Outotec hydrometallurgical technologies for zinc

Environmentally sustainable zinc solutions Outotec's expertise and experience provide the path to optimized solutions and complete plants for the production of high-quality zinc, based on a wide range of zinc raw materials. Outotec offers innovative and proven roasting, leaching, precipitation, solution purification, solvent extraction, electrowinning and casting technologies as well as sulfuric acid plants.

002 Outotec hydrometallurgical technologies for zinc

A committed partner from the start

Outotec operates globally through a broad network of sales and service centers. We strive to build a longterm relationship with our customers, ensuring that they receive the very best solutions for their operating environment. Our expertise covers the whole chain of zinc production, from concentrator to zinc casting equipment. Outotec's early involvement in projects ensures the most profitable and competent solutions. We provide world-leading technologies, technology selection expertise based on laboratory test programs, feasibility studies, basic and detailed engineering, technology specific equipment supply, training, erection supervision and start-up assistance, as well as follow-up and technical support services. Such involvement, from a single partner, offers you the possibility to enhance your production processes and minimize operating costs throughout the lifetime of the plant.

Outotec offers: n n n n n n n n n Innovative and proven technologies Laboratory test programs and pilot test campaigns Feasibility studies Basic and detailed engineering Proprietary and key equipment supply Commissioning and start-up services Process automation Spare parts and maintenance services Plant audits, retrofits and machine upgrades

Outotec hydrometallurgical technologies for zinc 003

Caring for the environment Outotec zinc technologies are designed to minimize environmental impact. We strive to make effective use of raw materials, minimize the production of stable or re-usable residues and reduce water and energy consumption. Outotec zinc technologies legislation comply and with the

environmental

requirements.

Outotec's early project involvement ensures smooth environmental performance of the zinc production chain. Outotec designs the most favorable and environmentally compatible solution according to your operating conditions.

Roasting

Calcine leaching

Solution purication

Zinc ingot
Suldic zinc concentrate Oxidic and silicate zinc ore and secondary raw materials
Concentrate direct leaching Iron removal/ Neutralisation Electro winning

Oxide leaching

Solvent Extraction

Casting

Outotec zinc technologies:

Roasting Sulfuric acid plant Leaching: n n n n Atmospheric direct leaching of zinc concentrate Zinc calcine leaching Zinc silicate leaching Leaching of secondary raw materials e.g. EAF dust Precipitation processes: n n Iron precipitation Neutralization

Solution purification: n n n n n Copper removal Chloride removal Cobalt and nickel removal Arsenic or antimony process Cadmium removal Gypsum removal

Zinc solvent extraction Electrowinning Zinc casting Effluent treatment Residue treatment Reactors and equipment Process automation

004 Outotec hydrometallurgical technologies for zinc

Tailor-made solutions through inhouse research and development

Comprehensive laboratory testing and piloting facilities At the start of each project, Outotec's in-house research centers play an important role in actively developing and acquiring technologies according to customer needs and requirements. Our research centers have a unique set of research facilities and pilot plants, from bench-scale to industrial scale, wellequipped laboratories and an extensive network of research subcontractors. At our pilot plants, we test our customers' raw materials and feedstock, and tailor our processes accordingly. For example, in order to improve the atmospheric direct leaching process, we perform a mineralogy study of the feed material, based on which we conduct a batch-leaching test followed by a continuous pilot test to obtain process design data. Through this type of commitment, we are able to provide you with an optimized process with high guaranteed process performance figures. Continuous bench scale pilot, zinc leaching process at Outotec Research Center in Finland

