This work discusses a method to suppress the fugitive emissions of total solid particles (TSP) and save energy for industrial lead smelters. Pilot scale experiments simulating the industrial short rotary furnace (SRF) in lead smelters were studied. An energy study was manifested on a typical lead smelter. Factors affecting the objectives of this work have been investigated. The results obtained revealed that the rate of fuel consumption of heavy fuel (mazout) is highest in the early period of smelting. The flue gases in the existing small lead smelters are heavily loaded, with TSP outweighing the constrains given by law 4/94. About 60% of the energy input in the SRF escapes to the environment causing pollution hazards of TSP and spreading out excessive heat. Applying clean technology including pelletization of battery paste saved about 35% and 12.5% of heat and total energy consumption, whereas fugitive TSP decreases by about 67%. A theoretical model explaining the lead recovery process is given. It is based on heat and mass transfer and the thermodynamic properties of the species and reactions involved. Prediction of the findings of this model has been experimentally verified with a marginal accuracy of 4%. On an economic basis, nearly 14% of the plant turnover is saved annually.