Project Description

SECTION-I
PROJECT DESCRIPTION
160000 MTPA Zinc Residue Fuming Project
1. PROJECT DESCRIPTION
Project Overview
M/s Hindustan Zinc Limited (hereinafter referred to as HZL) has its zinc smelter for the
treatment of zinc Calcine 370,000 Mt/Annum and Zinc Ingot Production Capacity of 210000
Mt/Annum, using roaster, hot acid leaching process and Jarosite process. Currently Jarosite
which is converted into Jarofix has been stored in secured Land Fill.
HZL visited Chinas similar zinc smelters to understand the zinc smelting processes and
production of Leach residue treatment technology. HZL intends to choose appropriate
technology to transform its zinc smelting process and construct its Leach residue treatment
system, which means HZL wants to simplify the zinc Calcine leaching process with using the
conventional leaching process, so that the zinc Calcine after neutralized leaching and weak
acid leaching could have the neutralized overflow sent to the original solution purification
system, and the leaching residue can be directly processed in the Proposed residue
treatment facility.
M/s NFC and M/s ENFI recommended drying kiln- box fumer converting - zinc oxide
desulphurization - zinc sulphite solid (ZnSO3) process along with Decomposition, Halide
Removal processes to send the clean ZnSO4 Solution to neutral Leaching Section.as per
current practices adopted in Chinese smelters. The zinc sulfate solution obtained by zinc
sulphite and Halide removal will come back into the Calcine leaching system, with the lead
silver residue sent to the lead smelting system. After treatment of Zinc Residue in Furnace
there will two products out from the furnace. One is Lead/Zinc Dust which will be used in
desulphurisation section to absorb the SO2 and benign Slag, a product usable in cement
industry.
After implementation of fumer project, the leaching residue produced from weak acid
leaching section (WL Residue) will be fully recycled in fumer section to recover the valuable
metals such as Zn, Pb and Ag. The total zinc recovery will be: 98.22% from the zinc Calcine to
the zinc Ingot. Also the Lead and Silver recovery from zinc concentrate will be 90.45% and
92.68%.
1
Basic data
Design capacity;
The zinc calcine throughput for zinc hydrometallurgical smelter is 370,000 Mt/Annum to
produce 210,000 Mt/Annum Zinc Ingot.
The annual output of leaching residue from zinc calcine is about 153418Mt/annum, Leach
residue will be sent to the newly-built Box Fumer Leach residue treatment system for
further processing.
The box fumer will produce the zinc oxide dust about 46,167Mt/Annum, all of which will be
sent to its off-gas zinc oxide system for desulphurization, the zinc sulfate solution obtained
by zinc sulfite leaching will come back into the Calcine leaching system after purification
section (Decomposition, Halide removal and Hydrolysis).
Material composition;
Chemical composition of the Zinc Calcine provided by HZL;
Table 2-1 Chemical composition of zinc Calcine (dry basis, Wt %)
Element Zn Pb Cd Cu Fe Ca Cl F
Content (%) 58.158 1.380 0.24 0.114 10.238 0.044 0.008 0.002
Element SiO2 Mg Ni Co As Sb Mn Ag
Content (%) 5.112 0.122 0.003 0.004 0.015 0.187 0.219 0.0095
Element Bi Al Tl ST Ss Sso4
Content (%) 0.012 0.360 0.006 2.046 0.329 1.716
See Table 2-2 for the calculated chemical composition of the leaching residue provided by
M/s NFC.
Table 2-2 Chemical component of leaching residue (dry base, Wt %)
Element Zn Pb Cu Fe Sso4 Ss SiO2 CaO

wt(%) 20.858 3.310 0.164 24.558 3.686 0.840 12.262 0.148
Element MgO Al2O3 As Sb Bi Cd Ag* F*
wt(%) 0.485 1.632 0.020 0.202 0.029 0.115 240 10
Element Cl* Mn Ni* Co* Tl*
wt(%) 80 263 10 80 140
Note: The moisture content in leaching residue is based on M/s NFC filtering operation
which should be limited to 25% or below.
* Units are g/t.
See the table 2-3 for chemical composition of the raw coal provided by HZL; the raw coal is
mainly used for Coal pulverized which will be used in box fumer and dry kiln operation. The
total coal consumption in Box Fumer and Dry Kiln is about 114,623 t/a (dry basis). The coal
consumption for box fumer is about 107, 583t/a (dry basis) and for dry kiln is about 7040 t/a
2
(dry basis). The moisture in raw coal is 10%. For designing of VRM we should consider 10%
moisture in raw coal.
Table 2-3 Chemical composition of raw coal (Wt %) Assay (WT %)
Component Coal
Fixed Carbon 46.7%
C 10.22%
H 3.47%
O 8.16%
Volatile Matters
N 0.86%
S 0.78%
Sub-total 23.5%
Fe2O3 2.02%
SiO2 16.2%
Al2O3 8.04%
CaO 1.57%
MgO 0.27%
Ash
TiO2 0.31%
Na2O 0.01
K2O 0.11
P2O5 0.19
Mn3O4 0.04
SO3 0.93
Other 0.11%
Sub-total 29.80%
The CaO in the leaching residue is on lower side and need to be compensated by addition of
lime Stone, which will be around 14,590t/a. The limestone has 0.5% moisture.
Table 2-4 Limestone chemical composition (dry, Wt %)
Element Fe SiO2 CaO MgO Al2O3 Others Total

wt(%) 0.038 2.190 52.800 1.000 0.0044 43.970 100.00
See Table 2-5 for composition s of the spent electrolyte provided by HZL.
Table 2-5 Compositions of spent electrolyte
Component gpl Component ppm

Zn 55.0 Cd 0.4
Acidity 180.0 Co 0.2
Mn 9.5 Sb 0.003
Mg 11.5 As 0.05
Ca 0.4 Cu 0.2
Na 1.8 Cl 325.0
3
Meteorological and earthquake information
Ambient temperature
- Maximum 46.50 Deg C
- Minimum 1.12 Deg C
- Average 23.50 Deg C
Relative humidity
- Maximum 92.00 %
- Minimum 22.00 %
- Average 59.00 %
Rainfall
- Rainy season 3 months
- Number of the rainy 17 days/month
days/month
- Mean annual rate 749.0 mm
- Maximum in 24h 198.0 mm
- Maximum monthly 551.0 mm
Intensity of earthquake As per IS 1893-2002
- Zone factor Z=0.1
- Seismic Zone Zone - II
Barometric pressure
- Average 966.7 mbar
- Wind pressure According to IS-875
- wind velocity 47 m/sec
Technological process
Zinc Calcine leaching

Based on technical know-how of NFC, the existing roasting - hot acid leaching - jarosite
process is proposed to be changed into the roasting - conventional leaching - box fumer
leaching residue treatment. The zinc Calcine after roasting is sent to neutral leaching with its
overflow sent to the purification section, the under flow from the neutral leaching is sent to
the weak acid leaching with its leaching overflow sent back to the neutral leaching, the
under flow from weak acid leaching will be sent to the newly-built acid leaching residue
filtration and drying plant through the pressure filter and the filtrate will return to neutral
leaching, with the filtered residue being sent to box fumer process.
The zinc Calcine for neutral leaching and weak acid leaching uses the existing equipments,
but the acid leaching residue filtration and drying plant will be newly built.
See figure 2 for the process flow of Calcine leaching.
Leaching residue treatment

Due to solubility of the heavy metal ions , the leaching residue shall subject to nontoxic
treatment during conventional hydrometallurgical process; moreover, such valuable metals
as Zn, Pb and Ag are massively contained, so the leaching residue needs nontoxic treatment
with such valuable metals recycled. Therefore, the leaching residue treatment adopts the
box fumer process in line with the principle as follows: hazard-free and resourceful
4
treatment of the leaching residue and high rate for recycling of the valuable metals. The box
fumer technology is currently developed with copper water jackets and WHRB, for
treatment of leaching residue to achieve the technical and economic process indicators.
See figure 2-1 for Process flow for Zinc calcine leaching
See figure 2-2 for the process flow of leaching residue treatment.
5
Off-gas desulfurization and zinc oxide dust treatment

