Project Final

AN OVERVIEW OF THE INDUSTRY
1.1 INTRODUCTION
The Amara Raja group is Indian Conglomerate Company with its corporate office at
Anna Salai, Chennai. The group has presence in packaged foods and beverages, electronics
products manufacturing, infrastructure sector, power system production and fabrication of sheet
metal products and fasteners. The Amara Raja group is better known for its automotive battery
brand “AMARON” which is the second largest selling automotive battery brand in India today.
Amara raja group employs a work force of over 7000 employees and it has international joint
venture alliance with Johnson Controls Inc. Amara Raja batteries made it to Asia’s “Best under a
Billion” 2010 list of companies compiled by Forbes magazine.
Amara Raja believes in influencing and improving the quality of life by building
institutions that provide better access to better opportunities, goods and services to people all the
time. With innovative engineering, research and design, Amara raja has grown with partnerships
and information sharing with world leaders.
DEPT. OF CHEMICAL ENGG. SVUCE 1

1.2. PROFILE OF THE AMARA RAJA COMPANY
Dr. Ramachandra N. Galla has started his career as an Electrical Engineer in US Steel
Corporation and then moved on to Sargent & Lundy, USA as a Consulting Engineer for the
Designing of Nuclear & Coal Fired Power plant. He initiated various projects in these corporations
& mastered the ropes of this competitive business in a very short time. However, he soon
discovered that his natural inclination was serving his country and as a logical sequel he gravitated
towards Chittoor. Dr.Galla laid the foundation of Amara Raja Batteries in 1985 closer to Tirupati.
With his intense zeal and highly focused approach, he propelled Amara Raja Batteries in the top
league of battery companies in India.
Dr. Galla obtained his Bachelor and Master Degrees from Sri Venkateswara University,
& Roorkee University, (now upgraded to IIT), respectively and also holds M.S. Degree from
Michigan State University. Dr. Galla has been bestowed with Honorary Doctorate degrees from
Jawaharlal Nehru Technical University, Hyderabad & Sri Venkateswara University, respectively,
in2008 & 2007.
Dr. Galla has established various charitable trusts like Krishna Devaraya Educational
& cultural association (KECA), Rajanna Trust, Mangamma & Gangul Naidu Memorial Trust. He
is dedicated to rural development and improving economic conditions of farmers in Chittoor
District, Andhra Pradesh. KECA which was established in 1975 provides scholarship to the poor
and needy students to pursue their higher education.

1.3. Key Milestones of Amara Raja Group
 Designed and implemented the most advanced battery manufacturing facility in India in
1991-92
 Received the ISO-9001 Certification in February 1997
 Crossed 100 crore turnover mark in March 1997
 Commissioned in-house plastics and tool room section in August 1997
 Installed latest air pollution control equipment in April 1999
 Received the QS-9000 Certification in May 19999
 Launched Amaron Hi-Life (automotive batteries for the replacement market) in January
2000
 Implemented the ERP system in March 2000 for enhanced operational efficiencies and
closer integration of expanding operations and spread of business
 Launched Amaron Pit shops- exclusive state-of-the art showrooms for Amaron in July
2000
 Launched Amaron Shield inverter batteries in July 2001
 Launched Brute motive power batteries in September 2001
 Launched new corporate logo in September 2001
 Commissioned Phase-1 of fully integrated automotive battery in Tirupati, September 2001
 Received the ISO 14001 Certification for EMS in May 2002
 Received the ISO/TS 16949:2002 in the year 2004 for ARBL
 Received the ISO/TS 16949:2002 in the year 2006 for ARBL
 Commissioned SMT (Surface Mount Technology) Machine at AREL Diguvamagham in
2006
 Commissioned extruder plant at MPPL, Petamitta in the year 2007
 Commissioned VHT project in GFL with a view to export Fruits & vegetables to Japan in
2007
 Laid Foundation stone for establishing Two wheeler battery plant on 10 April 2007
 Launched Power Zone Batteries brand on May 2007
 Commissioned Beverage plant in GFL on 21 April 2008

1.4. Awards Received by Amara Raja Group
 Best Industry round Performance award in 1998 by FAPCCI

 Entrepreneur of the year award to Mr. R.N. Galla, chairman & Managing Director in 1998
by HMA
 Business Excellence Award in 1999 by industrial Economist
 Udyog Rattan Award in 1999 by the institute of Economic studies
 Most Significant Automotive product of the year in December 2000 by overdrive (India’s
leading auto magazine). This honor is in recognition of Amaron technological superiority
and innovative product features, which have created a new standards for automotive
batteries in India.
 ‘Excellence in Environmental Management’ in June 2002 by Andhra Pradesh pollution
control board
 Amara Raja received 5 Awards at the Mumbai Advertising club Awards 2003 for the
Amaron Hi-Life advertising campaign of the year Award, Advertiser of the year Award
and 2 silver and 1 Gold Abby in other categories.
 Amara Raja received Best 5S practices implementation award from CII, southern region
 MPPL Received award in recognition of excellence in cleaner production Technologies
and adoption of climate change mitigation measures from AP pollution control Board.
 Employee Branding Awards: “Award for Best HR strategy in line with Business’’ and
“Award for continuous innovation in HR strategy at work’’.
 Amara Raja power systems Ltd (ARPSL) has won the prestigious IEEMA SME Quality
Award, the highest award constituted by IEEMA for Excellence in Quality systems for
2010.

The Associate Amara Raja Group of Companies
 AMARA RAJA BATTERIES LIMITED (ARBL)

 AMARA RAJA POWER SYSTEMS PRIVATE LIMITED (ARSPL)
 MANGAL PRECISIONS PRODUCTS PRIVATE LIMITED (MPPL1)
 MANGAL PRECISIONS PRODUCTS PRIVATE LIMITED (MPPL2)
 AMARA RAJA ELECTRONIC PRIVATE LIMITED (AREPL)
 GALL FOODS PRIVATE LIMITED (GFPL)
 AMARA RAJA INFRA PRIVATE LIMITED (ARIPL)
Amara Raja Batteries Limited (ARBL)
Amara Raja Batteries Limited (ARBL) was established in the year 1985 as private limited
and then converted into public company in the 1990.The company is currently poised on a healthy
growth curve since its inception. Amara Raja Batteries has a strategic tie up with Johnson control
Inc. USA, who owns 26% stake in this company. Johnson Controls is a Fortune 500 company and
also the largest manufacturer of lead acid batteries in North America and a leading global supplier
to major automobile manufacturers and industrial customers. BL has demonstrated its commitment
to offer optimum system solutions of the highest quality. It has become the largest supplier of
standby power systems to core Indian utilities such as the Indian Railways, Telecommunications,
Electricity Boards and Major power generation companies in India.
Amara Raja has always offered time tested world class technology and processes
developed on international standards-be it high VRLA systems like Power Stack and Power Plus
or the recently launched high performance UPS battery –KOMBAT and Amaron hi-life
automotive batteries that are products of the collaborative engineers at Johnson Controls Inc. and
Amara Raja. Amara raja entered into an agreement with Honda, Japan for the development of
VRLA motor cycle batteries and Amara Raja is the first supplier of the batteries for India’s first
micro hybrid vehicle of Mahindra & Mahindra.

