Description:TECHNICAL FIELD

[0001] The present invention relates to the field of hydrometallurgy, and in particular relates to production of lead by performing a dross removal procedure during refining of lead.

BACKGROUND
[0002] In recent years, with the rapid growth of economy and a worldwide development has led to an increase in demand for various raw materials for consistent and smooth running of businesses. The present circumstances has put various industries related to the chemical sector under a lot of pressure to make ends meet when it comes to producing raw materials on a large basis. The proliferation of artillery, weapons, planes, building and machines demands for a higher yield of metals. To meet this burgeoning demand, industries are adopting various techniques to lower the cost of production, increase the yield, rate of production and quality of metal. Moreover, the demand for a few certain metals has increased swiftly as compared to other metals.
[0003] One of the few metals whose demand has increased rapidly over the years is lead. Moreover, many industries are investing a huge capital in the production of lead. In addition, tons of new technologies have been developed for the production of lead. Various new techniques and processes are being utilized for the production of lead. Nowadays, chemical industries are exploring for various anonymous and random sources for procuring materials containing high yield of lead. In general, the production of lead is carried out by employing various ores bearing lead, waste materials bearing lead, lead produced as a by-product from other processes and the like.
[0004] Going further, the production of lead is carried by conducting pyro-metallurgy of various ores, waste materials or by-products containing lead. Traditionally, the pyro-metallurgy of lead is carried out in a smelting furnace where various waste materials or ores are heated up at an extremely high temperature which provides molten lead. However, the final product obtained from the pyro-metallurgy is extremely impure and contains a high content of impure lead along with other impurities. Moreover, these impurities are obtained in the form of dross which generates over the surface of the molten lead. Further, the dross takes up most of the lead produced from the smelting which leads to a lower yield of lead in the final product.
[0005] Furthermore, it is a goal for every lead producer to delay or slow down the generation of dross for recovery of valuable materials that are consumed by the dross. It is highly necessary to ensure the removal of dross from the molten lead in order to obtain lead. In general, the removal of dross from the molten lead is carried out by cooling the dross generated by an air cooling mechanism. Moreover, the dross removal is carried out by using one or more kettles which transfer the molten lead containing the impurities from one area to another for further processing. The molten lead is continuously tapped into the one or more kettles which then carry the molten lead for further processing. In addition, the molten lead is tapped at a temperature ranging between 1100°C to 1400°C. The dross is accumulated over the top of the molten lead in the kettle due to a stirring process.
[0006] Going further, the molten lead is brought inside a refinery plant for performing the cooling of the dross accumulated over the top of the molten lead. The accumulated dross is cooled to a pre-defined temperature by blowing cool air over the top of the dross. The cooling is done for reducing the temperature of the dross. Lastly, the dross is then removed from over the top of the molten lead by an electric overhead travelling crane. In addition, pure lead is then obtained from the kettles after the removal of dross.
[0007] The present systems and methods for the production of lead by utilizing the air cooling mechanism are inefficient. In addition, the air cooling mechanism takes up a lot of time for reducing the temperature of the dross to a suitable temperature. This leads a large amount of dross inside the kettles resulting in a large amount of lead being consumed in the dross. Moreover, a lower quantity of lead is obtained resulting in a loss of metal. Further, a turnaround time associated with the one or more kettles increases due to a slow cooling of the dross. Furthermore, the cost of production of lead is high.
[0008] In light of the above stated discussion, there is a need for a method and system that
overcomes the above stated disadvantages.

SUMMARY
[0009] In an aspect of the present disclosure, a method for production of lead by performing refining of molten lead by removal of one or more impurities, the molten lead is procured from one or more sources. The method includes tapping a pre-determined amount of the molten lead into a plurality of ladles associated with ladle transfer vehicles at a pre-defined interval of time, initiating a controlled water spraying procedure above the each ladles containing the molten lead, removing a generated dross from over the surface of the molten lead in each ladle and transferring the ladle transfer vehicle to lead refinery after the removal of the dross. The molten lead is tapped at a first pre-defined range of temperature and the pre-determined amount of the molten lead is based on a capacity of the ladles associated with ladle transfer vehicle. The water spraying is done for enabling instantaneous generation of dross over a surface of the molten lead. The dross is removed instantly from the surface of the molten lead on the generation of the dross.
[0010] In an embodiment of the present disclosure, the water spraying procedure is performed for quenching temperature of the molten lead from the first pre-defined range of temperature to a second pre-defined temperature.
[0011] In an embodiment of the present disclosure, the second pre-defined temperature of the molten lead after the water spraying procedure is 500°C.
[0012] In an embodiment of the present disclosure, the first pre-defined range of temperature of the tapped lead bullion is in a range of 950°C to 1100°C.
[0013] In an embodiment of the present disclosure, the process of the production of lead is a batch process.
[0014] In an embodiment of the present disclosure, a number of tapping per batch for the tapping of the molten lead in to the plurality of ladles associated with ladle transfer vehicles is 4-5.
[0015] In an embodiment of the present disclosure, the quenching is performed for minimizing a time taken for cooling of the molten lead.