Due to presence of sulfur in the leaching residue, pulverized coal, the off-gas in the drying
kiln and the box fumer shall need desulphurization and purification treatment because of
excessive SO2 contents. Zinc oxide desulfurization technology is adopted to scrub &absorb
SO2 and form zinc sulfite, which can be decomposed by means of the spend electrolyte to
get SO2 gas and zinc sulfate solution. The SO2 gas is sent to the sulfuric acid system of the
zinc plants (both H1 &H2) while the zinc sulfate solution is delivered to the zinc Calcine
leaching system. In case of excessive F and Cl contained in the zinc sulphate, solution needs
to be sent for the treatment chlorine/fluorine, iron for removal of impurities and then
delivered to the zinc Calcine neutral leaching system.
See figure 2-3 for the process flow of off-gas desulfurization.
Figure 2-4 for the process flow of halide removal;
6
Work Scope and Battery limit;
Work Scope
The design and construction within the scope of work includes the construction of
corresponding civil structures and pipeline bridges of the plant (including over ground
structures as well as over ground and underground concrete structures). See Table 3-1 for
sub-items within the scope of work.
The project activity within the work scope includes design, Engineering, procurement,
Supply, erection, construction, Painting and anticorrosive measures of all necessary
equipments within the scope as well as assembly of all materials and equipment, quality
assurance and control, industrial test, inspection, packaging and transportation to the site,
on-site storage, installation, testing, commissioning and start-up technical services which is
further elaborated in commercial terms & conditions.
Newly built plants within the scope of design and construction are all covered in the Battery
limit document. General layout of the proposed plant is as per Annexure-Project Plot.
In this project, the leaching process is changed from the existing jarosite process into the
conventional leaching process, the existing leaching plant needs modification, the work
scope of this project includes the basic & detail engineering design, civil works modification,
equipment installation, debugging and operation guidance, etc. for the leaching plant
modification.
The battery limit connections from the modified existing leaching plant to the fuming area,
the piping connection from the water point in the existing leaching plant to fuming
area,
the cable connection from the switch yard and CDSS to the fuming area,
the diesel piping connection from the existing leaching plant to fuming area,
the DM water supply piping connection from existing leaching plant to fuming area,
the DCS cable connection from fuming area to the existing leaching plant,
the drain water piping connection from fuming area to existing leaching plant,
the SO2 off-gas piping connection from fuming area to the existing acid plant
The above modifications are all included in the scope of work with NFC/ENFI. The above
piping and cable will use the existing pipe rack for laying wherever possible. Any
additional pipe/cable rack, modification/strengthening needs to be done by NFC as
required based on site conditions.
The roads, lighting, rainwater collection and drainage, and walls are included in the scope of
NFC.
Anything more required for the completeness of the project to achieve designed capacity
shall be done by M/s NFC.
Table 3-1: Sub-items within the work scope
S/N Names of sub-items Description sub-item code

001 Acid leaching residue filtration and Kiln- Acid leaching residue RKD
Drying plant filtration and Kiln-
Drying plant
002 Blending storage Leaching residue Residue Material RMP
7
blending storage Preparation

003 Fuming furnace plant Fuming Furnace Plant FFP
004 Desulfurization plant Tail Gas Plant TGP
005 Residue filtering Plant The Geothite residue RFP
filtration
006 Blower and air compressor room and 11 Blower Houser and BHP
kV power distribution station Power distribution
007 Pulverized coal preparation plant Coal Pulverization CPL
Plant
008 Circulation water system of the box fumer Circulation Water CWS
and blower room and pulverized coal Station
preparation plant
009 Slag granulation circulating water plant Granulation Water GWP
Plant
010 Diesel generator house Diesel Generator DGH
House
011 Steam turbine generator Steam Turbine STG
Generator
012 Pipeline network Pipeline network GPN
013 Leaching plant transformation Calcine Leaching plant LPR
Contents included in the work scope
The work scope includes such six parts as follows:

1) Zinc Calcine leaching
2) Leaching residue treatment
3) Off-gas desulfurization and zinc oxide dust treatment
4) Auxiliaries and utilities
5) Decomposition section
6) Hydrolysis and halide removal section
1) The zinc Calcine leaching means that the existing jarosite process is changed into the
conventional leaching process. And the WL leaching residue is send to the box fumer for
treatment. The zinc Calcine leaching system has two parts, which are leaching plant
modification and leaching residue filtration and drying.
2) The leaching plant modification will be completed in the existing leaching plant, then the
weak acid leaching under flow produced from the leaching plant is sent to the leaching
residue filtration and drying plant through pumps/pipelines after modification.
3) The leaching residue filtration and drying plant starts from the battery limit
pump/pipelines connecting the leaching plant with the filtration and drying plant, until the
leaching residue after being filtered and dried has been sent to the blending storage of the
leaching residue through the belt conveyor.
8
1) The leaching residue treatment means a box fumer is used to treat the leaching residue
after being filtered and dried, the off-gas from the box fumer is sent to the off-gas
treatment system, the box fumer clean slag is sent for granulation, and the output zinc
oxide is sent to the off-gas treatment system.
2) The leaching residue treatment starts from the residue blending storage of the leaching
residue until the outlet of the high-temperature fan for collection of the off-gases from the
box fumer, including blending storage bins and fuming furnace plant.
3) The blending storage of the leaching residue includes belt conveyor between the residue
blending storage bins and the fuming furnace plant until the head of the belt conveyor into
the fuming furnace plant;
4) The fuming furnace plant starts from the head of the belt conveyor for the leaching
residue after proportioning until the outlet of the fan for collection of the off-gas from the
box fumer, including the box fumer feeding system, box fumer, WHRB for box fumer, box
fumer dust collection, environmental ventilation and chimneys.
5) The off-gas from the fuming furnace plant is sent to the off-gas handling system for the
treatment until the zinc oxide receiving bin in the off-gas treatment plant;
6) The box fumer slag after slag granulation is sent to a slag field for temporary stockpiling
until the middle bin/Yard for box fumer slag.

1) The off-gas and zinc oxide dust treatment includes two parts which are off-gas
desulfurization and zinc oxide dust treatment, as well as a chlorine and iron removal plant.
2) The off-gas treatment starts from the outlet of the dust collection fans of the box fumer
and the drying kiln.
3) The off-gas and zinc oxide dust treatment starts from the bin for receiving of the off-gas
from the box fumer.
4) The equipment in the existing leaching plant is utilized for zinc sulfite leaching and Cl& Fe
removal. The slurry after reaction is sent to the slag filtering plant (RFP) for filtration,
5) The sulphur dioxide off-gas from the off-gas and zinc oxide dust treatment is sent to the
sulphuric acid plant (SAP) of the existing zinc smelter.
6) The acidic waste water from the off-gas treatment is sent to the existing effluent
treatment station.
7) The lead Silver Residue produced from zinc sulfite leaching is sent to the lead smelter for
processing. Temporarily Stock piling capacity considered is for 7 Days
9
8) The copper sulphate will be pump/Piping from the existing Pyro Smelter for chlorine
removal.
9) The limestone slurry for chlorine and iron removal comes from the existing zinc smelter.
10) The copper Halide residue produced from chlorine and iron removal is to be temporary
stored in stock yard for 7 Days.
11) The iron slag from chlorine and iron removal is sent to be stored in temporary stockpile
for 7 Days.
Auxiliaries and utilities
1) The auxiliaries and utilities include blower-air, compressor house, 11 kV power

