HYDROMETALLURGICAL

EXTRACTION OF ZINC
____________________________________
_
Roasting
Mainly concerned with preparation
ZnS + 2O
2
ZnO + SO
2

Leaching
Concerned with purifying
ZnO + H
2
SO
4
ZnSO
4
+ H
2
O
Cell House
Final Refinement
ZnSO
4
+ H
2
O H
2
SO
4
+ Zn + O
2

MAIN PROCESSES INVOLVED
ROASTING
MAIN PROCESSES INVOLVED
Raw material
coming from mines is
handled and get
conveyed from one
place to other and we
send it to roaster
furnace where we get
the Zn and then we
convert it to Zn0.
SO
2
is produced
and as it is harmful
for us so we make it
react with oxygen
and gets converted
into SO
3
and it
convert into H
2
SO
4

and we use this in
various purposes.

PROCESS IN LEACHING :-

1) STORAGE
2) NEUTRAL LEACHING
3) HOT ACID LEACHING
4) JAROSITE PRECIPITATION
5) PRE- NEUTRALIZATION

LEACHING
SOLUTION (ZNO) COMES FROM ROASTER AND GETS
STORED IN LEACHING SECTION.

WE STORE H
2
SO
4
ALSO WHICH IS COMING FROM
ROASTER PLANT.

1- STORAGE
2- NEUTRAL LEACHING
It is the 1
st
process in this leaching
section where we separate impurities from
the calcine (ZnO).

To convert zinc oxide into ZnSO
4
,
solution at 4.9-5 pH in presence of excess
calcine so as to get minimum impurities in
neutral overflow solution.

3- HOT ACID LEACHING
Zinc oxide remained after leaching is
leached at high temperatures (90-95 C )
and acidity (30-40 gpl).
Zinc ferrite formed during process is not
leached, more aggressive leaching is
required i.e. HOT ACID LEACHING II.--
We recover almost 97% of zinc from this
process.

4- JAROSITE PRECIPIATATION
It is required to remove the iron from
ZnSO
4
solution, which has leached during
hot acid leaching II-stage. Ferrous is
converted into ferric. This is done at high
temp (100 C) and sodium sulphate addition
is done as the result one complex of iron
and sodium is formed known as Jarosite by
adding sodium. The other impurities are
also precipitated along with Jarosite during
this stage.

5- PRE- NEUTRALISATION
This stage is to collect the residual iron
content in clear solution from jarosite
before entering the neutral leaching, to
precipitate impurities carried over from
jarosite and neutralize the residual acid
content. Calcine is added and pH - 4.5 - 4.9
is maintained to precipitate iron as ferric
hydroxide.

CELL HOUSE
PROJECT -1
Objective : Pneumatic Conveying Of Zinc Dust in Purification.

Pneumatic Conveying:
A pneumatic conveying system transfers powders, granules, and other dry materials
through an enclosed horizontal or vertical conveying line. The motive force for this
transfer comes from a combination of pressure differential and the flow of air supplied
by an air mover, such as a blower or fan. By controlling the pressure and the airflow
inside the conveying line, the system can successfully convey materials.
Zinc Dust Plant:
It is designed to produce the zinc dust, which is required at the purification and
cadmium plant. Two atomising furnaces are provided, each having a dust production
capacity of 1200 kg/h. This plant will be an integrated plant of the melting and casting
plant and will consist of the following main equipment:
One 600 kW induction furnace
One double expansion chamber / bin
One double deck zinc dust screen
Two zinc dust bins, one for coarse and one for fine dust with the corresponding
pneumatic zinc dust transport system


Different Components of pneumatic conveying Unit:
Expansion Chamber/ Bins
Vibrating Feeders
Bucket Elevators
Bag Filter
Vibrating Screen
Molten Metal Launder
Furnace ventilation Baghouse

PROJECT - 2
Objective : Installation of rotary control valves for calcine
silos.

ROTARY VALVE
Rotary Control Valves are eccentric valves for throttling
liquids, gases and slurries. They combine precise throttling
accuracy and control over a full 90 of rotation.
Rotary Control Valves are designed for bi-directional flow
capability and include four trim options for flexibility.
Designed for ease of maintenance with no internal threaded
components and self-aligning seat and plug.
In industry, a rotary valve (which can also be called airlock) is
often used to enter or extract material from two chambers
with different pressure level.

WHY ROTARY VALVES?
Before we were using reciprocating
control valves by using screw compressors
but in that there were so many leakage
points.
We used rotary control valves to
minimize the leakage and increasing the
efficiency as there is only one point of
leakage i.e. shaft.

PROJECT - 3
Objective : Development of alternate ac for kunz crane (used to lift
electrodes in cellhouse)

Equipment layout:-
The air conditioning unit consists of two parts, the mechanical section and the
actual air conditioning section.

Mechanical Section:
It consists of a robust steel casing with removable casing plates.
It houses the main components, i.e. condenser, refrigerant tank and the
necessary refrigerant lines and fittings.
On the side opposite to the condenser the casing is in the form of a grating,
allowing the heated exhaust air to escape.
The belt pulleys on compressor and drive motor are fixed on the shaft with
Taper-Lock bushes, allowing for easy mounting.

Air conditioning section:-
The air conditioning section
consists of an insulated steel
plate housing accomodating the
evaporator (air cooler), air
recirculation fan, electrical
heating, switch cabinet, stage
thermostat, fresh air filter,
expansion valve and the
pressure switches.
Three sides of the housing are
formed by removable, insulated
covers , affording easy access to
the inside of the air conditioning
section for maintenance work.
All three may be switched round
at will, allowing a variety of
arrangements for the air
connections as already
mentioned.


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