Acid, % 1.0 Max.

Ash Content, %10.5 (+/- 1.0)


Litharge :-Product Data SheetAppearanceCanary yellow to reddish yellow powder

PbO (% min)99.5

Free Pb (% max)0.01

Pb304 (% max)0.06

Melting point (C)888

Specific gravity9.50

Apparent density (g/ml)1.6 - 2.0

Residue on 63 micron I.S. sieve (% max)0.10

Volatile matter (% max)0.20

Water insoluble in acetic acid (% max)0.10

Water absorption100 - 105 mg/gm

Lead Stearate (LS):- Product Data SheetLead Stearate


Specific gravity1.40 0.02

Residue on 63 micron IS sieve (% max)-

Moisture (% max)0.10

Lead Oxide equivalent (% PbO)30 - 34

Free fatty acid (% max)0.60

Bulk density, tapped (g/ml)0.6 - 0.7

Dibasic Lead Phthalate (DBLP) :- Product Data Sheetsoft creamy powder

Specific gravity4.4 0.05

Residue on 63 micron, IS sieve (% max)0.50

Moisture (% max)0.50

Lead Oxide equivalent (% PbO)79 - 81

Bulk density, tapped (g/ml)1.0 - 1.2

Applications of Products

Litharge:-Litharge is widely used in lead stabilizers & as a basic raw material for manufacturing of TBLS (Tribasic Lead Sulphate), DBLS (Dibasic Lead Stearate), LS (Lead Stearate).

Tribasic Lead Sulphate(TBLS) :- For its good electrical properties it is widely used in cable sheathing. The material supplied by the company being treated by a special surface coating technique and thus highly cost effective, is used in production of1. Electrical conduit & cladding.2. Rigid extrusion of main water goods.3. Guttering and soil pipes.4. Pipes for conveyance of gases and liquids.5. Injection moulding.

Dibasic Lead Stearate(DBLS) :-

Dibasic Lead Stearate have wide application as a lubricant for Plasticised PVC compounds, particularly cable covering. For rigid PVC applications, it is necessary to use a well-balanced lubricant system.

Dibasic Lead Phthalate (DBLP) :- Suitable for use with all types of pigmented PVC compounds. Eminently suitable for cable sheathing when the cable is required to operate at high ambient temperature. Finds application as "Stabiliser-Kicker" in preparation of foamed PVC

Calcium Stearate :- As a stabilizer & lubricant in rigid PVC processing, PVC compounding & moulding, in Leather cloth manufacturing etc. As a lubricant in iron wire drawing. As an anti caking agent in Detergent Cakes. In cosmetics.

Lead Stearate (LS) :- Lead Sterate and Dibasic Lead Stearate have wide application as a lubricant for Plasticised PVC compounds, particularly cable covering. For rigid PVC applications, it is necessary to use a well-balanced lubricant system.

Manufacturing process of Products using flow chart

Equipments & their Specification used in Industry

Equipments

Baking Furnace Melting pot Cyclone Separator Bag filter Grinder Tray dryer Diesel dryer Flakers CSTR (Continuous stirred tank reactor) Centrifuge Boiler Ribbon Blender

Baking furnace is used for the manufacturing of Litharge (PbO). The furnace temp. is around 600C. It is a closed chamber with metallic body and an agitator is rotated inside the chamber to circulate the chemicals after sufficient heating the product is removed from the bottom.

The Diesel dyer has same working principle as a tray dryer. Where its efficiency is low as compared to the tray dryer and diesel consumption is more so that the cost of production is more. Hence it is not used continuously.

The Flaker is sometimes used in the industry to remove the moisture from the chemicals. The roller is rotated on the shaft. After sufficient drying the scraper on the left side of roller is removed the dry solid on the surface of the roller.

The CSTR(Continuous Stirred Tank Reactor) is widely used in the industry for continuous mixing and reacting for the production of different chemicals with a heating jacket on their outer periphery. After sufficient reacting the wet cake is goes into the centrifuge.

The Centrifuge is widely used in the chemical industry to remove the excess slurry from the wet cake. In the centrifuge the Solution in charged in it and it gets rotated and the aqueous slurry is removed from the side outlet and finally the wet cake is removed from it.

Specifications of Melting Pot 18 gauge stainless steel crucible 20 gauge stainless steel shell Cover-loose, aluminum with heat resistant knob 3 fiberglass insulation Multiple-circuit blanket heater for uniform heat Heated long-life, no-drip ball valve dispenser 6'' power cord Electronic temperature control-(60 to 250 and 150 to 550 range options) Two zone heat on 40 ands 60 quart models

Specification of Cyclone Separator Airflow or volumetric flow rate is the air flow generated or handled by a cyclone. This is usually given in cubic feet per minute. A cyclone with a higher airflow can accommodate larger gas streams for treatment. For effective operation, the airflow of the system at the point of installation should fall within the rated airflow range of the cyclone. Minimum filtered particle size is the smallest particle size a cyclone can filter to any measurable efficiency. It is generally measured in microns or micrometers (m). If a cyclone is being used as the primary or only means of particle separation, the smallest particle size needed to be removed should be above this minimum. Collection efficiency, capture rate, or recovery rate is the overall removal efficiency of PM from an air stream. Pressure drop is the amount of flow resistance the cyclone will create in the system. Pressure drop is usually measured in units of inches of water column (in WC) or Pascals (Pa). Pressure drop is a function of flow rate, gas density, and cyclone design.

