The document discusses zinc extraction processes. There are two main categories of processes: pyrometallurgical and hydrometallurgical. Approximately 80% of the world's zinc is produced via hydrometallurgical processes like the roast-leach-electrowin process. This process involves roasting zinc sulfide concentrate to produce zinc oxide, which is then leached and electrowon to extract zinc metal. An alternative is the pressure leach process, which combines roasting and leaching into a single step to produce zinc sulfate solution for electrowinning.
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CHAPTER 3 MINERALS ORES AND METHODES OF SEPARATION.pdfWeldebrhan Tesfaye
i. Introduction
ii. Minerals and ores
iii. Sources of metals
iv. Methods of beneficiation of ores and miners
a. Comminution
Size reduction by crushing and grinding
Minerals, ores and methods of beneficiation
Liberation
Laws of crushing and grinding
Sizing
b. Classification and concentration
c. Classification and concentration
d. Magnetic separation
e. Electro- static separation
f. Flotation
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CHAPTER 3 MINERALS ORES AND METHODES OF SEPARATION.pdfWeldebrhan Tesfaye
i. Introduction
ii. Minerals and ores
iii. Sources of metals
iv. Methods of beneficiation of ores and miners
a. Comminution
Size reduction by crushing and grinding
Minerals, ores and methods of beneficiation
Liberation
Laws of crushing and grinding
Sizing
b. Classification and concentration
c. Classification and concentration
d. Magnetic separation
e. Electro- static separation
f. Flotation
Non - Ferrous Extraction of Metals Lecture NotesFellowBuddy.com
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# Students can catch up on notes they missed because of an absence.
# Underachievers can find peer developed notes that break down lecture and study material in a way that they can understand
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Our Vision & Mission – Simplifying Students Life
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Introduction
Magnesium extraction
a. Pidgeon process
b. Magnotherm process
Extraction of metals from oxide members
c. Electrolytic process (Dow process )
Aluminum extinction
a. Baye’s process
b. Hall- heraoult process
c. Methods of titrating low grades ores
d. Newer process for Aluminum production
Tantalum extraction
Introduction
Winning of metals from sulphide ores
Extraction of Copper
a. Hydro - metallurgy of copper
b. Pyro - metallurgical extraction of copper
c. Newer process for copper extraction
d. Energy concepts in copper smelting
Extraction of metals from oxide members
Extraction of Lead
i. Treatments of ores of lead and its production
ii. Modern developments in lead smelting
Extraction of Zinc
a. Pyro - metallurgical extraction
b. Hydro – metallurgical extraction
c. Imperial smelting process
d. Production of other metals by ISP
e. Zinc from lead slags by slag fuming
Extraction of Nickel
Pyro – metallurgical process
Pelletization of iron ores and the type of wear liners used in thier eqipmentsGulshan Kumar Singh
Now a days about 60% of iron ore converted to fines during mining, handling and transporting so pellet is a process of utilizing iron ore fines up to size of 0.15 microns. i investigate its process,equipment used in process, wear and other problems in them and its future scope
Non - Ferrous Extraction of Metals Lecture NotesFellowBuddy.com
FellowBuddy.com is an innovative platform that brings students together to share notes, exam papers, study guides, project reports and presentation for upcoming exams.
We connect Students who have an understanding of course material with Students who need help.
Benefits:-
# Students can catch up on notes they missed because of an absence.
# Underachievers can find peer developed notes that break down lecture and study material in a way that they can understand
# Students can earn better grades, save time and study effectively
Our Vision & Mission – Simplifying Students Life
Our Belief – “The great breakthrough in your life comes when you realize it, that you can learn anything you need to learn; to accomplish any goal that you have set for yourself. This means there are no limits on what you can be, have or do.”
Like Us - https://www.facebook.com/FellowBuddycom
Introduction
Magnesium extraction
a. Pidgeon process
b. Magnotherm process
Extraction of metals from oxide members
c. Electrolytic process (Dow process )
Aluminum extinction
a. Baye’s process
b. Hall- heraoult process
c. Methods of titrating low grades ores
d. Newer process for Aluminum production
Tantalum extraction
Introduction
Winning of metals from sulphide ores
Extraction of Copper
a. Hydro - metallurgy of copper
b. Pyro - metallurgical extraction of copper
c. Newer process for copper extraction
d. Energy concepts in copper smelting
Extraction of metals from oxide members
Extraction of Lead
i. Treatments of ores of lead and its production
ii. Modern developments in lead smelting
Extraction of Zinc
a. Pyro - metallurgical extraction
b. Hydro – metallurgical extraction
c. Imperial smelting process
d. Production of other metals by ISP
e. Zinc from lead slags by slag fuming
Extraction of Nickel
Pyro – metallurgical process
Pelletization of iron ores and the type of wear liners used in thier eqipmentsGulshan Kumar Singh
Now a days about 60% of iron ore converted to fines during mining, handling and transporting so pellet is a process of utilizing iron ore fines up to size of 0.15 microns. i investigate its process,equipment used in process, wear and other problems in them and its future scope
This presentation gives an overview of the two main approaches to processing copper ore into a refined product: the pyrometallurgical approach (copper concentrates), and the hydrometallurgical approach (SX-EW). Process flow diagrams and key equipment are also highlighted.
