pre- feasibility report -...

PRE- FEASIBILITY REPORT(In terms of provision of EIA Notification 2006)

The Proposed Expansion of Dariba

Zinc Smelter (2,50,000Lead Smelter (1

Captive Power Plant (2 x 85 MW to 3 X 85 MW)

HINDUSTAN

DaribaDariba

Ministry of Environment Forest & Climate Change

FEASIBILITY REPORT(In terms of provision of EIA Notification 2006)

For

Proposed Expansion of Dariba Smelter Complex

,50,000 TPA to 5,00,000 TPA + Fumer Plant)1,25,000 TPA to 1,50,000 TPA) and

Captive Power Plant (2 x 85 MW to 3 X 85 MW)

By:

HINDUSTAN ZINC LIMITED,

Dariba Smelter Complex, Dariba – 313 211, Rajsamand,

Rajasthan

To:

inistry of Environment Forest & Climate Change

(MoEF & CC) New Delhi

December, 2017

FEASIBILITY REPORT (In terms of provision of EIA Notification 2006)

Complex

TPA + Fumer Plant) and

inistry of Environment Forest & Climate Change

Proposed Expansion of Dariba Smelter Complex TPA + Fumer Plant), Lead Smelter (0.125 Million TPA to 0.150 Million TPA) and Captive Power Plant (2 x 85 MW to 3 X 85 MW) at Village Dariba , Relmagra, District - R

CHAPTER 1: INTRODUCTION

1.1 Preamble

1.2 Identification of Project

1.3 Need for the Project and Its Importance

1.4 Legal Aspects

CHAPTER 2: PROJECT DESCRIPTION

2.1 Project Description

2.2 Project Details

2.3 Process Description

CHAPTER 3: SITE ANALYSIS

3.1 Connectivity

3.2 Land use and Land ownership

3.3 Topography

3.4 Existing Infrastructure

CHAPTER 4: PLANNING BRIEF

4.1 Planning Concept

4.2 Population Projection

4.3 Land use planning

4.4 Assessment of Infrastructure Demand (Physical & Social)

4.5 Amenities/Facilities

CHAPTER 5: REHABILITATION AND RESETTLEMENT (R & R) PLAN

CHAPTER 6: PROJECT SCHEDULE AND COST ESTIMATES

6.1 Time Schedule for the Project

6.2 Project Cost

CHAPTER 7: ANALYSIS OF PROPOSAL

7.1 Financial and social benefits

7.2 Environment Friendly Project

CHAPTER 8: CONCLUSION

8.1 Conclusion

Proposed Expansion of Dariba Smelter Complex - Zinc Smelter (0.25 to 0.50 Million TPA + Fumer Plant), Lead Smelter (0.125 Million TPA to 0.150 Million TPA) and Captive Power Plant (2 x 85 MW to 3 X 85 MW) at Village Dariba ,

Rajsamand, Rajasthan

TABLE OF CONTENTS

CHAPTER 1: INTRODUCTION

Identification of Project & Project Proponent

Need for the Project and Its Importance

CHAPTER 2: PROJECT DESCRIPTION

CHAPTER 3: SITE ANALYSIS

Land use and Land ownership

Existing Infrastructure

CHAPTER 4: PLANNING BRIEF

Population Projection

Assessment of Infrastructure Demand (Physical & Social)

: REHABILITATION AND RESETTLEMENT (R & R) PLAN

SCHEDULE AND COST ESTIMATES

Time Schedule for the Project

: ANALYSIS OF PROPOSAL

Financial and social benefits

Environment Friendly Project

Zinc Smelter (0.25 to 0.50 Million TPA + Fumer Plant), Lead Smelter (0.125 Million TPA to 0.150 Million TPA) and Captive Power Plant (2 x 85 MW to 3 X 85 MW) at Village Dariba , Tehsil -

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CHAPTER

INTRODUCTION


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CHAPTER - 1

INTRODUCTION


1.1 PREAMBLE

1.1 About HZL

Hindustan Zinc Limited (HZL) is an India

mining and smelting of

segments are mining and smelting of

Company's operations include five

Lead Smelter, a Zinc-Lead

plant and over six captive power plants in the state of Rajasthan. In addition, the Company also has a rock

and Zinc, Lead, Silver

Uttarakhand. The Company also has wind power plants in the States of

Rajasthan, Gujarat, Karnataka, Tamil Nadu and Maharashtra. It has a metal

production capacity of over one million tons per annum with its key

mines in Rampura Agucha and Sindesar

Chanderiya and Dariba, all in the state of Rajasthan

1.2 Identification of Project & Project Proponent

Hindustan Zinc Ltd. is one of the largest Leading producer of silver with more than 60 years of experience in Mining &

Smelting. Reserves & Resources of about 404.4 MT as on 31

sufficient for more than 25 years of mine life. Environment Clearance Capacities

Ore Production- 16.55 MTPA,

TPA, Silver- 772 TPA. Captive Thermal Power generation

power 35 MW & Wind power 274 MW and 16.2 MW solar power plant.

Development Mechanism (CDM) projects on waste heat recovery & win

have an annual Certified Emission Reduction potential of over 5

CO2. Total Exchequer to Government during 2016

including Royalty, taxes and

Plant at Udaipur under PPP

water in its operations. Udaipur Smart City Ltd for another 40 MLDon 25

the quality of life and economic

operations, mainly SAKHI, MARYADA, KHUSHI campaigns, reaching over 5 lakh

people spread over 184 villages across Rajasthan.

Dariba Smelter Complex was established in the year 2010

Complex of Hindustan Zinc

MTPA) and Captive Power Plant (170 MW).

by MoEF&CC for Integrated Project at Darib

(5,00,000 TPA), Lead Smelter

expansion of Rajpura

Beneficiation Plant (9,00,000 to 12,00,000 TPA)

11011/380/2008-IA II (I) dated 4.11.2009.

Dariba Smelter Complex

The nearest railway station is Fatehnagar, about 15.5

broad gauge railway line. Plant

Udaipur, Chittorgarh, Bh

falls in Survey of India Topo

The proposed expansion of

TPA of Zinc Smelter,1,25



Limited (HZL) is an India-based company, which is engaged in the

mining and smelting of Zinc, Lead and Silver metal in India. The Company's

ining and smelting of Zinc, Lead and Silver and Wind energy. The

Company's operations include five Zinc-Lead mines, over four Zinc

Lead Smelter, seven sulphuric acid plants, a silver refinery

plant and over six captive power plants in the state of Rajasthan. In addition, the Company also has a rock-phosphate mine in Maton near Udaipur in Rajasthan

, Silver processing and refining facilities in the State of



production capacity of over one million tons per annum with its key

Agucha and Sindesar Khurd, and smelting complexes in

Chanderiya and Dariba, all in the state of Rajasthan.

f Project & Project Proponent

Ltd. is one of the largest Lead-Zinc integrated producer & a ing producer of silver with more than 60 years of experience in Mining &

Smelting. Reserves & Resources of about 404.4 MT as on 31st

sufficient for more than 25 years of mine life. Environment Clearance Capacities

16.55 MTPA, Zinc metal- 11.25 lakh TPA, Lead metal

TPA. Captive Thermal Power generation 474 MW, Waste heat

power 35 MW & Wind power 274 MW and 16.2 MW solar power plant.

Development Mechanism (CDM) projects on waste heat recovery & win

have an annual Certified Emission Reduction potential of over 5,83,685 TPA of

Total Exchequer to Government during 2016-17 was Rs.17,

including Royalty, taxes and dividend. HZL has established Sewage Treatment

Plant at Udaipur under PPP model to treat 20 MLD sewage and utilize treated

water in its operations. With the successof Phase-1,MOU has been signed with Udaipur Smart City Ltd for another 40 MLDon 25thJune 2017. Vision to enhance

the quality of life and economic wellbeing of the communities around its


people spread over 184 villages across Rajasthan.

Complex was established in the year 2010-11 in Rajpura

Zinc with Zinc Smelter (0.25 MTPA), Lead Smelter

MTPA) and Captive Power Plant (170 MW). Environment Clearance was granted

Integrated Project at Dariba, Hindustan Zinc Ltd. (

Smelter (1,25,000 TPA), Captive Power Plant (255 MW) and

Dariba Mine (6,31,000 to 9,00,000 TPA) along with

Beneficiation Plant (9,00,000 to 12,00,000 TPA) vide Letter No. J

IA II (I) dated 4.11.2009.

Complex (DSC) is located at a distance of 76 km NNE of Udaipur.

station is Fatehnagar, about 15.5 km, on Chittorgarh

broad gauge railway line. Plant is well connected by a metalled road from

Udaipur, Chittorgarh, Bhilwara and District head quarter Rajsamand. The

y of India Topo sheet No. 45/L1.

The proposed expansion of Dariba Smelter Complex is from 2,50,000

25,000 to 1,50,000 TPA of Lead Smelter and from


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based company, which is engaged in the

ia. The Company's

and Wind energy. The

Zinc Smelters, a

, seven sulphuric acid plants, a silver refinery

plant and over six captive power plants in the state of Rajasthan. In addition, the phosphate mine in Maton near Udaipur in Rajasthan

cilities in the State of



production capacity of over one million tons per annum with its key Lead-Zinc

Khurd, and smelting complexes in Debari

integrated producer & a ing producer of silver with more than 60 years of experience in Mining &

March 2017

sufficient for more than 25 years of mine life. Environment Clearance Capacities-

metal-2.20 lakh

MW, Waste heat

power 35 MW & Wind power 274 MW and 16.2 MW solar power plant. Clean

Development Mechanism (CDM) projects on waste heat recovery & wind power

83,685 TPA of

,760 Crores,

. HZL has established Sewage Treatment

sewage and utilize treated

1,MOU has been signed with n to enhance

of the communities around its


11 in Rajpura Dariba

Smelter (0.125

Environment Clearance was granted

(Zinc Smelter

(1,25,000 TPA), Captive Power Plant (255 MW) and

Dariba Mine (6,31,000 to 9,00,000 TPA) along with

vide Letter No. J-

is located at a distance of 76 km NNE of Udaipur.

km, on Chittorgarh-Udaipur

metalled road from

Rajsamand. The plant

0,000 to 5,00,000

from 170 MW


(2 X 85 MW) to 255 MW (3 X 85 MW) of Captive Power Plant

to install Fumer plant (pyro metallurgical process) within leaching circuit of

Smelter to eliminate the generation of Jarosite, which is presently stabilized with

lime and cement to convert into stabilized Jarofix and stored in Jarofix disposal

yard.

1.3 Need for Project And It’s Importance

Global Zinc & Lead consumption is expected to grow steadily by 4

coming years which needs to be met by higher mine &one of the fastest growing economies in the World, adequate support from metal

sector is essential to support & s

Galvanized iron products play key role in infrastructure development and therefore

the requirement of Zinc

increasing with Automobile Industry expansion & powe

expansion project shall augment the supply of

Industrial growth. The proposed expansion will generate additional dir

employment of approximately 700

opportunity for increase in indirect employment due to transport, workshop,

garages and other services. Skill development & training programs to make local

youth employable shall continue for development of community.

Zinc is a very versatile non

4th most common metal in use after iron, aluminum and copper.

consumption is forecast to grow at a compound average annual rate of 2.4 % p.a.

over the period 2016-2021. Global

in 2035 representing average annual increase of 0.28 Mt.

1.3.1 Demand-Supply Gap

In the aftermath of the financial crisis of 2008

momentum. Growth in industrial

2000-2008 to 3.9% over the period 2010

DOMESTIC REFINED

Year 2016

Demand (kt) 699

Supply (kt) 643

Source: Wood Mackenzie Long Term Outlook

1.3.2 Import Vs Indigenous Production

The present production capacities of

domestic requirements. However, the demand for

at a 7.1% which makes it viable for the expansion of the

Further the deficit in international market during the upcoming years provides

opportunity for export.

1.3.3 Export Possibility

Indian exports majorly catered to South East Asian and African nations. In India,

since Hindustan Zinc is the largest producer of primary

feasible and shall bring value addition.



MW (3 X 85 MW) of Captive Power Plant. It is also proposed

Fumer plant (pyro metallurgical process) within leaching circuit of

to eliminate the generation of Jarosite, which is presently stabilized with


or Project And It’s Importance

consumption is expected to grow steadily by 4-5% per annum in

coming years which needs to be met by higher mine & Smelter output. As India is one of the fastest growing economies in the World, adequate support from metal

sector is essential to support & sustain infrastructure development & growth.


Zinc metal is essential. Lead requirement in batteries is

increasing with Automobile Industry expansion & power back up. Proposed

expansion project shall augment the supply of Zinc to the domestic market for

Industrial growth. The proposed expansion will generate additional dir

employment of approximately 700 man power. In addition to this, there is ample

tunity for increase in indirect employment due to transport, workshop,


youth employable shall continue for development of community.

is a very versatile non-ferrous metal. Zinc’s different applications rank it as the

most common metal in use after iron, aluminum and copper.


2021. Global Zinc consumption is projected to grow to 20 Mt

in 2035 representing average annual increase of 0.28 Mt.

In the aftermath of the financial crisis of 2008-2009, the Indian economy lost

momentum. Growth in industrial production slowed from an average of 7.9% during

2008 to 3.9% over the period 2010-2015.

TABLE-1.1

DOMESTIC REFINED ZINC SUPPLY & DEMAND (KT ZN)

2016 2017 2018 2019 2020

699 844 833 828 824

643 838 811 849 837

Source: Wood Mackenzie Long Term Outlook

Import Vs Indigenous Production

The present production capacities of Zinc in India are sufficient to meet the

domestic requirements. However, the demand for Zinc in India is expected to grow

at a 7.1% which makes it viable for the expansion of the Zinc production capacities.



is the largest producer of primary Zinc, export of

feasible and shall bring value addition.


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It is also proposed

Fumer plant (pyro metallurgical process) within leaching circuit of Zinc

to eliminate the generation of Jarosite, which is presently stabilized with


5% per annum in

output. As India is one of the fastest growing economies in the World, adequate support from metal

ustain infrastructure development & growth.


requirement in batteries is

r back up. Proposed

to the domestic market for

Industrial growth. The proposed expansion will generate additional direct

power. In addition to this, there is ample

tunity for increase in indirect employment due to transport, workshop,


’s different applications rank it as the

most common metal in use after iron, aluminum and copper. Global Zinc


consumption is projected to grow to 20 Mt

2009, the Indian economy lost

production slowed from an average of 7.9% during

2025

827

837

in India are sufficient to meet the

in India is expected to grow

production capacities.



, export of Zinc is highly


1.3.4 Domestic/Export Market

Zinc having found primary application in galvanization, a range of galvanized

products are produced to meet various Industrial an

Galvanized sheets (corrugated and plain), galvanized pipes, galvanized structure,

galvanized sheet, galvanized

Segment accounts for 68% share of the overall

Galvanizing accounts for 32% share. Among the major customer segments,

Galvanized Sheets accounts for major share of the

structure and Alloys. The following chart explains the demand for its segment wise break-

global Zinc demand continues to be high & driven mainly by galvan

the emerging of Asia and Africa. The reported increase in Chinese manufacturing

activities and US automotive sales along with emerging signs of stability in Europe’s

manufacturing and services sector are expected to support



Domestic/Export Market

having found primary application in galvanization, a range of galvanized

products are produced to meet various Industrial and consumer demands.

sheets (corrugated and plain), galvanized pipes, galvanized structure,

galvanized sheet, galvanized wires are used for various applications. Galvanizing

Segment accounts for 68% share of the overall Zinc demand in India while Non


Galvanized Sheets accounts for major share of the Zinc consumption followed by

structure and Alloys. The following chart explains the demand for Zinc-up India has the potential for exporting Zinc

demand continues to be high & driven mainly by galvanizing sector in



manufacturing and services sector are expected to support Zinc demand.


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having found primary application in galvanization, a range of galvanized

d consumer demands.

sheets (corrugated and plain), galvanized pipes, galvanized structure,

wires are used for various applications. Galvanizing

demand in India while Non-


consumption followed by

Zinc in India and profitably as

izing sector in



demand.


1.4 Legal Aspects

The relevant NOC’s and licenses will be obtained from the statutory agencies

under the following Acts, Rules and amendments and HZ

guidelines specified in:

• The Factories Act, 1948

• Environment (Protection)

• Manufacture, Storage and Import of Hazardous Chemical Rules 1989 amended

in 2010; • The Hazardous Waste (Management and

HZL will comply with the prescribed limits laid down for air, effluent and n

emissions for protection of the environment under the following Acts, Rules and

amendments:

• The Water (Prevention and Control of Pollution) Act, 1974

• The Air (Prevention and Control of Pollution) Act, 1981

• The Environment (Protection) Act, 1986

• The Environment Impact Assessment, Notification, 2006

under; • Environment (Protection) Act 1986 and Environment (Protection) Rules 1986

and amendments thereafter to date.

Compliance to State Rules and Notifications will also be ensured




cts, Rules and amendments and HZL will adhere to the

The Factories Act, 1948;

Environment (Protection) Act – 1986 and its amendments to date;

Manufacture, Storage and Import of Hazardous Chemical Rules 1989 amended

The Hazardous Waste (Management and Handling) Rules 1989.

L will comply with the prescribed limits laid down for air, effluent and n


The Water (Prevention and Control of Pollution) Act, 1974;

The Air (Prevention and Control of Pollution) Act, 1981;

The Environment (Protection) Act, 1986;

he Environment Impact Assessment, Notification, 2006 Rules issued

Environment (Protection) Act 1986 and Environment (Protection) Rules 1986

and amendments thereafter to date.

Compliance to State Rules and Notifications will also be ensured.


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L will adhere to the

;

Manufacture, Storage and Import of Hazardous Chemical Rules 1989 amended

L will comply with the prescribed limits laid down for air, effluent and noise


issued there

Environment (Protection) Act 1986 and Environment (Protection) Rules 1986


PROJECT DESCRIPTION



CHAPTER

PROJECT DESCRIPTION


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CHAPTER-2

PROJECT DESCRIPTION


2.1 Project Description

I. Type of Project including interlinked

This chapter describes the process, and sources of pollution

i.e. production of Zinc from 2,50,000 TPA to

TPA to 1,50,000 TPA and power generation from 170

MW to meet the needs of Dariba

The following were the principle objectives, kept in mind while working on t

feasibility of this proposal.

• Adopting environment friendly technology & e

reduction of pollution load

fumer plant.

• Conserving natural resources like water, t

• Waste reduction and recycling options

• Aiming at waste heat recovery to best possible extent by state of art proven

technology

• Value added By- Products

The proposed expansion project is

Ministry of Environment & Forest

September 2006.

II. Location (map showing general location, specific location, and project

boundary& project site layout) with

Dariba Smelter Complex is located at a distance of 76 km NNE of Udaipur. The

nearest railway station is Fatehnagar, about 15.5

gauge railway line.The Plant

Chittorgarh, Bhilwara and District of India Toposheet No. 45/L1.

map and study area satellite map

2.2 and Figure-2.3.Environmental Setting of the Site



I. Type of Project including interlinked and independent projects

chapter describes the process, and sources of pollution for proposed

from 2,50,000 TPA to 5,00,000 TPA, Lead from 1,25,000

and power generation from 170 (2 X 85) MW to 255

to meet the needs of Dariba Smelter Complex, in the existing premises.

were the principle objectives, kept in mind while working on t

feasibility of this proposal.

ironment friendly technology & equipment and working on

reduction of pollution load of hazardous solid waste i.e. Jarosite

natural resources like water, thermal & electrical energy.

reduction and recycling options

Aiming at waste heat recovery to best possible extent by state of art proven

Products

The proposed expansion project is classified as “CATEGORY-3(a) & 1(d)

inistry of Environment & Forest, New Delhi as per the EIA Notification d


boundary& project site layout) with coordinates:

is located at a distance of 76 km NNE of Udaipur. The

station is Fatehnagar, about 15.5 km on Chittorgarh-Udaipur

The Plant is well connected by a metalled road from Udaipur,

ilwara and District headquarter Rajsamand. The plant falls in Surveof India Toposheet No. 45/L1. Geographical location of the project site, study area

map and study area satellite map have been provided in the Figure-2

Environmental Setting of the Site is provided in the


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and independent projects

proposed expansion

from 1,25,000

85) MW to 255 (3 X 85)

, in the existing premises.

were the principle objectives, kept in mind while working on the

quipment and working on

of hazardous solid waste i.e. Jarosite by setting

hermal & electrical energy.

Aiming at waste heat recovery to best possible extent by state of art proven

3(a) & 1(d)” by

the EIA Notification dated14th


is located at a distance of 76 km NNE of Udaipur. The

Udaipur broad

is well connected by a metalled road from Udaipur,

falls in Survey site, study area

2.1, Figure-

is provided in the Table 2.1.