[0016] In an embodiment of the present disclosure, the instantaneous generation of the dross provides a decrease in a turnaround time of ladle transfer vehicles. The decrease in the turnaround time enables availability of plant.
[0017] In an embodiment of the present disclosure, the transferring of the molten lead by each of the plurality of vehicles is done in real time.
[0018] In an embodiment of the present disclosure, the dross generated by the controlled water spraying procedure is 8%.
STATEMENT OF THE DISCLOSURE
[0019] The present disclosure relates to a method for production of lead by performing refining of molten lead by removal of one or more impurities, the molten lead is procured from one or more sources. The method includes tapping a pre-determined amount of the molten lead into a plurality of ladle associated with ladle transfer vehicles at a pre-defined interval of time, initiating a controlled water spraying procedure above the each ladles of from ladle transfer vehicles containing the molten lead; removing a generated dross from over the surface of the molten lead and transferring the ladle transfer vehicle to lead refinery after the removal of the dross. The molten lead is tapped at a first pre-defined range of temperature and the pre-determined amount of the molten lead is based on a capacity of the ladles associated with ladle transfer vehicle.
The water spraying is done for enabling instantaneous generation of dross over a surface of the molten lead. The dross is removed instantly from the surface of the molten lead on the generation of the dross.
BRIEF DESCRIPTION OF THE FIGURES
[0020] Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
[0021] FIG. 1 illustrates a system for production of lead by performing refining of molten lead, in accordance with various embodiments of the present disclosure;
[0022] FIG. 2 illustrates a block diagram for the production of lead by performing the refining of the molten lead, in accordance with various embodiments of the present disclosure;
[0023] FIG. 3 illustrates a flowchart for the production of lead by performing the refining of the molten lead, in accordance with various embodiments of the present disclosure; and
[0024] FIG. 4 illustrates another flowchart for the production of lead by performing the refining of the molten lead, in accordance with an embodiment of the present disclosure.
DETAILED DESCRIPTION
[0025] In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present technology. It will be apparent, however, to one skilled in the art that the present technology can be practiced without these specific details. In other instances, structures and devices are shown in block diagram form only in order to avoid obscuring the present technology.

[0026] Reference in this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present technology. The appearance of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Moreover, various features are described which may be exhibited by some embodiments and not by others. Similarly, various requirements are described which may be requirements for some embodiments but not other embodiments.
[0027] Moreover, although the following description contains many specifics for the purposes of illustration, anyone skilled in the art will appreciate that many variations and/or alterations to said details are within the scope of the present technology. Similarly, although many of the features of the present technology are described in terms of each other, or in conjunction with each other, one skilled in the art will appreciate that many of these features can be provided independently of other features. Accordingly, this description of the present technology is set forth without any loss of generality to, and without imposing limitations upon, the present technology.
[0028] FIG. 1 illustrates a system 100 for production of lead by performing refining of molten lead by removal of one or more impurities, in accordance with various embodiments of the present disclosure. The one or more impurities may include cobalt, silver, bismuth antimony and the like. In an embodiment of the present disclosure, the one or more impurities are contained in the molten lead. In an embodiment of the present disclosure, the one or more impurities are formed due to a plurality of reactions taking place during a smelting of one or more lead ores, waste residue bearing lead and the like.
[0029] In addition, the system 100 is configured for the production of lead by performing procedures for removal of dross from the molten lead. Moreover, the system 100 is configured for performing the production of lead by extracting and refining the molten lead by executing a plurality of processes. The refining of the molten lead is performed for obtaining pure lead and for minimizing loss of lead through generated dross (as explained below in the patent application). Further, the plurality of processes includes roasting, sintering, cooling, quenching and the like.
[0030] Going further, the molten lead is procured from one or more sources. The one or more sources provide one or more raw materials bearing lead for the production of the molten lead. In addition, the one or more sources include lead ores, lead secondary, lead bearing residues, lead by-products and the like. In addition, the one or more sources may exist in any shape and state. The one or more sources are obtained from a plurality of sites. Furthermore, the plurality of sites includes ore deposits of lead, rock deposits of lead, dump sites of lead bearing residue and the like. In an embodiment of the present disclosure, the one or more sources may be any type of source which produce lead as a waste residue or lead as an ore and the like.
[0031] Moreover, the system 100 includes a furnace unit 102, a transport unit 104 and a refinery unit 106. The above stated units of the system 100 are configured for performing the plurality of processes for the production of lead. In an embodiment of the present disclosure, the above stated units of the system 100 are configured for performing the production of lead by refining of the molten lead by the removal of the one or more impurities. In an embodiment of the present disclosure, the above stated units of the system 100 perform the plurality of processes for providing the pure lead from the molten lead. In addition, the above stated units are working in a batch process for the production of lead.