distribution station, coal pulverization plant, water supply, drainage system, steam turbine
generator, diesel generator house, DM Water storage system, Diesel Storage System, Soft
water system, Filter water system, and pipeline network.
2) M/s NFC has to tap the power from Switch yard and CDSS Building and to provide the
required accessories to charge 11kV power distribution station which will supply the power
to new fumer plant.
3) The coal pulverization plant provides pulverized coal for the box fumer and drying kiln
and includes a raw coal bunker and a pulverized coal preparation system.
4) The water supply and drainage system includes supply and drainage of all production,
domestic and fire-fighting water within the work scope of NFC, the production, domestic
and fire-fighting water comes from the existing plant area, the production wastewater is
discharged into the existing sewage/ effluent treatment system which in the zinc plant. All
the piping includes supply and drainage will connect to the connection point.
5) The steam turbine generating station will use the steam from the WHRB of the box fumer
to generate power.
6) The diesel generator room provides emergency power supply for all Level-1 load
equipment within the scope of the work.
7) The general pipeline network includes the plant process piping, water supply pipes and
cables for power, instrument and telecommunications connection work.
Note: Though above philosophy given by NFC, but whatever required for the completeness
of the plant to achieve the designed capacity shall be done by NFC.
Battery limit
Refer the Section III: Battery Limit.
10
Plant description
The modified zinc Calcine leaching plant includes two parts which are neutral leaching and
weak acid leaching. Zinc Calcine from the calcination plant is stored in the existing neutral
leaching Calcine bin then charged into the neutral leaching tank through the existing
charging belt. Weak acid leaching over flow, spend electrolyte, manganese dioxide and
other reaction reagents are simultaneously added to the neutral leaching tank. After
reaction the slurry flows by gravity into the existing neutral leaching thickener and the
overflow flows by gravity into the overflow tank and then is pumped to the existing
purification plant. The thick underflow is then pumped into the weak acid leaching tank,
after reaction the pulp automatically flows into the existing weak acid thickener, and the
overflow returns to the neutral leaching tank, the underflow is sent to the acid leaching
residue filtration and drying plant.
Acid leaching residue filtration and drying
Thickened underflow from the zinc Calcine leaching plant goes into four agitated tanks
(35003800) and the slurry produced after agitation is pumped into eight membrane filter
presses (F=220m2).The filter residue is discharged through hopper to eight belt conveyers
(B=1400, L=8m) and then transferred to the feeding bin on the top of two drying kilns by
one reversible belt conveyer (B=1400, L=53.8M). Then the leaching residue is dried in the
drying kiln. The filtrate is returned to leaching thickener overflow tank in the zinc Calcine
leaching plant.
After filtering operation, acid leaching residue (moisture content 25%) is sent into a mix
drum by belt conveyer for mixing with limestone then to fed into one drying kilns
(2.2m18m).
The fuel for drying kiln is from pulverized coal preparation plant, and air is provided by
primary fan and secondary fan. The pulverized coal is sent to the burner by coal feeder
pump before injected into the kiln for combustion. Secondary air is adjusted to control the
temperature of hot off-gas at the inlet of the kiln to be about 800Deg C. Hot off-gases and
the residue flows in the opposite direction to dry the residue.
Off-gas from drying kiln is about 150Deg C. The volume of off-gas is about 26427 m3/h. The
off-gas goes directly into the dust collection system. The residue after being dried (moisture
content 15%) is discharged from the tap-hole at the bottom of the hood in the front of the
kiln, and sent to the leaching slag blending storage by belt conveyor.
Leaching residue blending storage
The leaching residue blending storage is used to store and mix the leaching residue and flux.
The leaching residue after being dried is delivered into the storage bin after weighing by belt
weigh feeder the residue was send to fuming plant by belt conveyor. The flux is transported
by trucks to the stacking area of the blending storage, the flux is fed into the blending
storage bins by Front end Loader, the leaching residue is fed by belt weight Feeder, the flux
11
is fed through a belt weight feeder, and the mixed material is sent into the fuming furnace
plant through feeding belt.
Fuming furnace plant
The fuming furnace plant is equipped with two 18 m2 box fumers, in which the leaching
residue will be charged for smelting and fuming processes.
The two box fumers in the fuming furnace plant are respectively equipped with a separate
feeding system, the leaching residue after mixing with flux is sent from the leaching residue
blending storage through belt conveyor to furnace front bin in the fuming furnace plant,
after weight by belt weigh feeder the mixed material fed into the box fumer through two
feeding ports by moveable belt feeder in front of the box fumer.
Box fumer is equipped with an off-gas outlet directly connected with the membrane wall of
the WHRB, and on one side of the diaphragm walls is provided two feeding ports for
uniform distribution of material inside the furnace, box fumer are equipped with slag tap
holes at both the end. Two tap holes (upper one and lower one) are arranged at one end
with the upper one for slag tapping during normal operation; and emergency slag tap-hole is
arranged at the other end.
On both sides of the box fumer are equipped with lances (tuyer), air and pulverized coal will
be evenly distributed into the furnace through multi-layer distribution pipes. Moreover, the
pulverized coal can be used as fuel and reductant.
The coal feeding systems have been set for the box fumer that include the injection system
and storage bin, including proper control and measuring system.
The fuming furnace plant is equipped with one 4.99m3 fuel tank and two diesel pumps to
provide diesel for Start-up of Box Fumer as well as for maintaining the furnace temperature.
The box fumer slag is transported to the intermediate storage bin/Yard by bucket crane
after granulation. And then is transported by trucks to a temporary slag field for storage.
The hot water after cooling tower will go into the slag circulating water pool.
WHRB of box fumer
Each box fumer has a WHRB for recovering the waste heat from high-temperature off-gas,
and also the off-gas will get cooled after the WHRB.
The box fumer WHB has its drum arranged in the main smelting building, including box
fumer hood, uptake, down-comer, radiation cooling chamber and convection zone. The box
fumer WHRB has its cover connected to the off-gas outlet of the box fumer through a
flexible expansion joint, and the off-gas passes through the box fumer hood, uptake, down-
comer, radiation cooling chamber and convection zone and discharged from the WHRB into
the dust collecting system after it has been cooled about below 380. The WHRB is
equipped with rapping devices to dislodge the dust from boiler walls/bundles which can
effectively remove the dust on the heating surface in time to ensure normal operation of
the boiler. At the bottom of the dust hopper on the WHRB is equipped with a drag chain
conveyor for dust removal, collection and transportation. The boiler body is supported on a
steel frame made from structural steel.
12
In order to guarantee the normal operation of the boiler and the supporting thermodynamic
system and WHRB system are designed for water circulation, steam production, off-gas
discharge, DM water and Steam sampling test system for safe operation of the WHRB.
Dust collecting system
Dust collection system mainly includes dust collection systems for drying kiln and box fumer.
The dust collection for drying kiln is for removing dust in off-gas from drying kiln. The off-gas
at the kiln outlet is about 150Deg C and goes directly into bag house for cleaning before it is
sent to off-gas desulfurization system.
The bag filter for dust collecting system is used for removal of the dust in the box fumer off-
gas, after reduction of temperature using surface cooler. The temperature of gases from
WHRB is about 380 when discharged into the surface cooler and the purified off-gas is
delivered to the off-gas desulfurization system, in which the zinc oxide dust collected by the
WHB and the dust collecting system is used as an absorbent.
Zinc oxide dust from box fumer and Dariba Lead Plant/Calcine is used as absorbent for off-
gas desulfurization and zinc oxide dust treatment. The de-dusted and dried off-gas from
drying kiln and box fumer is sent for desulfurization. Slurry containing zinc sulfite is
produced during off-gas desulfurization.
Off-gas desulfurization and zinc oxide dust treatment system is mainly composed of seven
parts: slurry preparation and supply, off-gas cleaning, sulfur dioxide absorption, process
water, zinc sulfite leaching, Cl& Fe removal and residue filtration.
The smelted off-gas, after dust collection, is pressurized by booster fan, washed in the
scrubber, enters into three ZnO absorption towers and then is vented to air through 80-
metre-high chimney after series absorption& purification.
After pressurization by booster fan, the off-gas from drying kiln and box fumer flows into
the scrubber for washing to remove As, F, Cl and dust. After preliminary cleaning, the off-gas
flows into absorption tower for scrubbing. The zinc oxide dust is delivered mechanically
from the dust collecting system to the zinc oxide blending storage bin in this system. After
weighing and proportioned fed in the slurry proportion tank, the zinc oxide is quantitatively
fed into the absorption tower by pumping. Two spray absorption towers and one rotating
stream tray tower are designed in series operation to treat the SO2 in the off-gas, the slurry
solution sprayed in the absorption tower is zinc oxide slurry made from zinc oxide dust in a
suitable concentration, and the slurry solution from the absorption tower is then sent to the
zinc sulfite slurry thickener (CN-02 C020) in the existing Calcine leaching plant. The off-gas
after treatment by these three towers and wet ESP is vented to air through 80 meters high
chimney.
After liquid-solid separation of slurry in thickener, the clear overflow returns to the
desulfurization device for reutilization. The dense underflow is pumped to the zinc sulfite
one-stage leaching tank (CN-02 C003 and CN-02 C004 in the existing Calcine leaching plant is
reutilized). The zinc sulfite one-stage leaching is carried out by adding two-stage leaching
filtrate and spend electrolyte. High-concentrated SO2 off-gas produced during one-stage
leaching, which is sent to the drying tower of Hydro#1 and Hydro#2 in the existing sulphuric
13
acid system by SO2 blower. After one-stage leaching, the slurry is pumped to the one-stage
leaching filter press in the new filtration plant for filter pressing. The filtrate returns to the
neutralization leaching tank or Cl removal tank in the existing Calcine leaching plant (the
conversion tanks CN-02 C001 and CN-02 C001 in the existing Calcine leaching plant are
reutilized). Zinc sulfite second-stage leaching is carried out by adding spent electrolyte and
concentrated sulphuric acid. After second-stage leaching, the slurry is pumped to the two-
stage leaching filter press in the new filtration plant for filter pressing. The filtrate returns to
the zinc sulfite one-stage leaching tank (CN-02 C003). The filter residue is lead and silver
residue, which is sent to lead plant to recover Lead and Silver.
When F and Cl content in the zinc sulfate solution is higher, the one-stage leaching solution
is pumped into the chlorine removal tank in the existing Calcine leaching plant for Cl
removal (the conversion tanks CN-02 C001 and CN-02 C002 in the existing Calcine leaching
plant are reutilized). The CuCl sediment is produced by adding copper sulphate and zinc
powder. The slurry after reaction is sent to the Cl removal filter press in the new residue
filtration plant. The filter residue is CuCl residue, which is stockpiled. The filtrate is sent to
the goethite tank in the existing Calcine leaching plant (the CN-02 C009 and CN-02
C010conversion tanks are reutilized) for Fe removal. Limestone slurry, air is added to the Fe
removal tank to produce goethite residue from Fe, F and other impurities in the solution
and make goethite settled. After reaction, the slurry flows by gravity to goethite thickener
for liquid and solid separation (the CN-02 C020 conversion thickener in the existing Calcine
leaching plant is reutilized). The thickener overflow returns to the existing neutral leaching
tank for Calcine leaching; and the underflow is sent to the goethite underflow filter press in
the new residue filtration plant. The filter residue is stockpiled and the filtrate returns to the
goethite thickener overflow tank (CN-02 C026).
Auxiliaries and Utilities
Water supply and drainage
All the water required for the fumer plant is in the scope of work of M/s NGC.M/s HZL will
provide the raw water from raw water ponds which has to be pumped and piped to the
required site. Fire fighting facilities shall be in the scope of the NFC.
Water supply:
Total water circulation: 126933m3/d

