​​​​​​Lead Smelting Furnace

Lead to be manufactured from Rotary Furnace can be obtained directly from scrapped batteries or as slag from Mini Blast Furnaces In case of former batteries are cut open or broken to segregate lead scrap, plastic and other materials from them;lead scrap in the form of lead powder/ plates etc. is charged in the furnace along with a proportionate charge of additives. In The case of latter, slag produced from Mini Blast Furnaces is charged into the Rotary Furnace, again with proportionate additives.

This process is a batch type process. After filling the required quantity of raw material (either manually or mechanically), thelid of the furnace at the front is closed. The burner attached to the moving door is then fired.
The Rotary Melting Furnace is very flexible and universal equipment used for recycling many non-ferrous metals. It is themajor lead production technology used in India and many other countries for Secondary Lead Production. A lead production system based on this technology has certain distinct characteristics such as:

Equipment scalable for installing higher capacities
Plates & powder from scrap battery as well as slag from Mini Blast Furnace can be used as raw material
Requires addition of certain consumables
Can be fired with various fuels
Generates high Pollution both as Flue Gases & Fugitive EmissionsApart from plates and paste of lead oxide from scrap batteries, slag from Mini Blast Furnace is charged in the Rotary Furnace.

In addition to these, certain compounds of sulphur are also present in the batteries. When this material is heated in thePresence of carbon, lead oxide is converted to lead. This conversion along with burning of fuel generates flue gases and fumescontaining dust, dirt, oxides of lead, lead particles and such other impurities etc.

Hence, to meet various goals of maintaining employees' health and factory environments as well as regulatory requirements,it becomes imperative to get high end Air Pollution Control Systems to be installed with the Rotary Furnaces.

Details of allow with Functions Equipment's

Rotary Chamber receives very hot gases from Rotary Furnace while cold gases from atmosphere are induced into chambervia specially designed profile. Thus chamber works as an equalizing chamber to reduce the temperature of gases and alsowhere sedimentation of dust particulate matter takes place.

Rotary Chamber Advantages

Recovers 100% lead in the first operation.
Slag produced is lead free.
Equipment can be scaled up for higher production capacities.
Many chemicals are required for operation.
High power consumption.
Rotary Chamber Disadvantages

Difficult to produce low Antimony lead suitable for soft lead purposes.
Fugitive Emissions need to be captured in addition to flue gases.
Need skilled operators and careful maintenance.

Discharge Characteristics required as per Norms
Tapping of Rotary Furnace also lead to generation of Fugitive Emissions which need to be captured at source and treated to maintain ambient air standards at workplace. Air Pollution Control Device for Rotary Furnace

Dust : Less than 50 mg / Nm
Lead (Pb) : Less than 10 mg / Nm
Temperature : 60-90 C
Gases : Traces of NOx and SO2

Lead Smelting Rotary Furnace Plant with Pollution Control System

Rotary Furnaces are used in secondary smelting units for re -processing  Lead from scrap. Rotary furnaces have an inner brick lining over which scrap is transformed from solid to molten state due to heat given by oil firing. Oil firing is done with the help of a high -pressure air blower.

For Lead smelting & refining: Refined material is discharged into moulds. Rotary furnace is installed on rotary base. It rotates on heavy wheels mounted on base & for pouring finished material; it is lifted by hydraulic cylinders through a power pack.

Our lead smelting rotary furnace is suitable for the recovery of lead out of lead-acid battery scrap, lead concentrate and lead ore. We manufacture & install the oil fired rotary furnace in different capacities with maximum production efficiency and least production cost such as fuel, labor and power consumption. The production capacity of our lead smelting plants can in different parameters may be 3 M Ton to 15 M Ton per day i.e. 24 hours. We provide very effective and efficient pollution control system with the smelting plants, through which a lot of smoke dust of lead is collected. The collected smoke dust from our pollution control system is not only useful to prevent the pollution spreading into in environment but also increase the profit for the extra increase of recovery of lead out of the lead smoke dust collected by the system provided. An estimated value of extra increase of profit is 3% to 4%, which is only capitalized from the further recovery of lead from the smoke dust collected.

Electric Lead Melting Furnace

We are the prominent manufacturer and supplier of Lead melting furnace which is highly demanded in many production industries. We offer these lead melting furnace in various capacities which is operated by using electricity. This Melting furnace is integrated with all kind of control equipments in order to control the flow of operation. The lead melting furnace that we offer are Lead melting furnace and electrical lead melting furnace. These furnace operated in maximum 800C temperature and it depends upon the type of lead. Our Lead melting furnace is renowned for high performance, heat resistance and low maintenance.

Battery Recycling Technology
We are committed to the employment of environment friendly technologies in our solutions for the used Lead-Acid Battery Recycling and Battery Manufacturing Industries, covering Secondary Lead Smelting, Lead Refining, Lead Alloying & Lead Oxides Manufacturing and Lead Pollution Control.

Our Battery Recycling Plant employ Pyro metallurgical processes. Typically, in pyrometallurgical Secondary Lead Smelting, Lead Bearing Battery Materials are charged into a furnace together with appropriate fluxes & reductants, drosses, returning slags and process dusts for smelting. Reduction of Lead bearing material to crude Soft/Antimonial Lead takes place along with the formation of Lead bearing slag. The slag may be collected and smelted in a separate slag campaign in the same or another furnace. Mostly Blast Tilting

Rotary Furnace
are used, either singly or in different combinations, for single/multi stage smelting. The process employed, furnace combination, fluxes, reductants etc. are finalized taking into account the required plant capacity, required product mix, pollution control plant and environmental concerns, the desired level of flexibility in plant operation and the composition of available battery scrap.