Outotec hydrometallurgical technologies for zinc 005

Innovative leaching and precipitation methods

Atmospheric direct leaching of zinc concentrate Outotec has developed a pioneering leaching method for zinc concentrate. The highly cost-effective and environmentally friendly process has been tested and proven on an industrial scale. The zinc concentrate is leached in sulfuric acid, either co- or counter-currently. Direct Leaching Reactors provide the essential dispersion of oxygen and slurry required for the related reactions. Online process control with Outotec OTI Titrators and Courier analyzer guarantees reliable and smooth operation. The iron can be removed as jarosite or goethite. As a result of the precise control of iron oxidation and the acidity of the process solution, precipitation is carried out either during or after the leaching process, depending on customer's needs. Benefits of atmospheric direct leaching: n n n n n n n Simple reactor construction High metal recovery Low operating costs Low maintenance need Easy to control Low energy requirement Low investment cost n n n n n n n Compact layout No explosion risk No molten sulfur High availability Flexibility with respect to various feed material Concentrate with low zinc content may be used Proven technology on an industrial scale The process is extremely flexible with respect to different raw materials and variations of feed materials. By using Outotec's atmospheric direct leaching, zinc recovery exceeds the industry norm. Atmospheric direct leaching can easily be constructed as stand-alone or combined with calcine leaching.

006 Outotec hydrometallurgical technologies for zinc

Zinc calcine leaching Zinc calcine produced in roasting contains zinc oxide and zinc ferrite. In order to obtain the maximum amount of high-quality zinc, the two must be leached in different conditions. Firstly, zinc oxides are leached in neutral leaching stages, during which ferrites do not dissolve. This process involves OKTOP reactors and Outotec High Rate Thickeners arranged in a cascade, with the acidity kept low.

Leaching of secondary raw materials Processing of secondary zinc raw materials and recycling of zinc are increasingly important. Outotec has designed a process to treat secondary zinc raw materials like electric arc furnace (EAF) dusts as well as Waelz oxides to produce Special High Grade (SHG) zinc. These raw materials with high chloride and fluoride content can be treated by a combination of Outotec leaching and solvent extraction processes. The halide concentration in the process circuit can be

Secondly, the underflow flows onto the Outotec conversion process, where the zinc ferrites are leached simultaneously with the precipitation of jarosite. This stage has proven low investment costs and a confirmed low environmental impact. Outotec provides an alternative solution to neutral leaching residue with high lead and silver content. The residue is leached in two counter-current Outotec hot acid leaching steps, in order to leach the incoming zinc ferrite to obtain an overall high zinc recovery and simultaneously to produce a leach residue with highest possible lead and silver content. The overflow is fed into the iron precipitation stage.

efficiently controlled by washing of the oxide before the leaching step. Outotec offers various methods to control the impurity levels in the solution to guarantee troublefree operation and to meet even the highest environmental regulations for the process outlet streams. Zinc can be recovered with exceptionally high recovery and low investment and operation costs with Outotec know-how in the leaching and solvent extraction processes combined with our process equipment and optimised equipment material selection.

Benefits of Outotec oxide and silicate leaching: Zinc silicate leaching Outotec has developed a leaching process also for zinc silicate and zinc carbonate ores. Special attention in the design is paid to the solubility and kinetics of silicates, which offers high zinc recovery and stable process operation. In addition, Outotec tailor-made process solution enables to optimise acid consumption in the leaching and to make processing of such a raw material economically viable. n n n n n Low investment cost Low environmental impact Simple process Flexible and adaptable Improved process performance through optimized reactor design

Outotec hydrometallurgical technologies for zinc 007

Iron removal Outotec offers jarosite and goethite processes for iron removal. Outotec processes have been proven to produce iron precipitate with a low zinc and high iron content. During iron precipitation, it is essential that the operating conditions can be controlled, in order to produce iron as the desired compound. This is mainly accomplished through optimizing the iron oxidation and precipitation rate and Outotec reactors. Furthermore, the circulation of oxygen from the gas phase back into the solution is performed in order to obtain the highest oxygen utilization efficiency. Our expertise in iron precipitation offers solution an to efficient zinc and reliable for iron producers acceptable

Neutralization Outotec provides an expert solution for removing metals from dilute process solutions. Neutralization is performed through the addition of lime milk; the metals in the solution are precipitated as hydroxides and lime as crystalline gypsum. The combination of three factors, pH control, powerful OKTOP Reactor Series 4000 agitators and seed circulation, makes Outotec's neutralization plant superior. All of these factors reduce the adhesion of particles to the neutralization reactor and piping in a controlled manner. Furthermore, optimal particle size distribution, a high settling rate, and the good filtering properties of disposed solids are obtained cost-effectively through a high degree of process utilization.

environmentally

residue storage or further use.