[0032] Further, the furnace unit 102 is configured for production of the molten lead. In an embodiment of the present disclosure, the furnace unit 102 produces the molten lead by utilizing the one or more raw materials bearing lead obtained from the one or more sources. Furthermore, in an embodiment of the present disclosure, the furnace unit 102 is configured to perform a process of the plurality of processes for the production of the molten lead along with the one or more impurities. Moreover, the furnace unit 102 is a pyro-processing device configured for heating each of the one or more raw materials bearing lead obtained from the one or more sources. The pyro-processing device enables reduction of the one or more raw materials bearing lead by heating the one or more raw materials bearing lead to a pre-defined temperature in the presence or absence of oxygen. In an embodiment of the present disclosure, the furnace unit 102 is at least one of a blast furnace, smelting furnace and the like.
[0033] Furthermore, the furnace unit 102 is associated with a feeding device. In an embodiment of the present disclosure, the feeding device is attached to the furnace unit 102. In another embodiment of the present disclosure, the feeding device is attached at any suitable area of the furnace unit 102. The feeding device is configured for transferring the one or more raw materials bearing lead from the plurality of sites to the furnace unit 102 for the production of the molten lead along with the one or more impurities. In an embodiment of the present disclosure, the one or more raw materials bearing lead are transferred through any type of transferring medium. Moreover, the pre-defined interval of time is based on a turnaround time associated with a ladle transfer vehicle (as elaborated in the detailed description of FIG. 2). Further, the one or more raw materials bearing lead are added in a pre-determined amount based on an amount of the molten lead required for the production.
[0034] Going further, the feeding device may be any type of device for transfer of the one or more raw materials bearing lead into the furnace unit 102. In an embodiment of the present disclosure, the feeding device is a hopper. In another embodiment of the present disclosure, the feeding device is a conveyor belt. In yet another embodiment of the present disclosure, the feeding device is a loader truck. Moreover, the one or more raw materials bearing lead are transferred in a pre-determined quantity based on an amount of the lead required by the feeding device to the furnace unit 102. In an embodiment of the present disclosure, the pre-determined amount and a pre-determined rate of transfer of the one or more raw materials bearing lead by the feeding device to the furnace unit 102 are electronically controlled.
[0035] Furthermore, the furnace unit 102 utilizes a furnace fuel to attain the pre-defined temperature to enable the reduction of the one or more raw materials bearing lead for the production of the molten lead along with the one or more impurities. Examples of the furnace fuel include but may not be limited to coal, coke, electricity, petroleum oil and natural gas. The one or more raw materials bearing lead in the furnace unit 102 undergo a series of chemical reactions at the pre-defined temperature to form the molten lead. In an embodiment of the present disclosure, the lead formed after the series of chemical reaction is the molten lead. The series of chemical reactions include oxidation of the one or more raw materials bearing lead to lead oxide followed by the reduction of the lead oxide to form the molten lead along with oxides of some metals at the pre-defined temperature. In addition, the pre-defined temperature is above the melting point of the lead.
[0036] Moreover, the pre-defined temperature of the molten lead is maintained by continuously heating the furnace unit 102 to prevent solidification of the molten lead. The furnace unit 102 is covered from the outside to prevent the loss of heat. The molten lead flows down to bottom of the furnace unit 102 along with the one or more impurities. In addition, the series of chemical reaction produces a plurality of gases. The plurality of gases produced after the series of chemical reactions include carbon dioxide (CO2), sulphur dioxide (SO2), carbon monoxide (CO) and the like. The plurality of gases is expelled from the furnace unit 102 through one or more vents associated with the furnace unit 102. The one or more vents are associated with the furnace unit 102 to enable movement of the plurality of gases released from the series of chemical reactions.
[0037] Going further, the furnace unit 102 is associated with the transport unit 104. In an embodiment of the present disclosure, the furnace unit 102 is mechanically connected to the transport unit 104. In another embodiment of the present disclosure, the mechanical connection is achieved through a transfer medium. Moreover, the furnace unit 102 is connected with the transport unit 104 for a limited time. The transport unit 104 is configured for performing tapping of a pre-defined amount of the molten lead. The pre-defined amount of the molten lead is based on a capacity of the ladles (as elaborated in the detailed description of FIG. 2).
[0038] The transport unit 104 lies in the vicinity of the furnace unit 102. The transport unit 104 includes the ladle transfer vehicle that carries the molten lead. The ladle transfer vehicle is configured to maintain the distance between the transport unit 104 and the furnace unit 102 to ease the transfer of molten lead. The ladle transfer vehicle is associated with ladles that stores the molten lead obtained from the furnace unit 102. The ladles associated with the ladle transfer vehicle are designed to persist the pre-defined temperature of the molten lead without sustaining any damage. The ladle can store the pre-defined amount of the molten lead at the pre-defined temperature.
[0039] Further, the molten lead is transferred to the ladle associated with the ladle transfer vehicle. The pre-defined temperature of the molten lead along with one or more impurities in the transport unit 104 is monitored and regulated in the ladle transfer vehicle. The ladle transfer vehicle or the transport unit 104 associated with the ladle carrying the molten lead enters the refinery unit 106. The transport unit 104 lies in the vicinity of the refinery unit 106. The distance between transport unit 104 and the refinery unit 106 is maintained to ease the removal of the one or more impurities. In an embodiment of the present disclosure, the distance between the transport unit 104 and the refinery unit 106 is such that the temperature of the molten lead does not decrease. In an embodiment of the present disclosure, the distance between the transport unit 104 and the refinery unit 106 is pre-defined.
