We build environmentally responsible, high-efficiency smelting plants for the recovery of high-purity lead from diverse sources ranging from spent batteries to ore concentrates. At IPS Makina, we deliver fully integrated lines - compliant with international emission standards - that return hazardous-waste-category materials to the economy through advanced engineering solutions.
Production Capacity & Solutions
• Short Rotary Drum Furnace Systems: High thermal efficiency for the smelting of scrap batteries and lead scrap.
• Refining Kettles: Purification and alloying of molten lead (Antimonial Lead, Soft Lead, etc.).
• Ingot Casting Lines: Automatic or semi-automatic lead ingot production systems to standard weights.
• Slag Processing: Specialised processes that minimise waste volumes and recover metal from slag.
Lead Smelting Process Stages
• Raw Material Preparation & Feeding: Conveying crushed battery paste or lead ore, together with carbon and fluxing additives, into the furnace.
• Smelting (Rotary Furnace Process): Transition of the material to the liquid phase and separation of metal from slag at 1,000°C–1,200°C in conjunction with burner systems.
• Filtration & Gas Treatment: 99.9% capture of heavy lead-oxide-bearing dusts and harmful gases using high-efficiency, heat-resistant filter systems.
• Refining & Alloying: Transfer of molten lead to refining kettles for purification from impurities and alloying to customer specifications.
• Automatic Casting: Casting of molten metal into moulds, cooling, and stacking by robotic/mechanical systems.
Our Technical Advantages
• Advanced Emission Control: Central dust collection and gas scrubber systems specifically designed against lead fumes and dust, meeting environmental licence requirements.
• High Metal Recovery: Minimisation of residual metal in slag through optimised furnace geometry and combustion management.
• Long-Life Refractory Design: Durable internal lining solutions resistant to chemical corrosion and high thermal shock.
• Occupational Health & Safety: Fully enclosed conveying and feeding systems that minimise operator exposure.
Unit Descriptions
• Rotary Smelting Furnace: Heavy-duty rotary reactor unit in which lead-bearing materials are melted at high temperature and separated into molten metal and slag phases.
• Refining Kettle: Thermal treatment vessel with stirring mechanism in which molten lead is purified according to chemical analysis or brought to the desired alloy values.
• Ingot Casting Machine: Automatic production line in which molten metal is cast into standard moulds, cooled by water or air, and formed into ingots.
• Process Dust Collection System: Emission control centre in which lead oxide dusts and gases generated during smelting are captured via specialised PTFE-bag filters before atmospheric release.