Amara Raja Power Systems Pvt. Ltd [ARPSL]
Amara Raja Power Systems Pvt. Ltd was incorporated in 1984 and was co-promoted by
AP ELECTRONIC DEVELOPMENT CORPORATION [APEDC].By virtue of APEDC’s equity
participation, ARSPL has become a deemed Public Limited company as per section 43(A) of the
companies Act. ARPS (P) is engaged in the manufacture of uninterruptible Power Systems (UPS),
Battery Chargers (BC) and Inverters. The company had a technical collaboration with HDR Power
System Inc. USA. The operations of the firm are highly satisfactory. The present credit rating of
the company is ‘A’.
Product(s): Conv. Chargers, Switch Mode Rectifiers (SMR) & Integrated Power Supply System
(IPS).
Customers: Telecom, Railways, and offshore platforms.
Mangal Precision Products Private Ltd (MPPL1)
Mangal Precision Products Private Limited was incorporated in the year 1990 for
manufacture of MS Cabinets, trays, UPS, Battery Chargers, Inverters, etc. and to manufacture
small battery parts. It is having all the sheet metal processing machinery starting from sheet cutting
to final painting with punching, bending, phosphate and power coating processes. The Plant is
located at Tirupati and is registered as an ancillary unit to ARBL and ARPSL. The operations of
the company are brisk and satisfactory.
Mangal Precision Products Private Ltd (MPPL2)
Mangal Precision Products Private Limited was started in the year 1996-97 to produce
battery components like copper connectors, copper inserts, hardware required by ARBL &
ARPSPL. The unit is located at Petamitta village, Puthalapattu Mandal, Chittoor District, AP at a
distance of 65 kms from Amara Raja Group of Companies, Karakambadi. To develop backward
villages, ARBL, CMD located the unit in Petamitta and provided an employment to nearly 35
persons. It will also produce quality hardware for Automobile manufactures coming up near
Madras. The unit is having required machinery and equipment like power press break, mechanical
press, cold forging machine, thread forming machine, lathe, drilling, trapping machine etc. to

produce the above components. These components are electroplated and dispatched to ARBL and
ARPSL.
Amara Raja Electronics Private Limited (AREPL)
Printed circuit Boards (PCB) assembly on job work basis for Amara Raja Power Systems
Pvt. Ltd., Tirupati. Populated Printed Circuit Board assembly for sale to Original Equipment
Manufacture [OEM].
Galla Foods Pvt. Limited
. Tropical fruits pulp and concentrate
(Used for-ice cream, Confectionery, Beverages and juices)
. Fresh fruits (Mango-Artificial ripening chamber) (Table variety for Exports only)
Activities:
. Fruit juice extraction
. Treatment
. Concentration
. Sterilization
. Packing in Aseptic condition
Amara Raja Infra Private Limited (ARIPL)
Amara raja group entered into a new business venture like infra & civil construction and
it was established on 29th May, 2008. ARIPL is a part Amara Raja Group of companies & taking
responsibility of internal Civil constructions, Electrical projects & infra development across the
Amara Raja Group.

Amara Raja Industrial Services Pvt. Ltd (ARISPL)
After a recent launch of Infrastructure Company ARIPL by Amara Raja last year (2008),
this year (2009) Amara Raja ventured into another business of industrial services. This company
will focus on facility management, property management and other hospitality related services.

2.1. Amara Raja Batteries Limited (ARBL)
Amara Raja Batteries Limited Company comprises three major divisions such as:
(i) Industrial Batteries Division [IBD]

(ii) Automotive Batteries Division [ABD]
(iii) Small Batteries Division [SBD]
2.1.1. Industrial Batteries division [IBD]:
ARBL is the first company in India to manufacture valve regulated Lead acid (VRLA)
batteries and (also named as sealed Maintenance Free batteries) with GNB industrial
battery Co. U.S.A. for manufacturing Valve regulated lead acid (VRLA) batteries. Amara
Raja Batteries Limited was established in the year 1985 as private limited and then it has
been shaped into public limited company. The company was located at karakambadi
village, Renigunta Mandal.
India is one of the largest and fastest growing markets for industrial batteries in the world
and Amara raja is leading the front, with an 80% market share for standby VRLA batteries.
Amara raja has become the benchmark in manufacturing industrial (VRLA) batteries. It is
also having the facility for producing plastic components required for industrial batteries.
The major application of VRLA batteries are given in the following.
. Power Plants
. Process & Service industry
. Railways
. Telecommunications
. Uninterruptible Power supply (UPS) systems
. Electronic private Automatic Branch Exchange [EPABX]
. Defense [onshore & offshore wireless communications, cellular radios]
. Motive Power, etc.

. Kombat: UPS, EPBX, Emergency lighting, SPV, Fire alarm, security systems, etc.
. Brute: Forklifts, Pallet trucks, Stackers, Platform trucks.
. Genpro: Generators starting
. Quanta: Bank, Insurance, Finance, Healthcare, Education, IT enabled services, Industry, etc.
Customers:
Amara Raja Batteries being the first entrant in this industry had the privilege of pioneering
the VRLA technology in India. With the requisite approvals and manufacturing facilities,
Amara Raja has established itself as a reliable supplier of high quality products to the major
segments like Telecom, Railways and power control.
2.1.2. Automotive Battery Division (ABD):
Amara Raja batteries Limited inaugurated its new automotive plant at karakambadi in
Tirupati on September 24th, 2001. This plant is part of the most completely integrated
battery manufacturing facility in India with all critical components, including plastics
sourced in-house from existing facilities on-site. This gives Amara Raja complete control
over inventory and product quality. In this project, Amara Raja’s strategic alliance partners
Johnson Controls, USA have closely worked with their Indian counterparts to put together
the latest advances in manufacturing technology and plant engineering. It is also having
the facility for producing plastic components required for automotive batteries.
Products:
 Amaron Fresh batteries

 Amaron Hi-way truck batteries
 Amaron Harvest tractor batteries
 Amaron PRO
 Amaron Hi-life batteries for Automobiles
 Amaron Shield for Inverters
 Amaron GO batteries

 Amaron Black
 Power Zone
Customers:
ARBL has prestigious OEM clients like FORD, General Motors, Daewoo Motors,
Mercedes-Benz, Daimler Chrysler, Maruthi, Premier Auto Ltd and recently acquired a
preferential supplier alliance with Ashok Leyland, Hindustan Motors, Telco, Mahindra &
Mahindra and Swaraj Mazda. The company entered the replacement battery segment with
the launch of Amaron Hi-life auto batteries.

