Hindustan Zinc Limited operates zinc, lead and silver mines and smelting facilities in India. It produces zinc, lead, silver and sulfuric acid. The document discusses Hindustan Zinc's hydrometallurgical plant processes which involve roasting zinc sulfide ore to produce zinc oxide, leaching the zinc oxide in sulfuric acid to produce zinc sulfate, and electrolysis in a cell house to electrowin zinc from the zinc sulfate solution. It also summarizes three student projects on pneumatic conveying of zinc dust, installation of rotary control valves for material handling, and development of air conditioning for a crane cabin.

1. Hindustan Zinc Limited
Summer Training Project
Presentation
HYDRO PLANT
Under Guidance of:
Mr. Sandeep Gupta
(Industry Guide)
Submitted By:
MANISH SHARMA
A2305411005
MAE-1x

2. About HZL:
Hindustan Zinc Ltd. (HZL) is a major producer of zinc, lead, and silver in the country.
Huge quantity of Sulphuric acid is produced as a by-product of zinc and lead refining
process which is marketed to different manufacturing industries.
HZL is the world's second largest zinc producer.
HZL is also the world's lowest cost zinc producer
OPERATIONS:
• Smelting
HZL operates Zinc and Lead smelters and refineries at Chanderiya (Chittorgarh),
Debari (Udaipur) & Dariba (Rajsamand) in Rajasthan. A smelting facility was
established at Pantnagar in Uttarakhand. It was initially intended to serve as a
smelting facility for Silver production, but later Zinc and Lead melting and casting
plants were also established here.
• Mining
HZL operates the world's third largest open-pit mine, and World's largest Zinc Mine
in Rampura Agucha, Rajasthan.
Other mines with HZL are located in Sindesar Khurd, Rajpura Dariba, Kayar and
Zawar, all in Rajasthan.

4. SAFETY:
Hierarchy Of Control Measures:
• Elimination
• Substitution
• Engineering Control
• Administrative Control
• PPE’s (Personal Protective Equipment)
Safety Helmet
Safety Shoes
Hand Gloves

5. Chanderiya Smelting Plant:
(Chittorgarh, Rajasthan)
Chanderiya Smelter Complex is the world's largest Lead-Zinc smelter
complex in the Chittorgarh district of Rajasthan state of India. It is
metallurgical type plant.
It refines Lead-Zinc ore from Rampura Agucha. It produces Zinc, Lead,
Silver, Cadmium and other precious metals.
It consists of 3 units:
• Pyro Metallurgical Process Plant
• Hydro Metallurgical Process Plant
• Captive Power Plant

6. HYDRO PLANT PROCESS
• Consist 3 process :-
1) Roasting
ZnS + 202
 ZnO + S푂2
2) Leaching
ZnO + 퐻2S04
 ZnS04 + 퐻2O
3) Cell House
ZnS04 + 퐻2O  퐻2S04 + Zn + ½ 푂2

7. ROASTING

8. • Raw material coming from mines is handled
and get conveyed from one place to other and
we send it to roaster furnance where we get
the Zn and then we convert it to Zn0.
• SO2 is produced and as it is harmful for us so
we make it react with oxygen and gets
converted into SO3 and it convert into H2SO4
and we use this in various purposes.

9. LEACHING
Process in leaching :-
1) Storage
2) Neutral Leaching
3) Hot Acid Leaching
4) Jarosite Precipitation
5) Pre- Neutralisation

10. 1) STORAGE
• Solution (ZnO) comes from roaster and gets
stored in leaching section.
• We store H2SO4 also which is coming from
roaster plant.

11. 2) Neutral Leaching

12. • It is the 1st process in this leaching section
where we separate impurities from the calcine
(ZnO).
• To convert zinc oxide into ZnSO4 , solution at
4.9-5 pH in presence of excess calcine so as to
get minimum impurities in neutral overflow
solution.

13. 3) HOT ACID LEACHING
• Zinc oxide remained after leaching is leached
at high tempertaures (90-95 ºC ) 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.

14. 4) JAROSITE PRECIPIATATION

15. • It is required to remove the iron from ZnSO4
solution, which has leached during hot acid
leaching II-stage. Ferrous is converted into
ferric. This is done at high temp (100 ºC) 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.

16. 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.

17. CELL HOUSE

18. 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

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

20. 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.

21. 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.

22. 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.

23. • 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.