GEOGRAPHICAL LOCATION OF THE PROJECT



FIGURE-2.1

GEOGRAPHICAL LOCATION OF THE PROJECT

Rajasthan



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FIGURE-2.2

STUDY AREA MAP


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STUDY AREA



FIGURE-2.3

STUDY AREA GOOGLE MAP


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ENVIRONMENTAL SETTING OF THE SITE

Sr. No. Particulars

1. Project Location

2. Latitude

3. Longitude

4. Elevation above MSL

5. Toposheet No.

6. Climatic conditions

IMD Dabok (Udaipur)

7. Nearest Highway

8. Nearest Railway Station

9. Nearest Airport

10. Nearest River

11. Nearest Port

12. Nearest Village

13. Nearest Town/City

14. Hills/Valleys

15. Monuments

16. Archaeologically important

places

17. Reserved/Protected forest

18. Protected areas as per Wildlife

Protection Act, 1972

(Biospheres, Tiger Reserves,

Elephant Reserves, National

Parks, Wildlife Sanctuaries,

Conservation Reserves, and Community Reserves)

19. List of Industries

20. Seismicity



TABLE 2.1

ENVIRONMENTAL SETTING OF THE SITE

Details


Village & Post – Dariba, Tehsil –

Dist. – Rajsamand, Rajasthan

N 24o57’22.16” to 24o58’10.24’’

E 74o06’45.89’’ to 74o08’02.44’’

480 m -490 m

45L/1

(Udaipur)

Annual maximum temp: 47.0oC

Annual minimum temp: 2.0oC Annual total rainfall: 550 mm

Annual predominant wind direction: NW, W

NH-162A - 500 m, W

Udaipur –Chittorgarh 4 Lane : (13.2

Nearest Railway Station Fatehnagar (15.5-km, SW)

Dabok, Udaipur (43.0 km, SW)

Banas (7.9 km, NNE)

Kandla (450 km, SW)

Mahenduriya (0.5 km, W), Anjana (

SSW), Rajpura(1 km,N), Dariba (0.5

km,SW)

Rajsamand, (25.0 km,NW)

Nil in 10-km radius

Nil in 10-km radius

Archaeologically important Nil in 10-km radius

Reserved/Protected forest Nil in 10-km radius

Protected areas as per Wildlife

(Biospheres, Tiger Reserves,

Elephant Reserves, National

Parks, Wildlife Sanctuaries,

Conservation Reserves, and Community Reserves)

Nil in 10-km radius

RajpuraDariba Mines (0.5

SindesarKhurd mines (3.0-km, NNE) owned

by HZL.

Seismic Zone II


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– Relmagra,

Annual predominant wind direction: NW, W

13.2 km, S)

Anjana (1.8 km

, Dariba (0.5

Dariba Mines (0.5 km, SE),

km, NNE) owned


Zinc Smelter

Considering various process options available such as Pyro

route & Hydrometallurgical route, HZL

at Dariba using conventional hydro

winning operations for the following reasons:

1. Higher recovery of

2. Production of Special high grade quality

Also, there is no plant operating in the world following pyro

for more than 0.12 MTPA.

Conventional hydro-metallurgical route for

Leach- Electro-winning” operations. The raw material for the

concentrate, which contains about 50

Zinc concentrate containing

Zinc oxide, which is leached in dilute sulphuric acid to produce a raw

sulphate solution. The impurities like copper, cadmium, nickel, cobalt etc also get

dissolved in the solution as sulphates.

thickeners & clear over flowactivators. The purified

cathodes, which are then melted and cast into

obtained during purification are sent to cadmium section.

from leaching is Jarosite, a waste which is being stabilized by addition of lime and

cement. The product is called Jarofix which is stockpiled at Jarofix yard and needs

recurring land.

To eliminate Jarosite generation, it is proposed to set up fuming process within

existing leaching circuit of

Salient Features

• Recovery of minor metals like reduction in waste generation

• Efficient gas cooling and cleaning pro

• Double Conversion Double Absorption (DCDA) process with Cesium catalyst

results in high SO2 recovery (>99.8 %) and low SO

• Thermally auto genous process with power generat

• High end automation and interlocking with pollution control equipments

• Pneumatic conveying system for calcine tanker unloading

• Online stack monitoring for SO

Fumer Plant

After modification, the current jarosite process will be converted to the

conventional leaching process, from which

will be treated with fuming furnaces.

In the fuming process, the leaching residue is treated in stages

furnace. The stages are: residue melting and heating, fuming, and slag tapping.

To reduce energy consumption and to facilitate leaching residue transfer after

filtration, the residue will be dried by drying kiln.

system consists of leaching residue drying,

heat recovery and dust collection



Considering various process options available such as Pyro-metallurgical ISF

route & Hydrometallurgical route, HZL has installed a hydrometallurgical

at Dariba using conventional hydro-metallurgical route of roast-leach

winning operations for the following reasons:

Higher recovery of Zinc and other by-products

Production of Special high grade quality Zinc (SHG)

Also, there is no plant operating in the world following pyro-metallurgical route

for more than 0.12 MTPA.

metallurgical route for Zinc extraction is through “Roast

winning” operations. The raw material for the Zinc Smel

which contains about 50% Zinc in the form of Zinc Sulphide

concentrate containing Zinc& other impurities is roasted to convert it into

oxide, which is leached in dilute sulphuric acid to produce a raw


dissolved in the solution as sulphates. The insoluble impurities are separated in

thickeners & clear over flowis purified by addition of Zinc dust / powder and The purified Zinc sulphate solution is then electrolysed to obtain

cathodes, which are then melted and cast into Zinc metal ingots. The filter cakes

obtained during purification are sent to cadmium section. Iron residue generated

site, a waste which is being stabilized by addition of lime and

called Jarofix which is stockpiled at Jarofix yard and needs


existing leaching circuit of Zinc Smelter.

Recovery of minor metals like Lead-Silver, Copper and Cadmium therebreduction in waste generation;

gas cooling and cleaning process to get optically clear gas

Double Conversion Double Absorption (DCDA) process with Cesium catalyst

recovery (>99.8 %) and low SO2 emission in acid plant

genous process with power generation from waste heat

High end automation and interlocking with pollution control equipments

Pneumatic conveying system for calcine tanker unloading;

Online stack monitoring for SOx.


conventional leaching process, from which 3,80,000 tons of residue (dry base)

will be treated with fuming furnaces.

In the fuming process, the leaching residue is treated in stages



filtration, the residue will be dried by drying kiln. The leaching residue treatment

system consists of leaching residue drying, proportioning, fuming, off gas waste

heat recovery and dust collection .Off gas from the drying kiln and the fuming


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metallurgical ISF

a hydrometallurgical Smelter

leach-electro-

metallurgical route

extraction is through “Roast-

Smelter is Zinc

Sulphide. The

& other impurities is roasted to convert it into

oxide, which is leached in dilute sulphuric acid to produce a raw Zinc


The insoluble impurities are separated in

dust / powder and sulphate solution is then electrolysed to obtain Zinc

metal ingots. The filter cakes

Iron residue generated

site, a waste which is being stabilized by addition of lime and

called Jarofix which is stockpiled at Jarofix yard and needs


Silver, Copper and Cadmium thereby

cess to get optically clear gas;

Double Conversion Double Absorption (DCDA) process with Cesium catalyst

emission in acid plant;

ion from waste heat;

High end automation and interlocking with pollution control equipments;


tons of residue (dry base)

In the fuming process, the leaching residue is treated in stages in a fuming



The leaching residue treatment

proportioning, fuming, off gas waste

.Off gas from the drying kiln and the fuming


furnaces will be sent to the off gas

desulfurization technology will be used,

produced from the fuming off gas and dust.

Salient Features

• The fuming slag is the clean slag;

• Valuable metals such as Zn, Pb, Ag will be extracted from the leaching

at high recovery rates;

• The fuming off gas will be de• The off gas waste heat will be recovered in steam for power generation, which

will serve the plant and save energy;

• In the material handling system, the

granulation area will be equipped with ventilation and dust removal facilities,

which improve the working environment;

• The two fuming furnaces will run in

flexibility; However if required one can also be operated in case of exigencies

• The furnace tuyeres have a long service life;

• The furnace is easy to operate and highly automatic.

Lead Smelter

Based on HZL’s prior experience and recent assessment of technology the

following process technology options were evaluated.

• Ausmelt Technology (Single Furnace Philosophy)

• Ausmelt Technology (Twin furnace philosophy)

• SKS Technology – China

Based on the evaluations done, SKS Technology route has been selected for the

following reasons:

• ENFI / NFC technology offer is including minor

facilities like Cu, Sb , Bi , Ag etc

• ENFI / NFC china offering a total turnkey solution from Technology to EPC

process Guarantees

Salient Features

• Pyro-route for smelting & hydro

• High Lead, Zinc and Silver Recovery

• Recovery of minor metals

• Process capability to accept

Smelter) and other Lead

• Effective dust collection and Hygiene systems

• Online stack monitoring for SOx

Captive Power Plant

Based on our proven and

steam turbine generator has been selected



furnaces will be sent to the off gas desulfurization plant (TGP).

desulfurization technology will be used, and the Zinc oxide needed will be

produced from the fuming off gas and dust.

The fuming slag is the clean slag;

Valuable metals such as Zn, Pb, Ag will be extracted from the leaching

at high recovery rates;

The fuming off gas will be de sulfurized to meet environmental requirements;The off gas waste heat will be recovered in steam for power generation, which

will serve the plant and save energy;

In the material handling system, the discharge points, slag tap holes, and the


which improve the working environment;

The two fuming furnaces will run in series, a pattern which provides high

However if required one can also be operated in case of exigencies

The furnace tuyeres have a long service life;

The furnace is easy to operate and highly automatic.


following process technology options were evaluated.

Ausmelt Technology (Single Furnace Philosophy) - Australia

Ausmelt Technology (Twin furnace philosophy) - Australia

China


ENFI / NFC technology offer is including minor metal & precious metal recovery

facilities like Cu, Sb , Bi , Ag etc

ENFI / NFC china offering a total turnkey solution from Technology to EPC

route for smelting & hydro-route for Lead refining

and Silver Recovery

Recovery of minor metals- Silver, Copper, Antimony and Bismuth

Process capability to accept Lead Silver compound (a by-product of

Lead Secondary

Effective dust collection and Hygiene systems

Online stack monitoring for SOx

Based on our proven and satisfactory experience, pulverised coal fired Boiler with

steam turbine generator has been selected.


15 | P a g e

desulfurization plant (TGP). Zinc oxide

oxide needed will be

Valuable metals such as Zn, Pb, Ag will be extracted from the leaching residue

sulfurized to meet environmental requirements; The off gas waste heat will be recovered in steam for power generation, which

discharge points, slag tap holes, and the


, a pattern which provides high

However if required one can also be operated in case of exigencies



metal & precious metal recovery

ENFI / NFC china offering a total turnkey solution from Technology to EPC to

Antimony and Bismuth

product of Zinc

satisfactory experience, pulverised coal fired Boiler with


Salient Features

• High efficiency ESPs with 8 nos. of fields

• Covered coal conveyors with water sprinkling system using waste water

• Bag filters at each coal transfer point, coal bunkers and fly ash silos to restrict

emission;

• SOx and D Nox systems such as FGD and SCR for meeting the latest

environmental norms

• Online stack monitoring for SOx, NOx and PM

Salient Features of the

• Integrated Utility plant

• Integrated Effluent treatment plant followed with two stage RO Plant

Multiple Effect Evaporator (MEE) Plant

• RO based DM plant thereby reducing effluent generation

• Transportation of raw material and finished products in 40 MT

• Cement concrete internal roads;

• Industrial sweeper;

• Truck / Tyre wash stations

2.2 Project Details

The Operational hydro-metallurgical

of Special High Grade

metallurgical route based on Roast

accepted process for manufacturing

Zinc production from 0.25 million TPA to 0.5million

this increase in production will take place in two phases, first from 0.25 to 0.375

million TPA then after successful commissioning 0.375 million TPA then the second

phase will start from 0.375 to 0.50 million TPA.

To eliminate the issue of Jwill stop producing Jarosite i.e. Hazardous waste and start producing Slag which is

non-hazardous waste. This important step is taken after inconsideration of

environmental concerns in whole world to reduce

environment for future generation i.e Sustainability

In this proposed expansion the

million TPA to 0.150 million TPA with same technology.

which is operational to meet the requirement of existing

due to rise in production of

meet the new requirements



High efficiency ESPs with 8 nos. of fields;

Covered coal conveyors with water sprinkling system using waste water

each coal transfer point, coal bunkers and fly ash silos to restrict

SOx and D Nox systems such as FGD and SCR for meeting the latest

environmental norms;

Online stack monitoring for SOx, NOx and PM.

Salient Features of the Smelters and CPP

Integrated Utility plant;

Integrated Effluent treatment plant followed with two stage RO Plant

Multiple Effect Evaporator (MEE) Plant;

RO based DM plant thereby reducing effluent generation;

Transportation of raw material and finished products in 40 MT bulkers

Cement concrete internal roads;

Truck / Tyre wash stations.

metallurgical Smelter is designed to produce 0.25 million

of Special High Grade Zinc annually from Zinc concentrate/Calcine. The hydro

metallurgical route based on Roast – Leach – Electro-winning process is widely

accepted process for manufacturing Zinc metal and it is proposed to increase the

production from 0.25 million TPA to 0.5million TPA with same technology.


fter successful commissioning 0.375 million TPA then the second

phase will start from 0.375 to 0.50 million TPA.

To eliminate the issue of Jarosite, the Fumer plant is proposed in this project rosite i.e. Hazardous waste and start producing Slag which is

waste. This important step is taken after inconsideration of

environmental concerns in whole world to reduce Hazardous waste for safer

environment for future generation i.e Sustainability.

In this proposed expansion the Lead Smelter production is increasing from 0.125

million TPA to 0.150 million TPA with same technology. There are 2 Plants of 85MW

rational to meet the requirement of existing Zinc Smelter

due to rise in production of Zinc there will be need of 1 more plant of 85

meet the new requirements Change in Plant Capacity is depicted in Table


16 | P a g e

Covered coal conveyors with water sprinkling system using waste water;

each coal transfer point, coal bunkers and fly ash silos to restrict

SOx and D Nox systems such as FGD and SCR for meeting the latest

Integrated Effluent treatment plant followed with two stage RO Plant and

bulkers;

is designed to produce 0.25 million TPA

cine. The hydro-

winning process is widely

and it is proposed to increase the

with same technology. But


fter successful commissioning 0.375 million TPA then the second

the Fumer plant is proposed in this project which rosite i.e. Hazardous waste and start producing Slag which is

waste. This important step is taken after inconsideration of

Hazardous waste for safer

production is increasing from 0.125

There are 2 Plants of 85MW

Complex but

there will be need of 1 more plant of 85 MW to

able-2.2.


Unit Existing Granted

Capacity (As per EC granted in

Nov.'2009)

ZincSmelter 0.5 MTPA

LeadSmelter 0.125 MTPA

Captive Power Plant

255 MW

Fumer Plant -

PRODUCTS AND BYPRODUCTS

Unit

Quantity (As per EC granted

in Nov.'2009)

Products

ZincSmelter

SHG Zinc Cathode/Ingot (Special High Grade)

Zinc (Continuous Galvanizing

Grade) (out of 500, 000 TPA SHG

Zinc)

LeadSmelter

Lead Cathode/Ingot

Lead Alloy (Pb-Sb&Pb-Ca, Pb-Bi) (out of 150, 000 TPA

Lead)

Captive Power Plant

Power

By-products (TPA)

Sulphuric Acid

Lead – Silver Compound

Cadmium metal / Sponge

(equivalent metal)

Calomel

Silver

Copper as Copper cement/

sulphate/ matte/ concentrate

/Compound(equivalent metal)

Antimony as Antimony

concentrate (equivalent metal)

Waste Heat power

Bismuth as Bismuth concentrate

(equivalent metal)

Zinc Oxide compound

Lead concentrate (Oxide)

Anode Slime

Lead Bullion



TABLE 2.2

PLANT CAPACITY

Existing Granted

Capacity (As per EC granted in

Existing

Status

Additional

Proposed Capacity

Total Capacities

AfterProposed

Expansion

0.25 MTPA 0.25 MTPA 0.5 MTPA

0.125 MTPA 0.025 MTPA 0.15

170 MW 85 MW 255

- Associated with

Zinc Smelter

Associated with

Smelter

TABLE-2.3

PRODUCTS AND BYPRODUCTS

Existing Granted

Quantity (As per EC granted

in Nov.'2009)

Existing Status Additional Proposed

Quantity



0.125 MTPA 0.125 MTPA 0.025 MTPA


255 MW 170 MW 85 MW

744000 744000 90,000

80000 40000 40000

1600 800 1200

44 44 -

400 400 400

1900 1400 1400

850 850 170

15 MW 15 MW 20 MW

16 16 30

20000 20000 16000

5000 5000 1000

4000 4000 800

- - 20000


17 | P a g e

Total Capacities

After Proposed

Expansion

0.5 MTPA

0.15 MTPA

5 MW

Associated with Zinc

Smelter

Additional Proposed

Quantity

Total Quantity

After Proposed

Expansion

MTPA 0.50 MTPA

MTPA 0.08 MTPA

0.025 MTPA 0.150 MTPA

MTPA 0.06 MTPA

255 MW

8,34,000

80000

2000

No Change

800

2800

1020

35 MW

46

36000

6000

4800

20000


Raw Material Storage

The concentrate is unloaded at unloading station and stored in

storage yard, of 12,000 T capacity. From t

material into different hoppers. By means of discharge and transport belt

conveyors including an over

to a transfer tower, from where concentrate

Similarly, separate silos

Leaching & Purification area

The major raw materials for the pro

The raw materials requirement is given in

and mode of transportation is given in

through import. Other raw materials are

coal/coke for Lead Smelter

sourced from the market, based on techno

The requirement of other consumables (fuels &

plant has been estimated and furnished in

BASIC RAW MATERIAL

Raw Material

Quantity (As

granted in Nov.'2009)

Zinc concentrate

Calcine (ZnO)

Aluminium metal

Lead concentrate

Coal for LeadSmelter

Coke for LeadSmelter

Coal for Fumer Plant

Cu2SO4 for Fumer

plant

Coal for power plant 11

Lead Silver Compound

*

Zinc Dross/ Ash/ Zinc

bearing waste*

Battery/Lead Scrap and secondary *

BASIC RAW MATERIAL

Sr. No. Item

1 Zinc concentrate

2 Calcine (ZnO)

3 Aluminium metal

4 Lead concentrate



unloaded at unloading station and stored in

000 T capacity. From the stockyard, a pay loader


conveyors including an over-belt magnetic separator, the material is

to a transfer tower, from where concentrate is routed to the roasting plant.

separate silos for storing calcine have been made in the Roaster and

Leaching & Purification area.

The major raw materials for the project are Zinc concentrates, calcine and coal.

The raw materials requirement is given in Table-2.3. the raw material source

and mode of transportation is given in Table-2.4. Deficit, if any, shall be met

through import. Other raw materials are aluminum metal for CGG

Smelter and coal for power production. These materials will be

sourced from the market, based on techno-economic feasibility.

The requirement of other consumables (fuels & process chemicals) required in the

plant has been estimated and furnished in Table-2.5.

TABLE-2.3 BASIC RAW MATERIAL– SMELTERS & CPP

Existing

Granted

Quantity (As per EC

granted in Nov.'2009)

Existing

Requirement

Additional

Requirement

6,48,000 6,48,000 25000

2,80,000 - 2,80,000

160 80 80

2,60,000 2,60,000 90,000

26000 26,000 14,000

27000 27,000 11,000

- - 2,50,000

- - 600

11,62,000 7,74,667 3,87,333

80,000 40,000 40,000

- 30,000 -

80,000 80,000 -

TABLE-2.4

BASIC RAW MATERIAL– SOURCE & TRANSPORTATION

Total

Quantity/year

(Tonnes)

Source of supply

Imported% Indigenous%

concentrate 6,73,000 - 100

280,000 - 100

Aluminium metal 160 - 100

concentrate 3,50,000 45.3 54.7


18 | P a g e

unloaded at unloading station and stored in concentrate

he stockyard, a pay loader feed the


is transported

routed to the roasting plant.

in the Roaster and

concentrates, calcine and coal.

. the raw material source

. Deficit, if any, shall be met

metal for CGG Zinc and

and coal for power production. These materials will be

process chemicals) required in the

Total

Requirement

After Proposed

Expansion

6,73,000

2,80,000

160

3,50,000

40,000

38,000

2,50,000

600

11,62,000

80,000

30,000

80,000

Probable transportation

Imported India

- -

- -

- -

Kandla port HZL mines-


Sr. No. Item

5 Lead silver compound for

Lead

6 Lead secondary’s

7 Coal for Fumer

Plant

8 Coal for LeadSmelter

9 Coke for LeadSmelter

10 Coal for power

plant

CONSUMABLES PER ANNUM

Consumables

Flocculants

Lime

SiO2

H2FiS6 (Silico Fluoric Acid)

LDO/LSHS/HSD/LNG

Sulphuric acid (internal)

MnO2 (internal)

Caustic Soda Solution

Ammonium Chloride

Limestone

Iron Ore

Cement

Power Requirement

The power requirement for the

power requirement for the Captive Power Plant is envisaged for

Smelter.

Water Requirement

Water requirement for

kundia Dam, Mansi wakal Dam and Common Sewage Treatment Plant installed in

Udaipur. Consumption pattern of water for the enhancement of

is given in Table-2.6.



Total Quantity/year

(Tonnes)

Source of supply

Imported% Indigenous

%

silver compound for

80,000 - 100

secondary’s 80,000 50.0 50

Coal for Fumer 2,50,000 60.0 40

Coal for 40,000 60.0 40

Coke for 38,000 - 100

Coal for power 1,162,000 76.0 24

TABLE-2.5

CONSUMABLES PER ANNUM

Unit Quantity

Tons 266

Tons 68,500

Tons 13,000

(Silico Fluoric Acid) Tons 3,000

KL 14,00

Sulphuric acid (internal) Tons 27,500

Tons 6,375

M3 1,500

Tons 638

Tons 74,000

Tons 18,000

Tons 2,000

The power requirement for the Smelter and CPP project is 240 MW.

uirement for the Smelter, CPP will be 252 MW. 255 MW coal based Captive Power Plant is envisaged for providing power to proposed

Water requirement for industrial and township usage will be met from

wakal Dam and Common Sewage Treatment Plant installed in

Consumption pattern of water for the enhancement of Smelter


19 | P a g e

Probable transportation

Imported India

RAM, SK

mine,

Zawar

mines

- CLZS &DaribaSm

elter

complex

Kandla port Mumbai

Navlakhi,

Morbi near Mundra

Gotor,

Kanika, Rajarh

(MP)

Navlakhi, Morbi near

Mundra

Gotor, Kanika,

Rajarh (MP)

Mundra port

Gandhidham

Kandla port -

Quantity

266

500

000

000

000

500

375

500

638

,000

000

000

and CPP project is 240 MW. The total

will be 252 MW. 255 MW coal based providing power to proposed expansion

met from Matri

wakal Dam and Common Sewage Treatment Plant installed in

Smelters and CPP



Quantity (As per EC granted in

Nov.'2009)(m3/day)

Zinc Smelter 11,000

Fumer Plant -

Lead Smelter 7,250

Captive Power Plant

17,000

Domestic 1,000

Total 36,250

Water is sourced from the

Table-2.7

Source

Matri-kundia dam

Mansi Wakal dam

STP Udaipur

STP Udaipur – Expansion

Total

An agreement has been signed between the Govt. of Rajasthan and HZL for

supply of 117 mcft water from Matri

Understanding (MoU) has been signed between Govt. of Rajasthan and HZL for

implementation of Mansi

diverted from the Mansi

point of the common carrier system shall be made available to HZL.