Production and Processing in SBD
In Small Batteries Division (SBD), the production of batteries is done by various processing
steps followed by the other. The manufacturing steps are shown below in flow sheet and are given in
detailed:-
Figure 1: The flow chart showing the manufacture of Lead Acid batteries in SBD

3.1. Grid Casting:
Melt the Pure Lead bars (99.9%) dropped into the lead pot which is maintained at
a temp of 280 0c. The dust fumes released inside the pot are extracted through Dust Fume
Extractors. The molten metal is pumped to the ladle by solenoid valve which flows through a series
of grid casting molds. The grids are designed in such a way that molten metal gets converted into
grids. During the process of grid casting, common deviations or defects observed are:
(i) Variation in thickness (ii) Shrinkage
(iii) Miss trimming (iv) Blow holes
(v) Flashes (vi) Wire missing
3.2. Oxide Plant:
Pure lead (99.97%) is used to prepare oxide powder using the Barton pot process,
where the lead ingots were melted and oxidized in the presence of air. The process parameters that
are maintained during the preparation of oxide powder are:
 Melting pot temp : 665±15 0F

 Reactor pot preheating temp : 425±15 0F
 Normal operation temp : 715±15 0F
 Reactor motor load : 35 to 45 0F
 Bag house temp : 200±20 0F
The lead ingots are melted with the help of heaters. The molten lead is fed into the
reactor pot and is broken up into droplets by revolving paddle. A stream of air is blown over the
droplets which oxidizes the lead. The resulting oxide powder is carried by air stream into the
cyclone where the powder further disintegrated and are moved to bag house (silos) which consists
of number of filters. Silos are used to store the lead oxide. Each silo have the capacity of 25 ton.

Figure 2: The process flow chart in oxide plant
3.3. Ox-Master Plant:
In Ox-Master the paste mixture is prepared which is applied over the grids
prepared from the grid casting section. The paste mixture is prepared in a batch reactor where the
input to the reactor is located in the Ox-Master plant. Demineralized water, Lead oxide powder,
H2SO4 are fed to the reactor. The mixture is allowed to mix evenly for some time. Then the mixture
is used as pasting line over the grids and thus plates are prepared.
3.4. Pasting lines:
Grids were made to pass through with help of conveyor. The paste mix pastes over
the grids as the grids passes along with the conveyor. The paste is applied through the grid structure
by paste feed roller that is located in upper orifice plate. The bottom orifice plate rollers trowel the
paste on the underside of grid. After stacking, the stacked plates were transferred to curing and
drying ovens. Before that the plates are to undergo aging period. Ensure that the plates should have
undergone aging for 24 hours (+ve plates).

Figure 3: The flow chart showing pasting process on the grids
3.5. Curing and Drying:
Curing and Drying is one of the critical process in tailoring the electrode plates
and is done at different stages with varying curing conditions. It is carried out to impart cohesion
and adhesions are imparted to the active material prior to formation. Adhesion is dependent upon
the strength of the bond, which is formed between the paste and the grid. These essential properties
are the best accomplished by conducting the curing procedure in the following sequence:
 Steaming period: Steam is applied to equalize the moisture content in all the plates
and it supports for the development of lead sulfates.
 Low humidity treatment to affect oxidation of free lead.
Drying process is to bring down the water content (moisture) to the low level for
the active material to have good stability. During the process physical, chemical and morphological
changes take place within the active material.

3.6. Assembly:
The tailored electrode plates of positive and negative are selected and grouped
alternatively and each process is discussed in the following sub sections. The process of assembly
of the lead acid battery is shown as flowchart in the following figure:
Figure 4: The flow chart showing the process of assembly
3.6.1. Group stacking:
Bottom shield is placed in the fixture, this prevents the plate damage. First an
unwrapped negative plate is placed in the fixture. Then a half-length separator is placed on the
negative plate.
 The separator is sheared by activating the cutter blade after getting the pre-defined length.
 Then positive plate is placed and separator is folded over this plate. Place the half-length
separator on the last positive plate and then place unwrapped negative plate on the top of
the half-length separators, complete the stack.
 Shields are provided on positive plates to avoid direct contact between positive and
negative plates.

3.6.1.1. Group burning:
 Aligning of bus bars with lugs is called group burning.

 By using the protection of jigs, these combinations can be shield rightly.
 Adjust the oxy-acetylene gas torch for neutral flame and length of inner core is 2.5 cm.
 Positive strap is burnt first as if requires more time for cooling.
 The molten metal is stirred with them.
 The post protection jigs are chilled with demineralized water and then they were removed.
3.6.1.2. Group strapping:
 Plates were strapped on strapping machine with poly-propylene. These straps held the
stacks together.
3.6.1.3. Group Insertion:
 The strapped plates are inserted into jars/containers shield in wrapped form on the plates
before insertion.
3.6.2. Heat Sealing:
The cover is placed over the jars such that the posts can slide inside the bushing.
The heaters are maintained at a temperature of range 440-480 0F. First take 10 seconds for melting
and other 10 seconds for welding them together. The covers must be positioned so that the polarity
marking on the cover corresponds to proper post/bushing location.

3.7. Formation:
The cells or batteries are placed in tub and packed with PPCP spacers and strapped
with metallic bale. The cells are connected in series using cable connectors and bolts.
Figure 5: The flow chart showing the formation process of Lead Acid Batteries
3.7.1. Acid filling:
At first the volume vessel is filled up to the present volume. The cycle starts by
pulling the vacuum in the battery until present vacuum level is reached. Then the acid is transferred
from volume vessel to the expansion vessel. The venting valve provided on top of the machine
will open and because of vacuum in the battery causes an air stream which will force down the
acid into the battery. If there is still electrolyte in expansion vessel another vacuum pulse will be
pulled.