Process water consumption: 3182m3/d
Domestic water: 30m3/d
Total Circulation water for the day: 123721m3/d
Backwater: 500m3/d
Water reuse rate: 97.86%
Production water supply, fire-fighting water supply system, domestic water supply system
and water circulating system are designed, supply, erection, commissioned. The production
water system supplies water in all workshops with process water while the circulating water
system supplies make-up water and plant ground flush water; the domestic water supply
system supplies all workshops with domestic water; the circulating water system has its
14
water from the box fumer and blower circulation, flushing circulation and circulation of the
waste heat power generation, which can be used for cooling and circulation supply to the
corresponding equipment or system water consumption.
A backwater system is also provided to collect the sewage drainage of the circulating water
system, neutralization pool drainage of the chemical water station and ground flushing
water through the production drainage pipelines, some of which will be pumped into the
flushing circulating water system as make-up water. Same is also defined in Interfacing
document.
Drainage:
Drainage capacity: 566m3/d

Including: acidic wastewater 36m3/d
Domestic water drainage: 30m3/d
Process water drainage system, acidic wastewater drainage system, domestic water
drainage system and rain water drainage system are designed. The process water drainage
system mainly undertakes the sewage drainage of the circulating water system, as well as
drainage of the ground flushing and the neutralization pool of the chemical water station
(excluding pollutants) through the production water drainage pipes to the backwater
reservoir, with the excess water overflow discharged into the original production drainage
pipes in the plant and with the quality of the drainage water identical to that of the existing
plant; the acidic contaminated water from the off-gas desulfurization system contains a
small amount of As, F, CL and dust, and is delivered to the original acidic contaminated
water treatment station for the treatment in the plant. The domestic sewage is drained into
the original domestic water drainage system in the plant; the rainwater in the newly-built
plant site is collected through the rainwater ring and discharge into the existing storm water
pond.
Fire fighting:
The fire protection will be designed as per fire protection standard implemented in the NFC
Dariba Lead Plant project. All firefighting piping shall be above ground.
Power supply and distribution
Power source:
Four 11kV power supply lines are introduced from the switch yard and CDSS which located
in the existing leaching plant to the 11kV power distribution station in the lower house of
this project as the power supply. All associated cable and requirement will be met to M/s
NFC to have connection from switch yard and CDSS along with feeders supply. And a new
diesel power station will be built to undertake the emergency power supply for all Level-1
load equipment within the scope of the plant.
15
Power load:
The electrical equipments has the total installed capacity of about 18,735kW, and the active
power is about 9797 kW. The total power consumption in year will be around
72797X103kWh (waste heat power generation is excluded from the calculation).
In Fumer project, the smelting circulating cooling water pumps(2x250kW), WHRB water
feed pump(2x200kW), granulation water pump(2x160kW) and circulating pumps (1x200kW)
and hot water circulating pumps(1x110kW) are mainly connected with the Level-1 power
load, installed DG Capacity is about 1530 kW, while the rest are mainly Level-2 power load.
Power supply and distribution system:
According to the plant load distribution, the blower house and heat recovery power station
will have an 11 kV power distribution station. The 11kV power distribution station in the
blower house has its power supply provided by the NFC. whatever power will be generated
from the Turbine Generator same will be connected with the Fumer Plant and excess power
will be back to the grid in normal conditions, power will be drawn from all four lines but in
case of issue with any two power sources, another two lines will be capable to provide the
required power for fumer plant. The 11kV power distribution station of the heat recovery
power Plant has one 11kV in-grid interconnection line designed to the 11kV power
distribution station in the blower house.
For better and more reasonable distribution of the electric energy, the heat recovery power
station is connected with the 11kV power distribution station in the blower room and its
power generation is around 74400103kWh/Annum.
Automatic control
M/s NFC design has considered necessary detection and control circuits for each production
process in accordance with design principles as follows: Detect the general technological
parameters in the process of production, in order to facilitate the operation and process
control, necessary automatic control are considered to realize automatic control. operation
control will be in place to control, monitor and record each and every consumable required
to control the process from centralise DCS control.
The design adopts a computer-controlled systematic solution DCS (distributed control
system). The technological parameters, running status of the electric equipment, start-stop
operation, Ready to start signal, emergency stop, flow meters and others parameters will be
displayed and controlled from the DCS operation panel.
One box fumer centralized control room is arranged in fumer project and another one
considered is for Turbine generator. the box fumer centralized control room will display and
control the detection and control parameters in fumer technological process,
The instrument power will be supplied by M/s NFC with two independent 110V DC power
lines configured to supply power to the on-site instrument and control systems via UPS.
Ventilation and air conditioning
The ventilation and air-conditioning facilities are considered for the ventilation, dust
removal and air-conditioning systems in the plants are in the scope of the M/s NFC design.
16
Ventilation and dust removal system:
A complete ventilation and dust removal system has been design in Fumer project to ensure
HZLs requirements and environmental protection, Such ventilation and dust removal
system are set up in accordance with full covering of the off-gas system and dust-affected
places, dust emission from the stack considered is 30 mg/Nm3 and for coal it is 30
mg/Nm3.along with this a large set of ventilation and dust removal system is considered to
be set up in the fuming furnace plant and in other areas will have small ventilation and dust
removal system to take care of individual areas.
In the fuming furnace plant, the off-gas and dust-affected points includes- feed port for belt
conveyor, feed port for box fumer, slag tapping hole for box fumer, slag chute for box fumer
and the emergency slag hole, the total (maximum) air volume of the system is 175000m3/h,
and a low-pressure long pulse-jet bag dust collector is considered with the total filter area
3020m2. The clean off-gas after filtering will discharged into the air through a 60-meter-high
steel chimney.
Air conditioning:
Floor or wall-mounted air-conditioners are provided to in DCS Room, control rooms and
Staffs room and the needs for temperature control in some rooms are considered with
centralised ACS
Civil engineering
Constructional engineering:
The civil engineering design will follow the standard as shared with M/s NFC during
discussion and same has been signed off. Civil engineering will follow the meteorological
data, seismic intensity and other relevant information provided by the M/s HZL.
Steel structures are preferred by M/s NFC in all buildings. Roofs and walls adopt Colour
profiled steel sheets. Except for such buildings subject to special requirements, almost all
the places enclosure has been considered, the outer walls adopt colour profiled steel sheets
while the interior walls use brick/block masonry. Wall bases, equipment foundations and
water pools adopt reinforced concrete structures while the raw coal storage is of steel
structure.
The constructional engineering has considered the energy-saving and environmental-
protection design based on the local climatic features, such as considerate acoustic
absorption measures, sufficient natural ventilation and utilization of environmental
protection materials, the desulfurization system ground is designed subject to strict
anticorrosion measures and the building fire protection is designed in accordance with the
standard implemented in the NFC Dariba Lead Plant project and signed off document.
Structural engineering:
Foundation: All buildings and structures adopt different foundation forms and embedment
depth according to different conditions. The plant columns adopt reinforced concrete
independent foundations and the concrete foundation forms will be further optimized and
17
adjusted based on the detailed survey report. Geo technical study will be done after basic
engineering to optimize the overall civil and structural details.
In consideration of the local actual situation, steel structures are preferable in all buildings.
Special treatment shall be provided for the floor mainly in acidic area.
Special structures:
Chimney: The 60-meter-high chimney adopts a steel wall while the 80-meter-high FRP
chimney uses a steel tower.
Pools and pits: Waterproof cast-in-place reinforced concrete structures
Pipe support: steel structure
Main structural materials: The steel structures adopt steel as specified in Signoff document.
The concrete adopts as per the signoff document.
The reinforcement adopts Indian local reinforcing steel bars FE500 and as per signoff
document.
Coal pulverization plant
The pulverized coal for the box fumers and drying kiln will be supplied from the coal
pulverization plant, which has vertical rolling mill process design to run 2 shift operations
(16h/day) and the rated capacity is 25Mt/hour. Figure 4-1 for the coal pulverization plant
flow is given below.
The N2 generation system has been set for the coal bin protection and pulverized coal
injection system and conveying the coal to site bin. NFC has considered the hot air
recirculation system to optimize the Fuel requirement.
18
Waste heat power station
Box fumer WHRB generates saturated steam at 4.0MPa pressure and sent to waste heat
power station for electricity generation. All the steam will be used in the power generation
process. NFC has considered condensing type turbine condenser is capable to condense the
100% steam in case of any issue with turbine.
As the steam output of box fumer WHRB fluctuates in a production cycle, the type of
selection of steam-turbine generator considers the requirement of maximum steam intake.
The combined steam generation from two furnaces is 60t/h to 75 t/h.
Condenser: NFC will generate steam from both the fuming furnaces at the rate of 60 to
90 t/hr (average 70 t/hr) whereas maximum power generation will be at the rate of 70
t/hr steam input to TG. Balance steam over and above 70 t/hr will be charged to the
condenser & the DM water will be recycled in the boiler. No venting of steam will be
allowed.
STG: NFC will also give a provision to add any future steam from existing plants (10 t at
temperature of 390 degree & pressure 40 bar).
M/s NFC has to take low pressure steam tapping from Hydro-2 steam piping network for
initial start-up. Technical parameters and generating capacity of generator set are given
below;
Parameters of steam turbine:

Steam flow and pressure : 60~75t/h at a pressure of 4.0 MPa
Steam temperature condition : Saturation
Parameters of generator:
Power output (at generator terminals) :10000kW
Annual power generation : 74400103kW/h
Generating voltage : 11kV
Frequency : 50Hz
When waste heat power generation system is operating in normal condition with 4.0MPa
saturated steam coming from WHRB, enters the first level turbine to do work, steam id
discharge at 0.50.8MPa pressure, same will be used for process requirement and the rest
0.50.8MPa steam enters the second level turbine to do work, after work is done, dead
steam enters condenser, compensated water is pumped into DE-aerator through
condensate pump for deoxygenating, then it is supplied to WHRB for usage. And when
process steam is not required that time total steam will go for second stage and then to
condenser. Piping is considered for the supply of process steam to process requirement in
Fumer, decomposition, hydrolysis and halide section.
When steam-turbine generator is under the state of overhaul or failure, a complete steam
be diverted to condenser to condense the 100% steam in to DM water and same will be
pumped to deaerator.
Circulation water pumps & feed water pumps are on 415V VFD driven system and
connected with emergency power.
19
Blower house
Box fumer blowers and air compressors are placed in blower house to supply the air to box
fumer and the compressed air to each workshop of the plant.
Blower specification: Q=750m3/minP=0.1MPa.
In total, there are three air blowers with two for use, one for standby.
Two screw air compressors are designed, 10Nm3/min P=0.8MPa is for the instruments air
and 60Nm3/min P=0.8MPa is for other air consumption.
Diesel generator room
Two sets of power generator with capacity of 1000kW have been considered in the DG
house, and power generation voltage is 415V. It is mainly used for the emergency power
supply of all first level loads in the fumer plant. It is used as temporary power supply
measure at the time of power failure, and mainly used to ensure process safety and
operational issues.
Generator will take 15 second to start in auto mode and thereafter it will take 30 second to
come on full load. Boiler feed pumps & circulation pumps will start automatically after
power failure in 30 second and there will be no impact in boiler in 30-40 second duration.
Others
In the fumer project, some intermediate products are produced, which need to be treated
in existing production facilities of HZLs. Detailed treatment of the products is attached in
Annexure of battery limit.
Acid-making
2525 Nm3/hr concentrate SO2 will be generated after decomposition of zinc acid sulphate
and concentration of SO2 is 24.2% and this part of gas will be treated in existing Hydro-1 or
Hydro-2 Sulphuric Acid Plant. Checking of the Acid plants to treat SO2 Gas in to existing set
up and taking the required measures is in NFC Scope.
Sewage treatment
Sewage water will be diverted to sewage treatment plant. Blow down process water will be
used in Slag granulation system as well as rest will be connected to existing setup in ETP and
acid waste water will be connected to existing Effluent treatment plant.
Process waste water mainly includes the wastewater from circulating water system, sewage
and floor washing water. The process waste water contains no pollutants with water volume
of around 500m3/d. The acid sewage discharged from off-gas desulfurization system
contains As, F, CL, and dust with water volume about 36m3/d, the domestic sewage
quantity is about 30m3/d.
20
Slag/Residue treatment
The slags/residues generated from the plant mainly include box fumer slag, copper residue,
goethite residue and lead sliver residue.
The total amount of box fumer slag (dry basis) is 111, 740 t/Annum, the main component
are Pb 0.43%, Zn 2.41%, Cu 0.22%, Fe 33.54%, SiO2 31.89%, CaO8.36%, MgO 1.03% and
Al2O3 9.75%, which is benign slag.
Copper residue (CuCl) generated from de-chlorination plant is around 192t/Annum, its main
component are Cu 55% and Cl4%, Goethite residue is generated from de-ironing plant,
output (dry basis) is around 3168t/aits main component are Fe 12% and CaSO4 49%; this
part will be fix with Lime and cement and sent to SLF.
Lead sliver residue is generated from the decomposition of zinc sulfate acid, output (dry
basis) is around 15,235t/Annum, which includes Pb 4,593t/Annum, Zn 896t/Annum, and Ag
32.32t/Annum and same will be treated in Lead Plant.
Process description
Leaching process of zinc Calcine;
Neutral leaching;
Calcine discharged from the conical bottom of the storage after star feeder and belt feeder
into neutral leaching tank.
The spent electrolyte solution coming from electrolytic plant is pumped into electrolyte
storage tank. Anode mud is charged into ferromanganese reactive tank. All kinds of zinc-
containing solutions coming from the treatment of de-chlorination and de-ironing plant,
filtering solution from wl filtering press plant, and liquid coming from different areas are
mixed into liquid storage tank.
Spent electrolyte, ferromanganese fluid, and recoverable zinc-containing solution sent to
oxidation tank (existing equipment: NL-1) with pump, tank acidity shall be controlled to be
H2SO4 5080g/L, Fe20.1g/L.
After oxidation, pulping solution flows into the rest five neutral leaching tanks (existing
equipment: NL-2~6) through overflow launders, HZL has provision to charge in the first,
second, and third reactor tanks but charging in one and third number reactor only. its
quantity of addition in tanks depends on measured pH value. Final pH to be maintained in
leaching section is in between pH=5.05.2. the pulping solution from neutral leaching flows
by gravity to two parallel-connected neutral leaching thicker (existing equipment: NL-7~8)
from the sixth reactor tank, its overflow goes into neutral liquid storage tank. Thicker
bottom flow is continuously pumped to weak acid leaching tank (existing equipment: WL-
1~4).
Main reaction is as the followings:
21
ZnO+H2SO4 =ZnSO4+H2O
MnO2+2FeSO4+2H2SO4=Fe2(SO4)3+MnSO4+2H2O
Fe2(SO4)3+6H2O=2Fe(OH)3+3H2SO4
Neutral leaching generates 267m3/ h neutralized clean liquid. See Table for the neutralized
clean liquid composition.
Main Composition of Neutralized clean liquid through Calcine Leaching
Element Zn Cd Cu Co Ni Fe Cl F
Content(g/L) 144.2 0.476 0.08 0.005 0.004 0.005 ~0.01 ~0.001
Weak acid leaching;
There are four numbers of weak acid Leaching reactors in existing, neutral leaching bottom
flow is pumped into the first weak acid reactor tank, and some spent electrolyte and
concentrated sulphuric acid charged to reduce the Leaching pH to 2.0-3.0 and solution is
heated to 7585 by steaming, Acid leaching solution automatically flows from the fourth
tank into an acid leaching thicker (existing equipment: WL-30), its pulping solution flow is
pumped to two vacuum belt type filters (existing equipment: HBF-20~30) through middle
tank. Its overflow returns to neutral leaching tank (existing equipment: NL-1).
Main reaction is as the followings
Fe2O3+3H2SO4 = Fe2(SO4)3+3H2O
ZnO+H2SO4 =ZnSO4+H2O
Treatment process of leached Residue;
Filtering of acid leaching residue