Production, Manufacturing and Extraction of Silver, Gold, Copper, Magnesium,...Ajjay Kumar Gupta
Electroplating involves passing an electric current through a solution called an electrolyte. This is done by dipping two terminals called electrodes into the electrolyte and connecting them into a circuit with a battery or other power supply. The electrodes and electrolyte are made from carefully chosen elements or compounds. When the electricity flows through the circuit they make, the electrolyte splits up and some of the metal atoms it contains are deposited in a thin layer on top of one of the electrodes—it becomes electroplated. All kinds of metals can be plated in this way, including gold, silver, tin, zinc, copper, cadmium, chromium, nickel, platinum, and lead.
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Children are more susceptible to lead poisoning, and the effect on childhood mental development has been a significant issue in the formulation of environmental controls.
A revolutionary new hydro-metallurgical technology has been developed by two companies; Doe Run Company, USA in partnership with M/s Engitec, Italy. A commercial plant for producing 60,000 tonnes per annum of lead metal at an estimated capital cost of 150 million US Dollar is envisaged setting up by Doe Run Company, St. Louis, Missouri, USA. The breakthrough technology not only envisages improvements in lead processing efficiencies but also is expected to drastically reduce air emissions, waste generations and water pollution and will have smaller carbon footprint.
Meteorite takes out roof and wall of russian zinc smelter plantPushkar Raj Chandna
The key drivers for Zinc industry will be macroeconomic developments, especially in China and to some extent in the European countries, and increase in supply as new projects in pipeline come on stream in the year 2013. An ideal situation would be one where miners continue to keep refined metal production growth under check while demand recovers to comfortable levels.
Zinc is one of the strategic non-ferrous metal next only to Aluminium and Copper. It plays a very important role in country’s economy and development. It finds use in applications like galvanizing of iron and steel; die-casting alloys, brasses, dry cells, agriculture, chemicals, pharmaceuticals etc., with industrial development in India use of zinc has increased considerably, however, specific consumption is much lower as compared to other developing countries.
The most important raw material for the production of zinc is the sulphide ore from which zinc is extracted either through pyro-metallurgical route or through hydro metallurgical – Roast – Leach – Electrowin (RLE) route. At present nearly 80 - 85% of the world’s production of primary zinc is through hydrometallurgical route, the balance is through pyro – metallurgical route.
Zinc’s largest use is in corrosion protection. Galvanising is the main method of protection against corrosion of steel, i.e. the steel is coated with a layer of zinc in order to protect it from decay.
Brasses are alloys of copper and zinc, and they have good mechanical properties and good corrosion resistance.
Diecastings are precision castings that can be mass-produced. Rolled zinc is used for architectural and building applications, and for dry cell batteries. Zinc oxide has its main use in tyres and rubber products. Many other zinc chemicals are used in a wide range of applications.
The most commonly used non-ferrous metals are aluminium, copper, lead, and zinc. Millions of tonnes of nonferrous scrap are recovered annually and used by smelters, refiners, ingot makers, foundries, and other manufacturers. Secondary materials are essential to the industry’s survival because even new metals often require the combined use of recycled materials.
Every government employee has the right to know his performance evaluation and the grades obtained by him. Such information are helpful in improving work performance. Therefore, there is no justification for withholding ACR grades of employees.
The Landmark Decision is available at the Central Information Commissioners (CIC) web site @ http://rti.india.gov.in/cic_decisions/5973_IC_A__2010_M_42690.pdf
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1. Zinc Metallurgy
ZINC EXTRACTION PROCESSES
T he most important raw material for production of Zinc is Zinc Sulphide (ZnS) ore
commonly known as Sphalerite. Next in the importance are Zinc Carbonates
(Calamine/Smithsonite) and Zinc Silicate. Most of the zinc production worldwide originates
from sulphide ores.
The principal processes by which zinc is extracted from its ores can be categorised under pyro-
metallurgical processes and hydro-metallurgical processes.
A. Pyrometallurgical Processes:
i) Horizontal Retort Process
ii) Vertical Retort Process
iii) Electro Thermal Process
iv) Imperial Smelting Process
B. Hydrometallurgical Processes:
i) Roast Leach Electrowin Process
ii) Pressure Leaching Process
2. PYROMETALLURGICAL PROCESSESS
P resently about 15 - 20% of the world's zinc production comes from pyrometallurgical route.
The horizontal and vertical retort processes and electrothermal process were used in the past for
zinc production but have become obsolete due to high power consumption and low recovery.
The only pyrometallurgical process of importance presently is Imperial Smelting Process (ISP).
Imperial Smelting Process (ISP):
Currently about 8 -10% of the world's primary - zinc production are through the Imperial
Smelting Process. The process co-produces lead bullion in addition to zinc metal using a mix of
lead and zinc concentrates or complex lead-zinc concentrates as raw material. The Imperial
Smelting Process is similar to blast furnace processes except that it is operated with hot top
whereby preventing reoxidation of zinc vapours. The process consists of basic two operations
namely; sintering and blast furnace smelting of sintered lumps to extract lead and zinc
simultaneously. The Imperial Smelting Process has the following demerits:
• Process requires mix of zinc and lead concentrates.