Specific gravity of H2SO4 is 1.257 ± 0.005 H2SO4 is chilled to 100 C and filled.
Funnel is installed on cell to be filled and must not be removed until the formation discharge. Once
the funnel has been secured, place the filling hoses from the jar into the funnel tubes. Soaking time
is 20-75 min. Fill the tubes with water before connecting them for first charge. Water regulates the
temperature during formation temperature of cell (electrolyte) should be between 40-650c during
formation change maximum of 108 cells be formed on any given circuit.
The first charge is 60 hour with a rest period for 10-15 min and then formation and
discharge of 10hr. The capacity verification is done at the end of the 10th hour and the cells that
are showing voltage more than 1.75V should be considered acceptable. During capacity discharge,
water is added the bank current shall be monitored and recorded for every 2hr once the discharged
has started it will continue until a reading at 90% capacity is taken. The vent plug is fixed without
silicon sealant within 1hr from the start float charge. Recharge the battery for 10hrs (10%) and
then 12hrs (3%). The float voltage of the cell or battery is 2.25V and time is around 12hrs.
During the cell cleaning all the inter connections are removed and the cells were
flushed with fresh water. They are cleaned with is propyl alcohol and the petroleum jelly is applied
to post and ensured that there is no water residue.
3.8. Finishing & Dispatching:

The vent plug is and sealant compound is applied to it. Resin is applied for IP series
cells. Screen printing of the cell details is done on the vertical side of the tray. Boost charging is
done if required before going for dispatch. If the cells are stored for more than 30 days, boost
charging is required i.e. charge at 3% for 24 hrs and the rest the cells for about 30 min. the capacity
discharge is done for 10 hrs.
In dispatching the cells were packed and the necessary accessories required for
functioning of the cells is supplied to the customer. The accessories include connectors, bolts,
washers, cables etc.

INTRODUCTION TO WATER
Water is essential for life. People, animals, and plants all need water to live and to
grow. On worldwide basis the amount of fresh water available is approx.8300 m 3 per person per
year. However, neither the population nor the availability of fresh water is uniformly spread across
the globe.
Water in our body has a very important role and an excellent water circulating
system is established in our digestive tract. The human body consists of around 65% water and if
we lose 3% of it, we will have symptoms of dehydration. If we lose 10~15% of it, body conditions
get affected.
Usually adults drink around 2~2.5 liters of water every day, but in our body
approximately 6~7 liters of water is circulated in our digestive tract to digest and absorb the
nutrients of foods.
In 1970, the clean water Act provided 50 billion dollars to cities and states to utilize
waste water, this act helped control water pollution from industrial and municipal areas. In 1972
the clean water Act was passed by the government, each state had to comply with the set required
standard from government and follow the guidelines to control water pollution. Our Government
can’t do it alone. It is up to us as human beings to be aware, informed and educated .We must
become familiar with our local water resource by being educated and learn who, what, when ,
where, why and how to dispose certain chemicals, car oil, fertilizers, pet waste, leaves, and grass
clipping out of the gutters and storm drains. These are just few requirements that are necessary to
prevent water pollution .We can also protect ourselves by learning which is most beneficial home
water filter to use for certain type of minerals that comes from our water supply. We as human
beings need to take responsibility for our own actions on health, and ocean life to help prevent to
add to the event.

4.1 Total availability of water on the earth
Figure 6: Total availability of water on the earth
4.2 Percentage of Drinking water on the earth
Only a small percentage of water is suitable for humans to drink. Not all of the
water in the ground and in lakes and rivers is easy to reach or clean enough to drink. Ice caps and
glaciers are certainly hard to use for humans, plants, and animals. Some work is being done to take
the salt out of ocean water (desalination of water), but that is an expensive process. The drinking
water percentages: 0.419% total and 2.799% grand total.
4.3 Water usage in industries
Industrial water use includes water for such purposes as processing, washing, and
cooling in facilities that manufacture products.
4.3.1. Major water-using industries
 Steel industries.
 Chemical and allied products
 Paper and allied products
 Petroleum refining

4.4. Effluent waste water Recycling
Reusing water provides at least three important benefits: it reduces the demand for
clean water, reduces the quantity of wastewater requiring treatment, and reduces the amount of
treated wastewater discharged back into the environment. Some industries have been particularly
effective in reusing water. They reuse process water for washing and cleanup rather than using
clean water.
Some municipalities reuse treated and disinfected wastewater for irrigation. Using
the same water more than once in the same or alternate forms—is the third conservation practice
that helps prevent water pollution. For example, paper recycling helps prevent water pollution by
lowering the demand for raw timber, allowing more trees to remain on the mountainside for
stabilizing the soil, cooling tributary waters, and otherwise benefiting water quality.
Recycled paper is also easier to pulp than timber. It takes less energy, less water,
and fewer chemicals to create recycled paper than it does to create paper from raw wood.

INTRODUCTION TO WASTE WATER
Wastewater Treatment is one of the most important services a municipality may provide
and one of the least viable. Wastewater or sewage water is the byproduct of many uses of water.
There are the household uses such as showering, washing, laundry and of course flushing the toilet.
Additionally, companies use water for many purposes including processes and cleaning or rinsing
of parts. After the water has been used, it enters the wastewater stream, and it flows into the
wastewater treatment plant. Rapid development of industry and society led to serious environment
problems such as contamination of groundwater and surface chemical treatment with organic
compounds coming from agriculture (pesticides, herbicides, etc.) or inorganic compounds in
industries(pigments, heavy metals, etc. ).
5.1 What is Waste Water???
Natural water in contact with foreign matters during either industrial process or
domestic use becomes polluted. Such polluted water is termed as waste water.
Every day, 2 million tons of sewage and industrial and agricultural waste are discharged
into the world’s water (UN WWAP 2003). The UN estimates that the amount of wastewater
produced annually is about 1,500 km3, six times more water than exists in all the rivers of the
world (UN WWAP 2003).
5.2 Sources of Waste Water
Wastewater can originate from many sources such as homes, businesses and industries.
Storm water, surface water and ground water can enter the wastewater collection system and add
to the volume of; wastewater. The source of wastewater will determine its characteristics and how
it must be treated. For example, wastewater from homes and businesses (domestic wastewater)
typically contain pollutants such as fecal and vegetable matter, grease and scum, detergents, rags
and sediment. On the other hand, wastewater from an industrial process (industrial wastewater)
may include; toxic chemicals and metals, very strong organic wastes, radioactive wastes, large
amounts of sediment, high temperature waste or acidic/caustic waste.

