LEEKHA CHEMICALS PVT. LTD.

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

JHAJJAR
HARYANA
Factory 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

[2]

Index
Page No.
a. Introduction of Leekha Chemicals Pvt. Ltd.

(4)

b. Raw material

(5-6)

c. Manufacturing Products

(7-8)

d. Chemical & Physical Properties of Products

(9-12)

e. Applications of Products

(13-14)

f. Processing using Flow-chart

(15-19)

g. Equipments & Specifications used in Industry

(20-34)

h. Environmental issues & Treatment

(35-37)

i. Risks & Precautions

(38)

j. Conclusion

(39)

[3]

Introduction of Leekha Chemicals Pvt. Ltd.

Leekha Chemicals Pvt Ltd was founded by Mr. Ravi Leekha (Managing
Director) in 1981. Ravi Leekha is a B.Sc. in Chemistry. Since his graduation,
Mr. Ravi Leekha has worked with various reputed organizations. In 1981, Mr.
Ravi Leekha established Leekha Chemicals Pvt. Ltd. and started manufacturing
Stearates of various metals such as TBLS, DBLS, DBLP etc to a score of PVC pipe
manufacturers in India.
Besides PVC pipe industry, They are also supplying chemicals to Cable Industry,
Paint Industry, PVC/PP Compounding Industry etc. Many of their clients are ISO
certified too. The company has well-established manufacturing facilities, supported
by the laboratory and technical staff.
Leekha Chemicals Pvt. Ltd., the first fully integrated PVC stabilizers manufacturing
plant in Northern India has been providing support to plastic industry for nearly
three decades.
Leekha Chemicals Pvt. Ltd. is the manufacturer & supplier of various Lead
Chemicals suh as Litharge (PbO), TBLS (Tribasic Lead Sulphate), DBLS (Dibasic
Lead Stearate), DBLP (Dibasic Lead Phthalate), Calcium stearate, Lead stearate.
And produce chemicals as 1500 tonns per annum.
The company has its factories located at Bahadurgarh, Dist. Jhajjar, (Haryana).
Well-trained staff and workforce manage the factory. The current strength is about
50 persons.
Under the capable guidance of Mr. Ravi Leekha , the Leekha Chemicals Pvt.
Ltd. is ready to take up any challenge in the field of manufacturing and services.

[4]

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 non-radioactive element (some radioactive elements, like
technetium, are lighter).
Lead is used in building construction, lead-acid batteries, bullets and shot,
weights, as part of solders, pewters, fusible alloys, and as a radiation shield.

Sulphuric acid (H2SO4) :-

Sulphuric acid is a highly corrosive strong

mineral acid with the molecular formula H2SO4 and molecular weight 98.079 g/mol. It is
a pungent-ethereal, colorless to slightly yellow viscous liquid which is soluble in water at
all concentrations. Sometimes, it is dyed dark brown during production to alert people to
its hazards Sulfuric acid has a wide range of applications including domestic acidic drain
cleaner,
electrolyte in lead-acid batteries and various cleaning agents. It is
also a central substance in the chemical industry. Principal uses include mineral
processing, fertilizer manufacturing, oil refining, wastewater processing, and chemical
synthesis. It is widely produced with different methods, such as contact process, wet
sulfuric acid process and some other methods.

Acetic acid (CH3COOH) :- Acetic acid systematically named ethanoic acid

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

[5]

HCl :-

Hydrochloric acid is a clear, colorless, highly pungent solution of hydrogen

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

Phthalic acid :-

Phthalic acid is an aromatic dicarboxylic acid, with formula

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

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

Sodium meta bi sulfite :- Sodium metabisulfite or sodium pyrosulfite (IUPAC

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

[6]

Manufacturing Products

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

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

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

Lead Stearate (LS):[7]

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

particularly at high temperatures, besides being also effective as a light stabiliser.

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 costabilisers 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.[2] Unlike soaps containing sodium and potassium, calcium stearate is insoluble in
water and does not lather well. Commercially it is sold as a 50% dispersion in water or as a
spray dried powder. As a food additive it is known by the generic E number E470.
[8]

Chemical & Physical Properties of Products

Tri Basic Lead Sulphate (TBLS):Product Data Sheet
Molecular Formula
Appearance
Molecular Weight
Specific Gravity
Moisture , %
Melting Point
Particle Size
Lead Content(as PbO ), %
Purity, %
Free Fatty Acid , %
Packing

3PbO.PbSO4.H2O
White Powder
990.74
2.66
1.0 Max.
900*C
-200 Mesh
87-89
99.0 Min.
Not Applicable
25 Kg. HDPE bags with LDPE liners