[0040] Going further, the refinery unit 106 is configured to perform removal of the one or more impurities through a plurality of operations performed sequentially on the ladle associated with the ladle transfer vehicle. In addition, the plurality of operations performed sequentially includes cooling the molten lead by spraying water on the ladles associated with the ladle transfer vehicle followed by removal of the one or more impurities (as elaborated in the detailed description of FIG. 2). The cooling of the molten lead by the water spraying separates out the one or more impurities in the form of a solid insoluble mass floating on surface of the molten lead (as elaborated in the detailed description of FIG. 2). .
[0041] In addition, the solid insoluble mass is dross formed after a reaction of the one or more impurities with oxygen. The dross is further removed by using a cleaning device. The cleaning device is further configured to remove the dross floating on the surface of the molten lead (as elaborated in the detailed description of FIG. 2). In an embodiment of the present disclosure, the cleaning device is an automatic crane. In another embodiment of the present disclosure, the cleaning device is chisel operated manually by one or more workers. The plurality of operations increases the grade and quality of the molten lead stored in the ladle associated with the ladle transfer vehicle. Further, the molten lead is transferred from the refinery unit 106 for a plurality of processes. The plurality of processes includes casting, grinding, forging, alloying and the like.
[0042] Further, it may be noted that in FIG. 1, the transport unit 104 transfers the molten lead from the furnace unit 102 to the refinery unit 106; however, those skilled in the art would appreciate that more number of transport units transfer the molten lead along with the one or more impurities from more number of furnace units to more number of refinery units. In addition, it may be noted that in FIG. 1, the furnace unit 102 is performing the plurality of processes for the production of molten lead; however, those skilled in the art would appreciate that more number of furnace units are the performing the plurality of processes for the production of molten lead. Moreover, it may be noted that in FIG. 1, the refinery unit 106 is performing the plurality of operations for the removal of the one or more impurities present along with the molten lead; however, those skilled in the art would appreciate that more number of refinery units are performing the plurality of processes for the removal of the one or more impurities present along with the molten lead.
[0043] FIG. 2 illustrates a block diagram 200 for the production of lead by performing the refining of the molten lead by removal of the one or more impurities, in accordance with various embodiments of the present disclosure. The block diagram 200 is designed for a process of production of the lead by extracting and refining the one or more sources of the lead bearing the one or more impurities. In addition, the process of the production of lead is a batch process. It may be noted that to explain the system elements of FIG. 2, references will be made to the system elements of FIG. 1.
[0044] Further, the block diagram 200 includes a smelting unit 202, a ladle transfer vehicle 204 and the refining unit 206. Furthermore, the refining unit 206 includes one or more units. Moreover, the one or more units include a cooling unit 206a, dross separating unit 206b and a collecting unit 206c. Each of the one or more units performs a sub-operation of a plurality of operations. The above stated units are configured for performing the production of the molten lead by extracting and refining the one or more sources of the lead bearing the one or more impurities. The process of the production of the lead starts with extraction of the lead from the one or more raw materials bearing lead obtained from the one or more sources in the smelting unit 202.
[0045] Moreover, in an embodiment of the present disclosure, the smelting unit 202 is performing the operations performed by the furnace unit 102 (as explained earlier in the detailed description of FIG. 1). In addition, the smelting unit 202 may be any type of furnace for the production of the molten lead. Examples of the smelting unit 202 include but may not be limited to blast furnace, steelmaking furnace, vacuum furnace and reverberatory furnace. The smelting unit 202 is configured to performing the production of the molten lead by extracting the lead from the one or more raw materials bearing lead obtained from the one or more sources. Further, the smelting unit 202 performs the extraction by heating the one or more raw materials bearing lead along with the one or more impurities with a reductant chemical. Examples of the reductant chemical include CO, Coke, any bio reducer and the like. The smelting of the molten lead by the smelting unit 202 is a dynamic process consuming continuous supply of energy. In an embodiment of the present disclosure, the molten lead is heater at a temperature in a range of 1000°C-1400°C.
[0046] Further, the smelting unit 202 includes a plurality of devices. Each of the plurality of devices is configured to perform an operation of the plurality of operations. The plurality of operations include charging the one or more raw materials bearing lead, heating, oxidizing, reducing, storing and transferring the molten lead bearing the one or more impurities obtained from the one or more raw materials bearing lead . Furthermore, the plurality of devices includes furnace wall, an air inlet, an effluent gas outlet, a feed material inlet, a slag outlet, one or more taps and a heating device.
[0047] Further, the smelting unit 202 is a closed system with the furnace wall made up of a heat resistant material to prevent the loss of heat. Furthermore, the heat resistant material in the furnace unit 202 includes fire clay bricks, concrete and the like. The heat resistant material is configured to reflect the heat inside the furnace wall of the smelting unit 202 to increase rate of the plurality of operations for the extraction of the molten lead from the one or more raw materials bearing lead. Furthermore, the smelting unit 202 is associated with the feeding device. The feeding device is configured to perform transferring of a pre-determined amount of the one or more raw materials bearing lead obtained from the one or more sources along with a pre-defined amount of the reductant to the smelting unit 202.