Wastewater could even come from streets and parking lots during a rainstorm (storm wastewater)
that could contain motor oil, gasoline, pesticides, herbicides and sediment.
5.3 Effects of Discharged Waste Water into the Environment
Wastewater can potentially contain any disease causing organism, or pathogen, that the
people contributing waste to the collection system are infected with common diseases caused by
water borne pathogens include typhoid, hepatitis, cholera, dysentery and polio. If pathogens are
discharged without treatment into the natural environment, they will pose a danger to anyone that
is exposed to them. For this reason, one of the primary goals of wastewater treatment is to disinfect
the effluent before it is discharged.
Most living organisms live in a narrow pH range that is near neutral. If an effluent has
a pH that is higher or lower than that of the receiving water, the organisms in the receiving water
may be killed off. In addition, if the pH of the influent coming into a wastewater treatment plant
changes rapidly and significantly, the plant treatment processes may be disrupted.
Figure 7: Discharge of untreated industrial waste water into a river

5.4 Types of Waste Water
1. Domestic waste water (sewage)
2. Process waste water (effluent)
1. Domestic Waste Water
Waste water discharged from residence and from commercial, institutional, and
similar facilities. Wastewater is usually treated by supplying oxygen so that bacteria can utilize the
wastewater contents as food. In general it is considered as:
Wastewater + oxygen treated wastewater + new bacteria
The nature of domestic wastewater is so complex that it precludes its complete analysis. However,
since it is comparatively easy to measure the amount of oxygen used by the bacteria as they oxidize
the wastewater, the concentration of organic matter in the wastewater can easily be expressed in
terms of the amount of oxygen required for its oxidation. Thus if for example, half a gram of
oxygen is consumed in the oxidation for each liter of a particular wastewater, then we say that this
wastewater has an ‘Oxygen Demand’ of 500 mg/l, by which we mean that the concentration of
organic matter in a liter of the wastewater is such that its oxidation requires 500 mg of oxygen.
Common Steps for Sewage Treatment
Figure 8: Common steps for sewage treatment

Composition of domestic waste water
Figure 9: Composition of domestic waste water
2. Process Waste Water
Industries require large quantities of water, which gets contaminated during the various
industrial processes. The contaminants include acid, caustic, dissolved solids, toxic metals, metal
compounds and color. Studies conducted by the CPCB (Central Pollution Control Board) reveal
that about 13000 million liters of waste water is generated daily, of which only 60% generated
from large and medium industries is treated.
Industrial waste water usually contains specific and readily identifiable chemical
compounds. Water pollution is concentrated within a few subsectors, mainly in the form of toxic
wastes and organic pollutants. Out of this a large portion can be traced to the processing of
industrial chemicals and to the food products industry. Most major industries have treatment
facilities for industrial effluents but this is not the case with small-scale industries, which cannot
afford enormous investments in pollution control equipment as their profit margin is very slender.
The effects of water pollution are not only devastating to people but also to animals, fish, and
birds. Polluted water is unsuitable for drinking, recreation, agriculture, and industry.

5.5. Waste Water Treatment Methods
Treatment methods are two types. They are
A. Unit operations
B. Unit processes
A. Unit operations
Methods of treatment in which the application of physical forces are predominate are
known as unit operations. Ex:-Screening, Filtration, Sedimentation, Adsorption, Clarifier, Settling
tank.
5.5.1. Screening
Screening is employed for removal of suspended solids of various sizes. Screen openings
range in size depending on their purpose, and cleaning of screens is done either manually or
mechanically. Screenings are disposed off by burial, incineration, or anaerobic digestion.
Figure 10: Screening process.

5.5.2. Filtration
The process of removing solids by passing water through bars, screens, and filters that
allow the water but not the solids to pass. Filtration also occurs in nature as water passes through
vegetation or percolates through the soil.
5.5.3. Sedimentation
Sedimentation is utilized in waste water treatment to separate suspended solids from the
waste water. Removal by sedimentation is based on the difference in specific gravity between solid
particles and bulk of the liquid, which results in settling of the suspended solids.
Figure 11: Sedimentation Tank
5.5.4. Adsorption
Adsorption technology can remove organic materials from wastewater that resist removal
by biological treatment. These resistant, trace organic substances can contribute to taste and odor
problems in water.
Figure 12: Adsorption

5.5.5. Clarifier or settling tank
Clarifier also known as a settling tank, removes solids from wastewater by gravity settling
or by coagulation. Tanks designed for the Physical separation of wastewater floatable solids and
settle able solids. The clarifier separates the treated slurry from clean water. The sludge settles
down and treated water at the top flows down to the cooling tower from where it is cooled and
recycled. .
Figure 13: Clarifier
5.5.6. Filter press
Sludge from the sludge tank will be pumped to the Filter Press equipment for dewatering
purpose. Dewatering is accomplished by pumping a slurry or sludge into chambers.
(A) Surrounded by filter membranes.
(B) As pumping pressure is increased the filtrate is forced through the accumulated filter
cake.
(C) Filter until the chamber is full of solid filter cake. The chambers are formed by two
recessed plates held together under hydraulic pressure.

(D) Moves the follower.
(E) Against the stack of filter plates.
(F) Closing the press. The ram continues to apply sealing pressure of sufficient force to
counteract the high internal compaction pressures.
Figure 14: Filter Press Equipment
B. Unit processes
Methods of treatment in which the removal of contaminants is broad about by chemical or

biological reactions are known as unit processes.
Unit processes
Chemical unit processes Biological unit processes
Treatment methods in which the removal or Treatment methods in which the removal or
conversion of constituents is brought about conversion of constituents is brought about by
by the addition of chemical or by other biological activity are known as Biological unit
chemical reaction are known as Chemical processes.
unit processes.
Ex: disinfection, oxidation, precipitation. Ex: activated sludge, trickling-filter.
Table 1: Difference between Chemical and Biological unit processes

5.6. Waste Water Treatment Levels and Processes
Effluent can be treated in a number of different ways depending on the level of treatment
required. These levels are known as preliminary, primary, secondary and tertiary. The mechanisms
for treatment can be divided into three broad categories: physical, chemical and biological, which
all include a number of different processes. Many of these processes will be used together in a
single treatment plants.
Table 2: Wastewater treatment levels and processes
Flow diagram for Wastewater Treatment level
Figure 15: Flow diagram for wastewater treatment levels

INTRODUCTION TO ETP
Waste water treatment plants are very essential at different places. Now-a-days
installation of waste water treatment plants has become obligatory for industries, commercial
places or residential complexes where a large volume of waste water is discharged every day. The
installation of waste water treatment plant separates all contamination from the waste water and
makes it safe to release in the waste bodies or in the environment.
Common Effluent Treatment Plant
Figure 16: Effluent Treatment Plant
6.1. Effluent: Industrial effluents are liquids or water carrying wastes discharged from various
processes in industries. Wastewater or other liquids, partially or incompletely treated waste water
flowing from a reservoir, basin, treatment processes or treatment plant.
Influent: Wastewater or other liquids flowing into a reservoir, basin, or treatment plant. Influent
is the raw material that has been collected and conveyed to the plant for treatment. It includes all
the water and debris that entered the collection system.