008 Outotec hydrometallurgical technologies for zinc

Advanced zinc solution purification and solvent extraction

Outotec offers extensive solution purification processes. During leaching, other metallic components nobler than zinc such as copper, cobalt, nickel and cadmium are leached and must be removed before electrowinning.

Copper removal The first stage of solution purification is copper removal. Copper is precipitated from the zinc solution in a continuous and proficient way. It is essential to remove copper, as it will otherwise precipitate with zinc onto the cathode and, as a result, reduce current efficiency in electrolysis. Copper is cemented using zinc dust and copper, and cuprous oxide is produced, reducing zinc dust consumption and thus operating costs. The copper cake can be utilized in copper smelting processes. Chloride removal If necessary, chloride removal can be implemented at the copper removal stage. Outotec has devised an effective chloride removal method, improving the quality of zinc by keeping the chloride content under permissible levels. In order to avoid corrosion problems, it pays off to remove chloride from the zinc solution.

Cobalt and nickel removal Outotec offers cobalt and nickel removal, either using arsenic or a conventional antimony process. Cobalt and nickel are removed in Outotec's continuous arsenic process through the addition of arsenic trioxide and zinc dust. Cobalt and nickel removal is essential since the presence of these materials lowers the efficiency of the electrical current during electrolysis. In addition, Outotec has built antimony-based purification processes all over the world and has a vast experience in this field. The antimony process is a three stage process consisting of copper-cadmium removal and separate cobalt-nickel removal, followed by polishing. Cobalt and nickel are precipitated using antimony trioxide and zinc dust. The cobalt and nickel removal process by arsenic gives lower zinc dust consumption, higher quality of the product solution and ability to treat solutions with higher impurity levels.

Outotec hydrometallurgical technologies for zinc 009

Cadmium removal Cadmium is removed in Outotec's state-of-the-art fluidized bed system which gives the lowest possible zinc dust consumption and produces cadmium sponge with a high cadmium and low zinc content. This cadmium cake can be briquetted and subsequently fed into a cadmium refining furnace. The refined metal can then be cast into wire or sticks, the refining process yielding 99.98% pure cadmium. Gypsum removal Gypsum must be removed from the zinc solution prior to being sent to the electrowinning department, as it will form crystals in the tankhouse cells. Gypsum removal is performed by cooling the solution with Outotec Cooling Towers, and by separating the precipitate from the main zinc solution using Outotec High Rate Thickeners. Continuous and efficient control of the process is essential in order to extract the maximum amount of gypsum. Zinc solvent extraction Solvent extraction is an alternative to zinc solution purification by metals precipitation and is especially suitable for solutions with lower zinc concentration. Outotec offers innovative solvent extraction technology. Our expertise covers the chemistry of the related processes and how to implement it, alongside highperformance equipment, in a zinc solvent extraction plant. Zinc solvent extraction is suitable for leach solutions such as secondary, oxidic or silicate zinc raw materials. Outotec's continuous development of mixer- settler technology has resulted in ground-breaking Outotec VSF solvent extraction technology, which significantly decreases operating costs and improves profitability. Its scalability makes this technology suitable for plants of any size. Outotec VSF comprises the Outotec DOP Overflow Pump, Separation Fences. two Outotec SPIROK Mixers, and a proprietary settler design including Outotec DDG
DOP generates optimal droplet distribution. SPIROK maintains smooth mixing with optimal reaction surface.

010 Outotec hydrometallurgical technologies for zinc

Optimized solution through industrial equipment design

Outotec equipment solutions optimise the metallurgical results and ensure reliable operations. Outotecs equipment is designed to be an economical solution for the entire lifetime of your plant. Furthermore, we guarantee high level equipment performance. Outotec proprietary equipment: n n n n n Outotec reactor delivery package: Agitator: n n n n Bridge and design of support Electric motor Drive Shaft and impeller n n n n n n n n OKTOP reactors Outotec cooling towers Scrubbers Thickeners Filters Flotation cells Cathode stripping machines Permanent cathodes Bales DOP pumps SPIROK mixers Settlers DDG separation fences

Tank Baffles Integrated heat exchangers Reactor stands or support Launder between reactors