[0048] Going further, the feeding device may be any device for the transfer of the one or more raw materials bearing lead obtained from the one or more sources. In an embodiment of the present disclosure, the feeding device is the hopper. In another embodiment of the present disclosure, the feeding device is the conveyor belt. In yet another embodiment of the present disclosure, the feeding device is the loader truck. Moreover, the feeding device is associated with the feed material inlet present on top of the smelting unit 202. Moreover, the feed material inlet is configured to enable pouring of the one or more raw materials bearing lead inside the smelting unit 202. The one or more raw materials bearing lead are fed through the feed material inlet in the smelting unit 202 through the feeding device to start the extraction process of the molten lead.
[0049] In addition, the feed material inlet is designed for distributed feeding in a cup and cone arrangement present inside the furnace unit 202. The cup and cone arrangement includes a cup fitted inside the feed material inlet and a conical feeder to distribute the one or more raw materials bearing lead evenly. The one or more raw materials bearing lead reach bottom of the smelting unit 202. Moreover, the bottom of the smelting unit 202 includes the heating device. The heating device present in the bottom of the smelting unit 202 is configured to provide sufficient heat for initiating the oxidation and the reduction of the one or more raw materials bearing lead for producing the molten lead along with the one or more impurities.
[0050] Further, the heating device may be any type of heat transfer device. In an embodiment of the present disclosure, the heating device is a coal burner. In another embodiment of the present disclosure, the heating device is an oil burner. In yet another embodiment of the present disclosure, the heating device is a gas burner. Going further, the heating device is associated with a fuel storage tank configured for storing a furnace fuel. The fuel storage tank stores the furnace fuel for the purpose of providing necessary fuel for heating the one or more raw materials bearing lead to enable the extraction of the molten lead. The furnace fuel is transferred from the fuel storage tank to the heating device for ignition. The furnace fuel is ignited in the heating device for providing a controlled amount of heat pertaining to a pre-determined amount of the furnace fuel consumed.
[0051] Further, a stream of air from the air inlet is transferred inside the smelting unit 202. The air inlet is configured to perform the oxidation of the one of more raw materials bearing lead by sucking a pre-determined amount of air. The one or more raw materials bearing lead along with the one or more impurities are oxidized by the reaction of oxygen and the heat from the heating device. Furthermore, the oxidation of the one or more raw materials bearing lead forms oxides of lead and corresponding oxides of the one or more impurities.
[0052] Further, the oxides of the lead and the corresponding oxides of the one or more impurities are reduced to the molten lead bearing the one or more impurities by the reaction with the reductant. The oxidation and the reduction of the one or more raw materials bearing lead along with the one or more impurities produce effluent gases and a layer of slag. The effluent gases are a mixture of sulphur dioxide, carbon dioxide, carbon mono-oxide and the like. The effluent gases are expelled from the smelting unit 202 through the effluent gas outlet present in the middle of the smelting unit 202. Moreover, the effluent gas outlet is configured to perform the expelling of the effluent gases to ease the extraction of the molten lead from the one or more raw materials bearing lead. Further, pressure built inside the smelting unit 202 is reduced after the effluent gases are expelled through the effluent gas outlet.
[0053] Furthermore, the smelting unit 202 uses the slag outlet to discharge the layer of slag present along with the molten lead. The slag outlet present in the bottom of the smelting unit 202 is configured to perform the discharging of the layer of slag. Accordingly, the bottom of the smelting unit 202 is filled with the molten lead along with the one or more impurities at a temperature favorable in the range of 950 OC to 1100 OC.
[0054] Further, the smelting unit 202 is linked to each of ladles 204a associated with each of ladle transfer vehicle 204. The ladles associated with each ladle transfer vehicle 204 are configured for storing or containing the molten lead produced by the smelting unit 202. The ladles 204a associated with each ladle transfer vehicle 204 lays in the vicinity of the smelting unit 202. The ladle 204a is a part of ladle transfer vehicles 204. Moreover, the ladle 204a is mounted on ladle transfer vehicles 204.
[0055] In an embodiment of the present disclosure, the ladle 204a is made up of any kind of metal. In addition, the ladle 204a is entitled to possess a shape that effectively determines the strength and efficiency in storing the molten lead along with the one or more impurities. Further, the ladle 204a may possess any shape of a plurality of shapes. The plurality of shapes includes conical, cylindrical, drum, torpedo and the like. Moreover, the ladle 204a includes a ladle mount; a refractory lining and a ladle shell to enable the storing of the molten lead without sustaining any damage.
[0056] Going further, the refractory lining of the ladle 204a is configured to perform by protecting the ladle shell from any damage sustained as a result of the pre-determined temperature of the molten lead. Further, the ladle mount is used to attach the ladle 204a with each ladle transfer vehicles 204. In an embodiment of the present disclosure, each ladle transfer vehicles 204 is remotely operated. In another embodiment of the present enclosure, each ladle transfer vehicles 204 is manually operated. The ladle 204a associated with each ladle transfer vehicles 204 is configured to store the molten lead by tapping the pre-determined amount of the molten lead into the ladle 204a associated with each ladle transfer vehicles 204 at the pre-defined interval of time. Moreover, the molten lead is tapped at a first pre-defined range of temperature.
