Exide Industries Limited

Title- Operating Procedure for Oxide Mill/RP machine 2

Date- 23-11-2023

1. Objective- Preparation of Lead Oxide Powder

2. Responsibilities- Individuals involve are

 Operator – Filling of log sheet

 Lab Assistant- Filling of control chart/quality
inspection
 Non-Permanent
 Quality Assurance Department
 Maintenance

3. Material Required-
 Lead(99.99% Pure)
 Water
4. Equipment-
 Reaction Pot with Accessories
 Lead Pot with Accessories
 Hepa Filter
 T.C.C with Accessories
 Bag Filter
 Silo Storage for oxide
 Scoops for Oxide Sampling
 Hoist with Accessories
 Ladle for dross out

5. Set-up Verification-
 Start the heating process of Reaction Pot and
Lead Pot Burner approx. 5 hours before start
of operation.
  Ensure the temp of Lead Pot 440 +/- 30
DEG.C
 Ensure the temp of Reaction Pot 360 +/- 20
DEG.C
 Ensure the temp of Lead Pipe(Feed pipe) 400
+/- 20 DEG.C
 Exhaust Fan, Vibrators, Lead Pump, Agitator
& Pulse Jets will start in Auto Mode when
pre-set temperature are achieved by
machines.
 Open Exhaust Fan damper to approx. 50%
 Ensure all the parameters are defined by
technician
6. Troubleshooting-
Insufficient Airflow rate coming from system fan or
ductwork system.
Actions-
o Check wiring
o Make Sure Motor leads are
attached to proper terminals
o Check Connections
o Ensure no extra material
deposited on fan.
Excessive Airflow Rate.
Actions-
o Check Settings and adjust.
o Evaluate the ductwork system.
o Close all pores and ensure they are
seal properly.
Common Baghouse issues such as higher
anticipated pressure drop and moisture in the bag
house.
Actions-
o Clean all the pressure taps, check
houses for leaks, for proper fluid
pressure in manometer.
o Rise the gas temperature.
Note:- Any general issues are alerted immediately on the UI display and
 machine stops automatically.

7. Procedure-

 After Starting of reaction pot, ensure that

approved lead ingots are placed on conveyor
belt and put the belt on Auto mode.
 Ensure oxide filling in lead pot is in steady
mode.
 In case reaction pot temperature rises,
machine will add water in auto mode.
 Ensure PbO % is analyse by laboratory
periodically and recorded on control chart.
(If PbO % is more, Close the air damper to
decrease temperature and if it is less, Open
inlet air damper to increase temperature of
reaction pot by changing PID).
 Inform the lab assistant for taking sample 15
min after corrective action has been taken.
o If PbO% found OK, keep machine
running.
o If PbO% found NOT OK, stop the
machine.
 8. Record keeping –
 Log Sheet filled by operator on hourly basis
 Control Chart for PbO % filled by lab
assistant 2 times in a shift.
 Control Chart for apparent density filled by
lab assistant 1 time in a shift.

9. Waste Management-
 Residual waste after the process are sent for
recycling and reuse.
 Hepa Filter is connected to bag house which
filters the air present in bag house and then
into atmosphere. (PbO particles get filtered).

10. Safety Measures-

 Use of Safety Shoes
 Use of Nose Mask
 Use of Cotton Cap
 Use of Canvas Gloves
 Only dry Ingots should be used for
Melting( Moisture less)

Picture representation of Oxide Milling/ RP 2 operation

Picture Description
Input of Lead Ingot into Lead Pot through
Conveyor Belt.

Feeding Pipe linking Lead Pot and

Reaction Pot

Preparation of PbO fumes in Reaction

Pot.

Cyclone for Fume extraction from

Reaction Pot to Bag House
Inlet/Outlet air filtration

Bag House

Silo for Oxide Storage