2.3 Process Description

2.3.1 Zinc Smelter

• Roasting Plant

The Zinc concentrate, which is in

not leachable at normal temperature and acidity. It is therefore necessary to

convert this sulphide material to acid leachable form. The purpose of Roasting is to

convert the Zinc sulphide to

Roaster thereby expelling the sulphur as SOsulphuric acid in acid plant.

The Zinc concentrate to be treated is stored in a surge bin, with a holding

capacity for more than one shift.

The concentrate is discharged from the bin by means of a slow running rubber belt.

The capacity of Roaster furnace is 954 Tonnes of concentrate per day (Dry) with a

hearth area of 123 m2.



TABLE-2.6

WATER REQUIREMENT

Existing Granted

Quantity (As per EC granted in

Nov.'2009) /day)

Existing

Requirement (m3/day)

Additional

Requirement (m3/day)

Requirement

Proposed Expansion

(m

000 8,010 2,990

- 10,000

250 2,800 4,450

000 11,000 5,760

000 600 400

250 22,410 23,600

Water is sourced from the dams/ STP through pipelines, the details are given in

TABLE-2.7

SOURCES OF WATER

Availability (m3/day)

9,000

10,800

20,000

Expansion 20,000

59,800


supply of 117 mcft water from Matri kundia Dam. A Memorandum of


implementation of Mansi Wakal Project Stage-I. Under this MoU, the water

Wakal Stage-I project, 30% of water available at off

point of the common carrier system shall be made available to HZL.

concentrate, which is in Zinc sulphide form along with other sulphides, is



sulphide to Zinc oxide (Calcine) by burning with air in a fluo

Roaster thereby expelling the sulphur as SO2 gas and subsequently recovering as sulphuric acid in acid plant.

concentrate to be treated is stored in a surge bin, with a holding

acity for more than one shift.




20 | P a g e

Total

Requirement After

Proposed Expansion

(m3/day)

11,000

10,000

7,250

16,760

1,000

46,010

through pipelines, the details are given in

/day)


kundia Dam. A Memorandum of


I. Under this MoU, the water

I project, 30% of water available at off-take

sulphide form along with other sulphides, is



) by burning with air in a fluo-solid

gas and subsequently recovering as

concentrate to be treated is stored in a surge bin, with a holding




The principal roasting reactions

2ZnS + 3O2 = => 2 ZnO + 2SO

4FeS + 7O2 = => 2Fe2O

ZnO + Fe2O3 = => ZnOFe

In order to avoid any gas leakage, in particular through the charge openings, the

furnace is maintained under a slight

by the SO2 gas blower and controlled by a louver type damper. The roasting gas

at the furnace exit has a temperature of about 950 to 1000of approximately 9% (Vol.). In a waste heat boiler, t

3500C.

The waste heat boiler is of the forced circulation type. It is designed to produce

superheated steam at ~40 bar / 400

walls and the use of evaporator bundles. All the bundles ar

boiler roof. To avoid any air ingress, the roof is tight welded. A part of the flue

dust may adhere on the tube surface; all the bundles are equipped with an

effective rapping device, controlled by a timer to make this adhering calcine

fall. The rapping periods may be set as required to optimize operation.

Only de-aerated and treated feed water will be used for the boiler. This water is

prepared in the de-mineralized water treatment plant. It is fed into the boiler

drum by means of a boiler feed pump. From the drum, the circulating pump

delivers the water into the evaporator bundles and wall tubes and the cooling

coils of the roaster.

The calcine, collected in the waste heat boiler, drops into a longitudinal hopper

arranged underneath the boiler and is discharged by a conti

chain conveyor and water

roaster and waste heat boiler, passes through a rotating drum cooler, to be

cooled to a temperature below 150

The cooler discharge then passes through a ball mill. The mill discharge and the

fine dust coming from the cyclone and hot gas precipitator are combined and

transported to an intermediate bin. From the intermediate bin the calcine

pneumatically transported to the leaching plant. A bag filter is provided to ensure

de-dusting of the calcine handling system.

Before the first start-up, as well as for start

bed furnace and the waste heat boiler h

roaster is equipped with a preheating unit for starting

consists of an oil tank with a pump, oil burners and oil lances. The necessary

combustion air is taken from an air blower. Start

start-up fan and vented via a start

cleaning section.

• Gas Cleaning

The purpose of gas cleaning is to clean the gases of dust particles, saturated with

water vapour, cooling and making it optically clear by removing the mist

particles, thereby making it suitable for feed to the acid plant.



The principal roasting reactions are as follows;

= => 2 ZnO + 2SO2 + 223.6 Kcal

O3 + 4SO2+ Heat

= => ZnOFe2O3 (Zinc ferrite)


furnace is maintained under a slight negative pressure. This draught is provided

gas blower and controlled by a louver type damper. The roasting gas

at the furnace exit has a temperature of about 950 to 10000C and a SOof approximately 9% (Vol.). In a waste heat boiler, the gas is cooled to about


superheated steam at ~40 bar / 4000C. The boiler design provides for tube lined

walls and the use of evaporator bundles. All the bundles are suspended at the



effective rapping device, controlled by a timer to make this adhering calcine


aerated and treated feed water will be used for the boiler. This water is

mineralized water treatment plant. It is fed into the boiler

boiler feed pump. From the drum, the circulating pump



arranged underneath the boiler and is discharged by a continuous air

chain conveyor and water-cooled rotary valve. The calcine, collected from the


temperature below 1500C.



transported to an intermediate bin. From the intermediate bin the calcine


dusting of the calcine handling system.

up, as well as for start-ups after long shutdowns, the fluid

bed furnace and the waste heat boiler have to be preheated. For this purpose the

roaster is equipped with a preheating unit for starting-up purposes, which


combustion air is taken from an air blower. Start-up gases are withdrawn by a

up fan and vented via a start-up stack to the atmosphere provided after gas



particles, thereby making it suitable for feed to the acid plant.


21 | P a g e


negative pressure. This draught is provided

gas blower and controlled by a louver type damper. The roasting gas

C and a SO2 content he gas is cooled to about


C. The boiler design provides for tube lined

e suspended at the



effective rapping device, controlled by a timer to make this adhering calcine to


aerated and treated feed water will be used for the boiler. This water is

mineralized water treatment plant. It is fed into the boiler

boiler feed pump. From the drum, the circulating pump



nuous air-cooled

The calcine, collected from the




transported to an intermediate bin. From the intermediate bin the calcine is


ups after long shutdowns, the fluid

ave to be preheated. For this purpose the

up purposes, which


re withdrawn by a

up stack to the atmosphere provided after gas




The gas cleaning section

1. Hot gas cleaning

2. Wet gas cooling/condensing

3. Acid mist precipitator

4. Mercury removal system

1. Hot Gas Cleaning

The dust loaded SO2 gases from the waste heat boiler are deline three field hot ESP.

The hot gas electrostatic precipitator comprises of three separate electrostatic

fields arranged in series. The dust particles are charged and separated on the

collecting electrodes by the influence of the electrostatic fields. A gas distribution

plate located at the electrostatic precipitator inlet ensures the even gas

distribution over the sectional area of the electrostatic precipitator. The dust

adhering to the collecting electrodes, discharge electrodes and gas distribution

plate is removed at certain intervals by motorized rappers.

The removed dust drops into a longitudinal hopper arranged below the electrostatic precipitator casing and is discharged by a continuously operating

dust conveyor and two rotary valves arranged in series. The col

consist of cold-rolled strips of steel plate. They are arranged in passages. The

discharge electrodes of large cross section are rigidly fixed into pipe frames,

which are vertically suspended between the collecting electrodes. This rigid

design is highly efficient.

Both electrode system

equipped with highly efficient motorized rapping systems. Hot purge air will be

injected to prevent any condensation of Sulphuric acid mists o

supporting insulators of the discharge electrode systems.

The casing of the electrostatic precipitator will be fabricated from steel sheet and

welded gas tight. It has to be fitted with particularly carefully designed heat

insulation to avoid condensation of Sulphuric acid and corrosion. Each

transformer rectifier is controlled by an automatic high voltage control system.

2. Wet Gas Cleaning

Washing Tower

After pre-cleaning in the hot

gas section equipped with a washing tower, which cools the gas adiabatically to a

temperature of about 60

serves to wash out the bulk of the solids entering from the hot gas ESP’s, as well

as condensed volatile impurities. Excess liquid will be discharged to a stripper for

SO2 removal.

Cooling Tower

The cooling of the SO2

current flow, cooling liquid (weak acid) is sprayed into the tower and

downward through packing. By direct contact between the warm gases and the

cooling liquid, heat is transferred. Flue gas cools down, gaseous water condenses



The gas cleaning section consists of the following units:

Wet gas cooling/condensing

Acid mist precipitator

Mercury removal system

gases from the waste heat boiler are de-dusted in one single







t certain intervals by motorized rappers.


dust conveyor and two rotary valves arranged in series. The collecting electrodes

rolled strips of steel plate. They are arranged in passages. The


which are vertically suspended between the collecting electrodes. This rigid

design is highly efficient.

Both electrode system – collecting electrodes and discharge electrodes


injected to prevent any condensation of Sulphuric acid mists on the surface of the

supporting insulators of the discharge electrode systems.



to avoid condensation of Sulphuric acid and corrosion. Each


cleaning in the hot-gas cleaning system, the gas is routed to the


temperature of about 600C by means of circulating liquid. The washing tower also


densed volatile impurities. Excess liquid will be discharged to a stripper for

2 gas is done in a packed gas-cooling tower. In counter

current flow, cooling liquid (weak acid) is sprayed into the tower and




22 | P a g e

dusted in one single








lecting electrodes

rolled strips of steel plate. They are arranged in passages. The


which are vertically suspended between the collecting electrodes. This rigid frame

collecting electrodes and discharge electrodes – are


n the surface of the



to avoid condensation of Sulphuric acid and corrosion. Each


gas cleaning system, the gas is routed to the wet


C by means of circulating liquid. The washing tower also


densed volatile impurities. Excess liquid will be discharged to a stripper for

cooling tower. In counter

current flow, cooling liquid (weak acid) is sprayed into the tower and flows




and the cooling liquid is heated. The condensate leaving the cooling tower is

collected in its sump from where it is delivered to the nozzles by means

cooler flushing pump. The surplus of condensate is withdrawn by gravity from the

sump to the washing tower weak acid circuit.

3. Acid Mist Precipitator

From the washing and cooling sect

ESP’s for mist elimination arranged in two stages. These ESP’s are of the proven

tubular type and are constructed mainly of plastic with high mechanical strength and a high chemical resistance. All parts in co

homogeneously Lead-lined steel. The materials are selected according to the

operating environment and stresses acting on the various components. The

gases pass through the ESP tubes in a vertical direction, in the firs

upwards and in the second stage flowing downwards. Spike design of discharge

electrodes ensure that the mist particles are charged and separated on the tubes.

The discharged condensate flows as a film along the tube surface to be collected

in the bottom section of the ESP from where it is drained. The condensate stream

is combined with the wash acid in the washing tower.

4. Mercury Removal System (Calomel Process)

The mercury contained in

mercury vapour during roasting. Some of the mercury may condense or re

combine with other components in the gas to form insoluble compounds. These

particles or compounds may be separated in the conventional

cleaning and cooling before the gases enter the Sulphuric acid plant. But some

amount of mercury vapour passes the conventional gas cooling and cleaning

system as metallic vapour that must be removed from the gas before feeding to

sulphuric acid plant.

Description of Mercury Removal System

The calomel process was originally developed for the purpose of removing

mercury vapour from Zinc

been treated in the conventional cleaning, washing and c

The reactor for removal of mercury treats gases at a temperature of 38

reactor is a counter current absorption tower made of glass fiber reinforced

plastic. The tower is packed with plastic rings made of polypropylene. The HgCl

solution is sprayed over the packing by nozzles. The mercury vapour comes in

contact with mercuric chloride solution and transforms to mercurous chloride.

When mercury content in circulating water increases, some of the mercurous

chloride is taken to a ch

chloride, which is used as make

(calomel) is withdrawn periodically and stored for sale to interested buyers. The

main reactions are as follows:

HgCl2 (l) + Hg0 (gas) ==> Hg

Hg2Cl2 (s) + Cl2 (gas) ==> 2 HgCl

The towers are furnished with demisters in order to prevent drops leaving the

tower with the purified gases. The clean gas then goes to sulphuric acid plant for

production of H2SO4.




its sump from where it is delivered to the nozzles by means

The surplus of condensate is withdrawn by gravity from the

sump to the washing tower weak acid circuit.

3. Acid Mist Precipitator

From the washing and cooling section, the gases are forwarded into two wet gas


tubular type and are constructed mainly of plastic with high mechanical strength and a high chemical resistance. All parts in contact with the gas are of plastic or

lined steel. The materials are selected according to the


gases pass through the ESP tubes in a vertical direction, in the first stage flowing





is combined with the wash acid in the washing tower.

4. Mercury Removal System (Calomel Process)

The mercury contained in Zinc concentrate is transferred mainly into metallic

mercury vapour during roasting. Some of the mercury may condense or re


particles or compounds may be separated in the conventional




Description of Mercury Removal System


Zinc concentrates roaster gases, after these gases have

been treated in the conventional cleaning, washing and cooling plant.

The reactor for removal of mercury treats gases at a temperature of 38


plastic. The tower is packed with plastic rings made of polypropylene. The HgCl




chloride is taken to a chlorination tank to convert mercurous chloride to mercuric

chloride, which is used as make-up in circulating water. The mercurous chloride


main reactions are as follows:

(l) + Hg0 (gas) ==> Hg2Cl2 (s)

(gas) ==> 2 HgCl2 (l)




23 | P a g e


its sump from where it is delivered to the nozzles by means of a gas

The surplus of condensate is withdrawn by gravity from the

ion, the gases are forwarded into two wet gas


tubular type and are constructed mainly of plastic with high mechanical strength ntact with the gas are of plastic or

lined steel. The materials are selected according to the


t stage flowing





concentrate is transferred mainly into metallic

mercury vapour during roasting. Some of the mercury may condense or re-


particles or compounds may be separated in the conventional unit for gas





concentrates roaster gases, after these gases have

ooling plant.

The reactor for removal of mercury treats gases at a temperature of 380C. The


plastic. The tower is packed with plastic rings made of polypropylene. The HgCl2




lorination tank to convert mercurous chloride to mercuric

up in circulating water. The mercurous chloride





• Sulphuric Acid Plant

The SO2 gas from the gas cleaning section is converted to sulphuric acid by first

converting the SO2 to SO

converter has four layers of V

and passed on to intermediate absorption tower where the SO

produce sulphuric acid. The residual SO

4thmass in order to achieve maximum conversion effic

SO3 gas after 3rd mass and converting it to Hto SO3 in fourth mass. Conversion of SO

in two stages is known as double conversion and double absorption (DCDA

this process, the conversion of SO

thus allowing very low SO

The Sulphuric acid plant mainly consists of 3 plant sections:

• The drying and absorption section

• The converter section with the gas

• The product acid tank farm

1. Drying and Absorption Section

The drying and absorption section mainly consists of the drying tower, the

intermediate absorber, the final absorber, the acid pumps, the acid pump

the acid coolers and the acid piping.

The gas flow through the towers is counter

flows from the bottom to the top of the tower. From the bottom of the tower(s)

the acid flows to the pump tank and is pumped fro

the acid coolers) back to the spray system.

Acid transfer lines between the drying tower, the intermediate absorber and the final absorber and injection lines for dilution water at the intermediate absorber

and final absorber allow control of the necessary acid concentration for each of

the towers.

The Sulphuric acid is produced as +98% H

from the final absorber pump tank. The acid is then cooled in the product acid

cooler and pumped to the

a. Converter System

In the converter, the SO

presence of Vanadium Pentoxide as catalyst, which is subsequently absorbed in

acid towers to convert into sulphuric acid.

The converter system consists of a four

intermediate absorption is follo

an insulated, vertical and cylindrical vessel divided in four sections called layers

or trays with a central tube. The catalyst required for the conversion of SO

SO3 is arranged on these layers. The

and down stream through layer 2, 3, 4.



Sulphuric Acid Plant

gas from the gas cleaning section is converted to sulphuric acid by first

to SO3 in converter in presence of V2O5 as catalyst. The

converter has four layers of V2O5 catalyst. After 3rd mass, the gas is withdrawn

and passed on to intermediate absorption tower where the SO3 gas is absorbed to

produce sulphuric acid. The residual SO2 is further converted to SO

mass in order to achieve maximum conversion efficiency. The withdrawal of

gas after 3rd mass and converting it to H2SO4 accelerates conversion of SOin fourth mass. Conversion of SO2 to SO3 in two stages and absorbing SO

in two stages is known as double conversion and double absorption (DCDA

this process, the conversion of SO2 to SO3 gas is very high (more than 99.7%)

thus allowing very low SO2 emission (less than 650 mg/Nm3).

plant mainly consists of 3 plant sections:

The drying and absorption section

section with the gas-to-gas heat exchangers

The product acid tank farm

1. Drying and Absorption Section


intermediate absorber, the final absorber, the acid pumps, the acid pump

the acid coolers and the acid piping.

The gas flow through the towers is counter-current to the acid flow, i.e. the gas


the acid flows to the pump tank and is pumped from there by the acid pumps (via

the acid coolers) back to the spray system.


r allow control of the necessary acid concentration for each of

The Sulphuric acid is produced as +98% H2SO4 and the product acid is taken


cooler and pumped to the existing acid storage tanks.

In the converter, the SO2 bearing gas is converted to SO3 (sulphur trioxide) in the


acid towers to convert into sulphuric acid.

The converter system consists of a four-layer central tube converter. The

intermediate absorption is following outlet of the 3rd layer. The converter itself is


or trays with a central tube. The catalyst required for the conversion of SO

is arranged on these layers. The SO2 gas flows up stream through layer 1

and down stream through layer 2, 3, 4.


24 | P a g e

gas from the gas cleaning section is converted to sulphuric acid by first

as catalyst. The

catalyst. After 3rd mass, the gas is withdrawn

gas is absorbed to

is further converted to SO3 gas in

iency. The withdrawal of

accelerates conversion of SO2 in two stages and absorbing SO3

in two stages is known as double conversion and double absorption (DCDA). In

gas is very high (more than 99.7%)


intermediate absorber, the final absorber, the acid pumps, the acid pump tanks,

current to the acid flow, i.e. the gas


m there by the acid pumps (via


r allow control of the necessary acid concentration for each of

and the product acid is taken


(sulphur trioxide) in the


layer central tube converter. The

wing outlet of the 3rd layer. The converter itself is


or trays with a central tube. The catalyst required for the conversion of SO2 to

gas flows up stream through layer 1


Three gas-to-gas heat exchangers II, III and IV are designed as mixed cross

flow/counter flow shell and tube heat exchangers. These heat exchangers mainly

consist of inlet and out let chambers, the tube sheets, the tubes and baffles. Heat

exchanger III ensures the optimum gas temperature for the intermediate

absorber as well as for the inlet of layer 4.

Another heat exchanger I, inside the converter, arranged in the bottom of

central tube between layer 1 and 2, is designed as counter flow for pre heating

SO2 gas to the inlet temperature of layer 1.

b. SO2 Gas Blower

The SO2 gas blower is arranged downstream of the drying tower and routes the

gas from the Zinc roaster sec

acid plant. The blower will be provided with an electric motor.

c. Pre-heater

A pre-heater is needed to preheat the converter system from cold condition to

operating temperature, whereas during normal

released within the process allows autoaddition, lower or varying SO

pre-heater preheats air or, in the start phases, SO

temperature.

d. Process Criteria for the Acid Plant

For the production of the sulphuric acid, SO

concentrate roasting are used. There are four main process criteria in the

production of these kinds of gases by the contact/converter process. They are

o Gas drying;

o Water balance; o Heat balance;

o Conversion of SO2 to SO

Gas Drying

Gas drying is an important process in this type of contact plant. Gas drying

protects cooler parts of the plant, such as heat exchangers, against corrosion by

acid condensation. It safeguards against the formation of acid mist, which can be

very difficult to absorb at a latter stage of the process. It also protects the

catalyst from acid condensation during plant shutdowns. Therefore, the life of the

plant and also the tail gas purity largely depend on appropriate gas drying.

The substantial amount of heat, not just the heat of dilution of the sulphuric acid

but also the heat of condensation of the water, is liberated in the gas drying

stage. For that reason the circulated acid is generally cooled by indirect heat

exchanger before being recycled t

Water Balance

The water balance of contact sulphuric acid plants in general may simply be

defined by the specific amount of process water required for achieving the desired

product acid strength from the amount of SO



gas heat exchangers II, III and IV are designed as mixed cross


d out let chambers, the tube sheets, the tubes and baffles. Heat


absorber as well as for the inlet of layer 4.