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OKTOP Reactor Family The OKTOP Reactor Family is a result of decades of experiments, design work and operational experience . The OKTOP Reactors are an optimal solution for solidliquid, gas-liquid, gas-liquid-solid and liquid-liquid systems for leaching, precipitation, crystallization, oxidation, reduction and solvent extraction. Process performance requirements are met by configuring reactor design elements, such as the agitator, tank design and baffles. Outotec has installed hundreds of reactors for a wide range of hydrometallurgical applications, from leaching to precipitation. We tailor our proprietary equipment according to the customers process requirements. We utilize our experience and expertise from numerous implementation projects in customizing our equipment to your process conditions. A complete technology package with proprietary equipment from Outotec ensures that you get an optimized process with maximal financial return. OKTOP reactor design begins with determining the process parameters. Outotecs comprehensive chemical knowhow is a key factor in the project and forms a solid basis for the project. The unique design cycle includes physical modelling, leaching and precipitation tests in laboratory, fluid dynamical analysis, computational mechanical design and life cycle analysis. The Outotec reactor design enables us to provide you with the optimal and most reliable equipment solution, excellent process performance and maximum equipment lifetime. The Outotec reactor design specifies optimal corrosion resistant materials and enables economical local manufacturing.

012 Outotec hydrometallurgical technologies for zinc

Outotec Cooling Towers The compact and innovative new design of Outotec Cooling Towers provides high efficiency direct solution cooling with significantly lower emissions and higher cooling air throughput. Additionally the innovative top structure enables maintenance while the cooling tower is in operation leading to higher availability. Higher efficiency leads to smaller amount of towers and higher availability to lower maintenance costs. Both capital and operational costs are decreased. Since the related emissions are therefore lower than in a conventional cooling tower, the impact on the environment is diminished. Furthermore, the cooling effectiveness allows for a more compact tower size. Housekeeping is easy due to the structure of the tower. Scrubbers Outotec Ventgas Scrubber package is an efficient solution for cleaning hydrometallurgical plant offgases. Outotec delivers several types of gas scrubbers for different off-gases in the zinc process. Scrubber design is integrated with Outotec reactors. With tailored gas cleaning solutions we can ensure maximum environmental safety for Outotec processes. Flotation cells The world-leading Outotec

reports to a separate tailings dam or lead smelter as intermediate lead/silver products depending on process configuration. In addition, we offer tailored flotation cells suitable for zinc concentrators. At Outotec, we provide the required testing to determine the size of flotation cell and froth recovery arrangement fitting your plant. This enables compact, economical and efficient plant design. Solid-liquid separation The solid-liquid separation offered by Outotec

comprises both thickeners and filters. Combining these technologies gives an optimal process solution which guarantees the highest possible metal recovery, control of water balance and high-purity by-products for all of the process steps in hydrometallurgical zinc production. Outotec offers pressure filters, belt filters and polishing filters, according to the requirements of each process step and customers targets. The exceptional Outotec High-Rate Thickener and Outotec Clarifier play an important role in the zinc process, when reliable and smooth plant operation are considered. Outotec pays special attention to designing feedwells, rake profiles, drive systems and control

Flotation Cells enable

strategies. High reliability and low capital costs are just a few of the advantages.

to separate sulfur and undissolved sulfides from the zinc concentrate leach residue. The residue

Outotec hydrometallurgical technologies for zinc 013

Efficient zinc electrowinning process with jumbo cathodes

Outotec is the right partner for delivering an efficient, productive and safe electrowinning plant with optimized cathode and cell sizes, current densities, busbars, and an automatic material flow of cathodes. Outotec has a vast experience in supplying zinc electrolysis processes and equipment for greenfield plants and modernizations, based on its own process knowledge, continuous R&D and technology. The material management system, with key equipment such as automatic cathode stripping machines, anode washing/flattening machines and cellhouse cranes, ensures safe material flow and the smooth harvesting of cathodes with minimum labor force. Advanced systems for casting zinc ingots Outotec offers full line of automated equipment to reduce human exposure to molten metal. Outotec electrowinning plant:: Engineering services and design Proprietary equipment: n n n n n n Cathode stripping machines Anode cleaning machines Cellhouse cranes Aluminum cathodes Water-cooled busbars Highly efficient cooling towers n n n n Benefits: n Precise control of metal flow and ingot weight Tireless robotic skimming Efficient cooling and long life of the mould Reliable robotic stacking High capacity linear jumbo casting
Alternative methods available for cathode stripping. Optional features for improving efficiency: the handling of rejected and in-feed cathodes, online washing, weighing of single cathodes.