[0057] Further, the first pre-defined range of temperature of the tapped molten lead is in the range of 950°C to 1100°C. Furthermore, the pre-determined temperature of the molten lead in the ladle 204a associated with each ladle transfer vehicles 204 is regulated and monitored through a temperature sensor. Moreover, the pre-determined amount of the molten lead is based on the capacity of the ladle 204a associated with each ladle transfer vehicles 204. In addition, a number of tapping are required for completing the batch process for the production of the lead. In an embodiment of the present disclosure, the number of tapping per batch for the tapping of the molten lead in the ladle 204a of each ladle transfer vehicles 204 is 4-5.
[0058] Further, in an embodiment of the present disclosure, the ladle transfer vehicle 204 completes the batch process of the production of the lead by processing the tapped molten lead along with the one or more impurities in the ladle 204a followed by transferring the molten lead from the ladle 204a. In an embodiment of the present disclosure, the transferring of the molten lead by the ladle transfer vehicle 204 is done in real time. In addition, the ladle transfer vehicle 204 enters the refining unit 206. Furthermore, the ladle 204a associated with the ladle transfer vehicle 204 enters the vicinity of the refining unit 206. The refining unit 206 is configured to perform the removal of the one or more impurities through the plurality of operations performed sequentially on the ladle 204a associated with the ladle transfer vehicle 204.
[0059] Moreover, the plurality of operations performed sequentially includes cooling the molten lead followed by removal of the one or more impurities (as explained further in the patent application). Further, the refining unit 206 includes the cooling unit 206a, the dross separation unit 206b and the collecting unit 206c to enable the removal of the one or more impurities. The above stated units includes in the refinery unit 206 are performing the refining of the molten lead by performing the plurality of operations. Further, the refining unit 206 is designed to enable a controlled regulation of the pre-determined temperature of the molten lead. The controlled regulation is necessitated following a need to monitor and regulate the temperature of the molten lead.
[0060] Furthermore, the ladle 204a reaches the cooling unit 206a present in the refining unit 206. The cooling unit 206a is configured for initiating a controlled water spraying procedure above the ladle 204a of the ladle transfer vehicle 204 containing the molten lead. Moreover, the water is sprayed on top of the molten lead along with the one or more impurities in the ladle 204a associated with the ladle transfer vehicle 204. Moreover, the cooling unit 206a includes a coolant, a coolant transfer device, a temperature regulator and a flow controller working coherently together to perform the cooling of the molten lead. The controlled water spraying utilizes the water as the coolant.
[0061] In addition, the water as the coolant is filled in the coolant transfer device. The water spraying procedure is performed for quenching temperature of the molten lead from the first pre-defined range of temperature to a second pre-defined temperature. In an embodiment of the present disclosure, the second pre-defined temperature of the molten lead after the water spraying procedure is 500°C. The second pre-determined temperature is kept above the melting point of the molten lead. Further, the instant cooling of the ladle 204a bearing the molten lead along with the one or more impurities is the quenching process.
[0062] Going further, the quenching of molten lead consumes a time taken by the molten lead to cool above the second pre-defined temperature. The quenching is performed for minimizing the time taken for cooling of the molten lead. Accordingly, the water quickly absorbs the heat of the molten lead along with the one or more impurities. The water quickly evaporates into steam leaving the ladle 204a cooler than before and enables an instantaneous generation of the dross over the surface of the molten lead in the ladle 204a of the ladle transfer vehicle 204. The ladle 204a associated with the ladle transfer vehicle 204 is attached to the temperature regulator.
[0063] Further, the temperature regulator is configured to perform by monitoring the second pre-determined temperature of the molten lead along with a pre-defined temperature of the coolant in the ladle 204a associated with the ladle transfer vehicle 204. Furthermore, the flow controller present in the cooling unit 206a measures rate of spraying of water. The rate of spraying of water is a pre-determined value measured to enable regulation in change of the pre-determined temperature to the second pre-determined temperature of the molten lead.
[0064] Going further, the instantaneous generation of the dross enables a lower quantity of lead in composition of the dross. In an embodiment of the present disclosure, the dross generated by the controlled water spraying procedure is 8%. The ladle 204a associated with the ladle transfer vehicle 204 enters the dross separating unit 206b. The dross separating unit 206b is configured for removing the generated dross from over the surface of the molten lead in the ladle 204a of the ladle transfer vehicle 204.
[0065] The dross separating unit 204b may include any mechanical tool for performing the removal of dross from the top of the ladle 204a. Examples of the mechanical tools include but may not be limited to a scraper, a chisel and a press. In an embodiment of the present disclosure, the dross is removed instantly from the surface of the molten lead on the generation of the dross. Accordingly, the ladle transfer vehicle 204 enters the vicinity of the collecting unit 206c present in the refining unit 206.