Another heat exchanger I, inside the converter, arranged in the bottom of


gas to the inlet temperature of layer 1.

gas blower is arranged downstream of the drying tower and routes the

roaster section via the gas cleaning plant through the Sulphuric

acid plant. The blower will be provided with an electric motor.

heater is needed to preheat the converter system from cold condition to

operating temperature, whereas during normal operation of the plant the heat

released within the process allows auto-thermal operation of the plant. In addition, lower or varying SO2-concentrations can be compensated. The separate

heater preheats air or, in the start phases, SO2-gas to the requi

d. Process Criteria for the Acid Plant

For the production of the sulphuric acid, SO2 containing gases from the



to SO3 at the required O2/SO2 ratio.




difficult to absorb at a latter stage of the process. It also protects the



nt of heat, not just the heat of dilution of the sulphuric acid



exchanger before being recycled to the dryer.



product acid strength from the amount of SO2 converted to SO3.


25 | P a g e

gas heat exchangers II, III and IV are designed as mixed cross


d out let chambers, the tube sheets, the tubes and baffles. Heat


Another heat exchanger I, inside the converter, arranged in the bottom of the


gas blower is arranged downstream of the drying tower and routes the

tion via the gas cleaning plant through the Sulphuric

heater is needed to preheat the converter system from cold condition to

operation of the plant the heat

thermal operation of the plant. In concentrations can be compensated. The separate

gas to the required

containing gases from the Zinc






difficult to absorb at a latter stage of the process. It also protects the



nt of heat, not just the heat of dilution of the sulphuric acid






In the case of acid gas plants (like roaster plants) the process water requirements

are usually balanced nearly completely by the water vapour content of the SO

feed gases entering in the drying tower except for a small margin necessary for

the automatic acid strength control.

Thus at a given SO2 gas concentration and SO

product acid strength, the only variable that can and has to be controlled or

limited is water vapour content of the feed gasses entering the drying tower in

order not to exceed the water balance of the whole system. This is done in the wet gas purification system by cooling the SO

temperature corresponding to the maximum allowable water vapour content. For

determination of the req

consider the negative pressure, for which the gas purification system is designed,

but also the external barometric pressure, which depends largely on the elevation

of the plant above sea level.

Absorption of SO3

Sulphur trioxide formed by catalytic oxidation of sulphur dioxide is absorbed in

sulphuric acid of at least 98% concentration, in which it reacts with existing or added water to form more sulphuric acid. The process gas leaving the conve

system is cooled, first in a gas

1600 C before entering the absorber. The gas entering the absorber is therefore

not completely cold and it transfers heat to absorber acid as it passes through

absorber, by the time it reach

as the incoming absorber acid.

A substantial amount of heat is also generated in the absorber acid from the

absorption of sulphur trioxide and the formation of sulphuric acid, and t

temperature rises as a result by a margin, which depends on the acid circulation

rate. The acid concentration is maintained constant by adding process water to

the acid leaving the absorber and the acid cross flow from the dryer (to the intermediate absorber only) at a rate controlled by a concentration measuring

device. The circulated acid is cooled by indirect cooling.

Heat Balance

The SO2 gases leaving the wet gas cleaning system enter the acid plant at a

temperature of 350-400C (depending on

the residual water content in the dryer, the process gases must be heated up to

the required converter inlet temperature of 440

heat exchange with the available sensible gas heat relea

the converter. The main objective of designing such a cold gas plant is to attain

auto thermal operating conditions, which becomes primarily a question of the

required gas heat exchanger surface, depending on the feed gas SO

concentration.

The reaction heat in a double catalysis plant based on roaster gases is released

from;

- Catalytic oxidation

SO2 + ½O2 ==> SO3 + 23.45 Kcal

- Sulphur trioxide absorption and sulphuric acid formation



the case of acid gas plants (like roaster plants) the process water requirements

are usually balanced nearly completely by the water vapour content of the SO


d strength control.

gas concentration and SO2 conversion rate and at a fixed



order not to exceed the water balance of the whole system. This is done in the wet gas purification system by cooling the SO2 gasses down to the dew point


determination of the required dew point temperature, it is important not only to



of the plant above sea level.


sulphuric acid of at least 98% concentration, in which it reacts with existing or added water to form more sulphuric acid. The process gas leaving the conve

system is cooled, first in a gas-to-gas heat exchanger to a temperature of about

C before entering the absorber. The gas entering the absorber is therefore


by the time it reaches the outlet it is virtually at the same temperature

as the incoming absorber acid.


absorption of sulphur trioxide and the formation of sulphuric acid, and t



the acid leaving the absorber and the acid cross flow from the dryer (to the e absorber only) at a rate controlled by a concentration measuring

device. The circulated acid is cooled by indirect cooling.

gases leaving the wet gas cleaning system enter the acid plant at a

C (depending on the SO2 concentration). After removing


the required converter inlet temperature of 4400 C. This is achieved by indirect

heat exchange with the available sensible gas heat released by SO2



required gas heat exchanger surface, depending on the feed gas SO


Catalytic oxidation

+ 23.45 Kcal (1)

Sulphur trioxide absorption and sulphuric acid formation


26 | P a g e

the case of acid gas plants (like roaster plants) the process water requirements

are usually balanced nearly completely by the water vapour content of the SO2


conversion rate and at a fixed



order not to exceed the water balance of the whole system. This is done in the gasses down to the dew point


uired dew point temperature, it is important not only to




sulphuric acid of at least 98% concentration, in which it reacts with existing or added water to form more sulphuric acid. The process gas leaving the converter

gas heat exchanger to a temperature of about

C before entering the absorber. The gas entering the absorber is therefore


es the outlet it is virtually at the same temperature


absorption of sulphur trioxide and the formation of sulphuric acid, and the acid



the acid leaving the absorber and the acid cross flow from the dryer (to the e absorber only) at a rate controlled by a concentration measuring

gases leaving the wet gas cleaning system enter the acid plant at a

). After removing


C. This is achieved by indirect

2 oxidation in



required gas heat exchanger surface, depending on the feed gas SO2



SO3 + H2O = => H2SO4

- Dilution to the acid production strength of 98.5% H

Condensation heat for water content of the gases entering the drying tower system.

Conversion of SO2 to SO

The catalytic oxidation of sulphur dioxide with atmospheric oxygen in the

presence of a solid catalyst to form sulphur trioxide can be described as the

classical example of an exothermal, reversible reaction

SO2 (g) + ½ O2 (g) ==> SO

The decisive factor for conversion is in each case also the O

feed gas. Although, from stoichiometric aspects, a SO

sufficient, it results already from the consideration of the chemical equilibrium

that oxygen in excess will have a

In practice, the O2 content of the gas entering the converter corresponds to 1.0

up to 1.8 times the SO

SO2/O2 ratio on the activity of the catalyst.

The heat of reaction liberated by SO

the gas on its adiabatic passage through the catalyst layer so that the conversion

is limited in accordance with the temperature equilibrium curve. With respect to

obtaining a maximum SO

oxidation in several steps and to cool the gas to the most

before it enters the next catalyst layer.

The theoretical basis of the double catalysis process is relatively simple and can

be derived from the law of mass action. After a def

conversion, after 3rd catalyst layer, the SO

the chemical equilibrium by intermediate absorption so that the equilibrium is shifted in favour of SO3

On the basis of the corresponding te

possible to note already qualitatively that with the same number of contact layers

as compared to the normal catalyst process, an essentially higher final SO

conversion is achievable which is more than 99.7% in pract

A decisive advantage of the double catalysis process is the possibility of feeding

gases of higher SO2 concentration than with the normal catalysis process and this

means smaller gas volumes and consequently smaller equipment dimensions at

comparable production capacities.

O2/SO2 Ratio

For the conversion of SO

the converter called SO2

e. Product Acid Storage Tank

The total acid production received in the intermediate and the final absorber is

pumped from the final absorber pump tank via the product acid cooler to the acid

storage tanks.



(2)

the acid production strength of 98.5% H2SO4


to SO3


catalyst to form sulphur trioxide can be described as the

classical example of an exothermal, reversible reaction

(g) ==> SO3 (g) + 23.45 Kcal

The decisive factor for conversion is in each case also the O2 concentration of the

though, from stoichiometric aspects, a SO2/O2 ratio of 1:0.5 would be


that oxygen in excess will have a favorable influence on SO3 formation.

content of the gas entering the converter corresponds to 1.0

up to 1.8 times the SO2 content, this being especially due to the influence of

ratio on the activity of the catalyst.

The heat of reaction liberated by SO2 oxidation (1) Leads to a temperature rise of



obtaining a maximum SO2 conversion efficiency to perform the catalytic SO

idation in several steps and to cool the gas to the most favorable

before it enters the next catalyst layer.


be derived from the law of mass action. After a defined preliminary SO

catalyst layer, the SO3 formed at this stage is removed from

the chemical equilibrium by intermediate absorption so that the equilibrium is formation.

On the basis of the corresponding temperature/conversion equilibrium it is


as compared to the normal catalyst process, an essentially higher final SO

conversion is achievable which is more than 99.7% in practice.


concentration than with the normal catalysis process and this


production capacities.

For the conversion of SO2 to SO3 the proportion of O2 volume in the feed gas to

2/O2 ratio, is an important factor for the conversion rate.

Product Acid Storage Tank

production received in the intermediate and the final absorber is



27 | P a g e



catalyst to form sulphur trioxide can be described as the

concentration of the

ratio of 1:0.5 would be


formation.

content of the gas entering the converter corresponds to 1.0

content, this being especially due to the influence of

rature rise of



conversion efficiency to perform the catalytic SO2

temperature


ined preliminary SO2

formed at this stage is removed from

the chemical equilibrium by intermediate absorption so that the equilibrium is

mperature/conversion equilibrium it is


as compared to the normal catalyst process, an essentially higher final SO2


concentration than with the normal catalysis process and this


volume in the feed gas to

ratio, is an important factor for the conversion rate.

production received in the intermediate and the final absorber is



Leaching Plant

As the concentrate will have high silver viable for its recovery, thus the

being upgraded with fumer technology for

concentrate/ Calcine having high silver.

The Calcine produced in the roaster and the cal

Smelters is stored in the silos. This calcine is conveyed

where the leaching plant tanks are located. From there it is distributed

throughout the different stages of the process by variable speed screw feeders and conveyors, which are regulated by pH meters that control the process

variables.

Neutral Leaching (NL)

The slurry that comes from the cells cleaning and the spent from the Electrolysis

area, are pumped into the Head Tank, where Iron content is adjusted in order to

improve impurities removal. During the Neutral Leaching stage, the

contained in the Head tank is pumped to the first tank. The control room

predetermines the flow rates. Calcine from the hopper is fed into this tank. The

stream from the first tank passes through the tanks successively.

The stream from the last

flocculant. The neutral overflow,

Plant. The Underflow is pumped into the Weak Acid Leaching tanks.

Weak Acid Leaching (WAL)

The Underflow from the Neutral Leaching and Pre

into the first of a series of tanks, together with spent electrolyte,

these tanks, remaining Zinc

the last tank flocculent

Leaching thickeners. The Underflow from the thickener is pumped to the Strong Acid Leaching stage while the Overflow is pumped to

Zinc Fuming Process:

In the fuming process the weak acid leaching underflow is filtered, dried and fed

to fuming furnaces (2 No’s)in series where at elevated temperatures

fumed and Iron is converted into slag. Coal is added for raising the temperature

and also creating reducing atmosphere. Air/Oxygen is added for combustion. The

slag so produced is removed from the bottom of the furnace. The

furnaces in form of off gas is captured in boiler and gas cleaning section &

for SO2 scrubbing and the same slurry will be sent to the fume oxide treatment

section. In the process of the

waste heat boiler and the saturated steam is used to produce electricity (~

MW) from the waste heat.

The main equipment’s in this section are as follows:

1. Fuming Furnaces with Hygiene Stack

2. Waste heat recovery boilers

3. Turbine- Generator set with auxiliaries

4. ESP & Bag Filter

5. Filter Presses



As the concentrate will have high silver viable for its recovery, thus the

being upgraded with fumer technology for recovery of Lead-

concentrate/ Calcine having high silver.

The Calcine produced in the roaster and the calcine procured from the other

s is stored in the silos. This calcine is conveyed to two hoppers situated



(NL)



improve impurities removal. During the Neutral Leaching stage, the



stream from the first tank passes through the tanks successively.

e last tank flows by gravity to neutral thickners after adding

The neutral overflow, free of solids, is pumped into the Purification

Plant. The Underflow is pumped into the Weak Acid Leaching tanks.

(WAL)

The Underflow from the Neutral Leaching and Pre-Neutralization thickener is fed

into the first of a series of tanks, together with spent electrolyte, as

Zinc oxide and some Zinc ferrite are leached. After leaving

is added to the stream before it enters the Weak Acid

. The Underflow from the thickener is pumped to the Strong Acid Leaching stage while the Overflow is pumped to Zinc fuming section

uming Process:


to fuming furnaces (2 No’s)in series where at elevated temperatures


reducing atmosphere. Air/Oxygen is added for combustion. The

slag so produced is removed from the bottom of the furnace. The Zinc

furnaces in form of off gas is captured in boiler and gas cleaning section &

scrubbing and the same slurry will be sent to the fume oxide treatment

section. In the process of the Zinc fuming, saturated steam is generated at the

waste heat boiler and the saturated steam is used to produce electricity (~

MW) from the waste heat.

The main equipment’s in this section are as follows:

Fuming Furnaces with Hygiene Stack

Waste heat recovery boilers

Generator set with auxiliaries


28 | P a g e

As the concentrate will have high silver viable for its recovery, thus the plant is

-silver using

cine procured from the other

to two hoppers situated





improve impurities removal. During the Neutral Leaching stage, the solution



tank flows by gravity to neutral thickners after adding

free of solids, is pumped into the Purification

Neutralization thickener is fed

as required. In

ferrite are leached. After leaving

is added to the stream before it enters the Weak Acid

. The Underflow from the thickener is pumped to the Strong fuming section .


to fuming furnaces (2 No’s)in series where at elevated temperatures Zinc is


reducing atmosphere. Air/Oxygen is added for combustion. The

Zinc oxide from

furnaces in form of off gas is captured in boiler and gas cleaning section & used

scrubbing and the same slurry will be sent to the fume oxide treatment

fuming, saturated steam is generated at the

waste heat boiler and the saturated steam is used to produce electricity (~ 20


6. Quench Tower

7. Raw material section with Stack

8. Coal Handling & Pulve

9. Oxygen & Nitrogen Plant

10. Slag Granulation system

The steps which are involved in this Fuming process are:

Acid Leaching Residue Filtration and D

Weak acid leaching thickener

bottom flow agitated tank

eight membrane filter presseseight both-way belt conveyers (B=1000, L=8400) and then transferred to the

feeding bin on the top of drying kilns by two

leaching residue is dried in the drying kiln

leaching tank in Zinc calcine leaching plant.

After filtering, acid leaching residue (moisture content 25%)

feeder by belt conveyer and

drying method adopts counter flow drying, with two drying kilns in total.

The fuel for drying kiln comes

provided by primary fan and secondary fan. The pulverized coal is sent to the

burner by impeller feeder before injected into the kiln for combustion. Secondary

air is adjusted to control the temperature of hot off

800℃. Hot off-gases and the residue flows in the opposite direction

exchange to dry the residue.

Off-gas from drying kiln is about 150

about~22000Nm3/h. The off

residue after being dried (moisture content 15%) is discharged from the tap

at the bottom of the hood in

blending storage by belt conveyor.

Leaching Residue Blending Storage Blending S

The leaching residue blending storage is used to store and mix the leaching

residue and flux. The leaching residue after being dried is delivered into the

storage bin conveyor by belt conveyor and is then sent to fuming plant by

weighing belt. The flux is

storage and is fed into the blending storage

residue is fed by belt weight

feeder and the mixed material is sent into

feeding belt.

Melting and Fuming P

There is one melting furnace (24m

The leaching residue will be charged

residue will be charged into fuming furnace through chute for converting.

The fuming furnace plant is also equipped with an electric heating fore well

(20m2) for start-up of furnaces.



Raw material section with Stack

Coal Handling & Pulverizing Plant

Oxygen & Nitrogen Plant

Slag Granulation system

The steps which are involved in this Fuming process are: -

esidue Filtration and Drying

Weak acid leaching thickener underflow from Zinc calcine leaching plant goes into

agitated tank sand the slurry produced after agitation is pumped into

membrane filter presses. The filter residue is discharged through hopper to way belt conveyers (B=1000, L=8400) and then transferred to the

e top of drying kilns by two transfer belt conveyers. Then the

leaching residue is dried in the drying kiln and the filtrate is returned to neutral

calcine leaching plant.

After filtering, acid leaching residue (moisture content 25%) is sent to wet disc

by belt conveyer and is then fed into the drying kiln(ф2.2m


The fuel for drying kiln comes from pulverized coal preparation plant, and air is


feeder before injected into the kiln for combustion. Secondary

air is adjusted to control the temperature of hot off-gas of the kiln to be about

gases and the residue flows in the opposite direction

to dry the residue.

gas from drying kiln is about 150℃. The volume of off

/h. The off-gas goes directly into dust collection system. The

ing dried (moisture content 15%) is discharged from the tap

at the bottom of the hood in the front of the kiln, and sent to the leaching slag

blending storage by belt conveyor.

Leaching Residue Blending Storage Blending Storage




weighing belt. The flux is transported by trucks to the stacking area of blending

d into the blending storage by carry-scraper. The

residue is fed by belt weight feeder while the flux is fed through constant weight

and the mixed material is sent into the fuming furnace plant through

Melting and Fuming Plant

melting furnace (24m2) and one fuming furnace (20m2) in the plant.

The leaching residue will be charged into melting furnace for process and melting



up of furnaces.


29 | P a g e

calcine leaching plant goes into

sand the slurry produced after agitation is pumped into

. The filter residue is discharged through hopper to way belt conveyers (B=1000, L=8400) and then transferred to the

belt conveyers. Then the

and the filtrate is returned to neutral

is sent to wet disc

into the drying kiln(ф2.2m×18m).The


from pulverized coal preparation plant, and air is


feeder before injected into the kiln for combustion. Secondary

gas of the kiln to be about

gases and the residue flows in the opposite direction for full heat

. The volume of off-gas is

gas goes directly into dust collection system. The

ing dried (moisture content 15%) is discharged from the tap-hole

the front of the kiln, and sent to the leaching slag




transported by trucks to the stacking area of blending

scraper. The leaching

constant weight

the fuming furnace plant through

) in the plant.

furnace for process and melting




The leaching residue after mixing with

blending storage through belt conveyor to furnace front bin in melting and fuming

plant. Weighing by belt weigh

furnace through two feeding ports by moveable belt f

The furnace structure of melting furnace is the same with fuming furnace, but in

production process, melting furnace

oxygen concentration of 25%.

Off-gas outlets are on the upper of melting furnace and fudirectly connected with the membrane wall of waste heat boiler.

On one side of diaphragm

for evenly feeding of leaching residue into

speed and reduce coal

and melting residue can be fed into fuming furnace through chutes.

Fuming furnace has one hot slag feeding hole and two slag discharging holes at

both ends. Two tap holes (upper one and lower one) are arranged at one end,

with the upper one for slag tapping during normal operation.

emergency slag tap-hole is arranged at the other end.

Melting furnace and fuming

and pulverized coal will be evenly distributed into the furnace through multi

distribution pipes. Moreover, the pulverized coal can be used as fuel

reductant. Melting furnace and fuming furnace adopt

injection system (including pulverized coal injection device

In drying plant, oil tank and oil pump are equipped to provide diesel for start

of furnaces.

The fuming furnace slag is transported to the intermediate storage bin

crane after granulation and is then transported by trucks to yard for storage. The slag washing

down.

Waste Heat Boiler of Fuming F

A waste heat boiler will be set

heat from high-temperature off

The drum of fuming furnace is placed in the main melting building, and it mainly

consists of fuming furnace hood

chamber and convection zone. The fuming furnace waste heat boiler has its cover

connected to the off-gas outlet of fuming

and the off-gas passes through fuming

radiation cooling chamber and convection zone successively and will be

discharged from waste heat boiler

360℃. The waste heat

remove dust on heating surface in time to ensure normal operation of the boiler.

At the bottom of the dust hopper of the boiler, a chain conveyor

transport settling dust of boiler and ashes cleaned by dust removal devices to

dust collection system. The boiler body is supported on a steel fr

structural steel.



The leaching residue after mixing with flux is sent from the leaching residue


belt weigh feeder, the mixed material is then fed into melting

two feeding ports by moveable belt feeder.


melting furnace adopts oxygen-enriching process

oxygen concentration of 25%.

gas outlets are on the upper of melting furnace and fuming furnace and are directly connected with the membrane wall of waste heat boiler.

On one side of diaphragm wall of melting furnace, two feeding ports

for evenly feeding of leaching residue into the furnace, so as to accelerate melting

speed and reduce coal consumption. Melting furnace has slag discharging

and melting residue can be fed into fuming furnace through chutes.


oth ends. Two tap holes (upper one and lower one) are arranged at one end,

with the upper one for slag tapping during normal operation.

hole is arranged at the other end.

Melting furnace and fuming furnace are equipped with lances on both

and pulverized coal will be evenly distributed into the furnace through multi

distribution pipes. Moreover, the pulverized coal can be used as fuel

Melting furnace and fuming furnace adopt quantitative pulveriz

injection system (including pulverized coal injection device and storage

In drying plant, oil tank and oil pump are equipped to provide diesel for start

The fuming furnace slag is transported to the intermediate storage bin

crane after granulation and is then transported by trucks to the temporarystorage. The slag washing water will return for slag washing after cooling

Waste Heat Boiler of Fuming Furnace

waste heat boiler will be set behind each fuming furnace for recovering waste

temperature off-gas and for cooling and dust collection as well.


furnace hood, uptake flue, decline flue, radiation cooling


gas outlet of fuming furnace through flexible expansion joint,

gas passes through fuming furnace hood, uptake flue, decline flue,


discharged from waste heat boiler to dust collection system after being

boilers equipped with dust removal devices to effectively

ove dust on heating surface in time to ensure normal operation of the boiler.

