Xstrata Technology - Jarofix

Hindustan January 2010

History of Jarofix CEZ

Imposed end to jarosite storage technology 1993 5 Years

Research of all existing technologies 1993 - 1994
Development of residue fixation technology at NTC 1995
Testing and Pilot Plant - CEZ - Golder NTC 1996
Production CEZ 1998
Jarofix sale to Austurianna 2002
Jarofix sale to Hindustan 2004
Jarofix sale to Binani 2006
Development package Jarosite Sulfur to Kokkola 2008
Included in Xstrata Technology January 2009
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Zinc Hydrometallurgical Process

3 stage counter current leaching process
Zinc oxide recovered in a neutral leach and a low acid leach
Iron ferrites are then leached and precipitated in a third stage
Iron is precipitated as a sodium jarosite in this stage
In preparation for filtration, the jarosite is seeded
This seeding gives a particle diameter mean near 9 microns

Basic Information CEZ

Annual zinc production capacity 280,000 tonnes
Annual sulphuric acid production of 500,000
500,000 tonnes of concentrate treated - 8 to 10 % iron
Iron is precipitated as a sodium-jarosite
Annual production of residue 160,000 tonnes

Jarosite Particle Size Distribution

120

9
8

100

Cumulative

80

Differential

60
4
40

Diff. Volume (%)

Cum. Volume (%)

2
20
1
0
0.1

10

0
100

Particle Diameter (microns)

Selective Precipitation Circuit

Used to remove circuit inerts such as Mn and Mg
Used to maintain and modulate the water balance
The liquid effluent is sent for further water treatment
The gypsum solids generated are filtered with the jarosite

Integrated Circuit

Jarosite thickener

Return to process

Wash water
To Jarofix

Wash water
Lime

Selective precipitation circuit

To plant effluent
treatment system

Repulp tank

Jarofix Process Block Diagram

Filtrate

Slurry

Leaching and
Jarosite Precipitation

S/L Separation

Jarosite Filtration

Solution

Selective
Precipitation
pH 6 - 7

Filtrate

Residue

residue

Water Treatment
pH 9.5

Residue

Fixation
Residue

Filtrate

Residue

Rain and effluents

Disposal Area

Jarosite Fixation
Lime addition for pre-neutralization of contained solution
Cement addition to the alkaline paste
Requirements
A well washed jarosite, gypsum, sulfur, cake
A relatively small range of humidity
A maximum temperature
Short-term fluidity to transport
Long term physical strength and chemical stability

Jarofix Operation
Lime
Jarosite

Lime Mixer

Cement

Transportation

Cement Mixer

Stockpile
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Transportation Alternatives
Liquid trucking CEZ current technique
Solid trucking Austurianna current technique
Paste trucking Hindustan current technique
Liquid pumping Tested loop NTC Golder
Liquid pumping Testing proposed Binani

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Chemical and Physical Characterization

Water Leaching Test TCLP 1311
Method 1312
BC Initial Test
Dynamic Leach Test
Unconfined Compressive Strength
Hydraulic Conductivity

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Chemical Characterization Details

A sample of Jarofix residue taken from a fully controlled normal operation (pH) will pass
tests (1311) designed to allow material to be placed in a mixed residue environment. As
in any other sample, we consider that the water of hydration be removed from the sample
before starting the test. However, we have always recommended that Jarofix be stored
independently of any other residue. This is because there will always be minor upsets to
a zinc process that could make the residue vulnerable to leaching in a mixed residue
storage situation. Once the logic has been accepted that the material is stored in a very
thick independant area with engineered filling drainage and engineered final surface
drainage we have usually increased the pH target so that there is always a high level of
available neutralization capacity from the cement and the lime. Government agencies
must agree with this logic because it produces samples that at times do not pass the prescreening of the 1311 tests because of the excessive pH.

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Liner Considerations
At CEZ an agreement was reached with the Canadian government that Jarofix at CEZ would not
require a lower liner nor an upper liner before re-vegetation. The agreement was reached by reviewing
the environmental conditions in Canada, the hydrological parameters of the proposed storage site, the
results of chemical and physical tests, hydraulic conductivity of Jarofix and the final proposed shape
of the strorage site.
A short term bottom liner would have been required if there was a risk of contaminating the ground
water before the Jarofix sealed the ground itself. We have opted for a liner in our operation in Spain
but consider the thick layer of very low hydraulic conductivity Jarofix as being the protection for the
environment for the centuries to come.
The upper liner under the vegetation is not required for the vegetation as can be seen in our Photo
Annexes. We have found that we can get vegetation to grow on fairly steep but controlled slopes
without a plastic liner. Slopes must be reduced if a liner is required despite their not being a real logic
for an upper liner. Again, we were required to place an upper liner below the vegetation in Spain. We
have been required to repair one problem areas on our outer profile probably due to effects from
freezing during the winter. This work is also included in the Photo Annexes.

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Environmental Monitoring
Sampling of current production
Leaching tests
Physical caracterization

Sampling of cured Jarofix at site

Leaching tests
Physical caracterization

Effluent monitoring

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TCLP 1311 and TCLP 1312 Test Results

TCLP 1311
Al

As

Be

Cd

Co

Mn

Ni

Pb

Zn

Year

(mg/L)

(mg/L)

(mg/L)

(mg/L)

(mg/L)

(mg/L)

(mg/L)

(mg/L)

(mg/L)

2000

<0.1-0.2

0.02-0.06

<0.01

<0.005

0.09

0.02-0.03

<0.01

<0.05

0.01-0.03

2001

<0.1-0.2

0.03-0.04

<0.01

<0.005-0.006

0.09-0.10

0.05-0.20

<0.01

<0.05

<0.01-0.12

Al

As

Be

Cd

Co

Mn

Ni

Pb

Zn

Year

(mg/L)

(mg/L)

(mg/L)

(mg/L)

(mg/L)

(mg/L)

(mg/L)

(mg/L)

(mg/L)

2000

0.1-0.3

<0.01-0.03

<0.01

<0.005

<0.02-0.04

<0.01-0.02

<0.01

<0.05

0.01-0.03

2001

0.2-0.3

0.01-0.03

<0.01

<0.005

0.03-0.04

0.01

<0.01

<0.05

<0.01

TCLP 1312

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Disposal Area at the End of Construction

17

Jarofix Impoundment - August 2000

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Jarofix Impoundment - Access Road

19

Jarofix Impoundment - Unloading Point

20

21

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Jarofix Impoundment - Dike Construct

23

Jarofix Impoundment Jarosite dikes

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Progressive development concept- year 5

25

Jarfix stacking at the end of year 25

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Conclusions
Jarosite residue can be engineered for filtration

Selective precipitation can also be engineered for filtration

Good filtration technology increases metal recovery

Jarofix is major breakthrough in the zinc industry

Jarofix residue is chemically and physically stable
Progressive revegetation is feasible and economical

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Technology Recognition
Falconbridge Innovation Award (2003)
(Award presented at the 42nd Conference Metallurgist of the Canadian
Institute of Mining and Metallurgy (CIM) Vancouver 2003)

Teck-Cominco Environmental Award (2008)

(Award presented to Gary Monteith at the 47th Conference Metallurgist of
the Canadian Institute of Mining and Metallurgy (CIM) Winnipeg
2008)

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