The leaching residue filtration and drying plant is built for the project, where the membrane
filter press is used for filtration, and the rotary kiln is used for drying of the weak acid
leaching residue. One drying kiln (2.2m18m) is arranged with pulverized coal as fuel.
Moisture content at the outlet of the drying kiln is controlled to be 15%. The dried leaching
residue is sent to box fumer.
Blending of leached slag;
To maintain the perfect chemistry with weak acid Leach residue lime is added before
charging into Box.
Smelting of box fumer
The smelting process of box fumer includes the melting and converting of the leaching
residue.
22
After blending, movable belt feeder in front of furnace will charge mixed material into the
furnace through two feeding ports which are located at box fumer membrane type wall. The
lance on the side of box fumer will charge air and pulverized coal into the box fumer. After
melting and converting process, generated zinc oxide fume, slag, and off-gas will be
discharged from the furnace. The off-gas generated from box fumer will go to WHRB section
for the recovery of waste heat then it is sent to surface cooler and bag collector system for
dust collection. Finally, it is sent to de-sulfurization plant as absorbing agent. The box fumer
slag will be granulated, and the generated slag is sent to temporary slag yard and used as
the raw material for cement plant.
Box fumer will be operated in batch mode. The operation cycle of each box fumer is about 4
hours, in which feeding and melting is 2 to 2.5 hours; converting is 1 to 1.5 hours; slag
tapping about 0.5 hours. During feeding and melting processes, part of Pb and Zn will be
volatilized.
The converting operation of Zinc leach residue is the reduction volatilization process of
metals, that is, the mixed pulverized coal and air is blown into the melting slag of box fumer,
which makes the lead and zinc compound in melting slag revert to lead and zinc vapour,
volatilized vapours enter the upper space of furnace and uptake flue system, and is oxidized
to PbO and ZnO again by blown air of furnace gas, and is captured in dust collection
equipment. In addition, Pb and Zinc, Sb, Cd, and part of Ag also get volatilize and get
captured together with ZnO dust.
Slag fuming belongs to smelting of Zinc Lead Residue, in which gas, liquid, and solid react
and in top space gas-gas reaction are completed in a single reacting furnace. Fuming course
reaction shall include the burning and gasification reaction of coal, as well as the reduction
reaction of metallic oxide.
During fuming process- the are as upper part reaction

follows;
C+O2=CO2 Zn+O2=2ZnO
CO2+C=2CO 2Pb+O2=2PbO
ZnO+C(CO)=Zn+CO(CO2) 2CO+O2=2CO2
PbO+C(CO)=Pb+CO(CO2) PbS+1.5O2=PbO+SO2
Box fumer slag tapping;
After Converting operation, slag will be ready to tap-out from the furnace and the slag
tapping time considered is 0.5hours. The one end of box fumer is provided with two holes
one is at the top and another is at bottom. During normal Operation some slag will be kept
inside the furnace to start the next operation. so to have optimum slag level inside furnace
it is required to use top hole of the furnace and bottom hole will be used in case of draining
the furnace.
The other end of box fumer is provided with emergency slag tap hole. In case of emergency,
it can be tapped via emergency slag tap hole into emergency slag Pit.
Automatic slag tapping device provided to tap out the Slag from the Box fumer. In case of
power failure, box fumer feeding equipments, box fumer centrifugal fan, dust collection
fan, pulverise coal feeder, and other equipment shall be stopped in operation. Feed water
23
circulating water pump for WHRB, circulating water pump of box fumer, diesel unit of box
fumer, box fumer granulating unit, minimum Air to avoid Tuyer Chocking and other first-
class-load equipment will be started by using diesel generator as the emergency power
source, so as to ensure the safety of box fumer, box fumer WHRB and other equipment.
In case of power failure, the box fumer is immediately handled by adopting slag tapping
measures, namely opening the emergency slag tap hole and the box fumer slag is dumped
into the emergency pit. After slag tapping furnace temperature will be maintained by the
use of diesel oil burner can maintain the furnace temperature. After slag tapping tuyer will
be required to clean to clear the chocking, so as to ensure smooth tuyer operation, and to
resume production when back to normal.
When dust collection fan is not in operation, coal supply cannot be started.
Box fumer start-up
The two ends of box fumer are provided to insert the diesel oil burner which will be used for
the furnace start-up. During furnace start-up, the furnace is fed with a certain amount of
coke and granulated slag, the burner is used for furnace heating. As granulated slag is
melted and coke will get consumed, as per the furnace temperature, again coke and
granulated slag will be added to increase the bath level. When the furnace bath depth is
close to tuyer, the diesel oil burner can be taken out, and converting air into the furnace is
to be started. According to the change of bath depth and the change of furnace
temperature and Tuyer pressure, the air volume is slowly adjusted to increase the melting
rate. When the bath height is above tuyer level, pulverized coal is to be started for injection.
Box fumer WHRB
WHRB of Box fumer is composed of five parts, including box fumer hood, uptake flue, down-
take flue, radiant cooling zone and convection zone in the boiler. The WHB is provided with
forced circulation.
The box fumer WHRB hood is connected with box fumer flue gas outlet by flexible
expansion joint, and it is composed of heating surface of membrane wall structure, and the
pipe spacing is around 60mm. The WHRB uptake and down take are of radiant heat transfer
area, and flue gas flows over the radiation area, which is cooled down by radiant heat
exchanger to ~750. The flue gas flow in radiation area is relatively low in temperature.
This is good for dust precipitation. Radiation chamber, cooling chamber and convection
zone are horizontally arranged, and the radiation chamber, cooling chamber are composed
of heating surface of membrane wall structure, the pipe spacing is 80mm. The flue gas flows
over the radiation and cooling chamber and then enters the convection zone, the
convection zone exterior wall is of all membrane wall structure, and the pipe spacing is
100mm and along the flue gas flow direction. After flowing through the convection zone,
the gas drops its temperature to about 380, and then it is discharged from WHRB and
enters dust collection system.
The WHRB wall is of membrane wall structure, made of boiler steel pipe and flat steel by
welding.
Main technical parameters of WHB:

Steam output : 30~45t/h
24
Boiler operating pressure : 4.0MPa

Steam temperature : 251.8
Feed-water temperature : 104
Temperature of flue gas from the boiler 38020
Dust collection system
The box fumer gas will be at high temperature and may contain unburned CO gas, dust is
fine particles from volatilization of Metals, dust particles are fine and viscous dust is difficult
to dislodge from the WHRB. As per the off-gas and dust characteristic it is required to cool
down to a given level 380 Deg.C and then to send for the recovery of the dust. Off-Gas
temperature will be further reduced to below 180 Deg. C in tubular cooler.
Dust collection process: box fumerWHRBcooling flue ductbagfilterflue gas

desulfurization.
The temperature of the off-Gas from the outlet of the boiler is about 380 and same will be
passed to tubular cooler to further reduce the gas temperature to 180 and then it has to
be passed through the Bag Filter. The purified off-gas is delivered to the off-gas
desulfurization system, in which the zinc oxide dust collected from WHRB, Tubular coolers,
Bag Filter will be slurred and used in desulfurization
The design adopts two-stage cooling, and the WHB is used to recover most of heat, and
then to use cooling duct with simple structure to lower the temperature to a range suitable
for bag filter operation required. The bag filter is to use waterproof membrane high
temperature resistant filter material, to ensure dust content in discharged off-gas to satisfy
the environment norms of 30 mg/Nm3. The bag filter itself is provided with anti-explosion
valve, to take care of impact of CO explosion during abnormal condition. The flue gas duct
between box fumer boiler outlet and air cooling unit inlet is designed to be of chevron
type, so as to prevent dust build up. The whole system runs under negative pressure,
reducing dust hazard, improving operational environment. In order to prevent equipment
and pipeline corrosion, all equipment (apart from cooling flue duct) and pipelines are
provided with external heat insulation.
In order to ensure safe operation of bag filter and to prevent filtering bag from burn due to
higher flue Gas temperature, the cloth of the bag is provided with cold-blast valve. When
flue gas temperature is higher than 200, it automatically opens for suction of cold air and
closed when temperature is lower than 150.
Main design parameters:
Dust collection efficiency (include WHRB) : 99.9%

Resistance : 4400pa
Air ingress rate (including WHRB) : 30%
Flue gas desulfurization and zinc oxide dust treatment
The whole system includes Zinc dust slurry preparation with process water and supply of
slurry to off-gas scrubbing system for the absorption of SO2 gas. Zinc sulphite leaching, Cl&
Fe removal and residue filtration.
25
Slurry preparation and supply
The plant for dust collection from flue gas system and the desulfurization plant are close to
each other in plant layout, the ZnO dust is sent by belt conveying to zinc oxide storage, and
then it is sent via star feeder and belt feeder to slurry mixing tank for mixing with water, and
slurry mixing tank is used for the preparation of zinc oxide slurry with 10~15% solids, which
is pumped to absorbent storage tank.
Fresh zinc oxide slurry from absorbent storage tank is sent via slurry pump into two spray
header and one rotating-stream-tray tower, which is used for removing sulphur dioxide in
flue gas. The ZnO slurry feed rate is controlled by pH value in absorber. There will suitable
online PH Analyser in tanks to control the sulphite flow.
Off-gas scrubbing
Off-gas scrubbing is mainly used to remove the dust and As, F ,Cl from the off-Gas and clean
gas will go for desulfurization, The flue gas scrubbing mainly includes booster fan, scrubber
and scrubbing pump.
During operation, flue gas, pressurized by booster fan, enters the scrubber from the middle,
reverse contact with washing solution pressurized from slurry pond of scrubber. Off-gas is
quenched to about adiabatic saturation, most of the As, F, Cl and dust in off-gas is collected
by washing solution and enter the waste liquid. Flue gas after scrubbing is discharged from
the top of the scrubber and enters the absorber, while carrying over a large amount of
steam, therefore it is necessary to regularly make-up water for scrubber so as to maintain
water balance inside, at the same time, discharging a certain volume of wastewater
containing As, F, Cl and dust to the ETP Section.
Sulphur dioxide absorption
The absorption system mainly includes ZnO absorber, rotating stream tray tower, circulating
pump, discharge pump, and oxidization blower. The zinc oxide absorption is provided with
two absorbers in series. When flue gas enters the ZnO absorber, it turns 90 for up flow, the
counter current contact with slurry, and SO2 in the flue gas is washed by absorbed slurry,
and cleaned flue gas is removed with fog drops by demister from the stream and then sent
to rotating stream tray tower. The ZnO will be absorbed in the rotating stream tray tower
for further treatment in order to make sure the emission follow the environmental
protection standard. After wet ESP the cleaned off-gas is discharged out from 80m stack.
SO2 absorbed from flue gas reacts with ZnO in slurry and the absorptive SO2 exists in the
form of ZnSO35/2H2O. Due to the existence of oxygen, a small amount of ZnSO35/2H2O is
converted into ZnSO4. The system continues supplementing fresh zinc oxide slurry for
absorber, at the same time continues discharging out a certain amount of zinc sulphate
slurry and zinc sulfite cake.
26
The demister at the upper part of absorber is provided with on-line automatic flushing
system, and the demister flushing water is supplied from process water pump. The absorber
slurry pond and rotating stream tray tower slurry pond are provided with sideway type
agitator for agitation, so that solid particles in slurry pond maintain suspended state one
oxidization blower is provided to convert zinc sulphite into Zinc Sulphate. Only some part of
the Zinc Sulphite will be required to oxidize to maintain the fluidity of Zinc Sulphite slurry
and System blocking. The fan can be either on or off as per the system condition.
In the absorber;
The reaction of zinc oxide slurry with SO2 in flue gas is as follows:
SO2+ZnO+5/2 H2O = ZnSO3.5/2H2O
The absorptive reaction mechanism of SO2 can be considered such as that SO2 is dissolved
in water:
SO2+H2O =H2SO4 =HSO3- + H+