6.2. Treatment in ETP:-The removal of excessively accumulated matter from the waste
water is known as treatment. Treatment facilities incorporate numerous processes which in
combination achieve the desired water quality objectives. These processes involve the separation,
removal and disposal of pollutants present in the wastewater. The treatment of wastewater is
accomplished by 4 basic methods or techniques.
1. Physical
2. Mechanical
3. Biological
4. Chemical.
1. Physical methods of treatment include the use of tanks and other structures designed to contain
and control the flow of wastewater to promote the removal of contaminants.
2. Mechanical treatment techniques involve the use of machines, both simple and complex in
design and operation.
3. The action of bacteria and other micro-organisms are biological methods of treatment, which
play a vital role in the removal of pollutants which cannot be effectively achieved by other means.
4. Chemical treatment methods enhance the efficiency of other process operations and provide
specialized treatments as a result of their addition at various treatment stages.
6.3. The Need for Waste Water Treatment
When untreated wastewater accumulates and is allowed to settle, the decomposition

of the organic matter contained in it will lead to the unhygienic conditions include the production
of malodorous gases. In addition to the unreacted waste water contains numerous pathogenic
microorganisms that dwell in the human intestinal tract. Waste water also contains nutrients, which
can stimulate the growth of aquatic plants, and may contain toxic compounds or compounds that
potentially may be mutagenic or carcinogenic. For these reasons, the immediate and nuisance-free
removal of waste water from its sources of generation, followed by treatment, reuse or disposal
into the environment is necessary to protect public health and the environment.

Waste Water Treatment in Amara Raja Batteries Limited
The waste water of Amara raja Batteries Ltd, treated by using three individual effluent
treatment plants at three divisions(IBD, SBD, ABD) of production for process waste water and
cooling water (effluent water).
7.1. Sources of Effluent Water in Small Industrial Batteries (SBD) Production
Figure 17: The flow chart showing the sources of Effluent Water

7.2. Effluent treatment plant observation in SBD
All the collected waste water from the different sources of plant is sent into the settling
tank. A batch containing 8000 liters of effluent water is sent to the reaction tank. Initially pH of
the effluent is maintained at required level by addition of lime to the effluent and stirring it with
an stirrer. After maintaining the pH at required level add the chemicals like lead precipitator,
coagulant to the effluent. The flocculent solution is prepared and is poured slowly into the reaction
tank. After reaction of the effluent with the added chemicals the lead present in the effluent gets
precipitated and settles down to the bottom of the reaction tank. Then the treated effluent is pumped
to the clarifier. The clarifier tank contains two wells separated by walls. The treated effluent is
pumped to the center well where the minute lead particles if any settles to the bottom of the
clarifier. Settling of micro particles takes place in the clarifier. Then the treated effluent is sent to
the collection tank where it is stored. At last the treated effluent is passed through the Multi Grade
Filter (MGF).
7.3. Procedure for SBD-ETP
 Collect the effluent water into the settling tank, keep the collected effluent
undisturbed for some time.
 Send the effluent from the settling tank to the reaction tank.
 In settling tank sludge will be removed by using Bag filter.
 Before adding the chemicals into the reaction tank we need to check the pH range
of the effluent to be treated.
 If pH range is below 6.5-7 then we need to add lime to increase the alkalinity of the
effluent.
 Add 800g of lead precipitator solution for 8KL of water.
 After adding the lead precipitator solution, stir the effluent with an agitator for half
an hour.
 Now add 2 kg of coagulant solution for 8KL of water.
 After adding the coagulant solution, stir the solution for half an hour.
 Prepare the flocculent solution by adding 250 grams of hydro flock powder to 10
water and mix the solution using a high speed rotating agitator.

 Then add the prepared flocculent solution to the 8KL of water.
 After adding the flocculent solution, stir the solution.
 Because of addition of the coagulant, flocculent solution lead particles gets
precipitated and settles to the bottom of the reaction tank.
 The treated water is pumped to the clarifier tank.
 In clarifier tank by using agitation, the lead content settles to the bottom and treated
water gets separated.
 95% of the pure water is collected into a clarifier collection pit.
 After that collected pure water is sent to the multi grade filter (MGF).
 The purified water is collected in the storage tank or send to gardening.
Process flow chart for SBD-ETP
Figure 18: Flow chart for effluent treatment plant in SBD

7.4. Experimental Procedure:
The Effluents from all the sources of the small battery division are collected into
the settling tank. After collection of effluent into the settling tank, it is kept undisturbed for some
time. The coarse particles present in the effluent settles down to the bottom of the tank and they
are removed from the bottom of the settling tank. Then the effluent is pumped to the collection
tank. It is the inlet for the effluent treatment plant.
Collect the inlet effluent from collection tank into cans. Keep the collected effluent
in a cool place using refrigerant as collected sample effluent may change its properties at room
temperature. Take 500 ml of effluent sample into 3 beakers from the collected effluent. Maintain
the sample at 8 pH.
Check for the initial pH of the taken sample.
(i) If the sample pH is less than 8, add few grams of lime to it so as to bring the sample pH to 8.
(ii) If the sample pH is more than 8, add a small drop of H2SO4 to it to maintain 8 pH.
After adding lime to the sample stir it for 3-5 minutes using a magnetic stirrer
bring the samples to 8 pH. After maintaining 8 pH add 0.01, 0.02, 0.03 grams of lead precipitate
into the samples respectively. Now place the sample on the magnetic stirrer and stir it for 5
minutes. Addition of lime to the sample increases the bonding nature of the lead molecules in the
sample. Allow the sample undisturbed so that the particles get precipitated to form lead precipitate.
Check for the pH of the sample. Now add 0.1, 0.2, 0.3 grams of coagulant into the samples
respectively and stir the samples for 5 minutes. Addition of coagulant increases the affinity of lead
molecules present in the sample. Now check for the pH of the sample.
Preparation of flocculent solution:
Weigh 0.1, 0.2 grams of flocculent powder. Take 100 ml of water into two different
beakers. Place the beakers on a magnetic stirrer, maintaining high speed slowly add the weighed
powder to obtain uniform mixture and it finally turns into a jelly form. The obtained flocculent
solution is 0.1%, 0.2% solution respectively.

