One Pakistani recycler faced significant hurdles with their outdated setup, including uneven melting, excessive slag generation, and high fuel consumption. Their search for a reliable and efficient lead ore smelting solution ended with the successful procurement and installation of guanma machinery 10t/Furnace Lead Ore Smelting Rotary Furnace.
The Client’s Core Challenges in Lead Smelting
The client’s existing furnace technology was hindering their growth. Key pain points included:
Inconsistent Melt Quality: Irregular temperature distribution led to variable lead purity.
Low Operational Efficiency: Lengthy batch cycles and high manual intervention reduced overall throughput.
Elevated Operational Costs: Poor thermal efficiency resulted in wasted fuel and higher energy expenses.
Environmental & Safety Concerns: Inadequate fume capture and control posed challenges in meeting operational standards.
10-Ton Rotary Smelting Furnace System Solution
Understanding the need for a robust, high-capacity lead smelting furnace, we engineered a comprehensive solution centered on our 10t/Furnace Lead Ore Smelting Rotary Furnace. This was not just a furnace delivery but a complete system integration.
The system’s key features included:
Precision Engineering
The furnace is designed for optimal rotational speed and tilt, ensuring complete mixing and uniform heat distribution for a high-efficiency lead ore smelting process.
Advanced Refractory Lining
High-alumina refractory bricks were selected for superior thermal retention and resistance to corrosive slag, directly extending furnace lifecycle.
Integrated Afterburner & Fume Management System
A complete rotary furnace for lead battery recycling package was provided to ensure thorough combustion of organics and effective fume capture, addressing environmental compliance.
Full Automation & Control
A customized PLC-based control panel allows precise regulation of temperature, rotation, and tilt, enabling semi-automatic lead melting furnace operation that minimizes human error and maximizes repeatability.
Custom-Configured Furnace Design
The furnace was tailored to their specific feedstock mix (lead ore and battery scrap).
Implementation & On-Site Success in Pakistan
Our team managed seamless delivery and provided comprehensive technical support. The installation phase included:
Pre-delivery Inspection
All components were pre-tested at our facility.
Supervised Installation & Commissioning
Our engineers were on-site in Pakistan to oversee assembly and furnace start-up.
Hands-On Operational Training
We trained the client’s technicians on safe and efficient rotary furnace operation, maintenance protocols, and troubleshooting.
Tangible Results & Operational Benefits Achieved
The operational data post-installation confirmed a significant return on investment:
Throughput Increase: Achieved consistent 10-ton per batch lead production, reducing batch cycle time by approximately 25%.
Fuel Efficiency Gains: Optimized combustion and heat retention lowered fuel consumption per ton of lead by an estimated 18%.
Improved Metal Recovery: More efficient slag separation and reduced dross formation increased metal yield.
Enhanced Compliance: The integrated scrubbing system ensured fumes were effectively managed, simplifying environmental compliance for smelters.
Reduced Labor Dependence: Automated controls streamlined the process, allowing skilled operators to manage multiple tasks.
The successful delivery and operation of our 10t/Furnace Lead Ore Smelting Rotary Furnace in Pakistan. This project delivered a durable and cost-effective lead smelting plant upgrade.
Explore the detailed technical specifications of our Lead Smelting Rotary Furnaces or contact our engineering team today for a custom solution tailored to your plant’s needs.