[0066] Further, the collecting unit 206c is configured for obtaining the lead from the ladle 204a of the ladle transfer vehicle 204 after the removal of the dross. Furthermore, the ladle 204a associated with each the ladle transfer vehicle 204 bearing the molten lead without the one or more impurities is tapped into the collecting unit 206c. The collecting unit 206c is any device that handles the molten lead without melting. Moreover, the collecting unit 206c includes a mold, a cast, a die and the like. The ladle 204a associated with the ladle transfer vehicle 204 pours the molten lead in the collecting unit 206c based on a design associated with the ladle transfer vehicle 204. Moreover, the obtained lead includes a higher yield of lead.
[0067] In addition, the designs include a lip-pour design; a teapot spout design, lip-axis pour design and a bottom pour design. In an embodiment of the present disclosure, the molten lead flows from the bottom of the ladle 204a through the lip pour spout in the teapot spout design. In another embodiment of the present disclosure, the lip-axis pour designs have a pivot point of the ladle 204a as close to tip of the pouring spout as can be practicable. In yet another embodiment of the present disclosure, the bottom pour design use a stopper rod inserted into a tapping hole in the bottom of the ladle 204a associated with the ladle transfer vehicle 204. Further, the stopper rod is raised vertically to pour the molten lead into the collecting unit 206c.
[0068] Moreover, the collecting unit 206c utilizes the molten lead for a plurality of purposes. The plurality of purposes includes casting, forging, alloying, grinding and the like. The dross removed is used in a plurality of ways to meet the demand of metals in one or more impurities. The plurality of ways includes chemical treatment for recovery of silver, gold, antimony and zinc, sold to ancillary industries and the like. Further, the ladle 204a is emptied after the completion of the batch process of the production of the lead and the ladle 204b is transferred back to the smelting unit 202 to start another batch process.
[0069] Moreover, it may be noted that in FIG. 2, the smelting unit 202 produces the molten lead along with the one or more impurities; however, those skilled in the art would appreciate that more number of smelting units are producing the molten lead along with the one or more impurities. It may also be noted that in FIG. 2, the cooling unit 206a sprays water on the ladle 204a of the ladle transfer vehicle 204, however, those skilled in the art would appreciate that more number of cooling units spray water on the ladle 204a associated with the ladle transfer vehicle 204. It may also be noted that in FIG. 2, the dross separation unit 206b removes the dross formed on the surface of the ladle 204a associated with the ladle transfer vehicle 204 filled with the molten lead along with one or more impurities; however, those skilled in the art would appreciate that more number of dross separation units are removing the dross formed in the ladle 204a associated with the ladle transfer vehicle 204.
[0070] FIG. 3 illustrates a flowchart 300 for production of lead by performing refining of the molten lead by the removal of the one or more impurities, in accordance with various embodiments of the present disclosure. It may be noted that to explain the process steps of flowchart 300, references will be made to the system elements of FIG. 1 and FIG. 2. Further, it may be noted that the flowchart 300 may have lesser or more number of steps which enables the production of the lead from the one or more raw materials bearing lead.
[0071] The flowchart 300 initiates at step 302. Following step 302, at step 304, the ladle transfer vehicle 204 taps the pre-determined amount of the molten lead into the ladle 204a associated with the ladle transfer vehicle 204 at the pre-defined interval of time. Moreover, the molten lead is tapped at the first pre-defined range of temperature. The pre-determined amount of the molten lead is based on the capacity of the ladle 204a associated with the ladle transfer vehicle 204. At step 306, the ladle 204a associated with the ladle transfer vehicle 204 transfers the tapped molten lead in the ladle 204a of the ladle transfer vehicle 204 for the refining of the molten lead.
[0072] Furthermore, at step 308, the cooling unit 206a initiates the controlled water spraying procedure above the ladle 204a of the ladle transfer vehicle 204 containing the molten lead. The water is sprayed on top of the molten lead to facilitate quicker and instantaneous generation of the dross. The water spraying procedure is performed for quenching the temperature of the molten lead from the first pre-defined range of temperature to the second pre-defined temperature and enabling the instantaneous generation of the dross over the surface of the molten lead in the ladle 204a of the ladle transfer vehicle 204. At step 310, the dross separation unit 206b removes the generated dross from over the surface of the molten lead in the ladle 204a of the ladle transfer vehicle 204. The dross is removed instantly from the surface of the molten lead on the generation of the dross. At step 312, the collecting unit 206c obtains the lead from the ladle 204a of the ladle transfer vehicle 204 after the removal of the dross. The flow chart 300 terminates at step 314.
[0073] It may be noted that the flowchart 300 is explained to have above stated process steps; however, those skilled in the art would appreciate that the flowchart 300 may have more/less number of process steps which may enable all the above stated embodiments of the present disclosure.
[0074] FIG. 4 illustrates another flowchart 400 for the production of the potassium antimony tartrate, in accordance with an embodiment of the present disclosure. It may be noted that to explain the process steps of the flowchart 400, references will be made to the system elements of the FIG. 1, the FIG. 2 and the process steps of the FIG. 3. In addition, the flowchart 300 describes an additional alternative method for the production of lead by performing the refining of the molten lead. In an embodiment, the method employs a use of two ladle transfer vehicles for carrying the molten lead obtained from the smelting unit 202. Further, each of the two ladle transfer vehicles includes a plurality of ladles.