Di Basic Lead Stearate (DBLS) :Product Data Sheet

Molecular Formula
Appearance
Molecular Weight
Specific Gravity

2PbO.Pb (C17H35COO)2
White Powder
1219.87
1.90
[9]

Moisture , %
Melting Point
Particle Size
Lead Content(as PbO ), %
Purity, %
Free Fatty Acid , %
Packing

1.0 Max.
115 - 117*C
-200 Mesh
54-55
99 Min.
2.0 Max.
25 Kg. HDPE bags with LDPE liners

Calcium Stearate :Product Data Sheet

Molecular Formula
Appearance
Molecular Weight
Specific Gravity
Moisture, %
Melting Point
Bulk Density Gm/CC
Particle Size
Calcium Content (as CaO), %
Free Fatty Acid, %
Ash Content, %
Packing

Ca (C17H35COO)2
White Powder
606.61
1.035
1.0 Max.
150 (+/- 5)* C
0.2 (+/- 0.03)
-200 Mesh
9.5 (+/- 0.5)
1.0 Max.
10.5 (+/- 1.0)
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

[10]

Pb304 (% max)

0.06

Melting point (C)

888

Specific gravity

9.50

Apparent density (g/ml)

1.6 - 2.0

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

0.10

Volatile matter (% max)

0.20

Water insoluble in acetic acid (% max)

0.10

Water absorption

100 - 105 mg/gm

Lead Stearate (LS):Product Data Sheet

Lead Stearate
Appearance

White Powder

Specific gravity

1.40 0.02

Residue on 63 micron IS sieve (% max)

Moisture (% max)

0.10

Lead Oxide equivalent (% PbO)

30 - 34

Free fatty acid (% max)

0.60

Bulk density, tapped (g/ml)

0.6 - 0.7

Dibasic Lead Phthalate (DBLP) :Product Data Sheet

soft creamy powder

[11]

Specific gravity

4.4 0.05

Residue on 63 micron, IS sieve (% max)

0.50

Moisture (% max)

0.50

Lead Oxide equivalent (% PbO)

79 - 81

Bulk density, tapped (g/ml)

1.0 - 1.2

[12]

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
1. Electrical conduit & cladding.
2. Rigid extrusion of main water goods.
3. Guttering and soil pipes.
4. Pipes for conveyance of gases and liquids.
5.

Injection moulding.

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

Dibasic Lead Phthalate (DBLP) :[13]

 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.

[14]

Manufacturing process of
Products using flow chart

[15]

[16]

[17]

[18]

[19]

[20]

[21]

Equipments & their Specification

used in Industry

[22]

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

[23]

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.
[24]

[25]

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.

[26]

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.
[27]

[28]

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.
[29]

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.
[30]

[31]

Melting Pot

Specifications of Melting Pot

18 gauge stainless steel crucible
20 gauge stainless steel shell
Cover-loose, aluminum with heat resistant knob
3 fiberglass insulation
Multiple-circuit blanket heater for uniform heat
[32]

 Heated long-life, no-drip ball valve dispenser

6'' power cord
Electronic temperature control-(60 to 250 and 150 to 550 range
options)
Two zone heat on 40 ands 60 quart models

Cyclone Separator

[33]

Specification of Cyclone Separator

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

[34]

Bag Filter

[35]

[36]

Grinder

Specification of Grinding mill

[37]

Tray dryer

[38]

Specification of Tray dryer

Fired Boiler

[39]

Specification of Fired Boiler

[40]

Ribbon Blender

Specification of Ribbon Blender

[41]

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.

[42]

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.

[43]

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.
[44]

[45]

Risk & Precautions

The Lead and their products are poisonous for human beings and is considered as a
slow poison. Various health issues arise for continuous contact with lead products.
Some risk factor with lead and lead industry are:

Lead:It can cause Learning, behavior & health problem in human being, cause high
Blood Pressure & Kidney damage. It is considered as a slow poison.

Sulphuric acid:It is highly reactive, incompatible with many common chemicals, reacts violently
with water, corrosive, cause skin burns, & eye damage, strong inorganic acid. Harm
respiratory system & cause Lung cancer.

Hydrochloric acid (HCL):HCL is corrosive to eyes, skin & mucous membrane, cause coughing, hoarseness,
inflammation & ulceration, chest pain, vomiting, dermal contact may produce
severe burns.

Prevention methods for their hazards

(a)
(b)
(c)
(d)

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.
(e)
Use protecting shield and gloves in the industrial area.
(f)
Use suitable containers for the chemicals.
(g)
Store the chemicals & products in a dry place.
[46]

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.

[47]

[48]