This study aims to save the production cost and control the secondary lead recovery to abate the fugitive solid emissions (FSE) for smelters using relatively poor technology. The method involves mixing a de-sulphurized battery paste with active petroleum coke, iron oxide, soda ash, lime and water glass. The mix is then pelletized and smelted at 1050degreesC. A computer modeling is designed to control the FSE of the plant at the minimum. It is found that 2% by weight of the battery paste escapes as FSE, exceeding the pollution limits given by the law. The suggested method promotes high extent of lead recovery and FSE concentration complies with the law. The smelting process is accomplished at 1050degreesC compared to 1450degreesC in the existing technology. saving 12.5% by weight of fuel consumption per ton of lead. The volume flow rate of the flue gases and the laden-flue gas dust decrease by 65%. Also, metal lead, other heavy metals going into the slag and the running cost of the scrubbing system for the gas cleaning decrease. Preliminarly, nearly 4% of the annual production cost of the secondary lead industry can be saved.