At the bottom of the dust hopper of the boiler, a chain conveyor


m. The boiler body is supported on a steel frame made from


30 | P a g e

flux is sent from the leaching residue


mixed material is then fed into melting


enriching process, requiring

ming furnace and are

melting furnace, two feeding ports are provided

, so as to accelerate melting

. Melting furnace has slag discharging holes


oth ends. Two tap holes (upper one and lower one) are arranged at one end,

with the upper one for slag tapping during normal operation. Accidental

ances on both sides. Air

and pulverized coal will be evenly distributed into the furnace through multi-layer

distribution pipes. Moreover, the pulverized coal can be used as fuel and

quantitative pulverized coal

and storage bin).

In drying plant, oil tank and oil pump are equipped to provide diesel for start-up

The fuming furnace slag is transported to the intermediate storage bin by bucket

the temporary slag will return for slag washing after cooling

for recovering waste

and for cooling and dust collection as well.


, decline flue, radiation cooling


flexible expansion joint,

, decline flue,


system after being cooled to

devices to effectively

ove dust on heating surface in time to ensure normal operation of the boiler.

is placed to


ame made from


In order to guarantee normal operation of the boiler, a supporting waste heat

boiler room is designed and

steam production, waste discharging, and sampling test for safe operation of

waste heat boiler.

Dust Collection System

The dust collecting system is mainly composed of dry kiln dust collecting system,

melting furnace dust collecting system and fuming furnace dust collecting system.

The dry kiln dust collecting system is used for collecting dust of flue gas from the

dry kiln, and each of the two dry kilns is equipped with a dust collecting system.

The flue gas comes out form the outlet of the kiln at temperature of about

150℃and directly enters the bag

sent to the flue gas desulphurization system and the collected dust by the bag

type dust collector will be delivered t

through a buried scraper and will be transferred to the fuming workshop along

with the leached residue.

The melting furnace dust collecting system is used for collecting dust of flue gas from the melting furnace and t

collecting system. The flue gas comes out form the outlet of the waste heat boiler

at temperature of about 360

purification. The purified flue gas will be sent to the flue gas desulphurization

system and the Zinc oxide smoke dust collected by the waste heat boiler and the

dust collecting system will be used as a

system.

The fuming furnace dust collecting system is used for collecting dust of flue gas

from the fuming furnace and there is a fuming furnace equipped with a dust collecting system. The flue gas comes out form

at temperature of about 360

through a surface cooler. Afterwards, the purified flue gas will be sent to the flue

gas desulphurization system and the

waste heat boiler and the dust collecting system will be used as absorbent for the

flue gas desulphurization system.

Off-gas Desulfurization and

Zinc oxide dust from melting and f

desulfurization and Zincfrom drying kiln and fuming

Zinc sulfite will be produced during off

Off-gas desulfurization and

of seven parts: slurry preparation and supply, off

absorption, process water,

filtration.

The melting off-gas, after dust collection, is pressurized by

the scrubber, enters into two ZnO absorption towers, a swirl board scrubber in

sequence and then is vented to air throughan80

absorption& purification.




boiler room is designed and its thermodynamic system includes water circulation,


ystem


dust collecting system and fuming furnace dust collecting system.



ut form the outlet of the kiln at temperature of about

and directly enters the bag-type dust collector. The purified flue gas will be

sent to the flue gas desulphurization system and the collected dust by the bag

type dust collector will be delivered to the dedicated melting belt conveyor


with the leached residue.

The melting furnace dust collecting system is used for collecting dust of flue gas from the melting furnace and there is a melting furnace equipped with a dust


at temperature of about 360℃ and directly enters a electrostatic precipitator for


oxide smoke dust collected by the waste heat boiler and the

dust collecting system will be used as absorbant for the flue gas desulphurization


from the fuming furnace and there is a fuming furnace equipped with a dust collecting system. The flue gas comes out form the outlet of the fuming furnace

at temperature of about 360℃ and enters the bag filter after being cooling down


gas desulphurization system and the Zinc oxide smoke dust collected by the


flue gas desulphurization system.

esulfurization and Zinc Oxide Dust Treatment

oxide dust from melting and fuming furnace is used as absorbent

Zinc oxide dust treatment. The de-dusted and dried offfrom drying kiln and fuming furnace is sent for desulfurization. Slurry containing

sulfite will be produced during off-gas desulfurization.

desulfurization and Zinc oxide dust treatment system is mainly composed

of seven parts: slurry preparation and supply, off-gas cleaning, sulfur dioxide

absorption, process water, Zinc sulfite leaching, Cl & Fe removal and residue

gas, after dust collection, is pressurized by booster fan


and then is vented to air throughan80-metre-high chimney after series

absorption& purification.


31 | P a g e


system includes water circulation,



dust collecting system and fuming furnace dust collecting system.



ut form the outlet of the kiln at temperature of about

type dust collector. The purified flue gas will be

sent to the flue gas desulphurization system and the collected dust by the bag-

o the dedicated melting belt conveyor


The melting furnace dust collecting system is used for collecting dust of flue gas here is a melting furnace equipped with a dust


and directly enters a electrostatic precipitator for


oxide smoke dust collected by the waste heat boiler and the

nt for the flue gas desulphurization


from the fuming furnace and there is a fuming furnace equipped with a dust the outlet of the fuming furnace

and enters the bag filter after being cooling down


collected by the


nt for off-gas

dusted and dried off-gas sent for desulfurization. Slurry containing

oxide dust treatment system is mainly composed

gas cleaning, sulfur dioxide

& Fe removal and residue

booster fan, washed in


high chimney after series


After pressurization by booster fan, the off

furnace flows into the scrubber for washing to remove As, F, Cl and dust. After

preliminary cleaning, the off

Zinc oxide dust is delivered mechanically from the dust collecting system to the

Zinc oxide blending storage bin in this system. After weighing and proportioned

mixed in slurry proportion tank, the

absorption tower by pumping. Two

in series operation to treat the SO

in the absorption tower is

suitable concentration, and the slurry solutionsent to the existing leaching residue filtration and drying plant. Sodium

absorption tower uses sodium

make sodium hydroxide

sulfate will be sent to waste water treatment station.

After liquid-solid separation of slurry in filter press, the

desulfurization device for reutilization. The slurry filter residue is transported to

one-stage leaching tank for

leaching filtrate and waste electrolyte. High

produced during one-stage leaching, which is sent to the drying tower of existing

sulphuric acid system. Afteroverflow returns to the pre

existing calcine leaching plant. The dense underflow is pumped to the

two-stage leaching tank for

electrolyte and concentrated

is pumped to the two-stage leaching filter press in the new filtration plant for

filter pressing. The filtrate returns to chlorine removal tank. The filter residue is

Lead and silver residue, which is sent to

When F and Cl content in the

leaching solution is pumped into the chlorine removal tank (utilize

tank in existing calcine leaching

produced by adding copper sulphate and sent to the Cl removal filter press in the new residue filtration plant. The filter

residue is CuCl residue, which is

sent to the goethite tank

plant are reutilized) for Fe removal. Limestone slurry, air is added to the Fe

removal tank to produce goethite residue from Fe, F and other impurities in

solution and make goethite settled. After

goethite thickener for liquid and solid separation. The thickener overflow returns

to the existing neutral leaching tank in existing calcine leaching; and the under

flowis sent to belt filter press (

is stockpiled and the filtrate returns to the goethite thickener overflow tank.

Process General Description

Zinc concentrate will first be roasted and calcine will be produced. The calcine will

be conventionally leached, and the slurry pumps to the new residue filtering plant (RFP), where the residue will be

pressure filtered and then send to the kiln to dry. The residue after drying will be

sent by belt conveyor, together with flux, into the fuming furnaces after

proportioning. The process block diagram



After pressurization by booster fan, the off-gas from drying kiln and fuming

flows into the scrubber for washing to remove As, F, Cl and dust. After

preliminary cleaning, the off-gas flows into absorption tower for scrubbing. The

is delivered mechanically from the dust collecting system to the

oxide blending storage bin in this system. After weighing and proportioned

slurry proportion tank, the Zinc oxide is quantitatively fed into the

absorption tower by pumping. Two identical spray absorption towers are designed

in series operation to treat the SO2 in the off-gas, and the slurry solution sprayed

in the absorption tower is Zinc oxide slurry made from Zinc oxide dust in a

suitable concentration, and the slurry solution from the absorption tower is then sent to the existing leaching residue filtration and drying plant. Sodium

uses sodium hydroxide (or sodium carbonate) as absorbent to

hydroxide solution for desulfurization. The by-product

sulfate will be sent to waste water treatment station.

solid separation of slurry in filter press, the filtrate returns to the


stage leaching tank for Zinc sulphite one-stage leaching by adding two

leaching filtrate and waste electrolyte. High-concentrated SO2off

stage leaching, which is sent to the drying tower of existing

system. After liquid-solid separation of slurry in thickener, the clear overflow returns to the pre neutral leaching tank or chlorine removal

ng calcine leaching plant. The dense underflow is pumped to the

stage leaching tank for Zinc sulphite two-stage leaching by adding waste

electrolyte and concentrated sulfuric acid. After second-stage leaching, the slurry

stage leaching filter press in the new filtration plant for


and silver residue, which is sent to Lead plant to recover Lead and silver.

When F and Cl content in the Zinc sulfate solution is higher, the one

leaching solution is pumped into the chlorine removal tank (utilize the

existing calcine leaching plant) for Cl removal. The CuCl sediment is

copper sulphate and Zinc powder. The slurry after reaction is sent to the Cl removal filter press in the new residue filtration plant. The filter

residue is CuCl residue, which is temporarily stock piled for sale. The filtrate is

sent to the goethite tank (the conversion tanks in the existing calcine leaching


removal tank to produce goethite residue from Fe, F and other impurities in

solution and make goethite settled. After reaction, the slurry flows by gravity to



press (utilize the used one) for filtrating. The filter residue


escription

concentrate will first be roasted and calcine will be produced. The calcine will

be conventionally leached, and the Zinc-bearing residue will be transferred by slurry pumps to the new residue filtering plant (RFP), where the residue will be

red and then send to the kiln to dry. The residue after drying will be


he process block diagram given below.


32 | P a g e

gas from drying kiln and fuming

flows into the scrubber for washing to remove As, F, Cl and dust. After

gas flows into absorption tower for scrubbing. The

is delivered mechanically from the dust collecting system to the

oxide blending storage bin in this system. After weighing and proportioned

oxide is quantitatively fed into the

identical spray absorption towers are designed

gas, and the slurry solution sprayed

oxide dust in a

from the absorption tower is then sent to the existing leaching residue filtration and drying plant. Sodium

or sodium carbonate) as absorbent to

product sodium

returns to the


stage leaching by adding two-stage

off-gaswill be

stage leaching, which is sent to the drying tower of existing

solid separation of slurry in thickener, the clear chlorine removal tank in

ng calcine leaching plant. The dense underflow is pumped to the Zinc sulfite

by adding waste

stage leaching, the slurry

stage leaching filter press in the new filtration plant for


and silver.

sulfate solution is higher, the one-stage

the conversion

Cl removal. The CuCl sediment is

powder. The slurry after reaction is sent to the Cl removal filter press in the new residue filtration plant. The filter

for sale. The filtrate is

in the existing calcine leaching


removal tank to produce goethite residue from Fe, F and other impurities in the

reaction, the slurry flows by gravity to



filtrating. The filter residue


concentrate will first be roasted and calcine will be produced. The calcine will

bearing residue will be transferred by slurry pumps to the new residue filtering plant (RFP), where the residue will be

red and then send to the kiln to dry. The residue after drying will be



Purification Plant

The neutral overflow is pumped

removed until levels drop to the point which facilitates the best possible results in

the Electrolysis Section.

� The plant has to produce the best qua

� Minimum Zinc dust consumption

� To obtain the best by

� The plant has to be fully automated

� The control philosophy for the plant design is to

Control System, managing at the same time

Plants. Main instrumentation in the file is:

� Frequency speed drives

� pH meters

� Flow meters, regulation and control



verflow is pumped to the Purification Section where impurities are


. Special considerations in the design of this plant are:

The plant has to produce the best quality purified solution

dust consumption

To obtain the best by-products quality

The plant has to be fully automated

The control philosophy for the plant design is to be integrated in a Distributed

Control System, managing at the same time Leaching and Purification

Plants. Main instrumentation in the file is:

Frequency speed drives

Flow meters, regulation and control


33 | P a g e

to the Purification Section where impurities are


Special considerations in the design of this plant are:

be integrated in a Distributed

Leaching and Purification


� Automatic reagents feeding as a function of the flow

� Temperature measurement, regulation and control

� Density meters, regulation and control (thickeners’ Underflow)

� Torque measurement, regulation and control (thickeners)

� Zn, Cu, Co, Cd, analyzers

The Purification Section consists in the following stages:

� Pre-filtration

� Cu removal � Hot purification/Cobalt Removal

� Polishing/Gypsum removal

� Copper Cement leaching

� Cadmium recovery

The neutral solution that is fed into the Purification Section shall comply with the

following requirements:

Solid matter <0.2 g/l

Zn 140 – 150 g/l

As <0.200 mg/l Sb <0.200 mg/l

Ge <0.100 mg/l

Fe <10 mg/l

Mn 2 – 5 g/l

Mg <10 g/l

Cl <300 mg/l

F <10 mg/l

Pre Filtration

In the Pre-filtration section, neutral over flow solution (containing app. 150 gpl of

Zn as Zinc sulphate) produced in the leaching plant at >65to pre filtration to remove any cake or mica etc.

Copper Removal

The Neutral Leaching overflow is processed in a series of reactors along with

dust in order to remove the copper and cadmium in the solution. The amount of

Zinc dust added is adjusted according to the results obtained from the control

analysis every hour. The solution flows by gravity in reactors, from there it flows

by gravity by means of a launder into a new thickener where solids are settled.

The thickener overflow is collected in a tank where a small portion of Neutral

Leaching overflow is added in order to increase the copper content up to the

required level for the cobalt removal in the Hot Purification stage and finally

pumped to the Hot Purification stage

The Copper Removal thickener underflow is treated with spent electrolyte (at

controlled pH) in separate reactors to allow for the selective leaching of cadmium

and excess Zinc dust. The solution flows by gravity into the second tank and then

it is pumped to filter presses, where the solid matter containing the copper is

retained as cake. The filtrate is collected in a tank which it is pumped to be mixed



Automatic reagents feeding as a function of the flow

Temperature measurement, regulation and control

regulation and control (thickeners’ Underflow)

Torque measurement, regulation and control (thickeners)

Zn, Cu, Co, Cd, analyzers

The Purification Section consists in the following stages:

Hot purification/Cobalt Removal

ng/Gypsum removal

Copper Cement leaching


filtration section, neutral over flow solution (containing app. 150 gpl of

sulphate) produced in the leaching plant at >65oC temperature is sent to pre filtration to remove any cake or mica etc.

The Neutral Leaching overflow is processed in a series of reactors along with

order to remove the copper and cadmium in the solution. The amount of

dust added is adjusted according to the results obtained from the control



erflow is collected in a tank where a small portion of Neutral



pumped to the Hot Purification stage for further treatment.



dust. The solution flows by gravity into the second tank and then




34 | P a g e


filtration section, neutral over flow solution (containing app. 150 gpl of

C temperature is sent

The Neutral Leaching overflow is processed in a series of reactors along with Zinc

order to remove the copper and cadmium in the solution. The amount of

dust added is adjusted according to the results obtained from the control



erflow is collected in a tank where a small portion of Neutral





dust. The solution flows by gravity into the second tank and then




with the Copper Removal

Purification stage

Hot Purification/Cobalt Removal

The Cu removal Overflow is pumped through heat exchangers to the first of a

series of tanks. The temperature at the entrance of this tank is a constant 75

and is regulated by controlling the supply of steam to the heat exchangers. In the

first tank both a solution containing K, Sb, tartrate (premixed in the preparation

tanks) and Zinc dust are added. After leaving the last tank of the series, the mixture is pumped to the

containing the removed impurities, is retained.

This filtrate is further purified in polishing section

where Zinc dust is added for removing of any residual impurities, if any. After

leaving the last tank of the series, the mixture is pumped to the Filter Presses,

where the solid matter containing the removed impurities, is retained.

The working cycle of the Filter

cycle has been completed the filter press is isolated

is discharged onto re-pulping tank, and then to the first tank of the Cadmium stage for further removal of Cadmium and Co

washed online to remove the solid particles adhering to them.

The pH of the solution, previously filtered through the Hot Purification stage

adjusted by the controlled addition of spent, before the solution enters in

from where it is pumped up to the cooling towers.

Cadmium Recovery

Cu-Cd cake generated from purification is treated in cadmium plant. The

impurities are separated during cementation process and sponge generated is

leached, purified and filtereSheets are stripped every 24 hours dried, melted, and casted into pencils.

Typical analysis of Cadmium:

Cd - 99.95 %

Pb - 250 ppm

Ni - 150 ppm

Zn - 10 ppm

Cu -100 ppm

Electro-Winning

The purified and cooled

(electrolytic cells) using aluminum cathodes and

gets deposited on the cathodes and the spent electrolyt

with depleted level of Zinc

cathodes will be pulled out and stripped off with automatic stripping machines

once in 48 hours cycle.

For the proposed plant, large size cells have been selected for reducing

requirement. The current density, temperature etc. have been selected to



with the Copper Removal thickener overflow and finally sent to the Hot

Hot Purification/Cobalt Removal


series of tanks. The temperature at the entrance of this tank is a constant 75



dust are added. After leaving the last tank of the series, the is pumped to the automatic Filter Presses, where the solid matter

containing the removed impurities, is retained.

This filtrate is further purified in polishing section by pumping to series of tanks,

dust is added for removing of any residual impurities, if any. After



The working cycle of the Filter Presses is between eight to twelve hours. Once the

ed the filter press is isolated from the circuit and the cake

pulping tank, and then to the first tank of the Cadmium stage for further removal of Cadmium and Cobalt. The filter cloths are also

to remove the solid particles adhering to them.

The pH of the solution, previously filtered through the Hot Purification stage

adjusted by the controlled addition of spent, before the solution enters in

from where it is pumped up to the cooling towers.

Cd cake generated from purification is treated in cadmium plant. The


leached, purified and filtered. The Cd neutral solution obtained is fed to Cd cells. Sheets are stripped every 24 hours dried, melted, and casted into pencils.

Typical analysis of Cadmium:

The purified and cooled Zinc sulphate solution is electrolyzed in cell house

(electrolytic cells) using aluminum cathodes and Lead anodes. The

gets deposited on the cathodes and the spent electrolyte containing sulphuric acid

Zinc is returned to leaching section. The Zinc


For the proposed plant, large size cells have been selected for reducing



35 | P a g e

thickener overflow and finally sent to the Hot


series of tanks. The temperature at the entrance of this tank is a constant 750C,



dust are added. After leaving the last tank of the series, the Filter Presses, where the solid matter

by pumping to series of tanks,

dust is added for removing of any residual impurities, if any. After



Presses is between eight to twelve hours. Once the

from the circuit and the cake

pulping tank, and then to the first tank of the Cadmium r cloths are also

The pH of the solution, previously filtered through the Hot Purification stages, is

adjusted by the controlled addition of spent, before the solution enters in the tank

Cd cake generated from purification is treated in cadmium plant. The


d. The Cd neutral solution obtained is fed to Cd cells. Sheets are stripped every 24 hours dried, melted, and casted into pencils.

sulphate solution is electrolyzed in cell house

anodes. The Zinc metal

e containing sulphuric acid

deposited on


For the proposed plant, large size cells have been selected for reducing floor area



optimize the area required, deposit quality and power consumption while

rendering high operational efficiency.

This plant consists of the following sections:

1 Cooling, gypsum and basic salt separation

2 Cell house

3 Automatic handling and stripping of cathodes

4 Anode cleaning and flattening

1. Cooling and Basic Salt Separation (Gypsum Removal)

The purified solution from the hot purification section must be cooled down from

75oC to approx. 35oC prior to being fed to the electrolyte cycle. During this

cooling operation, basic

impurities are partly precipitated in line with the temperature

solubility limits in aqueo

Cooling is achieved in atmospheric cooling towers, where the solution is contacted

with air in counter current flow. The cooled solution is collected in a launder

system and flows to a settler where the solids, mainly basic gypsum crystals, will settle. The settler overflow is fed to th

The cooler cake obtained while periodical cleaning of cooling tower is discarded.

2. Cell House

The purified solution, after having been treated for basic

purified solution tank. The tank house will be designed according to the latest

commercial technology using 3.5 m

transport system and full automatic stripping of the

Spent electrolyte discharged from the tank

collected in spent electrolyte storage tanks. From there a certain amount of spent electrolyte is pumped directly to the neutral leaching plant.

The major portion of the spen

where the spent electrolyte is cooled down to approximately 35

towers are of the same design as those for the neutral solution. The mixing of

neutral leach solution and spent electroly

under the influence of turbulence.

The electrolytic recovery of

current through the aqueous

insoluble electrodes, causing the decomposition of the

The metallic Zinc settles on the cathode and the oxygen on the anode, thereby

recovering Sulphuric acid from the hydrogen of the water.

This process takes place in

114 cathodes each. The tank

are coupled in parallel by bus bar.

The electrolyte is supplied to the individual cells via distributing launder an

Reagents, such as strontium carbonate, Arabic gum, are added to improve deposit

quality, increase current efficiency and suppress acid mist formation.




rendering high operational efficiency.

