Study of Zinc Plant

Satyendra Pal Singh 2008UCH151 M.N.I.T., Jaipur

Introduction of Zinc
Metallic chemical element Its only common oxidation state is +2. Zinc is the 24th most abundant element in the Earth's crust The most exploited zinc ore is sphalerite, a zinc sulfide.

Applications
Galvanizing around 48% of global zinc usage.

protection against corrosion- used in building, construction, infrastructure,, automobiles, steel furniture
Zinc Oxide around 10% of global zinc usage

vulcanization of rubber, as well as in ceramics, paints, Animal feed, pharmaceuticals, and several other products and processes.

Applications
Die Castings - 17% of zinc used used in hardware, electrical equipments, automotive and electronic components. Alloys - 11% of global zinc usage. making alloys, especially brass, which is an alloy of copper and zinc. Rolled Zinc used extensively in the building industry for roofing, flashing and weathering applications

Steps of Process

Steps of Process
Main By-products
Zinc Concentrate Roasting
Direct Leach Oxide

Oxides & Other Secondary Materials

Sulphuric Acid Leach Product Fe Waste Gypsum CuSO4 Co/Ni Residue Cd Spent Electrolyte (Recycled)

Calcine Impure Solution Purified Solution Cathode

Leaching

Zinc Dust

Purification

Electrolysis Casting Alloy Material

Zinc / Alloy Market Metal

Dross and Zinc Dust (Recycled)

Input

Intermediate

output

Raw Material Handling Section

Various kinds of equipments are assembled in this section 1. Hopper 2. Conveyor Belts 3. Magnetic Separator 4. Vibrating Screen 5. Crusher

Flow Sheet of Raw Material Handling Section

spraying nozzles Zinc concentrate by Trucks Belt Conveyor Pay loader

Two Underground Bins

Concentrate Storage Hall

Two Hoppers

Belt Conveyor

Belt Conveyor

Concentrate Feed Bin

Fines

Vibrating Screen
Coarse

Magnetic Separator

Blended feed Belt Conveyor

Dross material

Hammer Mill or Ball Mill

SO2+calcine+CO2+NOx+920C

Rotary Table Feeder

Two Slinger Belt

Furnace

920C

Roaster Plant
Material

Feeding System and Fluid Bed Furnace Fuel Oil Supply (Burners and Lances) Waste Heat Boiler Hot Gas Cleaning Cyclones Hot Gas Electrostatic Precipitator

Some Equipments Used In Roaster Plant

Drum

Cooler Pneumatic Conveyor Ball Mill Bucket Elevator Silos

The reaction undergoing in this Section is

2 ZnS + 3O2

2 ZnO + 2SO2

H = -446 kJ/mol

ROASTER
Cyclone Separator HGP

Gaseous mixture

WHRB
Calcine

Rapping system 920C Air GCP

Inclined chain conveyor

Pneumatic conveyor

Cooler

Calcine Silos

To Leaching Plant

Furnace And Silos

Ball Mill And EGP

Gas Cleaning Section

Quench

Tank

Packed Gas Cooling Tower Wet Gas Plant

Gas Cleaning System

Acid Plant
Process Description
Drying Tower Convertor

Intermediate Absorber Section

Final Absorber Section

Acid Plant
3. Reactions
In Convertor
2SO2(g) + O2(g)
V2O5

2SO3(g) + 98.2 kJ

In Absorption Tower H2SO4 + SO3 H2S2O7 H2S2O7 + H2O 2 H2SO4

Acid Working
H2SO4 -96%, 55C, 565 m/h
SO2 Blower

130C
HE-4 270C Drying Tower
75C

HE-1 450C 300C 600C

Gases, 38C H2SO4

Intermediate Absorption Tower (IAT)

75C

425C

HE-2

Candle Filter

443C 433C

economizer

Final Absorption Tower (FAT)

85C

98.5%

HE-3B

HE-3A

400C

410C

180C
85C

Convertor 165C

Acid Plant

Leaching and Purification

Neutral Leaching Of Zinc Calcine

Acid Leaching
Residual Treatment Plant(RTP)

Purification
Cadmium plant

Neutral Leaching Of Zinc Calcine

Reactions
ZnO
CuO CdO PbO

+
+ + +

H2SO4

ZnSO4
CuSO4 CdSO4 PbSO4

+
+ + +

H2 O
H2O H2O H 2O

H2SO4 H2SO4 H2SO4

2 FeSO4 + 2 H2SO4 + MnO2 Fe2 (SO4)3 +MnSO4 + 2 H2O

2 FeSO4 + 2 H2SO4 + O2 Fe2(SO4)3 + 3 ZnO + 3 H2O 4 Fe(OH)3 + ZnO Fe2 (SO4)3 + ZnSO4 + 3 ZnSO4 + 2 H2O

2 Fe(OH)3

+ Sb/As/Al/Ge-complex

Fe-OH-Sb-As-Ge-Complex

CLASSIFIER

DORR THICKENER

Acid Leaching

Reactions

ZnO
MeO

+
+

H2SO4
H2SO4

ZnSO4
MeSO4 +

H2 O

H2O (Me = Cu, Cd etc.)

Residual Treatment Plant(RTP)

Purification

Electrolysis
Reaction in Cells Cathode
ZnSO4 + ZnSO4 H2O H2SO4 SO4(-2) + Zn + 0.5 O2 + Zn (+2)

SO4(-2)
Zn(+2)

+
+

H2O
2e(-)

H2SO4
Zn

+ 0.5 O2

Anode
MnSO4 + O2 +H2O MnO2 H2SO4

DOUBLE COOLING OF NEUTRAL SOLUTION

SPENT Tank NO. 326 S/T

Neutral Solution from L & P

Atmospheric Cooler

Tank NO. 326

Atmospheric Cooler PH-4.1 Dorr Thickener NO. 05 Overflow

RTP (06 Thickener)

NEuTRAL STORAGE TANK By Pumps TO MIXING CHANNEL

MELTING AND CASTING

Zinc Ingot

Jumbo Zinc Ingot

600 kg +/-50