Pyrometallurgical processes have been the most widely used for Lead recycling. In a comparison with some other technologically more complex processes, the pyrometallurgical process scores high on para meters like low capital & lifecycle costs and requirement of highly skilled manpower, economic viability of a range of capacities and relatively low core electrical power requirements, among many others. The use of modern pollution control technologies and design ensures environmental compliance. Smaller scale Battery Recycling Plant are a more economically and environmentally viable alternative to large-scale units for many reasons, particularly for developing and small market areas/countries.

Our well-designed tilting Rotary Furnaces, integrated with modern accessories and pollution control equipment form the core of our Battery Recycling Plant, which have proven to be technically and economically viable for a range of capacities, while showing good compliance with environmental standards.

Rotary FurnacesRotary Furnaces have a variety of fitment options, optional tilting mechanisms, a simple, reliable and robust design and display good operating/efficiency characteristics.

Reverberatory Furnaces

Reverberatory Furnaces are those furnaces which is designed and operated in the production of a nearly pure and soft Lead. During charging and tapping Reverberatory Furnace emit high level of Lead Fume.

In Reverberatory Furnace Tapping process the molten Lead and slag is poured from the furnace into Ladles or Molds. Like Blast Furnace, to keep the metal molten, some smelters tap metal directly into a holding kettle. Then comes the task of solidification of molten lead. The smelter casts the molten lead into blocks so that it can be used for the further treatments or operations in various purposes.

Pollution Control Systems

Dust Collection and Gas Purification:

Flue gases from furnaces and air from exhaust ventilation systems are thoroughly cleaned in a state of the art pollution control system. Flue gases pass through settling chamber, cyclone, cooling tower, bag house by induced draft and after that through scrubber to stack with forced draft. 

All equipments in the dust collection system have to be properly operated, cleaned, and maintained to control dust particles. The remaining emission is then treated to remove flue gases. Finally the pollution free air, as per international norms, is sent to the atmosphere through a stack.

Equipments Commonly Used​​
Settling Chamber:

It is used to reduce the inlet loading of particulate matter to downstream collection devices by removing larger, abrasive particles. Settling chambers are also referred to as gravity settling chambers or expansion chambers.

In the expansion chamber, the velocity of the gas stream is reduced significantly, as the gas expands in a large chamber. The sudden reduction in velocity forces larger particles to settle out of the gas stream. To improve settlement efficiency in this settling chamber, baffle plates are provided.


In a Cyclone, the particulate matter is removed by centrifugal and inertial forces. This is induced by forcing particulate laden gas to change direction.

It is provided after the settling chamber to collect the smaller particulate matter that could not be collected in the settling chamber.

Typical gas flow rates in a cyclone varies from 0.5 to 12 cubic meters per second, depending upon the particulate matter to be removed.

Cooling Tower:

To cool down the flue gases down to a temperature that does not burn the filter bags in the Bag House in the pollution control setup. The design is based upon the heat transfer through conduction, convection and radiation. 

There is considerable zigzag movement of flue gases in the cooling tower which results in some particulate matter settling down. This matter is removed through valves provided at the discharge end.

Air Filter Bag House:

“Air Filter Bag House” contains 100% polyester Non-woven fabric filter bags fitted in the bag holding cage. The bag house is equipped with pulse jet type cleaning arrangement. Pulsejet cleaning unit is designed for continuous operation that operates at appropriate pressure of compressed dry air.

Top view of the Bag House &
Pulse Jet Cleaning System
Dust at Filter Bag surface
Dust removed by Pulse jet 

Pulse Jet-cleaning mechanism and non-woven polyester filter bags are provided for high efficiency of filtration at considerably high temperatures. All the compressed air nozzles are controlled with the help of electronic device to control pulse time and time interval that gives continuous better cleaning by ensuring efficient and best performance of the bag house.

A vertical type chamber in which flue gases enter from the lower end and move upwards. The air velocity is also brought down. The Sulfur Di-Oxide in the flue gases react with the water being sprayed in the chamber and form Sulfurous Acid which flows out into a water tank with some fine particulate particles. The water is circulated with the help of a pump and sprayed through venturi nozzles.

The Scrubber is lined with PVC from inside to reduce corrosion. The acidic water is neutralised in a sequential chambers  setup. 

Super furnace provides well-designed pollution control system to meet international norms. We ensure world-class services for plant erection and commissioning with our experienced engineers in the minimum possible time. Our team works with latest technological skills and engineering methods.

We never compromise with the quality of the product. Ensuring safety of the workers and human beings living in the surrounding areas remains our foremost priority. All the pollution related equipments are designed and engineered before fabrication to customize and meet out the toughest rules of air pollution control.

Super furnace on National small industries corporation (NSIC)Faridabad furnace manufacturer


Mr. Pankaj chauhan
Email :- pankajchauhan.c@gmail.com
Plot no- 44, 16/2 karkhana bagh, Mathura road
              Faridabad (Haryana
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