Environmental issues with Lead & their Products ,ChemicalsLead PollutionEstimated Population at Risk:1.9 MillionDescriptionLead processing and smelting plants work with both primary and secondary lead. Primary lead is mined, separated from ore, and refined into various products, whereas secondary lead is recovered from used objects such as used lead-acid batteries for reuse in other products. Smelting is a key process in lead product production, and involves heating lead ore or recovered lead with chemical reducing agents. Both secondary and primary smelting processes can be responsible for releasing large amounts of lead contamination into the surrounding environment.

In addition, the mining process for extracting primary lead ore if not performed with the necessary safety and environmental precautions can create large piles of waste that contains lead toxins. If these piles are left out in the open, lead dust can be blown into surrounding areas, and lead can also leach into the ground and contaminate water systems.Global ContextLead is a very useful material found in many different products, with approximately six million tons used annually across the world.30 Though much of this lead is recycled and reused, the US Geological Survey estimated that the world production of primary lead in 2009 was over 3.8 million metric tons.31 The extraction and smelting of lead can cause a large amount of toxic pollution, and emissions from lead smelting are a big contributor to global lead contamination.32 Lead smelting can also pollute the environment with large amounts of particulate matter, toxic effluents, and other various solid wastes.

Effects of lead on the environment Effects of lead on soilIt is known that lead accumulates in the soil, particularly soil with a high organic content. Lead deposited on the ground is transferred to the upper layers of the soil surface, where it may be retained for many years (up to 2000 years). It may hinder the chemical breakdown of inorganic soil fragments and lead in the soil may become more soluble, thus being more readily available to be taken up by plants. Effects of lead on plantsPlants on land tend to absorb lead from the soil and retain most of this in their roots. The uptake of lead by the roots of the plant may be reduced with the application of calcium and phosphorus to the soil. Some species of plant have the capacity to accumulate high concentrations of lead The pores in a plant's leaves let in carbon dioxide needed for photosynthesis and emit oxygen. Lead pollution coats the surface of the leaf and reduces the amount of light reaching it. This results in stunting the growth or killing the plants by reducing the rate of photosynthesis, inhibiting respiration, encouraging an elongation of plant cells influencing root development 0; by causing pre-mature aging. Effects of lead on micro-organismsEvidence exists to show that lead at the concentrations occasionally found near roadsides , can wipe out populations of bacteria and fungi on leaf surfaces and in soil. This can have a significant impact, given that many of these micro-organisms are an essential part of the decomposing food chain. The micro-organism populations affected are likely to be replaced by others of the same or different species, although these may be less efficient at decomposing organic matter. Evidence also suggests that micro-organisms can make lead more soluble and hence more easily absorbed by plants. That is, bacteria exude organic acids that lower the pH in the immediate vicinity of the plant root. Effects of lead on animalsLead affects the central nervous system of animals and inhibits their ability to synthesize red blood cells. Lead blood concentrations of above 40 g/dl can produce observable clinical symptoms in domestic animals. Calcium and phosphorus can reduce the intestinal absorption of lead .Grazing animals are directly affected by the consumption of forage and feed contaminated by airborne lead and somewhat indirectly by the up-take of lead through plant roots. Invertebrates may also accumulate lead at levels toxic to their predators.

Risk & Precautions

The Lead and their products are poisonous for human beings and is considered as a slow poison. Various health issues arise for continuous contact with lead products. Some risk factor with lead and lead industry are:Lead:-It can cause Learning, behavior & health problem in human being, cause high Blood Pressure & Kidney damage. It is considered as a slow poison.Sulphuric acid:-It is highly reactive, incompatible with many common chemicals, reacts violently with water, corrosive, cause skin burns, & eye damage, strong inorganic acid. Harm respiratory system & cause Lung cancer.Hydrochloric acid (HCL):-HCL is corrosive to eyes, skin & mucous membrane, cause coughing, hoarseness, inflammation & ulceration, chest pain, vomiting, dermal contact may produce severe burns.Prevention methods for their hazards(a) Wear protecting clothes on the job.(b) Take a shower after the job.(c) Do not eat, drink or smoke in an area where lead is used.(d) Take buttermilk so that it can absorb the lead from the body and reduce their effect.(e) Use protecting shield and gloves in the industrial area.(f) Use suitable containers for the chemicals.(g) Store the chemicals & products in a dry place. Conclusion

The Lead industry in India is characterized by the presence of only a few players in the primary segment. Indias Lead market was estimated by 1.5 lacks tons by 2004 which surged to 3.5 lacks tons by 2007 due to enormous growth in Industrial consumption mainly from battery sector.

By, 2007 imported primary Lead accounted for 40-50 percent of demand, domestic Lead firms contribute 15-20 percent & the rest comes from recycled sources. But, due to exponential growth programme by the market India is set to make a dent into export market.

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Documents

Industrial Training Report on Lead(Pb) Industry