This plant consists of the following sections:

sum and basic salt separation

Automatic handling and stripping of cathodes

Anode cleaning and flattening

Cooling and Basic Salt Separation (Gypsum Removal)


C prior to being fed to the electrolyte cycle. During this

cooling operation, basic Zinc salts as well as gypsum crystals together with some

impurities are partly precipitated in line with the temperature

ity limits in aqueous Zinc sulphate solutions.



system and flows to a settler where the solids, mainly basic Zincgypsum crystals, will settle. The settler overflow is fed to the spent electrolyte.


The purified solution, after having been treated for basic salt, is stored in the


commercial technology using 3.5 m2 cathodes as well as an automatic cathode

transport system and full automatic stripping of the Zinc deposits.

electrolyte discharged from the tank house via the main collecting launder is

collected in spent electrolyte storage tanks. From there a certain amount of spent electrolyte is pumped directly to the neutral leaching plant.

The major portion of the spent electrolyte is pumped to atmospheric cooling towers,

where the spent electrolyte is cooled down to approximately 35oC. The cooling


neutral leach solution and spent electrolyte takes place in the collecting launder

under the influence of turbulence.

The electrolytic recovery of Zinc is brought about by passing continuously electric

current through the aqueous Zinc sulphate electrolyte acidified with H

ectrodes, causing the decomposition of the Zinc sulphate and the water.

settles on the cathode and the oxygen on the anode, thereby

recovering Sulphuric acid from the hydrogen of the water.

This process takes place in lined and insulated cells equipped with 115 anodes and

ach. The tank house contains 136 cells. The electrodes of each cell

are coupled in parallel by bus bar.

The electrolyte is supplied to the individual cells via distributing launder an


quality, increase current efficiency and suppress acid mist formation.


36 | P a g e



C prior to being fed to the electrolyte cycle. During this

salts as well as gypsum crystals together with some

impurities are partly precipitated in line with the temperature-dependent



Zinc salts and e spent electrolyte.


salt, is stored in the


cathodes as well as an automatic cathode

house via the main collecting launder is

collected in spent electrolyte storage tanks. From there a certain amount of spent

t electrolyte is pumped to atmospheric cooling towers,

C. The cooling


te takes place in the collecting launder

is brought about by passing continuously electric

sulphate electrolyte acidified with H2SO4 and the

sulphate and the water.

settles on the cathode and the oxygen on the anode, thereby

cells equipped with 115 anodes and

cells. The electrodes of each cell

The electrolyte is supplied to the individual cells via distributing launder and pipes.



The direct current is fed from the rectifiers to the individual cells via bus bars

mounted on isolators, which rest on special supports. The basic reaction in

electrolysis is as follows;

ZnSO4 + electricity ==> Zn++ + SO

Zn++ +2e- = => Zn

3. Stripping of Cathodes

During the electrolysis process as already mentioned the

aluminum cathodes, which in a cycle of 48 hours have to be taken out from the cells

in order to remove the

stripping machines.

The transport of the cathodes to the stripping machin

and anode transport system provided with a special grab device, which is able to lift

un stripped cathodes from the cell.

The cathodes are washed in a washing device prior to being distributed to the

stripping unit of the stripping machine. The feeding of the inlet chain conveyors of each stripping machine with the cathodes is automatically regulated by the control

system.

The stripped Zinc sheets are stacked below the stripping machine, weighed and

transported by forklift to

The cathode transport system is also used for the anode cleaning operation.

Melting and Casting Plant

The Zinc sheets coming from the stripping machines are first stored on the

storage platform in order to ensure that they are completely dry prior to feeding

them into the melting furnaces.

1. Melting of Zinc Cathodes

The Zinc sheets are fed into the induction furna

Zinc sheets are melted down under a layer of ammonium chloride which serves

the purpose to destroy the oxide film that may be formed during the melting

operation, thus ensuring that the amount of

relatively low.

The molten Zinc is pumped from the furnace’s sump by graphite made vertical

pumps through steel launders lined with heat resistant materials to t

slab/jumbo casting machines

2. Casting of Zinc Slabs

The Zinc ingot production will be cast into standard 25 kg slabs / 1,000 kg

blocks. The molten Zinc

launders to the casting machine. The casting machine is provided with automatic

Zinc pouring and skimming devices that ensure the proper filling of each casting

mould with the required amount of molten

down inside the casting machine by water sprays




isolators, which rest on special supports. The basic reaction in

+ electricity ==> Zn++ + SO4-- --

During the electrolysis process as already mentioned the Zinc is deposited on


in order to remove the Zinc deposit. The cathodes are automatically stripped in

The transport of the cathodes to the stripping machines is performed by a cathode


stripped cathodes from the cell.


pping machine. The feeding of the inlet chain conveyors of each stripping machine with the cathodes is automatically regulated by the control

sheets are stacked below the stripping machine, weighed and

transported by forklift to the storage platform inside the melting and casting plant.


Melting and Casting Plant

sheets coming from the stripping machines are first stored on the


them into the melting furnaces.

Cathodes

sheets are fed into the induction furnaces by means of forklifts. The

sheets are melted down under a layer of ammonium chloride which serves


operation, thus ensuring that the amount of Zinc going into the dross is kept

is pumped from the furnace’s sump by graphite made vertical

pumps through steel launders lined with heat resistant materials to t

slab/jumbo casting machines

Slabs

ingot production will be cast into standard 25 kg slabs / 1,000 kg

Zinc is pumped from the induction furnace through the


pouring and skimming devices that ensure the proper filling of each casting

mould with the required amount of molten Zinc. The Zinc slabs/blocks are cooled

down inside the casting machine by water sprays.


37 | P a g e


isolators, which rest on special supports. The basic reaction in

is deposited on


deposit. The cathodes are automatically stripped in

es is performed by a cathode



pping machine. The feeding of the inlet chain conveyors of each stripping machine with the cathodes is automatically regulated by the control

sheets are stacked below the stripping machine, weighed and

the storage platform inside the melting and casting plant.


sheets coming from the stripping machines are first stored on the


ces by means of forklifts. The

sheets are melted down under a layer of ammonium chloride which serves


going into the dross is kept

is pumped from the furnace’s sump by graphite made vertical

pumps through steel launders lined with heat resistant materials to the

ingot production will be cast into standard 25 kg slabs / 1,000 kg Zinc

is pumped from the induction furnace through the


pouring and skimming devices that ensure the proper filling of each casting

slabs/blocks are cooled


Afterwards, the slabs are automatically stacked

on a scale. The bundles of

magazine conveyors from where they are transported to the storage section by

forklift and finally strapped.

3. Dross Treatment Section

The dross from the Zinc

up to 90% of Zinc, is firstly stored and cooled down in the transport containers.

The dross mills are discontinuously charged with dross produced at the main

induction furnaces. During the grinding operation a suction fan continuously

withdraws the fine dross particles mainly consisting of

ammonium chloride. The mixture of air and dust passes through a cyclone and

afterwards the bag filter. The clean air is di

fine dust is collected and conveyed to the raw

is sent to the Zinc dust plant for melting/ charging in the induction furnace.

• Zinc Dust Plant

The Zinc dust plant consists mainly of three sections:

� atomizing furnace

� expansion chamber with a de

� dust screening and storage

A portion of the molten

of the gas/electric heated atomiz

a special plug which permits to drain about 1 to 2 tph of liquid

designed compressed air jet nozzle atomizes these 5 to 8 liquid

blowing them into the expansion chamber/cycl

In the expansion chamber/cyclone, which is under slightly negative pressure the solid Zinc dust will precipitate and collect in a bin, which discharges onto vibration

conveyors that extract the

The main quantity of Zinc

transported to the Zinc

is separated which is recycled to the induction furnace. The clean air passes

through bag filter before i



Afterwards, the slabs are automatically stacked in the stacking device and weighed

on a scale. The bundles of Zinc slabs with a weight of 1000 kg are collected on


forklift and finally strapped.

Dross Treatment Section

Zinc cathode melting furnaces, which contains approximately

, is firstly stored and cooled down in the transport containers.


. During the grinding operation a suction fan continuously

withdraws the fine dross particles mainly consisting of Zinc


afterwards the bag filter. The clean air is discharged to atmosphere; whist the

fine dust is collected and conveyed to the raw-material storage. The metallic

dust plant for melting/ charging in the induction furnace.

dust plant consists mainly of three sections:

expansion chamber with a de-dusting bag house

dust screening and storage

A portion of the molten Zinc from the induction furnace is charged into the ladle

of the gas/electric heated atomizing furnace. This furnace has at its lowest point

a special plug which permits to drain about 1 to 2 tph of liquid Zinc

designed compressed air jet nozzle atomizes these 5 to 8 liquid Zinc

blowing them into the expansion chamber/cyclone.

In the expansion chamber/cyclone, which is under slightly negative pressure the dust will precipitate and collect in a bin, which discharges onto vibration

conveyors that extract the Zinc dust, from the expansion chamber.

Zinc dust, which is precipitated in the expansion chamber, is

dust screening station. At this screen, oversize


through bag filter before it leaves into the atmosphere through stack.


38 | P a g e

in the stacking device and weighed

slabs with a weight of 1000 kg are collected on


cathode melting furnaces, which contains approximately

, is firstly stored and cooled down in the transport containers.


. During the grinding operation a suction fan continuously

oxides and


scharged to atmosphere; whist the

material storage. The metallic Zinc

dust plant for melting/ charging in the induction furnace.

from the induction furnace is charged into the ladle

ing furnace. This furnace has at its lowest point

Zinc. A special

Zinc streams by

In the expansion chamber/cyclone, which is under slightly negative pressure the dust will precipitate and collect in a bin, which discharges onto vibration

dust, which is precipitated in the expansion chamber, is

dust screening station. At this screen, oversize Zinc dust


t leaves into the atmosphere through stack.


EXISTING PROCESS FLOW DIAGRAM



FIGURE-2.1

EXISTING PROCESS FLOW DIAGRAM


39 | P a g e


MODIFIED PROCESS FLOW DIAGRAM



FIGURE-2.2

MODIFIED PROCESS FLOW DIAGRAM


40 | P a g e


Lead Smelter

In line with HZL’s long term strategy of meeting India’s

decided to up our Lead

adopting the proven pyro metallurgical processing route. With the installation of

this new Lead capacity HZL’s overall primary

0.245 MTPA.

Details of Selected Process Technology

The SKS process is discussed below in the following steps


As like any other pyro smelting technology, a robust feed storage facility is

considered for the storage of Concentrate, Coal fluxes, intermediates and

secondary’s. This will primarily consist of storage bunkers, conveyors and storage

bins for plant consumption with necessary weigh feeding arrangement. This

system will also include feed preparation facility like

SKS Smelting Furnace

The SKS smelting furnace is a horizontal cylindrical vessel with bottom blowing

capability. The furnace will be fed with feed materials from the top through feed

port and oxygen shall be blown from the bottom of the furnace. The furnace is

operated on a continuous sm

at regular intervals and cast into ingots. The bullion ingots are then transported

to the refinery for further purifications. The slag with approximately 45%

content will be cast on a cooled chain

furnace to recover balance

WHRB, Hot ESP, Wet gas cleaning facility followed by a conventional Sulphuric

acid plant.

SKS Furnace Inputs

• Mixed Feed (Fresh

Furnace Dust +Limestone + Iron Ore).

• Oxygen at 16 bar Pressure.

• Nitrogen (Only in case of Oxygen Failure) at

should be Started within

• DM water.

SKS Furnace Outputs

1. Lead Bullion (97% Purity).

2. Lead Oxidation Slag (SKS Slag)

3. SO2(~13% rich off gas).

4. SKS dust in off gas.

SKS Furnace Reactions

PbS + O2 1150°C PbO + SO

PbO + PbS 1150°C Pb + SO



In line with HZL’s long term strategy of meeting India’s Lead demand, it has been

Lead production capacity from 0.125 MTPA to 0.15 MTPA


capacity HZL’s overall primary Lead production capacity shall re

Details of Selected Process Technology

is discussed below in the following steps




. This will primarily consist of storage bunkers, conveyors and storage


system will also include feed preparation facility like pelletizing system.

SKS Smelting Furnace

lting furnace is a horizontal cylindrical vessel with bottom blowing



operated on a continuous smelting philosophy. Bullion from the furnace is tapped


to the refinery for further purifications. The slag with approximately 45%

content will be cast on a cooled chain conveyor which will then be fed to the blast

furnace to recover balance Lead in the slag. The off gas system shall consist of a


(Fresh Lead Conc. + Lead Silver Complex+ SKS Dust +Blast

Furnace Dust +Limestone + Iron Ore).

bar Pressure.

(Only in case of Oxygen Failure) at 16 Bar Pressure (Nitrogen

should be Started within 15 minutes of O2 Failure).

Bullion (97% Purity).

SKS Slag)

(~13% rich off gas).

SKS Furnace Reactions

C PbO + SO2

C Pb + SO2


41 | P a g e

demand, it has been

to 0.15 MTPA by


production capacity shall reach



. This will primarily consist of storage bunkers, conveyors and storage


system.

lting furnace is a horizontal cylindrical vessel with bottom blowing



elting philosophy. Bullion from the furnace is tapped


to the refinery for further purifications. The slag with approximately 45% Lead

conveyor which will then be fed to the blast

in the slag. The off gas system shall consist of a


Silver Complex+ SKS Dust +Blast

Bar Pressure (Nitrogen


At 1150°C, Lead Sulphide reacts with Oxygen to form

oxide. The Lead Oxide in turn reacts with

and Sulphur-di-Oxide is liberated. The Heavier

of the furnace and the Slag flo

tap out the Lead bullion.

hole at the opposite side of the siphon. Sulphur forms Sulphur

escapes through Off Gas.

Off-Gas Collection

The SO2 rich Off gas with

continuously removed under the negative pressure created by an Induced Draft

Fan in the Off-Gas System. Along, with the Smelting Off Gas, air sucked from

throat and feed inlets also enters the Off gas stream. Arou

Conversion takes place in the off gas. The off gas stream passes through the

Waste Heat Recovery Boiler (WHRB) and Electro

entering the Acid Plant Battery Limit(Gas Cleaning Plant).

Almost 97.67% of sulphur fed into the furnace enters the off gas and rest being

carried in the SKS Slag.

Waste Heat Recovery Boiler

The excess heat in the Off

the Waste Heat Recovery Boiler System along with collection of off

Some of the Dust in the stream gets collected at the bottom of the Boiler which is

conveyed by a chain conveyor to the common dust chain conveyor of Dust

Collection System. This dust which is rich in

is then sent to the SKS feed Pelletiser through a weigh feeder and a Bucket

Elevator.

Electrostatic Precipitator

The Off-gas leaving the WHRB enters the Hot ESP, which is having 60 m

collection area in five fields. The discharge electrodes in the fields are charged

with high voltage and the collecting plates are neutral which collects the statically charged dust. The dust from the collecting plates is discharged by rapping system

during each cycle of operation. Dust gets collected at the bottom of the ESP,

which is conveyed by a chain conveyor to the intermediate chain conveyor. The

Off-Gas with a dust load of ~400 mg/Nm

enters the Gas cleaning section for recovery of SO

Blast Furnace

The slag from SKS furnace shall be fed to a conventional blast furnace along with

coke for recovering the

ingots and transported to the refinery for further treatment. The slag from blast furnace containing approximately 3%

holding furnace. Off-gas from the blast

Bag filter to recover dust in the off

and Bag Filter is re-cycled as they have high

Blast Furnace Inputs

1. Lead Oxidation Slag (40%

2. Limestone.



Sulphide reacts with Oxygen to form Lead Oxide and Sulphur

Oxide in turn reacts with Lead Sulphide to form pure

Oxide is liberated. The Heavier Lead bullion collects at the bottom

of the furnace and the Slag floats at the top. The Furnace has an inbuilt Siphon to

bullion. Lead Oxidation Slag is tapped out through a slag tap

hole at the opposite side of the siphon. Sulphur forms Sulphur-

escapes through Off Gas.

rich Off gas with Lead dust generated in the smelting process is


Gas System. Along, with the Smelting Off Gas, air sucked from

throat and feed inlets also enters the Off gas stream. Around 15 % PbS to PbO


Waste Heat Recovery Boiler (WHRB) and Electro-Static Precipitator (ESP) before

entering the Acid Plant Battery Limit(Gas Cleaning Plant).

phur fed into the furnace enters the off gas and rest being

carried in the SKS Slag.

Waste Heat Recovery Boiler

The excess heat in the Off-Gas (which is at ~1150°C) is recovered as steam in

the Waste Heat Recovery Boiler System along with collection of off


n conveyor to the common dust chain conveyor of Dust

Collection System. This dust which is rich in Lead (~60% Pb) in the form of PbO


Electrostatic Precipitator

gas leaving the WHRB enters the Hot ESP, which is having 60 m


with high voltage and the collecting plates are neutral which collects the statically st from the collecting plates is discharged by rapping system



Gas with a dust load of ~400 mg/Nm3 and at temperature ~350

enters the Gas cleaning section for recovery of SO2.


coke for recovering the Lead. Bullion produced from the blast furnace is cast into

ingots and transported to the refinery for further treatment. The slag from blast furnace containing approximately 3% Lead and 15% Zn is fed to the electric arc

gas from the blast furnace is treated through a Cooling Fin

Bag filter to recover dust in the off-gas. The dust collected from the Cooling Fin

cycled as they have high Lead content.

Oxidation Slag (40% Lead content).


42 | P a g e

Oxide and Sulphur-di-

Sulphide to form pure Lead metal

bullion collects at the bottom

ats at the top. The Furnace has an inbuilt Siphon to

Oxidation Slag is tapped out through a slag tap-

-di-oxide and

dust generated in the smelting process is


Gas System. Along, with the Smelting Off Gas, air sucked from

nd 15 % PbS to PbO


Static Precipitator (ESP) before

phur fed into the furnace enters the off gas and rest being

Gas (which is at ~1150°C) is recovered as steam in

the Waste Heat Recovery Boiler System along with collection of off-gas dust.


n conveyor to the common dust chain conveyor of Dust

(~60% Pb) in the form of PbO


gas leaving the WHRB enters the Hot ESP, which is having 60 m2


with high voltage and the collecting plates are neutral which collects the statically st from the collecting plates is discharged by rapping system



and at temperature ~350°C then


. Bullion produced from the blast furnace is cast into

ingots and transported to the refinery for further treatment. The slag from blast and 15% Zn is fed to the electric arc

furnace is treated through a Cooling Fin

gas. The dust collected from the Cooling Fin


3. Coke

4. Air Blast from Blower House

5. Lean Slag from Noble

Blast Furnace Outputs

1. Lead Bullion(97 % purity).

2. Blast Furnace Slag.

3. Blast Furnace Dust.

Blast Furnace Reactions

PbO + C

Reduction

Off-Gas Dust Collection Section

The off-gas from blast furnace passes through the cooling flue (Surface Cooler)

and bag filter and then will be sent to

Draft Fan located at the Outlet of the Bag filter keeps the negative pressure in

operation for off gas flow from Blast furnace through Cooling flue and Bag Filter. The Dust load of the off gas is ~10.69

There are 3 sets of 900

installed on the inlet of cooling flue. When Off

this valve will automatically open for diluting the off gas with cold air. When

temperature becomes less than 100°C, it will automatically close. The Duct

between blast furnace and cooling flue is designed as up

avoid dust accumulation.

A cooling water jacket is equipped on the outlet pipe of the Blast furnace. When

the off-gas temperature is higher than the design value, the water feed system

will turn on automatically for cold water charging.

After the cooling Flue, the gas enters a Bag filter of collection area 2400m

bag filter is waterproof and covered with t

bag filter is designed to meet the gas emission requirements. Explosion valves

are equipped on the bag filter for safe operation as the off gas from blast furnace

contains good amount of CO (refer equation).

The Dust collected in the cooling flue and Bag Filter are conveyed to the

Dust receiving bin located at SKS furnace workshop through a Pneumatic

Conveying System. This Pneumatic conveying system uses compressed nitrogen

from the oxygen plant for SKS furnace.

Slag Fuming Furnace

The blast furnace slag is first taken to the electric arc furnace to maintain the

temperature of the slag and also to buffer a stock of slag for one batch of slag

fuming furnace operation. The slag fuming is done on batch processing

philosophy by using pulverized coal along with high pressure air. The final slag

produced after fuming is

applications. The off-gas system is designed to recover Waste heat through

WHRB. Zinc Oxide compound (with ~10 to 20%



4. Air Blast from Blower House.

5. Lean Slag from Noble Lead Furnace.

Blast Furnace Outputs

Bullion(97 % purity).

Blast Furnace Reactions

PbO + C Pb + CO + CO2

Reduction

Gas Dust Collection Section

gas from blast furnace passes through the cooling flue (Surface Cooler)

and bag filter and then will be sent to the Tail-gas Scrubbing section. The Induced


operation for off gas flow from Blast furnace through Cooling flue and Bag Filter. The Dust load of the off gas is ~10.69 g/m3.

m2 cooling flues for the Dust Collection. A cold air valve is

installed on the inlet of cooling flue. When Off-gas temperature is above 170°C,


re becomes less than 100°C, it will automatically close. The Duct

between blast furnace and cooling flue is designed as up-side-down ‘V’ shaped to

avoid dust accumulation.


gas temperature is higher than the design value, the water feed system

will turn on automatically for cold water charging.