[0075] The flowchart 400 initiates at step 402. At step 404, the smelting unit 202 taps the pre-determined amount of the molten lead into each of the plurality of ladles associated with each of the two ladle transfer vehicles at the pre-defined interval of time. Moreover, the molten lead is tapped at the first pre-defined range of temperature. The pre-determined amount of the molten lead is based on the capacity of each of the plurality of ladles associated with each of the two ladle transfer vehicles. At step 406, the plurality of ladles filled with the molten lead are transferred for the water spraying on each of the two ladle transfer vehicles.
[0076] Furthermore, at step 408, the cooling unit 206a initiates the controlled water spraying procedure above each of the plurality of ladles of each of the two ladle transfer vehicles containing the molten lead. The water is sprayed on top of the molten lead to facilitate quicker and instantaneous generation of the dross. The water spraying procedure is performed for quenching the temperature of the molten lead from the first pre-defined range of temperature to the second pre-defined temperature. Also, the water spraying procedure is performed for enabling the instantaneous generation of the dross over the surface of the molten lead in each of the plurality of ladles. At step 410, the dross separation unit 206b removes the generated dross from over the surface of the molten lead in the plurality of ladles of each of the two ladle transfer vehicles. The dross is removed instantly from the surface of the molten lead on the generation of the dross. At step 412, each of the two ladle transfer vehicle containing the plurality of ladles are transferred to a lead refinery for the refining. The collecting unit 206c obtains the lead from the plurality of ladles after the removal of the dross. The flow chart 400 terminates at step 414.
[0077] It may be noted that the flowchart 400 is explained to have above stated process steps; however, those skilled in the art would appreciate that the flowchart 400 may have more/less number of process steps which may enable all the above stated embodiments of the present disclosure.
[0078] In addition, a lower generation of generation of the dross to 8% significantly improves the yield of the molten lead. The improvement in the yield of the lead decreases the production cost per batch process. The time taken in completion of the batch process of the production of the molten lead is turnaround time. The instantaneous generation of the dross provides a decrease in the turnaround time for each of the plurality of the ladle transfer vehicles 206. Further, in an embodiment of the present disclosure, the decrease in the turnaround time enables a rapid production of lead.
[0079] The foregoing descriptions of specific embodiments of the present technology have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present technology to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the present technology and its practical application, to thereby enable others skilled in the art to best utilize the present technology and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions and substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but such are intended to cover the application or implementation without departing from the spirit or scope of the claims of the present technology.
[0080] While several possible embodiments of the invention have been described above and illustrated in some cases, it should be interpreted and understood as to have been presented only by way of illustration and example, but not by limitation. Thus, the breadth and scope of a preferred embodiment should not be limited by any of the above-described exemplary embodiments.

Claims:What is claimed is:
1. A method for production of lead by performing refining of molten lead by removal of one or more impurities, the molten lead being procured from one or more sources, the method comprising:
tapping a pre-determined amount of the molten lead into a ladle associated with each of the plurality of ladle transfer vehicles at a pre-defined interval of time, wherein the molten lead being tapped at a first pre-defined range of temperature and wherein the pre-determined amount of the molten lead being based on a capacity of the ladles associated with each of the plurality of ladle transfer vehicles;
Transferring the tapped molten lead in the ladle of each of the plurality of ladle transfer vehicles for the refining of the molten lead;
initiating a controlled water spraying procedure above the ladle of each of the plurality of ladle transfer vehicles containing the molten lead, wherein the water spraying being done for enabling instantaneous generation of dross over a surface of the molten lead;
removing the generated dross from over the surface of the molten lead in the ladle of each of the plurality of ladle transfer vehicles, wherein the dross being removed instantly from the surface of the molten lead on the generation of the dross; and
obtaining the lead from the ladle of each of the plurality of ladle transfer vehicles after the removal of the dross.
2. The method as recited in claim 1, wherein the water spraying procedure being performed for quenching temperature of the molten lead from the first pre-defined range of temperature to a second pre-defined temperature.
3. The method as recited in claim 2, wherein the second pre-defined temperature of the molten lead after the water spraying procedure being 500°C.
4. The method as recited in claim 1, wherein the first pre-defined range of temperature of the tapped lead bullion being in a range of 950°C to 1100°C.
5. The method as recited in claim 1, wherein process of the production of lead being a batch process.
6. The method as recited in claim 5, wherein a number of tapping per batch for the tapping of the molten lead in the ladle of each of the plurality of ladle transfer vehicles being 4-5.
7. The method as recited in claim 1, wherein the quenching being performed for minimizing a time taken for cooling of the molten lead.
8. The method as recited in claim 1, wherein the instantaneous generation of the dross provides a decrease in a turnaround time for each of the plurality of ladle transfer vehicles and wherein the decrease in the turnaround time enables a rapid production of lead.
9. The method as recited in claim 1, wherein the transferring of the molten lead by each of the plurality of vehicles being done in real time.
10. The method as recited in claim 1, wherein the dross generated by the controlled water spraying procedure being 8%.