Keeping the sample in stirring mode now slowly add the prepared 0.1% of
flocculent solution. After stirring it, place the treated sample aside for some time. The lead particles
gets precipitated and settles to the bottom of the beaker. Similarly treat the effluent sample with
prepared 0.2% of flocculent solution.
Now the treated water contains lead precipitates which needs to be separated. This
is done by filtration of the treated sample. Place the 40µm filter paper in a funnel, pour the treated
water into the funnel and then collect the filtrate into a beaker. The collected filtrate contains less
quantity of lead. Now check for the pH of the treated water after filtration. Separate 50 ml of this
filtered water for TDS test, Lead Content test.
Take remaining treated water into a beaker and add activated carbon (adsorbent)
to it and stir the sample for 5 minutes. Activated carbon as an adsorbent adsorbs the remaining
oxide metals present in the filtered water. So adsorption method using activated carbon reduces
the lead content to trace level. After stirring of the sample is completed place it aside for some
time, so that oxide metals adsorbs over the adsorbent. Now filter the sample using 40µm filter
paper. Then check for the pH of the filtrate. Separate 50 ml of this filtered water for TDS test, Lead
Content test. Similarly repeat the experiment at 9 pH and check for TDS and Lead Content test.
Comparision of Adsorbent:
The precipitation of lead particles is done by addition of lime, lead precipitate,

coagulant and flocculent solution. The adsorbent used in the above experimental process is
activated carbon. The adsorbent creates more surface area for the metal oxides to be adsorbed over
them and then the treated effluent is filtered.
Instead of using activated carbon as adsorbent, now use oil cake as adsorbent.
Take 500 ml of samples into 3 different beakers. Check for the initial pH of the sample. Maintain
each of the sample at 7, 8 and 9 pH by adding lime to the samples respectively. Add 0.01 gram of
lead precipitate to each of the samples and stir them for 5 minutes. Similarly add 0.1 gram of
coagulant to each of the samples and stir them for 5 minutes. Now add the prepare 0.1% of
flocculent solution to the samples and stir them. Allow the samples to settle and then filter them
using 40µm filter paper. Similarly repeat the experiment with 0.2% of flocculent solution.

After filtration of the treated samples with 40µm filter paper, they are to be treated
with adsorbent. For the set of samples treated at 0.1%, 0.2% of flocculent solution, use activated
carbon as adsorbent. Similarly repeat the above experiment and use oil cake as the adsorbent.
The treated water pH range must and should be in between 7 to 7.5. The lead
content in the treated water must be less than 0.1 mg/L. If the pH range and lead content are in
permissible limits, we can dispose of the treated effluent or we can use it for gardening, floor
cleaning. If not in permissible limits, send the treated water to recirculation system.

TREATMENTS

8(A) - Treatment 1
S.no Initial PH Lead Coagulant Floc. PH after PH after TDS TDS Lead in Lead in
PH taken ppt. in (%) filtration activated in in ppm ppm
in gms. carbon ppm ppm at at
gms. at at B A
B A
1 7.52 8 0.01 0.1 0.1 7.03 7.38 829 738 -0.201 -0.241
(Trace) (Trace)
2 7.54 8 0.02 0.2 0.1 7.27 7.43 806 868 -0.192 -0.213
(Trace) (Trace)
3 7.55 8 0.03 0.3 0.1 7.11 7.28 666 1086 -0.179 -0.224
(Trace) (Trace)
Table 3: Values at 8 pH (0.1% floc.)
Where B ----- Before Activated Carbon A ----- After Activated Carbon

8 pH, 0.1% floc.
1200 1086
1000 868
829 806
800 738
666
TDS in ppm
600
400
200
0.1 0.2 0.3 0.1 0.2 0.3
0
1 2 3 4 5 6 7
coagulant
Series1 Series2
Figure 20: Variation in TDS values of treated water before and after adsorption (8pH, 0.1% floc)
Series 1: Coagulant in grams Series 2: TDS in ppm

8(B) - Treatment 2
PH taken ppt. in (%) filtratio activated in in ppm ppm
in gms. n carbon ppm ppm at at
gms. at at B A
B A
1 7.33 9 0.01 0.1 0.1 7.25 7.22 881 861 -0.198 -0.219
(Trace) (Trace)
2 7.37 9 0.02 0.2 0.1 7.2 7.25 873 906 -0.182 -0.25
(Trace) (Trace)
3 7.51 9 0.03 0.3 0.1 6.5 7.21 511 892 -0.196 -0.178
(Trace) (Trace)
Table 4: Values at 9 pH (0.1% floc.)

9 pH, 0.1% floc.
1000
881 906 892
873 861
900
800
700
TDS in ppm
600 511
500
400
300
200
100
0.1 0.2 0.3 0.1 0.2 0.3
0
1 2 3 4 5 6 7 8
Coagulant
Series1 Series2

8(C) - Treatment 3
PH taken ppt. in (%) filtration activated in in ppm ppm
in gms. carbon ppm ppm at at
gms. at at B A
B A
1 7.43 8 0.01 0.1 0.2 7.03 6.91 819 854 -0.254 -0.25
(Trace) (Trace)
2 7.45 8 0.02 0.2 0.2 7.27 6.57 840 979 -0.201 -0.212
(Trace) (Trace)
3 7.49 8 0.03 0.3 0.2 7.11 6.69 939 1031 -0.17 -0.211
(Trace) (Trace)
Table 5: Values at 8 pH (0.2% floc)

8 pH, 0.2% floc.
1200
1031
979
1000 939
840 854
819
800
TDS in ppm
600
400
200
0.1 0.2 0.3 0.1 0.2 0.3
0
1 2 3 4 5 6 7 8
Coagulant
Series1 Series2

8(D) -Treatment 4:
PH taken ppt. in in (%) filtration activated in in ppm ppm
gms. gms. carbon ppm ppm at at
at at B A
B A
1 7.36 9 0.01 0.1 0.2 7.27 7.33 848 802 -0.218 -0.243
(Trace) (Trace)
2 7.33 9 0.02 0.2 0.2 6.95 7.36 956 911 -0.1468 -0.3
(Trace) (Trace)
3 7.40 9 0.03 0.3 0.2 7.04 7.20 965 918 -0.248 -0.497
(Trace) (Trace)
Table 6: Values at 9 pH (0.2 floc)

9 pH, 0.2% floc.
1200
965
1000 911 918
848 856
802
800
TDS in ppm
600
400
200
0.1 0.2 0.3 0.1 0.2 0.3
0
1 2 3 4 5 6 7
Coagulant
Series1 Series2
Series 1: Coagulant Series 2: TDS in ppm

Activated Carbon
1000 881
829 861
900 812
800 738 738
700
TDS in PPm
600
500
400
300
200
100 0.1 0.2 0.3 0.1 0.2 0.3
0
1 2 3 4 5 6 7 8
Coagulant
Figure 24: Variation in TDS values of treated water before and after adsorption using activated
carbon at 0.1% flocculent
Oil Cake
2500
1910 1920
2000 1730 1700
TDS in ppm
1500
1080
991
1000
500
0.1 0.2 0.3 0.1 0.2 0.3
0
1 2 3 4 5 6 7 8
Cogulant
Series1 Series2
Figure 25: Variation in TDS values of treated water before and after adsorption using oil cake at
0.1% flocculent