After the cooling Flue, the gas enters a Bag filter of collection area 2400m

bag filter is waterproof and covered with temperature resistant materials. The



contains good amount of CO (refer equation).

llected in the cooling flue and Bag Filter are conveyed to the



from the oxygen plant for SKS furnace.




ilosophy by using pulverized coal along with high pressure air. The final slag

produced after fuming is discard able quality with huge potential for downstream

gas system is designed to recover Waste heat through

Oxide compound (with ~10 to 20% Lead and ~55% Zinc


43 | P a g e

gas from blast furnace passes through the cooling flue (Surface Cooler)

gas Scrubbing section. The Induced


operation for off gas flow from Blast furnace through Cooling flue and Bag Filter.

cooling flues for the Dust Collection. A cold air valve is

gas temperature is above 170°C,


re becomes less than 100°C, it will automatically close. The Duct

down ‘V’ shaped to


gas temperature is higher than the design value, the water feed system

After the cooling Flue, the gas enters a Bag filter of collection area 2400m2. The

emperature resistant materials. The



llected in the cooling flue and Bag Filter are conveyed to the Lead






ilosophy by using pulverized coal along with high pressure air. The final slag

quality with huge potential for downstream

gas system is designed to recover Waste heat through

Zinc) in the off


gas shall be recovered from WHRB and Bag Filter system. The

utilized in the Leaching section of

Fuming Furnace Inputs

1. Blast Furnace Slag.

2. Pulverized Coal (fed to furnace by Air Blast Stream).

3. Blast Air (from Blower House).

Fuming Furnace Outputs

1. ZnO Fume.

2. Fuming Furnace Slag.

Discard Slag

The slag tapped from the fuming furnace will have ~0.5% of Pb and ~2.5% of

Zn. This slag is not viable for further recovery of metals and hence shall be

discarded. The slag is tapped and granulated by a jet of water in slag launder.

After water Granulation and Settlement, the Slag will be grabbed by bridge crane

and is stored in Slag Bin. From strucks.

Off-Gas Collection System

The Off-Gas generated is sucked by an Induced Draft Fan located at the Outlet of

the Bag filter and the fan keeps the negative pressure in operation. The off

passes through the WHRB and the temperature of off

enters the cooling flue (Surface Cooler) and bag filter where the

collected. The off gas leaving the bag filter will be sent to Tail gas Scrubbing unit.

The Dust load of the Off gas is ~79g/m

The dust collection in fuming furnace is similar to the dusBlast furnace section. The

collected in the cooling flue and Bag Filter are conveyed to the Intermediate

storage bin by chain conveyors. From the bin, the dust is collected and bagged in

nylon bags by bagging machine of capacity 10

stored in Zinc Oxide Storage building and before being sent for recovery of

Lead.

Coal Pulverization Plant

The Off-gas from pulverized Coal Combustion in the firebox is sent

through the spark catcher and after feeding with Cold Air. The Output of Coal mill

is classified by the separator to separate the large

back to coal mill) and fine granules enter the cyclone separator and Blow

filter which collect fine dust(sent to Intermediate Silo).

of Lead Smelter is shown in

Lead Refinery

The Lead refining section consists of the following three main

1. Copper De-drossing and Anode 2. Cell House 3. Cathode Preparation / Melting & Ingot Casting Section



gas shall be recovered from WHRB and Bag Filter system. The Zinc Oxide shall be

utilized in the Leaching section of ZincSmelter or in the Pyro Smelter.

Fuming Furnace Inputs

lag.

Pulverized Coal (fed to furnace by Air Blast Stream).

Blast Air (from Blower House).

Fuming Furnace Outputs

Fuming Furnace Slag.


not viable for further recovery of metals and hence shall be



nd is stored in Slag Bin. From slag bin, the slag is transported to s

Gas Collection System

Gas generated is sucked by an Induced Draft Fan located at the Outlet of

the Bag filter and the fan keeps the negative pressure in operation. The off

passes through the WHRB and the temperature of off-gas drops to 360°C.Then it

ng flue (Surface Cooler) and bag filter where the Zinc


The Dust load of the Off gas is ~79g/m3.

The dust collection in fuming furnace is similar to the dust collection system of Blast furnace section. The Zinc oxide compound (~55% Zn, 10~20% Pb)



bags by bagging machine of capacity 10-40 bags/hour. The Bags are then

Oxide Storage building and before being sent for recovery of

Coal Pulverization Plant

gas from pulverized Coal Combustion in the firebox is sent to the coal mill


is classified by the separator to separate the large-size granules (which are sent

back to coal mill) and fine granules enter the cyclone separator and Blow

filter which collect fine dust(sent to Intermediate Silo). The process block diagram

is shown in Figure 2.3.

refining section consists of the following three main sub-sections

drossing and Anode Fabrication.

Cathode Preparation / Melting & Ingot Casting Section


44 | P a g e

Oxide shall be

.


not viable for further recovery of metals and hence shall be



in, the slag is transported to slag yard by

Gas generated is sucked by an Induced Draft Fan located at the Outlet of

the Bag filter and the fan keeps the negative pressure in operation. The off-gas

gas drops to 360°C.Then it

Zinc rich dust is


t collection system of oxide compound (~55% Zn, 10~20% Pb)



40 bags/hour. The Bags are then

Oxide Storage building and before being sent for recovery of Zinc &

to the coal mill


size granules (which are sent

back to coal mill) and fine granules enter the cyclone separator and Blowback Bag

The process block diagram

sections


The cast bullion produced from SKS & Blast furnace is transported to the

electrolytic refinery for melting and drossing to remove copper from the bullion.

After copper drossing,

electro refining. The initial thin cathode sheets are produced from refined

and the final thick cathodes produced from the electro

removed on periodical basis for melting and

slime from the electro

valuable metals like silver, antimony, Bismuth etc.

Silver Refinery

The proposed plant shall have Rotary furnaces like Noble

furnace to produce silver bullion. The antimony and bismuth concentrate shall be

recovered from the off-

Fins and Bag Filter. The bismuth concentrate is skimmed from the Cupel furnace.

Lead rich slag (recyclable) and copper matte (saleable) is also recovered from the

Cupel furnace. The silver bullion is further refined by electrolysis. The pure silver

powder from the electrolytic process is melted and casted into silver ingot of

99.99% purity.

Copper Recovery Plant

The proposed plant will take the copper dross from the electro

will produce copper matte of around 40% purity. This plant uses the ball mill and

rever beratory furnaces to produce the copper matte. Copper matte shall

Off-Gas Collection

The Off-Gas having little content of sulphur as SO

chamber and bag filter system under negative pressure created by induced draft

fan and finally sent to Tail gas treatment plant. The

flue chamber and in turn, the inlet air for the burner of Rever

preheated. The dust is collected in the bag filter and is sent back to SKS Furnace.

PROCESS FLOW DIAGRAM

Blast Furnace

Acid Plant

Scrubber

Off-Gas

Off-Gas

Sulphuric Acid

Stack

Tail Gas

Lead

Conc.

Secondary





the Lead bullion is cast into anode forms suitable for

electro refining. The initial thin cathode sheets are produced from refined

and the final thick cathodes produced from the electro-refining process are

removed on periodical basis for melting and casting into saleable ingots. The

slime from the electro-refining operation is further treated for recovery of

valuable metals like silver, antimony, Bismuth etc.

The proposed plant shall have Rotary furnaces like Noble Lead furnace &


-gas handling system of the furnaces which has Cooling


ag (recyclable) and copper matte (saleable) is also recovered from the



per Recovery Plant

The proposed plant will take the copper dross from the electro-refinery plant and


beratory furnaces to produce the copper matte. Copper matte shall

Gas Collection

Gas having little content of sulphur as SO2 passes through a flue gas


fan and finally sent to Tail gas treatment plant. The hot off-gas is cooled in the

flue chamber and in turn, the inlet air for the burner of Rever beratory furnace is


FIGURE-2.3

PROCESS FLOW DIAGRAM – LEAD SMELTER

SKS Furnace

Blast Furnace

Fuming

Furnace

Refinery Plant

Lead Anode

Slilme/silver

BismuthCopper

Low Lead Slag

Discard Slag

High Lead Slag

Bullion

Bullion

Zinc Oxide

Compound

Antimony

Conc.

Lead Silver compoun

**

Flux Re-Cycle

*

Secondary

* - Re-Cyc

**- By-Product from Zinc Smelter


45 | P a g e



bullion is cast into anode forms suitable for

electro refining. The initial thin cathode sheets are produced from refined Lead

refining process are

casting into saleable ingots. The

refining operation is further treated for recovery of

furnace & Cupel


gas handling system of the furnaces which has Cooling


ag (recyclable) and copper matte (saleable) is also recovered from the



refinery plant and


beratory furnaces to produce the copper matte. Copper matte shall be sold.

passes through a flue gas


gas is cooled in the

beratory furnace is


Bismuth

Antimony


2.3.3 Captive Power Plant

Raw Material

Coal will be the only raw material required for the project apart from LDO which

will be required during start up of the plant.

around 3,320 TPD depending on the quality of coal used.

Process Description

Each process is dealt with detail in the following chapters.

proposed power plant is given in

� Fuel system

� Boiler and its auxiliaries

� Steam turbine & auxiliaries

� Generator and electrical system

� Water treatment plant

� Environment aspects, pollution control and safety measures

FLOW DIAGRAM




will be required during start up of the plant. The requirement of coal will be

320 TPD depending on the quality of coal used.

Each process is dealt with detail in the following chapters. The flow diagram of the

proposed power plant is given in Figure-2.4.

Boiler and its auxiliaries

& auxiliaries

Generator and electrical system

Water treatment plant

Environment aspects, pollution control and safety measures

FIGURE-2.4

DIAGRAM OF CAPTIVE POWER PLANT


46 | P a g e


The requirement of coal will be

The flow diagram of the


Fuel System

As coal is the prime fuel for a thermal power plant, adequate emphasis needs to

be given for its proper handling and storage. It is also important to have a

sustained flow of the fuel to maintain uninterrupted power generation. The

capacity of the coal sto

will be of capacity about 220 TPH for each unit. However, the conveying rate

depends on the gross calorific value of the fuel used.

Coal Bunkers

These are in-process storage silos used for storing

the coal handling system. These will be made up of welded steel plates with

vibrating arrangement at the outlet to avoid choking of coal. For each mill there

will be a bunker and all together there will be four bunkers for two cr

which will be fed through gravimetric feeders. These bunkers present on top of

the mill to aid in gravity feeding of coal to the mills.

Coal Conveying System

This section deals with two primary aspects of preparation and firing of coal in detail. The coal preparation equipment viz. feeders and mills, firing systems and

the firing equipment viz. the burners and their arrangement are described here

under.

Feeders

In most of the power stations, the types of feeders used for transportation of coal

from bunker to the mills are

� Drag chain feeders

� Belt feeders

� Table type rotary feeders� Gravimetric type of feeders

Mills

Pulverized fuel firing is a method whereby the

fineness such that 70-80% passes through a 200 mesh sieve, is carried forward

pneumatically directly to burners or storage bins from where it is passed into

burners. When discharged into combustion chamber, the mixture of

ignites and burns in fluidized state.

The economic motives for the introduction and development of pulverized fuel

firing are:

� Efficient utilization of low grade coals

� Flexibility in firing with ability to meet fluctuating loads

� Elimination of banking losses

� Better reaction to automatic control

� Ability to use high combustion air temperature increasing the overall

efficiency of boiler

� Better availability






rage for proposed CPP is 45,000 ton. The conveyor belts


depends on the gross calorific value of the fuel used.

process storage silos used for storing crushed coal conveyed from



will be a bunker and all together there will be four bunkers for two cr


the mill to aid in gravity feeding of coal to the mills.

Coal Conveying System

This section deals with two primary aspects of preparation and firing of coal in etail. The coal preparation equipment viz. feeders and mills, firing systems and



from bunker to the mills are

Table type rotary feeders Gravimetric type of feeders

Pulverized fuel firing is a method whereby the crushed coal, generally reduced to

80% passes through a 200 mesh sieve, is carried forward


burners. When discharged into combustion chamber, the mixture of

ignites and burns in fluidized state.


Efficient utilization of low grade coals

Flexibility in firing with ability to meet fluctuating loads

of banking losses

Better reaction to automatic control

Ability to use high combustion air temperature increasing the overall


47 | P a g e




000 ton. The conveyor belts


crushed coal conveyed from



will be a bunker and all together there will be four bunkers for two crushing units,


This section deals with two primary aspects of preparation and firing of coal in etail. The coal preparation equipment viz. feeders and mills, firing systems and



crushed coal, generally reduced to

80% passes through a 200 mesh sieve, is carried forward


burners. When discharged into combustion chamber, the mixture of air and coal


Ability to use high combustion air temperature increasing the overall


Even though the high capital cost is involved, the pulverized system is proposed

due to the above mentioned advantages.

Pulverizers

Milling plant is divided into three main types

having its own advantages and drawbacks. In proposed CPP the mills will be of

bowl mill type and will be operated at medium

Pulverized Coal Conveying System

The system for direct firing of pulverized coal utilizes bowl mills to pulverize the

coal and to admit the pulverized coal together with the air required for

combustion (secondary air) to the furnace. As crushed

its feeder, primary air is supplied from the primary air fans, which dries the coal

as it is being pulverized and transports the pulverized coal through the coal piping

system to the coal nozzles in the wind box assemblies. The

air discharged from the coal nozzles is directed towards the center of the furnace

to form a fire ball. Fully preheated secondary air for combustion enters the

furnace around the pulverized coal nozzles and through the auxiliary air

compartments directly adjacent to the coal nozzle compartments. The pulverized coal and air streams entering the furnace are initially ignited by a suitable ignition

source at nozzle exit. Above a predictable minimum loading condition the ignition

becomes self sustaining. Combustion is completed as the gases spiral up in the

furnace.

Air and Draft System

The air we need for combustion in the furnace and the flue gas that we must

evacuate would not be possible without using fans. A fan is capable of imparting

energy to the air/gas in the form of a boost in pressure. The losses through the

system are overcome by means of this pressure boost. The boost is dependent on

density for a given fan at a given speed. The higher the temperature, the lower is the boost. Fan performance (maximum capability) is represented as volume Vs

pressure boost. The basic information needed to select a fan is:

1) Air or gas flow

2) Density (as a function of temperature and pressure)

3) System resistance (losses)

Classification of fans

In boiler practice, we come across the following fans

Draft system

The term ‘draft’ refers to the difference between the atmospheric pressure and

the pressure in the furnace. Depending upon the draft used, we have

� Natural draft

� Induced draft

� Forced draft

� Balanced draft




the above mentioned advantages.

Milling plant is divided into three main types- low, medium and high speed; each


bowl mill type and will be operated at medium speed.

Pulverized Coal Conveying System



combustion (secondary air) to the furnace. As crushed coal is fed to each mill by



system to the coal nozzles in the wind box assemblies. The pulverized coal and




partments directly adjacent to the coal nozzle compartments. The pulverized coal and air streams entering the furnace are initially ignited by a suitable ignition


f sustaining. Combustion is completed as the gases spiral up in the





density for a given fan at a given speed. The higher the temperature, the lower is an performance (maximum capability) is represented as volume Vs

pressure boost. The basic information needed to select a fan is:

2) Density (as a function of temperature and pressure)

3) System resistance (losses)

In boiler practice, we come across the following fans




48 | P a g e


low, medium and high speed; each




coal is fed to each mill by



pulverized coal and




partments directly adjacent to the coal nozzle compartments. The pulverized coal and air streams entering the furnace are initially ignited by a suitable ignition


f sustaining. Combustion is completed as the gases spiral up in the





density for a given fan at a given speed. The higher the temperature, the lower is an performance (maximum capability) is represented as volume Vs




Air Heaters

Air heater uses a heat transfer surface in which air temperature is raised by

transferring heat from other fluids such as flue gas. Since air heater can be

successfully employed to reclaim heat from the flue gas

than is possible with economizer, the heat rejected to chimney can be reduced to

higher extent thus increasing the efficiency of the boiler. For every 20

flue gas exit temperature, the boiler efficiency increases by abou

Boiler and its Auxiliaries

A boiler is a device for generating steam for power, processing or heating

purposes. Boilers are designed to transmit heat from an external combustion

source (usually fuel combustion to fluid) contained within the boiler

heat generating unit includes a furnace in which the fuel is burned. With the

advent of water cooled furnace walls, super heaters, air pre

economizer, the term ‘steam generator’ was evolved as a better description of the

apparatus.

Boilers may be classified on the basis of use, pressure, materials, size, tube

content, tube shape and position, firing, heat source, fuel, fluid, circulations, furnace position, furnace type, general shape and other special features. As the

unit is primarily for power generation it is known as control station steam

generator or utility plants.

The boiler used in proposed

natural circulated bi-drum, dry bottom type unit. Each corner of the boiler is fit

with tangential burner boxes comprising of two high energy arc ignitors, two light

oil fired burners and four pulverized coal burners. The boiler is an external

combustion device in that the combustion takes place outside the region of

boiling water. A boiler furnace is that space under or adjacent to a boiler in which

fuel is burnt and from which the combustion products pass into the boiler. It

provides a chamber in which the combustion reaction can be isolated and confined so that the reaction remains

support or enclosure for the firing equipment.

Fuel Firing System

Fuel firing can be classified as direct firing system and indirect firing or

intermediate bunker system. Both the systems can use any type of

proposed expansion power plant direct firing of coal will be employed and hot gas

will be used for drying and transporting the coal in the form of primary air.

Tangential Firing

Tangential firing will be employed in the furnace here. In this system, burners are

set at each corner of the furnace and are directed to strike the outside of an

imaginary circle in the centre of the furnace. Because, the streams of the fuel so

strike each other, extremely good mixing is obtained. Since the body of the flame

produced is given a rotary motion it

spread out and fill the combustion chamber.





successfully employed to reclaim heat from the flue gas at low temperature levels


higher extent thus increasing the efficiency of the boiler. For every 20

flue gas exit temperature, the boiler efficiency increases by about 1%.

Boiler and its Auxiliaries



source (usually fuel combustion to fluid) contained within the boiler


advent of water cooled furnace walls, super heaters, air pre




ily for power generation it is known as control station steam

generator or utility plants.

The boiler used in proposed expansion power plant will be a radiant, n

drum, dry bottom type unit. Each corner of the boiler is fit




boiler furnace is that space under or adjacent to a boiler in which


provides a chamber in which the combustion reaction can be isolated and confined so that the reaction remains a controlled force. In addition, it provides

support or enclosure for the firing equipment.


intermediate bunker system. Both the systems can use any type of

power plant direct firing of coal will be employed and hot gas





h other, extremely good mixing is obtained. Since the body of the flame

produced is given a rotary motion it leads to a longer flame travel and the gases

spread out and fill the combustion chamber.


49 | P a g e



at low temperature levels


higher extent thus increasing the efficiency of the boiler. For every 20oC drop in

t 1%.



source (usually fuel combustion to fluid) contained within the boiler itself. The


advent of water cooled furnace walls, super heaters, air pre-heater and




ily for power generation it is known as control station steam

power plant will be a radiant, non reheat,

drum, dry bottom type unit. Each corner of the boiler is fitted




boiler furnace is that space under or adjacent to a boiler in which


provides a chamber in which the combustion reaction can be isolated and a controlled force. In addition, it provides


intermediate bunker system. Both the systems can use any type of mill. But in

power plant direct firing of coal will be employed and hot gas





h other, extremely good mixing is obtained. Since the body of the flame

s to a longer flame travel and the gases


Burner and Arrangements

Oil burner will be installed

essential requirements for an oil burner design are:

� It must completely atomise the oil without drooling, fouling or clogging.

� The jet must be so shaped that it will completely mix with the air neces

for combustion.

� Maintenance of atomization over a comparatively wide capacity range.

� Combustion must be complete and excess air at a minimum over the entire operating range.

� A ready accessibility for effecting repairs, thereby minimizing burner outage

as well as maintenance costs.

Furnace

The relative location of the furnace to the boiler is indicated by the description of

the furnace as being internally or externally fired. The furnace is internally fired if

the furnace region is completely

externally fired if the furnace is auxiliary to the boiler. Here, in the proposed

expansion power plant, the furnace will be internally fired as there is a water wall surface in the furnace. Boiler is classified a

boilers will be large capacity steam generators used purely for the electrical power

generation. The industrial boilers are mainly for use in the process industries. They

have partial steam generation in the boiler bank

Economizer

The basic function of an economizer in a steam generating unit is to absorb heat

from the flue gases and add this as sensible heat to the feed water before the

water enters the evaporative circuit of the boiler. Earlier the economizers

introduced mainly to recover the heat available in flue gas that leaves the boiler

and provision of this additional heating surface increased the efficiency of turbine unit and feed water temperature and hence the relative size of the economizer is

less than earlier units. This is a good proposition as the heat available in boiler exit

flue gas can be economically recovered using air heater which is essential for

pulverized fuel fired boilers.

Water Walls

Almost all the modern power boilers are equi

boilers, water walls completely cover the interior surfaces of the furnace providing

complete elimination of exposed refractory surface. Water walls serve as the only

means of heating and evaporating the feed water supplied

economizers. Water walls usually consist of substantially vertical tubes arranged

almost tangentially and is connected at the top and bottom to headers. These

tubes receive water form the boiler drum by means of down comers connected

between drum and water walls lower header. In a boiler, approximately 50 percent

of the heat released by the combustion of fuel in the furnace is absorbed by water

walls. Heat so absorbed is used in evaporation of all or relatively large percentage

of water supplied to the boiler.



Burner and Arrangements

Oil burner will be installed for burning LDO in proposed expansion power plant. The

essential requirements for an oil burner design are:

It must completely atomise the oil without drooling, fouling or clogging.

The jet must be so shaped that it will completely mix with the air neces

Maintenance of atomization over a comparatively wide capacity range.

Combustion must be complete and excess air at a minimum over the entire

A ready accessibility for effecting repairs, thereby minimizing burner outage

as well as maintenance costs.



the furnace region is completely surrounded by water cooled surfaces. It is


power plant, the furnace will be internally fired as there is a water wall surface in the furnace. Boiler is classified according to the end use. The utility



have partial steam generation in the boiler bank tubes.



water enters the evaporative circuit of the boiler. Earlier the economizers



ess than earlier units. This is a good proposition as the heat available in boiler exit


pulverized fuel fired boilers.

Almost all the modern power boilers are equipped with water walls. In large



means of heating and evaporating the feed water supplied to the boiler from the







er supplied to the boiler.


50 | P a g e

power plant. The

It must completely atomise the oil without drooling, fouling or clogging.

