LEEKHA CHEMICALS PVT. LTD.

20,M.I.E. PART-A, BAHADURGARH, DIST. JHAJJAR

HARYANA
Industrial training & Major report
(from 27-June-2015 to 20-July-2015)
Submitted to.
MEERUT INSTITUTE OF ENGG. & TECHNOLOGY
Meerut, Uttar Pradesh
In partial fulfillment of requirements
For B-Tech in
CHEMICAL ENGG.
DEEPAK CHOUDHARY
Roll No-1306851901
MIET, 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

Index
a.Introduction of Leekha Chemicals Pvt. Ltd.
b.Raw material
c.Manufacturing Products
d.Chemical & Physical Properties of Products
e.Applications of Products
f. Processing using Flow-chart
g.Equipments & Specifications used in Industry

Page No.
(4)
(5-6)
(7-8)
(9-12)
(13-14)
(15-19)
(20-34)

h.Environmental issues & Treatment

i.Risks & Precautions
j.Conclusion

(35-37)
(38)
(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 such as TBLS, DBLS of
various metals, 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 Materials
The major raw materials which are used in the industry are as follows:-

Lead :Lead is a chemical element in the carbon group with symbol Pb and atomic number 82. 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 nonradioactive 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 C 6H4(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 C 17H35CO2H. 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.

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 Na 2S2O5. 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, 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 C 17H35CO2H. 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 + H2O

It is also the main component of soap scum, a white solid that forms when soap is mixed
with hard water. 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.

Chemical & Physical Properties of

Products

Tri Basic Lead Sulphate (TBLS):Product Data Sheet

Molecular Formula

3PbO.PbSO4.H2O

Appearance

White Powder

Molecular Weight

990.74

Specific Gravity

2.66

Moisture , %

1.0 Max.

Melting Point

900*C

Particle Size

-200 Mesh

Lead Content(as PbO ), %

Purity, %

87-89
99.0 Min.

Free Fatty Acid , %

Not Applicable

Packing

25 Kg. HDPE bags with LDPE liners

Di Basic Lead Stearate (DBLS) :Product Data Sheet

Molecular Formula

2PbO.Pb (C17H35COO)2

Appearance

White Powder

Molecular Weight

1219.87

Specific Gravity

1.90

Moisture , %

1.0 Max.

Melting Point

115 - 117*C

Particle Size

-200 Mesh

Lead Content(as PbO ), %

Purity, %

54-55
99 Min.

Free Fatty Acid , %

2.0 Max.

Packing

25 Kg. HDPE bags with LDPE liners

Calcium Stearate :Product Data Sheet

Molecular Formula

Ca (C17H35COO)2

Appearance

White Powder

Molecular Weight

606.61

Specific Gravity

1.035

Moisture, %

1.0 Max.

Melting Point

150 (+/- 5)* C

Bulk Density Gm/CC

0.2 (+/- 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)

Packing

25 Kg. HDPE bags with LDPE liners

Litharge :Product Data Sheet

Appearance

Canary yellow to reddish yellow

powder

PbO (% min)

99.5

Free Pb (% max)

0.01

Pb304 (% max)

0.06

Melting point (C)

888

Specific gravity

9.50

Density (g/ml)

1.6 - 2.0

Volatile matter (% max)

Water absorption

0.20
100 - 105 mg/gm

Lead Stearate (LS):Product Data Sheet

Lead Stearate

Appearance

White Powder

Specific gravity
Moisture (% max)
Lead Oxide (% PbO)
Free fatty acid (% max)
Bulk density (g/ml)

1.40 0.02
0.10
30 - 34
0.60
0.6 - 0.7

Dibasic Lead Phthalate (DBLP) :Product Data Sheet

Appearance
Specific gravity
Moisture (% max)

soft creamy powder

4.4 0.05
0.50

Lead Oxide (% PbO)

79 - 81

Bulk density (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 of
Electrical conduit & cladding.
Rigid extrusion of main water goods.
Guttering and soil pipes.
Pipes for conveyance of gases and liquids.
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

 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.

Diesel dryer

 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.

Flakers

 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.

CSTR (Continuous stirred tank reactor)

 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.

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.

Melting Pot

 The Melting pot has stainless steel shell. The temperature

control (150 to 550 range). It is used for melting the
raw material by the blower to increase the flame length
for proper heating provided to the materials.

Cyclone Separator

 The Cyclone Seperator in which 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. It has an tangential inlet
where the air with dust and particles and the dust is collected
from the bottom and the clean air is removed from the top.

Bag Filter

 The Bag Filter is made by polypropylene or polyester

materials. Where the propylene has the pressure of 35PSIG
maximum for dirty air.It is used in the industry after the
product formed in the solid form and the dust particles are
necessary to removed from it.

Grinder

 The Grinder is used in which the grinding (hammer) roll is 4

in numbers where the diameter is 310mm and height is
170mm. The feeding size is <25mm and output is 0.6130.033mm. The capacity is 1.1-5.6t/h and the Motor power is
72.5kw.

Tray dryer

 The Tray Dryer in which the loading capacity is 48 trays. Its

external Dimension is 1980*1020*1880mm. Number od doors
is two and one blower and voltage is 415V. The tray size is
812*406*31mm. The steam consume is 60lb/hr. The Steam
pressure is 3.3kg/cm2.

Fired Boiler

 The Fired Boiler has the fuel consumption is 100kgs/hr.The

max. fluid outlet temperature is 300C. The thermal effeciency
is 75%.The thermic fluid flow is 14m3/hr and the thermic fluid
pump motor is 5.5kw. The total load is 6.24kw.

Ribbon Blender

 The Ribbon Blender is the holding capacity is 1000ltrs

where the working capacity is 800ltrs. The container
dimension is 1230*900*1700mm. The power required is 5H.P.

Environmental issues with Lead & their Products

,Chemicals
Lead Pollution
Estimated Population at Risk:
1.9 Million
Description

Lead 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 Context
Lead 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 soil
It 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 plants

Plants 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-organisms

Evidence 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 animals

Lead 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:

Wear protecting clothes on the job.

Take a shower after the job.
Do not eat, drink or smoke in an area where lead is used.
Take buttermilk so that it can absorb the lead from the body and reduce
their effect.
Use protecting shield and gloves in the industrial area.
Use suitable containers for the chemicals.
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.