Activated Carbon
854 848
900 819 802
800 724
685
700
600
TDS in ppm
500
400
300
200
100 0.1 0.2 0.3 0.1 0.2 0.3
0
1 2 3 4 5 6 7 8
Coagulant
Series1 Series2
Figure 26: Variation in TDS values of treated water before and after adsorption using activated carbon at
0.2% flocculent
Oil Cake
900 824
758 762
800
664 680
700 619
600
TDS in ppm
500
400
300
200
100 0.1 0.2 0.3 0.1 0.2 0.3
0
1 2 3 4 5 6 7 8
Coagulant
Series1 Series2
Figure 27: Variation in TDS values of treated water before and after adsorption using oil cake at 0.2%
flocculent

Comparative Study
The comparative study for the reduction in the lead content is taken at 8 pH, 9 pH. The
treatment of samples are treated by varying the lead precipitate (0.01, 0.02, 0.03) in grams,
coagulant (0.1, 0.2, 0.3) in grams, flocculent solution (10%, 20%, 30%). After treatment with the
chemicals, the treated effluent is filtered using 40µm filter paper and then it is treated with
adsorbent. The comparision is taken between activated carbon and oil cake. After treatment of the
effluent, it is tested for TDS and Lead content.
(1) TDS Comparision:
 From fig. 20 & fig. 21; before treatment with adsorbent the TDS content in the treated
water decreases with increase in coagulant weight.
 From fig. 22 & fig 23; after treatment with adsorbent the TDS content in the treated water
increases gradually.
 In all the cases of treatment; after treatment with adsorbent the TDS content in the treated
water increases gradually.
Variation in Adsorbent:
 Comparing the TDS content of the treated water treated by activated carbon and oil cake,
the TDS content of the treated water decreases after treating with the adsorbents than before
treating it with adsorbents.
(2) Lead Content Comparision:
 In all the cases of effluent treatment the lead content is reduced to trace level.
 The treatment done at 9 pH, 0.1% flocculent solution reduces the lead content level to a
low trace level.
 From table 7 & table 8, the lead content is reduced to very low trace level by using activated
carbon.
 Using activated carbon as adsorbent is more preferable than oil cake as adsorbent.

Conclusion
In Amara raja Batteries Ltd, pollutants released during the manufacture of

Lead acid Batteries are sent to the Effluent Treatment Plant for treatment of Lead and other
hazardous waste. The pollutants present in the water are being treated by using chemicals
like Lime, Lead precipitator, Flocculent solution, Coagulant. Here initially we need to
check the pH range depending upon the value of pH we need to add the chemicals. Doing
like this we can get the accurate results and also reduce the cost and time consumption.
Here our aim is to maintain the lead content to and pH range in permissible limit. The
permissible limit for lead content is 0.1 mg/L and the pH range is 6.5-8 pH. Doing
adsorption with activated carbon, traces of oxides and metals reduces to a lower level than
oil cake. In small scale operation adsorption with activated carbon is successful in reducing
the lead content level and pH range in permissible limits. From the above results we suggest
that, incase of large scale operations, lead content in the effluent can be reduced to lesser
trace level using Adsorption.

References....
1. Introduction to waste water management
---Environmental finance center
2. Clean water
---KENNETH.M VIGIL
3. Domestic waste water treatment in developing countries
---DUNCAN MARA
4. Waste water treatment
---HLTHMAN (volume 20)


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AN OVERVIEW OF THE INDUSTRY

DEPT. OF CHEMICAL ENGG. SVUCE 1

DEPT. OF CHEMICAL ENGG. SVUCE 2

DEPT. OF CHEMICAL ENGG. SVUCE 3

 Best Industry round Performance award in 1998 by FAPCCI

DEPT. OF CHEMICAL ENGG. SVUCE 4

 AMARA RAJA BATTERIES LIMITED (ARBL)

 AMARA RAJA INFRA PRIVATE LIMITED (ARIPL)

Amara Raja Batteries Limited (ARBL)

DEPT. OF CHEMICAL ENGG. SVUCE 5

Customers: Telecom, Railways, and offshore platforms.

Mangal Precision Products Private Ltd (MPPL1)

Mangal Precision Products Private Ltd (MPPL2)

DEPT. OF CHEMICAL ENGG. SVUCE 6

Amara Raja Electronics Private Limited (AREPL)

Galla Foods Pvt. Limited

. Tropical fruits pulp and concentrate

(Used for-ice cream, Confectionery, Beverages and juices)

. Fruit juice extraction

. Packing in Aseptic condition

Amara Raja Infra Private Limited (ARIPL)

DEPT. OF CHEMICAL ENGG. SVUCE 7

DEPT. OF CHEMICAL ENGG. SVUCE 8

(i) Industrial Batteries Division [IBD]

2.1.1. Industrial Batteries division [IBD]:

The major application of VRLA batteries are given in the following.

. Process & Service industry

. Uninterruptible Power supply (UPS) systems

. Electronic private Automatic Branch Exchange [EPABX]

. Defense [onshore & offshore wireless communications, cellular radios]

. Motive Power, etc.

DEPT. OF CHEMICAL ENGG. SVUCE 9

. Brute: Forklifts, Pallet trucks, Stackers, Platform trucks.

. Genpro: Generators starting

2.1.2. Automotive Battery Division (ABD):

 Amaron Fresh batteries

DEPT. OF CHEMICAL ENGG. SVUCE 10

DEPT. OF CHEMICAL ENGG. SVUCE 11

DEPT. OF CHEMICAL ENGG. SVUCE 12

(i) Variation in thickness (ii) Shrinkage

(iii) Miss trimming (iv) Blow holes

(v) Flashes (vi) Wire missing

3.2. Oxide Plant:

 Melting pot temp : 665±15 0F

DEPT. OF CHEMICAL ENGG. SVUCE 13

3.3. Ox-Master Plant:

3.4. Pasting lines:

DEPT. OF CHEMICAL ENGG. SVUCE 14

3.5. Curing and Drying:

DEPT. OF CHEMICAL ENGG. SVUCE 15

Figure 4: The flow chart showing the process of assembly

3.6.1. Group stacking:

DEPT. OF CHEMICAL ENGG. SVUCE 16

 Aligning of bus bars with lugs is called group burning.

3.6.1.2. Group strapping:

3.6.1.3. Group Insertion:

3.6.2. Heat Sealing:

DEPT. OF CHEMICAL ENGG. SVUCE 17

3.7.1. Acid filling:

DEPT. OF CHEMICAL ENGG. SVUCE 18

3.8. Finishing & Dispatching:

DEPT. OF CHEMICAL ENGG. SVUCE 19

DEPT. OF CHEMICAL ENGG. SVUCE 20