014 Outotec hydrometallurgical technologies for zinc

Stable process operation with Outotec Automation System

Our vast experience shows that a close link between process and automation design is vitally important to ensure a smooth process operation. The important aspects of automation in hydrometallurgical processes are the ability to stabilize processes and gain an overall view of production. Safety issues with respect to operation, equipment, the environment and personnel are improved in an easy and convenient manner. These benefits are gained with smooth equipment performance and ensuring that the consumption of additive agents and chemicals is diminished and variables such as impurity levels, process temperatures and element balances are fully controlled. Outotec Proscon is a process automation package for transferring our knowledge and experiences to our customers. The application includes a process control system, process instrumentation and process electrification with all of the required services. Outotec uses modern, renowned and respected hardware and software manufacturers. Outotec Automation System: Production ramp-up Outotec Proscon Benefits of Outotec automation: n n n n n n n n Link between process know-how and automation Process operated as designed Rapid production ramp-up Continuous and stable process Automation system pretested before installation at plant Smooth equipment performance Safety of operation, equipment and personnel Easy and convenient operation Tankhouse

Information

Management

System

(Outotec TIMS) is a new and modern data collection, reporting and management system to integrate Outotec's material handling machines, CellSense monitoring and process control systems. Significant benefits are gained in increasing the energy efficiency, product quality as well as improving maintenance and safety.

FASTER
100%

n n n

Process control system Process instrumentation Process electrification Outotec Courier Outotec OTI Titrators Outotec sampling systems

Process analyzers

MORE
50%
Theoretical max. Outotec automation Worst case

n n n

Material management system for electrolysis Outotec CellSense to improve efficiency of electrolysis Outotec TIMS Reporting systems

0%

Outotec automation ensures that production ramp-up is performed faster and more effectively, enabling a stable and continuous process.

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Outotec services improve your process performance

Outotec's comprehensive technology transfer package can be completed with expert services and support. Our customer service operates through a global network of local units that offers not only assistance meeting the customers' needs but also a commitment to providing advanced customer support whenever needed. Our service experts provide punctual spare parts logistics, maintenance and training, as well as assessment and consulting services that generate a competitive advantage for you. We can tailor services efficiently to your specific needs, when considering the necessary operational and maintenance services already from the beginning of the project. As your trusted service partner, Outotec ensures an optimized operation for the entire lifetime of your plant. Equipment services Obtaining all spare parts and maintenance from the same organization as process and equipment design ensures that your plant runs optimally. We make sure that you receive only the highest quality parts, consumables and upgrades, that can be seamlessly integrated into your plant. Plant and process support services Outotec's advanced plant and process assessment, ef-X Efficiency Explorer, indentifies the areas for potential improvements, e.g. equipment, automation systems, plants. metallurgical processes and complete Benefits of Outotec services: n n n n Critical original spare parts in stock Process and equipment know-how Minimize downtime and unscheduled stoppages Maximum operating performance What is more, we can make it much easier for you to fulfill current and future legislation, by ensuring that your plant and processes are running as efficiently as possible, and that maintenance is being carried out proactively.

Total service package from Outotec:

Equipment services n Spare parts and spare parts management n Equipment inspections and maintenance n Training Process support services n Process assessment n Process control analysis Plant services n Plant assessments n Operation and maintenance support services n Upgrades and modernizations n Shutdown maintenance services

Outotec develops and provides technology solutions for the sustainable use of Earths natural resources. As the global leader in minerals and metals processing technology, Outotec has developed over decades several breakthrough technologies. The company also offers innovative solutions for the chemical industry, industrial water treatment and the utilization of alternative energy sources. Outotec shares are listed on the NASDAQ OMX Helsinki.

hydro@outotec.com www.outotec.com Copyright 2012 Outotec Oyj. All rights reserved.

Finland, June 2012.