LEAD SMELTING

Smelting is the process of separating the metal from impurities by heating the concentrate to a high temperature to cause the metal to melt. Smelting the raw material produces a metal or a high-grade metallic mixture along with a solid waste product called Slag.

Lead Smelting is the process of reducing complex form of Lead in to free metallic Lead using heat, chemicals & suitable reducing agents in Furnaces/Ovens. The raw material for the Smelting operation can be:

• Lead Ore
• Lead Concentrate
• Lead Sinters
• Other form of Lead Scrap (Batteries etc.)

Lead and Zinc can be produced by following Pyrometallurgical or hydrometallurgical processes, depending on the type of ore used as a charge. In the Pyrometallurgical process, ore concentrate containing Lead, Zinc, or both is fed, in some cases after sintering, into a primary smelter. Lead concentrations can be 50–70%, and the sulfur content of sulfide ores is in the range of 15–20%. Ores with a mixture of Lead and Zinc concentrate usually have lower respective metal concentrations. During sintering, a blast of hot air or oxygen is used to oxidize the sulfur present in the feed to Sulfur dioxide (SO₂).

Lead Smelting Equipments / Lead Smelting Plant

Smelting Section : The Lead bearing material from Batteries, along with appropriate fluxes, reductants, Slag and other scrap & process wastes, is smelted in a Blast/ Rotary Furnace or a combination of the two, depending on the product mix required e.g. hard Antimonial Lead, soft crude Lead etc. The furnaces operate in a temperature range of 900-1250 degrees centigrade.

We supply both Rotary and Blast Furnaces designed as per the capacity requirement along with a customized complement of accessories and equipment. The blast and/ or rotary furnace's configuration is decided after taking into account factors like, the smelting, refining and pollution control plant configuration, designed battery processing capacity, expected capacity utilization range, desired degree of flexibility in product mix, composition of locally available raw material, consumables etc.

All our furnaces are designed to minimize Sulphur-dioxide emissions in flue gases by conversion into non-reachable solid compounds to the maximum possible extent. The flue gases released are treated by the air pollution control plant, of our proprietary design, in which a typical configuration comprises of dust collectors, cyclones, cooling towers, spark arrestors, bag-house filtration units, induced draft fans (ID Fan), wet scrubbers and a chimney/stack. We provide detailed process fine-tuning and training inputs in the commissioning phase to ensure optimum functioning of our Secondary Lead Smelting Plant.

For an overview of our entire range of available services from, feasibility studies to turnkey Plant, retrofitting and modernization of existing units for capacity expansion to pollution control reengineering; see our services & turnkey projects section.

Secondary Lead Smelting

The smelting of Lead involves several elements that are required to reduce the various forms of Lead (mainly Lead oxide and Lead sulphates) into metallic Lead. Mostly this includes:

• A source of carbon, usually in the form of metallurgical , petroleum coke, charcoal
• Energy, mostly available from natural gas, oil or electricity
• Neutralizing agents used to capture Sulphur such as caustic, soda ash, or lime
• Fluxing agents also used to capture Sulphur and improve Lead recovery. Frequently this includes various forms of iron and slag enhancing materials.

Secondary Lead Processing Machinery

Our Company exclusively engaged in establishing Lead Smelting Plant by providing Technology, Plant & Machinery, Training of personals etc. Our unique smelting technology has allowed the facility & opportunity to process a much wider range of industrial wastes and by-products than a traditional Lead recycling facility. Our secondary recovery plants use Lead paste desulphurization to reduce sulfur dioxide emissions and generation of waste sludge during smelting. Our smelting Plant is fully integrated with pollution control modules and can be configured for a wide range of Battery Recycling Capacities.

Used Lead Smelting Plant

We also deal in Used Lead Smelting Plant and its equipments.