The jet must be so shaped that it will completely mix with the air necessary

Maintenance of atomization over a comparatively wide capacity range.

Combustion must be complete and excess air at a minimum over the entire

A ready accessibility for effecting repairs, thereby minimizing burner outage



surrounded by water cooled surfaces. It is


power plant, the furnace will be internally fired as there is a water wall ccording to the end use. The utility





water enters the evaporative circuit of the boiler. Earlier the economizers were



ess than earlier units. This is a good proposition as the heat available in boiler exit


pped with water walls. In large



to the boiler from the








Soot Blowers

Due to the combustion of coal, there is soot deposition along the walls of the boiler

which is to be cleaned periodically by soot blowing for which soot blowers are used.

There are three types of soot blowers.

a) long retractable soot blowers

b) wall blowers

c) air heater blowers

Steam at a pressure of 103 kg/cm

purpose of soot blowing. Soot blowing is done when the furnace temperature goes

beyond 900oC. The pressure is reduced to 31kg/cm

reducing valve. The soot blowers are used for efficient on

super heaters and regenerative air heaters.

Drum and Drum Internals

The boiler drum forms a part of the

water drum serves two functions, the first and primary being that of separating

steam from the mixture of water and steam discharged into it. Secondly, the drum house’s all equipments used for purification of

water. This purification equipment is commonly referred to as the drum internals.

The quantity of water contained in the boiler below the water level is relatively

small compared to the total steam output.

Types of Super Heaters

Depending on the firing method, fuel fired etc., the super heaters are placed in the

boiler flue passes, horizontally, vertically or combined.

Pendant type

Radiant super heaters

Convection super heaters Combined super heaters

The combined type super heater will be used in proposed

Steam Turbine & Auxiliaries

A turbine, being a form of engine, requires, in

fluid, a source of high grade energy and a sink for low

flows through the turbine, part of the energy content is continuously extracted and

converted into useful mechanical work. Steam and gas turbines use heat energy,

while water turbines use pressure energy. The steam turbines offer many

advantages over other prime movers, both thermodynamically and mechanically.

From a thermodynamic point of view, the main advantage of a steam turbine over

reciprocating steam engine is that in the turbine, steam can be expanded down to

a lower back pressure thereby, making

highly impractical and uneconomical in the case of steam engines to construct

large cylinders to deal with large volumes for steam expansion. In addition the

internal efficiency of a turbine is high and so it i

proportion of this relatively large heat drop into mechanical work. From a

mechanical point of view, the turbine is ideal, because the propelling force is

applied directly to the rotating element of the machine and it is not as i

reciprocating engine where it is to be transmitted through a system of connecting





There are three types of soot blowers. They are:

long retractable soot blowers

Steam at a pressure of 103 kg/cm2 at 395oC is tapped from super heater for the


ure is reduced to 31kg/cm2 at 330oC by means of pressure

reducing valve. The soot blowers are used for efficient on-load cleaning of furnace,

super heaters and regenerative air heaters.

Drum and Drum Internals

The boiler drum forms a part of the circulation system of the boiler. The steam and


steam from the mixture of water and steam discharged into it. Secondly, the drum house’s all equipments used for purification of steam after being separated from



small compared to the total steam output.

Heaters


boiler flue passes, horizontally, vertically or combined.

super heater will be used in proposed expansion

Steam Turbine & Auxiliaries

A turbine, being a form of engine, requires, in-order to function a suitable working

fluid, a source of high grade energy and a sink for low-grade energy. When flui




er prime movers, both thermodynamically and mechanically.



a lower back pressure thereby, making available a greater heat drop. Whereas, it is



internal efficiency of a turbine is high and so it is easier to convert a high



applied directly to the rotating element of the machine and it is not as i



51 | P a g e



C is tapped from super heater for the


C by means of pressure

load cleaning of furnace,

circulation system of the boiler. The steam and


steam from the mixture of water and steam discharged into it. Secondly, the drum steam after being separated from




expansion power plant.

order to function a suitable working

grade energy. When fluid




er prime movers, both thermodynamically and mechanically.



available a greater heat drop. Whereas, it is



s easier to convert a high



applied directly to the rotating element of the machine and it is not as in the



links which are necessary to transform a reciprocating motion into a rotary motion.

Moreover, if the load on a turbine is kept constant, the torque developed at the

coupling is also constant. A generator at a steady load offers a constant torque.

Therefore, a turbine is suitable for driving a generator and particularly both the

turbine and the generators are high speed machines.

Another advantage of turbine is that, it

means that the exhaust steam is not contaminated with oil vapor and can be

condensed and fed back to the boilers without passing through filters. The major

advantage is that it can generate a much larger amount reciprocating engine.

Factors affecting Thermal Cycle Efficiency

Thermal cycle efficiency is aff

� Initial steam pressure

� Initial steam temperature

� Whether reheat is used or not, and if used reheat pressure

� Condenser pressure

� Regenerative feed water heating

Water Treatment Plant

The objective of water treatment is to produce a boiler feed water so that there is

no scale formation causing resistance to passage of heat and burning of tube, no

corrosion, no priming or foaming problems. This will ensure that the steam

generated will be clean and the boiler plant will provide trouble free uninterrupted

service. Water treatment plant is designed in such a way that it provides water

which is very low in dissolved solids known as “demineralised water”. There are

two stages in water treatment process viz. pretreatment section and

demineralization section.

Wastewater Generation

Wastewater generation due to indust

Table2.8

WASTEWATER GENERATIO

Units Existing

Wastewater

Generation

Quantity (As per

EC granted in

Nov.'2009)

Zinc Smelter

Lead Smelter

Captive Power

Plant

Fumer

Domestic

Total





pling is also constant. A generator at a steady load offers a constant torque.


turbine and the generators are high speed machines.

Another advantage of turbine is that, it does not need any internal lubrication. This



advantage is that it can generate a much larger amount of power than a

Factors affecting Thermal Cycle Efficiency

Thermal cycle efficiency is affected by the following factors:

Initial steam pressure

Initial steam temperature

Whether reheat is used or not, and if used reheat pressure and temperature

Condenser pressure

Regenerative feed water heating

Water Treatment Plant






ow in dissolved solids known as “demineralised water”. There are


Wastewater Generation

Wastewater generation due to industrial process after expansion is

TABLE-2.8

WASTEWATER GENERATION

Existing

Wastewater

Generation

Quantity (As per

EC granted in

Nov.'2009)

Existing

Generation

Additional

Generation

6400 3600 2800

2000 800 1200

3425 3200 1750

- - 2000

500 380 300

12325 7980 8050


52 | P a g e



pling is also constant. A generator at a steady load offers a constant torque.


does not need any internal lubrication. This



of power than a

and temperature






ow in dissolved solids known as “demineralised water”. There are


rial process after expansion is given in

Total

Generation

After

Proposed

Expansion

6400

2000

4950

2000

680

16030


Solid Waste Generation

Solid waste Generated due to

SOLID WASTE


Quantity (As per EC

granted in

Nov.'2009)(Tonnes)

ETP Cake 27500

Purification

Cake

19000

Cooler Cake 6000

Anode Mud 3200

Cobalt cake 1400

Used Oil 100KL/Year

Waste Oil 75KLYear

Spent

Catalysts(V205)

55KL/Year

Chemical

Sludge (MEE

Salt)

-

Discarded

Containers

-

Jerosite 310600

Geothite -

Fly ash 3,14,000

Process

Residue(Dross

etc. from Lead

plant)

-

Slag from

Fumer plant

(Zinc & Lead)

125000



Solid waste Generated due to Smelter complex in Table 2.9

TABLE-2.9

SOLID WASTE GENERATION

Existing Granted

Quantity (As per EC

granted in

Nov.'2009)(Tonnes)

Existing Status

(Tonnes)

Additional

Proposed

Quantity

(Tonnes)

27500 15000 12500

19000 9500 9500

6000 3000 3000

3200 1600 1600

1400 700 700

100KL/Year 75 KL/Year 25 KL/Year

75KLYear 50 KL/Year 25 KL/Year

55KL/Year 55KL/Year -

- 15000 -

- 1500 nos. -

310600 200000 -

- - 36000

3,14,000 - 1,00,000

- 12000 8000

125000 125000 315000


53 | P a g e

Total Quantity

After

Proposed

Expansion

(Tonnes/Annum)

27500

19000

6000

3200

1400

100KL/Year

75 KLYear

55KL/Year

15000

1500 nos.

0

36000

4,14,000

20000

440000




Chapter Site Analysis


54 | P a g e

Chapter – 3 Analysis


3.1 Connectivity

The site is well connected to

plant site) and interconn

Nearest city is Rajsamand (approx.

Nearest Railway station

direction from the plant site). Nearest Airpor

direction from the plant

facilities like telephone and as such, no constraints are envisaged

3.2 Land from Land Use And Land Ownership

Dariba Smelter Complex was established in 2010

already under the possession of M/s Hindustan

land was required. Land

proposed expansion of project, acquisition of 10 hectare of agricultural land is

envisaged. Topography of the land is almost

elevation of plant area is 480

Particulars

a) Zinc Plant

b) Lead Plant

c) Captive Power Plant

d) Utilities (ETP, RO etc)

e) Hazardous Waste Disposal Site

f) Fumer Plant

g) Others( Open space & internal roads)

Sub Total

3.3 Topography

The topography of the area is undulating

is dendritic and parallel, radiating in all directions. The area within leasehold does

not include any major streams or river across it. The drainage is mainly

flow. The surface water bodies in the area re characterized by

tanks.The main source of drainage is River Banas, which is ephemeral and flows

7.9-km, NNE of the plant

3.4 Existing Infrastructure

Dariba Smelter Complex consist of well

amenities such as school, hospital, community centre, recreational club and guest

house etc. A well-equipped occupational health monitoring facility with X

audiometry, lung function test, & blhospital. The industrial facility consists of

system; Water Treatment Plant, Effluent Treatment Plant, Central Store, Canteen,

approach road & parking Plaza, Central Worksho

distribution system, steam distribution and compressed air distribution for

process and instrumentation and Fire hydrants & surveillance infrastructure

Environmental and Quality Assurance Labs

Dariba. However, wherever required, the same shall be augmented.



The site is well connected to SH-12 (approx. 17.0 km in north direction from the

and interconnecting NH 162 A (approx. 500 m. In west direction)

Rajsamand (approx. 25 km in NW direction from the plant site).

Nearest Railway station Fatehnagar Railway Station (approx. 15.5

plant site). Nearest Airport is Dabok, Udaipur (43

direction from the plant site). The site is well connected with communica

and as such, no constraints are envisaged in this aspect.

rom Land Use And Land Ownership

Complex was established in 2010-11, in 162 ha,

he possession of M/s Hindustan Zinc Ltd., hence, no additional

. Land use of the existing land area is already industrial.


opography of the land is almost flat with minor undulation. The

elevation of plant area is 480-490m above MSL.

Land Requirement (As

per EC granted in Nov.'2009)

Additional Requirement

Total Requirement

Proposed Expansion

Total Area (ha)

34.00 -

28.58 -

18.86 10.0

6.46 -

53.00 -

-

21.10 -

162.00 10.0

The topography of the area is undulating. The drainage pattern in the lease area


not include any major streams or river across it. The drainage is mainly

flow. The surface water bodies in the area re characterized by the existence of

The main source of drainage is River Banas, which is ephemeral and flows

of the plant.

Existing Infrastructure

Complex consist of well-established township with all the


equipped occupational health monitoring facility with X

audiometry, lung function test, & blood Lead level monitoring is available in the hospital. The industrial facility consists of water storage tanks and distribution

Water Treatment Plant, Effluent Treatment Plant, Central Store, Canteen,

arking Plaza, Central Workshop, Electrical power and fuel


process and instrumentation and Fire hydrants & surveillance infrastructure

Environmental and Quality Assurance Labs. Surplus facilities are availa

Dariba. However, wherever required, the same shall be augmented.


55 | P a g e

direction from the

. In west direction).

direction from the plant site).

5.5 km in S

Dabok, Udaipur (43 km in SW

. The site is well connected with communication

in this aspect.

11, in 162 ha, which was

Ltd., hence, no additional

use of the existing land area is already industrial. For the


dulation. The

Total Requirement After

Proposed Expansion

34.00

28.58

28.88

6.46

53.00

172.00

The drainage pattern in the lease area


not include any major streams or river across it. The drainage is mainly sheet

the existence of

The main source of drainage is River Banas, which is ephemeral and flows

established township with all the


equipped occupational health monitoring facility with X-Ray,

level monitoring is available in the water storage tanks and distribution

Water Treatment Plant, Effluent Treatment Plant, Central Store, Canteen,

lectrical power and fuel


process and instrumentation and Fire hydrants & surveillance infrastructure and

. Surplus facilities are available at




CHAPTER 4PLANNING BRIEF


56 | P a g e

CHAPTER 4 PLANNING BRIEF


4.1 Planning Concept

Existing industry is metal industry

project will be provided as per req

final product is being / will be done via exi

concrete road has been developed within the existing plant premises.

4.2 Population Projection

Direct and indirect employment will be created due of people will be there as the managerial and supervisory staff will generally be

outsider.

4.3 Land Use Planning

Dariba Smelter Complex was established in 2010

already under the possession of M/s Hindustan

land was required. Land

proposed expansion of project, acqu

envisaged.

4.4 Assessment of Infrastructure Demand (Physical & Social)

Hindustan Zinc Ltd. has assessed the demand of infrastructure (Physical & Social)

in nearby area of the plant site and development activ

under corporate social responsibilities program for rural

for the up-liftment of the nearby communities from time to ti

infrastructure facilities available at the plant will be utilized for

expansion project. Same

4.5 Amenities/Facilities

Hindustan Zinc Ltd. has constructed hospital, schoolthe permanent and contract employees. It is proposed to develo

facilities in nearby area of the plant site as per

nearby area under corporate social responsibilities programme.



metal industry. Facilities required for the proposed expansion

will be provided as per requirement. Transportation of raw

product is being / will be done via existing road and rail network and


Population Projection

irect and indirect employment will be created due to project. Temporary influx people will be there as the managerial and supervisory staff will generally be

Complex was established in 2010-11, in 162 ha,

he possession of M/s Hindustan Zinc Ltd., hence, no additional

. Land use of the existing land area is already industrial.


f Infrastructure Demand (Physical & Social)

Ltd. has assessed the demand of infrastructure (Physical & Social)

in nearby area of the plant site and development activities are being undertaken

corporate social responsibilities program for rural development initiatives

liftment of the nearby communities from time to time. The existing

facilities available at the plant will be utilized for the proposed

expansion project. Same will be expanded as per requirement.

Ltd. has constructed hospital, school, canteen and club etc. for permanent and contract employees. It is proposed to develop the amenities /

y area of the plant site as per requirement of local people of the

corporate social responsibilities programme.


57 | P a g e

. Facilities required for the proposed expansion

uirement. Transportation of raw material and

sting road and rail network and cement


t. Temporary influx people will be there as the managerial and supervisory staff will generally be

11, in 162 ha, which was

Ltd., hence, no additional

use of the existing land area is already industrial. For the

isition of 10 hectare of agricultural land is

Ltd. has assessed the demand of infrastructure (Physical & Social)

ties are being undertaken

development initiatives

me. The existing

the proposed

, canteen and club etc. for p the amenities /

people of the


REHABILITATION ANDRESETTLEMENT (R & R) PLAN



CHAPTER 5

REHABILITATION ANDRESETTLEMENT (R & R) PLAN


58 | P a g e

CHAPTER 5

REHABILITATION AND RESETTLEMENT (R & R) PLAN


I. Policy to be adopted (Central/State) in respect of the project affected

persons including home oustees, land oustees and landless labourers

Proposed expansion will be done within the existing plant premises and

hectare of the agricultural

settlements in the additional area




ersons including home oustees, land oustees and landless labourers

Proposed expansion will be done within the existing plant premises and

hectare of the agricultural land shall be additionally acquired. There are no

settlements in the additional area hence R & R is not applicable.


59 | P a g e


ersons including home oustees, land oustees and landless labourers

Proposed expansion will be done within the existing plant premises and only 10

additionally acquired. There are no




CHAPTER 6

PROJECT SCHEDULE

COST ESTIMATES


60 | P a g e

CHAPTER 6

PROJECT SCHEDULE

AND

ESTIMATES


6.1 Time Schedule for the Project

The project will start only after obtaining Environmental Clearance and other

clearances from statutory authorities. Project will be completed in

from 2, 50,000 TPA to 3

successful commissioning of previous phase

approvals. Completion of construction work will be about

6.2 Project Cost

Estimated project cost along with ana

of the project

The total investment for the proposed project works

2825Crores. The estimated Investment Cost for the project

requirement of fixed and non

shown in the table below.

Zinc Smelter Expansion Phase I (0.25 MTPA to 0.375 MTPA)

Fumer Phase I (for 0.375 million TPA

CPP – ( 1 x 85 MW)

Zinc Smelter Expansion Phase II (0.375 MTPA to 0.50 MTPA)

Fumer Phase II (for 0.125 million TPA

Common Infrastructure/ Services

Water pipeline from Udaipur to Dariba

Total



he Project


clearances from statutory authorities. Project will be completed in

3, 75,000 TPA then from 3, 75,000 to 5, 00,000

successful commissioning of previous phase after getting all the regulatory

approvals. Completion of construction work will be about Dec 2022.

Estimated project cost along with analysis in term of economic viability

The total investment for the proposed project works out to approximately INR

Crores. The estimated Investment Cost for the project is based on the

fixed and non-fixed assets. The details of total investment are

shown in the table below.

Description Amount (Rs cr.)

Expansion Phase I (0.25 MTPA to 0.375 MTPA)

Fumer Phase I (for 0.375 million TPA Zinc Smelter)

Expansion Phase II (0.375 MTPA to 0.50 MTPA)

Fumer Phase II (for 0.125 million TPA Zinc Smelter)

Common Infrastructure/ Services

Water pipeline from Udaipur to Dariba


61 | P a g e


clearances from statutory authorities. Project will be completed in two Phases

, 00,000 TPA after

after getting all the regulatory

lysis in term of economic viability

out to approximately INR

is based on the

details of total investment are

Amount (Rs cr.)

450

900

425

450

300

200

100

2825


ANALYSIS OF PROPOSAL



CHAPTER 7



62 | P a g e

CHAPTER 7



7.1 Financial and Social Benefits

Proposed expansion project will result in growth of the surrounding areas by

increasing direct and indirect employment opportunities in the region including

ancillary development and supporting infrastructure. Special

financial and social benefits is being/ will be given to the local people.

Rajasthan state will get revenues in terms of taxes and local people will get direct

& indirect employment. Business opportunities for local community will be

available like transport of material to market, maintenance & housecontract work, supplying goods, food to people etc. In addition, lots of CSR

activities are being / will be carried out by the company.

7.2 Environment Friendly Project

Being concerned with the environmental

proposed projects is environmental improvements in nature in the existing

Smelter within its premises and mainly aims at waste minimization.

Following are the environmental

• Currently process is generating Jarosite as waste which is neutralized and

fixed by addition of lime & cement and converted into Jarofix which is

stable material a

usable slag and remove the liability of land, for storage of Jarofix

• Jarofix process consumes other resource like cement & lime. Fumer

operation will mitigate

• Fumer slag will be used in cement

industry in terms of reduction in Clinker Factor and specific GHG emission.

• Waste heat recovery based power generation would be ~

energy.

• Fumer process in addition to improving the environment also helps in

recovering lead, silver &



nd Social Benefits


direct and indirect employment opportunities in the region including

development and supporting infrastructure. Special emphasis on

benefits is being/ will be given to the local people.



like transport of material to market, maintenance & housecontract work, supplying goods, food to people etc. In addition, lots of CSR

activities are being / will be carried out by the company.

Environment Friendly Project

Being concerned with the environmental conservation and ecological balance, the


within its premises and mainly aims at waste minimization.

Following are the environmental key features of the project:

Currently process is generating Jarosite as waste which is neutralized and


nd then stored in jarofix yard. Fumer project

ble slag and remove the liability of land, for storage of Jarofix

Jarofix process consumes other resource like cement & lime. Fumer

mitigate the consumption of lime and cement.

Fumer slag will be used in cement manufacturing and benefit to

in terms of reduction in Clinker Factor and specific GHG emission.

Waste heat recovery based power generation would be ~

Fumer process in addition to improving the environment also helps in

, silver & copper from zinc concentrate.


63 | P a g e


direct and indirect employment opportunities in the region including

emphasis on

benefits is being/ will be given to the local people.



like transport of material to market, maintenance & house-keeping contract work, supplying goods, food to people etc. In addition, lots of CSR

and ecological balance, the


Currently process is generating Jarosite as waste which is neutralized and


project will generate

ble slag and remove the liability of land, for storage of Jarofix.

Jarofix process consumes other resource like cement & lime. Fumer

and benefit to cement

in terms of reduction in Clinker Factor and specific GHG emission.

Waste heat recovery based power generation would be ~20 MWH of

Fumer process in addition to improving the environment also helps in




Chapter

CONCLUSION


64 | P a g e

Chapter-8

CONCLUSION


8.1 Conclusion

Proposed expansion project will result in

growth of the surrounding areas by increased

opportunities in the region including ancillary

infrastructure. Special emphasis on Financial and Social

the local people. Development of social amenities will be in the form of medical

facilities, education to

adverse effect on environment is envisaged as proper mitigation measure will be

taken up for the proposed expansion units



Proposed expansion project will result in conservation of natural resources,

growth of the surrounding areas by increased direct and indirect

the region including ancillary development and supporting

infrastructure. Special emphasis on Financial and Social benefits will be given to

Development of social amenities will be in the form of medical

s, education to under privileged and creation of self-help groups.


taken up for the proposed expansion units.


65 | P a g e

conservation of natural resources,

employment

development and supporting

benefits will be given to

Development of social amenities will be in the form of medical

help groups. No


pre- feasibility report -...

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