• It is a labour intensive process.
• Present demand scenario does not call for addition of lead smelting capacity in the
country.
• Because of high temperature involved in maintainability of the plant.
• Low plant availability.
HYDRO-METALLURGICAL PROCESSESS
A bout 80% of world’s total zinc output is produced through conventional hydrometallurgical
route i.e. Roast-leach-electrowin (RLE) route. The three out of the four plants installed in India
3. are operating on hydrometallurgical process route, whereas the fourth one at Chittaurgarh,
Rajasthan, which was commissioned in the year 1991 is based on imperial smelting process route
for simultaneous extraction of lead and zinc.
The pre-requisite condition for zinc metal extraction from sulphide concentrate through a hydro-
metallurgical route is the elimination of its sulphur content in order to make it amenable to
further treatment by leaching, i.e., the zinc mineral into dissolved state in solution. Since zinc
sulphide mineral is not easily leached, it is first converted into zinc oxide, which is easily
leached. This is predominantly accomplished by roasting of zinc concentrate in fluid bed roasters
and fixation of SO2 bearing off gases thus generated as sulphuric acid by contact process. In the
recent past, an alternative technology to conventional roasting followed by leaching, has been
developed by Sherritt-Gordon of Canada, commonly known as “Pressure Leach Process” which
eliminates the need of roasting step prior to leaching. The process fixes the sulphide content of
concentrate as elemental sulphur, thus eliminates the need for a separate sulphuric acid
production facility, whereas the zinc metal content of the concentrate is converted into a zinc
sulphate solution, thus combining both roast-leach steps of conventional process into a single
unit operation.Thus there are two-process route for extraction of zinc hydrometallurgically:
• PRESSURE LEACH ELECTROWIN PROCESS
• ROAST–LEACH–ELECTROWIN (RLE) PROCESS
ROAST LEACH ELECTROWIN (RLE) PROCESS:
The main purpose of roasting of zinc sulphide concentrate is to convert it into a product, which is
amenable to further treatment through hydrometallurgical process for extraction of zinc.
Secondly, to fix the sulphide contents into sulphur dioxide gases for subsequent economical
recovery as sulphuric acid.The principal reaction during fluid bed roasting is:
2 ZnS + 3O2 = 2ZnO + 2SO2
These rich gases are cleaned and cooled to recover dust content as zinc calcine and to remove the
various harmful impurities such as Hg, Se, F, Cl, As, etc., before being led to double contact and
4. double conversion process (DCDA) plant for manufacture of sulphuric acid.
The dead roasted product, zinc calcine, is subjected to leaching with recycled electrolyte to
extract zinc content. The enriched zinc sulphate solution is further subjected to purification with
zinc dust to eliminate impurities like copper, cadmium, cobalt, nickel etc. before being subjected
to elecrolysis.
The zinc sulphate solution is fortified with return electrolyte solution, undergoes electrolysis in
lined concrete cells for deposition of zinc on aluminium cathodes. The lead- silver plates are
used as anodes. The deposited zinc on the cathodes are periodically stripped by automatic
stripping machines, melted in induction furnace and cast into saleable zinc ingots man automatic
casting and stacking machine. In order to maximise zinc extractions the leach residues mainly
zinc- ferrites, a bye product of leaching process, are subjected to treatment to hydrolyse its iron
content into disposable Jarosite / goethite / hematite. The zinc plants are also integrated with bye-
product cadmium recovery unit in order to maximise sales realization.
The standard zinc product is Special High Grade zinc (normally obtained from RLE process
route), with an assay of 99.995% zinc, i.e. it can contain a maximum of 50 parts per million of
impurities. There is also a grade of 98.5% zinc, the main impurity being lead, and this used to be
the standard grade, called GOB (Good Ordinary Brand) or PW (Prime Western), normally a
product from the Imperial smelting process (ISP). A SHG product from the ISP can also be
produced by distillation process of refining.
PRESSURE LEACH PROCESS:
The pressure leach technique was first successfully commercially applied for zinc extraction with
the commissioning of first plant in 1981 at Cominco, Trail, Canada.
There are presently three electrolytic zinc plants in the world where this technique has been
integrated into the existing facilities. A fourth green field plant with two-stage counter-current
pressure leach-electrowin is under consideration.
In this process zinc sulphide or bulk zinc concentrates are oxidized under oxygen overpressures
5. of 1200 kpa abs. at a temperature of 1500C in sulphuric acid medium to produce zinc sulphate
solution directly and the sulphide content is precipitated as elemental sulphur according to the
following overall reaction:
ZnS + H2S04 + 0.5 02 = ZnSO4 + H20 + Sº
The various factors influencing the kinetics of above reaction are the particle size, mineralogy,
surface active additives, acidities, reaction time, temperature and oxygen over-pressures where
by maximising metal extraction and fixation of lead and iron constituents into disposable Jarosite
and other types of residues. The zinc sulphate solution thus produced is amenable to further
processing for final zinc extraction through conventional leach-electrowin units.