HSO3- = SO3- + H+
Then
ZnO+2H+ =Zn2+ + H2O
Zn2+ + SO32- =ZnSO3 or
Zn2+ 2HSO3- =Zn(HSO3)2
As the sulfurous acid is diacid, therefore there is a possibility of generating two salts. In case
of ZnO surplus, it is the neutral salt ZnSO3, and in case of SO2 surplus, it is the acid salt [Zn
(HSO3)2]. During absorption process, as ZnSO3 and Zn (HSO3)2 are unstable compound; a
small amount of them from oxidation may cause the following reaction:
ZnSO3 + O2 =ZnSO4
Zn (HSO3)2+ O2 =ZnSO4+H2SO4
Process water
The process water system is provided with process water tank and process water pump.
Water supply is mainly used for absorber demister flushing, pipeline flushing, absorber
slurry pond water make-up, desulfurization system auxiliary mechanical cooling water
system, etc.
Zinc sulphite leaching
The underflow from zinc sulphite slurry thickener (CN-02 C020) is pumped to the one-stage
zinc sulphite leaching tanks (CN-02 C003 and C004), which are of ladder- shaped
arrangement. At the same time, two-stage leaching filtrate and waste electrolyte is added
for one-stage zinc sulphite leaching. The reaction temperature is controlled to be 6575,
and the acid at the end of leaching process is 20~30g/l (H2SO4). During leaching process,
the air outlet is arranged at the top of the leaching tank. SO2 is sent to the inlet of the
drying tower in the existing acid-making device Hydro#1 and Hydro#2. The SO2 gas
27
concentration produced is about 24%. After reaction, slurry is pumped to the one-stage
leaching filter press in the new residue filtration plant. The filtrate is sent to the two-stage
leaching tank (CN-02 C005) after filter residue slurry, the reaction temperature is controlled
by steam at around 8090. Spent electrolyte and concentrated sulphuric acid is added to
control the acidity at the end of leaching process to around 80~100g/l (H2SO4). After two-
stage leaching, slurry is sent to the two-stage leaching filters press in the new residue
filtration plant. After press filtering it will be temporarily stored in yard. Yard is having the
capacity of 7 days to store this material. The filter residue is transported by truck to the pyro
metallurgical lead smelting process for lead recovery. The filtrate returns to the First -stage
leaching tank.
Due to the high sulphur HGP Dust, balancing of the sulphur in the whole system has been
considered, transporting the Calcine leaching residue washing water from the acid leaching
residue filer press plant to the washing water neutral tank (CN-02 C006), by neutralising it
with the limestone slurry and neutralized slurry will be send to acid leaching residue filtering
operation. From there residue will be send to the drying kiln and the filtrate will be used for
washing water circulation.
ZnSO3+ H2SO4= ZnSO4+ H2O +SO2
Chlorine and iron removal
The solution after zinc sulfite stripping is pumped into two 45005000 DE chlorination
tanks. Copper sulphate and zinc powder is added at the same time to settle Cl ion in the
solution in form of cuprous chloride. After the reaction, slurry is pumped to the Cl removal
filter press in the new residue filtration plant. The filtrate is pumped to the Fe removal tank
with goethite process. The filter cake is cuprous chloride residue, which is temporarily
stockpiled in a 7 days storage yard.
Main reaction:
2Cu2++ Zn+ H2O= Cu2O+Zn2++2H+
2Cl-+Cu2O+2H+=2CuCl+H2O
The iron removal tanks (CN-02 C009 and C010) with goethite process are in series
connection. Limestone slurry is added as neutralizer and steam is used to heat the solution
to 75~85. The pH value at the end of leaching process is controlled to be 2.5~3.5. The
slurry after reactions flows by gravity into one 15m thickener (CN-02 C022). Overflow
solution flows into overflow tank (CN-02 C026) and then is returned to the existing neutral
leaching tank for Calcine leaching by overflow pump. Under flow is pumped to goethite
press filter in the new filtration plant. The filter residue is goethite residue, which will be
slurred and send to Lime and cement mixing System
Main reaction equations are as follows:
H2O+H2SO4+ CaCO3= CaSO42H2O+CO2

2FeSO4+1/2O2+ H2O+2CaCO3=2FeOOH+2CaSO4+2CO2
28
Technical and Economic Indicators

Comprehensive technical and economic indicators
The main technical and economic indicators provided in this section include the
comprehensive data of such information as consumption, output, recovery and manpower,
See Table 6-1 for details of such comprehensive technical and economic indicators.
S/N Name of indicators Unit Quantity Remarks

1 Design scale
Zinc Ingot t/a 210,000
2 Product output
2.1 Electrolysis zinc t/a 210,224
2.2 Lead silver residue t/a 15,235 Dry basis
Lead contained t/a 4593
Silver contained t/a 32.32
Zinc contained t/a 896
2.3 Sulphuric acid t/a 19530 Calculated by
100% H2SO4
3 Requisite raw materials
Zinc Calcine t/a 370,000
Zn contained % 58.16
Pb contained % 1.38
Ag contained % 0.01
4 Metal recovery
Zn % 98.22
Pb % 90.45
Ag % 92.68
5 Requisite main fuel and auxiliary materials
Limestone t/a 14,590 (Dry basis)
Coal t/a 114,623 (Dry basis)
Diesel oil t/a 900 FF and CPL
CuSO4 t/a 200 Cl F removal
6 Main Production technological indicators
6.1 Zinc Calcine leaching
Zinc Calcine throughput t/y 370,000
Zinc contents in zinc Calcine % 58.16
Output of neutralized clean liquid m3/h 267 Zn149g/L
Leaching residue output t/h 18.26 Dry basis
Zn contents in leaching residue % 20.86
Pb contents in leaching residue % 3.31
Ag contents in leaching residue % 0.024
6.2 Leaching residue treatment
29
Leaching residue throughput t/y 153418 Dry basis

Water contents in leaching residue % 15
Zn contents in leaching residue t/y 32,000
Pb contents in leaching residue t/y 5,078
Ag contents in leaching residue t/y 36.8
Number of box fumers set 2
Box fumer specifications m2 18
ZnO dust quantity t/a 46167
ZnO dust Zn contents % 63.48
ZnO dust Pb contents % 9.95
ZnO dust Ag contents g/t 738.74
Slag quantity t/y 111,740
Zn contents in furnace slag % 2.41
Pb contents in furnace slag % 0.43
Ag contents in furnace slag g/t 24.12
Pb recovery % 90.45
Zn recovery % 91.58
Ag recovery % 92.68
6.3 Off gas desulfurization and zinc oxide dust treatment
Off gas throughput (into the Nm3/h 214789
Scrubber)
SO2 concentration (into the mg/Nm3 17948
Scrubber)
Design desulfurization efficiency % 99.5
Tail gas SO2 concentration ppm 50
Acidic water discharge M3/d 36
Pure SO2 gas Nm3/h 611
7 Power supply indicators
Installed capacity kW 18,735
Computational load kW 9797
Annual power consumption 3
10 kWh 72797
8 Water supply indicators
Total water circulation m3/d 126933
Fresh water m3/d 3182
Domestic water m3/d 30
Circulating water m3/d 123721
Reused water m3/d 500
9 Plant Availability indicators
Slag and zinc oxide dust treatment day 310
Chlorine and iron removal day 150~200
General disclaimer:
All the individual capacities of equipment/utilities in the system described are indicative and
M/S NFC will change/Modify/Provide according to the detailed engineering to fulfil/Meet
the overall plant capacities.
30
Zinc metal balance;

Zinc metal balance throughout the plant (within the battery limit):
31

Project Description

Загружено:

Сведения о документе

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Project Description

Загружено:

Авторское право:

Доступные форматы

SECTION-I

Table 2-1 Chemical composition of zinc Calcine (dry basis, Wt %)

Table 2-2 Chemical component of leaching residue (dry base, Wt %)

Element Zn Pb Cu Fe Sso4 Ss SiO2 CaO

Table 2-3 Chemical composition of raw coal (Wt %) Assay (WT %)

Table 2-4 Limestone chemical composition (dry, Wt %)

Element Fe SiO2 CaO MgO Al2O3 Others Total

Table 2-5 Compositions of spent electrolyte

Component gpl Component ppm

Meteorological and earthquake information

Zinc Calcine leaching

Leaching residue treatment

Off-gas desulfurization and zinc oxide dust treatment

Figure 2-4 for the process flow of halide removal;

Work Scope and Battery limit;

Table 3-1: Sub-items within the work scope

S/N Names of sub-items Description sub-item code

blending storage Preparation

Contents included in the work scope

The work scope includes such six parts as follows:

Zinc Calcine leaching

Leaching residue treatment

Off-gas desulfurization and zinc oxide dust treatment

Auxiliaries and utilities

1) The auxiliaries and utilities include blower-air, compressor house, 11 kV power

Zinc Calcine leaching

Leaching residue treatment

Acid leaching residue filtration and drying

Leaching residue blending storage

Fuming furnace plant

WHRB of box fumer

Dust collecting system

Off-gas desulfurization and zinc oxide dust treatment

Auxiliaries and Utilities

Water supply and drainage

Total water circulation: 126933m3/d

Drainage capacity: 566m3/d

Power supply and distribution

Power supply and distribution system:

Ventilation and air conditioning

Ventilation and dust removal system:

Coal pulverization plant

Waste heat power station

Parameters of steam turbine:

Blower specification: Q=750m3/minP=0.1MPa.

Diesel generator room

Leaching process of zinc Calcine;

Main reaction is as the followings:

Main Composition of Neutralized clean liquid through Calcine Leaching

Weak acid leaching;

Main reaction is as the followings

Treatment process of leached Residue;

Filtering of acid leaching residue

Blending of leached slag;

Smelting of box fumer

During fuming process- the are as upper part reaction

Box fumer slag tapping;

Box fumer start-up

Box fumer WHRB

Main technical parameters of WHB:

Boiler operating pressure : 4.0MPa

Dust collection process: box fumerWHRBcooling flue ductbagfilterflue gas

Main design parameters: