HZL Chanderiya Pyro Training Report

Kunal Gupta M.B.M.
Engineering College, Jodhpur
CHAPTER 1 INTRODUCTION
LOCATION OF HZL PLANTS IN INDIA
M.B.M. Engineering College, Jodhpur 1

Kunal Gupta M.B.M. Engineering College, Jodhpur
VISION
Be a world-class zinc company, creating value, leveraging mineral resources and related core
competencies.
MISSION
• Be a lowest cost zinc producer on a global scale, maintaining market leadership.
• One million tonne zinc-lead metal capacity by 2010.
• Be innovative, customer oriented and eco-friendly, maximizing stake-holder value.
• Refined zinc production capacity 669,000 tonnes per annum.
• Refined lead production capacity 85,000 tonnes per annum.
Continuous operational improvements, meticulous planning, constant innovation, extensive

R&D, technological upgradation and so much more- HZL has come a long way and grown into
a multi-unit and multi-product company.
HISTORY
Hindustan Zinc Limited was incorporated from the erstwhile Metal Corporation of India on
10th January 1966 as a Public Sector Undertaking. In April 2002, Sterlite Industries (India)
Limited made an open offer for acquisition of shares of the company consequent to the
disinvestment of Government of India’s stake (26%) including management control to Sterlite
and pursuant to the regulations of SEBI Regulations 1997 acquired additional 20% of shares
from public. In August 2003, Sterlite Industries acquired additional shares to the extent of
18.92% of the paid up capital from Government of India (GOI).
HZL produces Zinc, Lead and some by-products including Sulphuric Acid, Silver and
Cadmium. HZL achieved an all-time high with a record output of 2,61,226 tonnes Zinc and
6,14,938 tonnes production of Zinc concentrate during 2003-04.
Today HZL is India’s leading base metal producer.
HZL is a vertically integrated Mining & Smelting company, gearing up to:

• Harnessing mining resources to help India achieve self-sufficiency in Zinc.
• Become a global leader in Zinc production.
• Create value for all entities whether it is Customers, Investors or Employees

HINDUSTAN ZINC (CHANDERIYA PLANT)
HZL operates smelters based on pyrometallurgical (Chanderiya Lead Zinc Smelter) and
hydrometallurgical (Debari and Vizag Zinc Smelters) process routes. The Chanderiya Lead
Zinc Smelter is one of the most cost-efficient pyrometallurgical Zinc Smelters in the world
Commissioned: 1991
Location: 120km east of Udaipur, Rajasthan
Capacity: 669,000 tpa of refined Zinc

85,000 tpa of refined Lead
Details: A pyrometallurgical smelter using ISP
technology. Main by-products are
Sulphuric Acid and Silver and one of
the by-product is Cadmium.
Certification: ISO 9001:2000, ISO 14001:1996, OHSAS
18001:1999
PRODUCTION CAPACITIES
PRODUCTS CAPACITY (TPA)
REFINED ZINC 70000

REFINED LEAD 35000
SULFURIC ACID 176000
SILVER 74
COPPER CATHODE / SULPHATE 2100
CADMIUM 375

CHAPTER 2 SAFETY DEPARTMENT
Safety is one of the fundamental needs of all living beings. Accident is an unwanted event held
due to carelessness. So precautions must be taken to avoid accidents.
There are two main reasons of accidents:
• Unwanted Acts
• Unwanted Conditions
In accidents occurred by unwanted acts, the worker is directly responsible. These occur due to
carelessness, lack of concentration and over confidence of the worker. It can be minimized by
maintaining concentration and being patient while working.
The main reasons for accidents in form of unwanted acts are:

• Use of machine or equipment without permission.
• Loading material improperly.
• Oiling or greasing machines in running condition.
• Standing in unsafe manner or condition.
• Use of unsafe tool and lack of safety equipment.
• Disobey the instructions and rules.
Some unsafe conditions which motivate accidents are:

• Work on gradeless machine.
• Presence of grease on floor.
• Bad housekeeping and unsafe clothing.
• Breaking or absence of railing on platform.
•
There are many rules for safety but main golden rules are:
• Follow all instructions and rules.
• Correct or report unsafe conditions immediately.
• Wear safety equipments whenever required.
• Keep the workplace clean and tidy.

CHAPTER 3 ABBREVATIONS USED
ABBREVATION: FULL NAME:

ISF Imperial smelting furance
SHG Special high grade Zinc
ESP Electrostatics prcipitate
LSHS Low sulphar high stuck
WGC Wet gas cleaning
LC Lead column
CC Cadium column
ZRP Zinc refinery plant
LRP Lead refinery plant

CHAPTER 4 LIST OF FLOW CHARTS
FIG NO: FIG NAME:

F.7.1 SMELTING PROCESS FLOW CHART
F.7.2 PYRO PLANT PROCESS FLOW CHART
F.8.1 SINTER PLANT FLOW CHART
F.9.1 PROCESS FLOW CHART OF SULPHURIC ACID PLANT
F.10.1 PROCESS FLOW CHART OF ISF PLANT
F.11.1 PROESS FLOW CHART OF ZINC REFINERY PLANT
F.12.1 PROCESS FLOW CHART OF LEAD\SILVER REFINARY

CHAPTER 5 LIST OF TABLES
TABLE: TABLE NAME:

T.1.1 PRODUCTION CAPACITIES
T.9.1 PARAMETERS OF ACID PLANTS
T.11.1 PROPERTIES USED IN REFINERY

CHAPTERS 6 LIST OF DIAGRAMS
DIAG.NO: DIAG.NAME:
D.1.1 VARIOUS OPERATING PLANT
D.8.1 SINTER PLANT
D.9.1 SULPHURIC ACID PLANT

SOURCES OF RAW MATERIALS
(A) Mines in Operation :

1.Zawar Group of Mines:
Zawar group of mines (Mochia, Balaria, Zawar Mala,& Baroi) is situated in the Girwa Tehsil of
Udaipur District of Rajasthan at a distance of about 35kms from Udaipur , amidst a valley of
Arawali hills.
2.Rajpura-Dariba Mines:
The multi-metal Rajpura-Dariba Mines, which is located about 85km away from Udaipur (Raj.)
has demonstrated ore reserve of about 16.4 million tones having metal content of about 6.9%
zinc& 2.2% lead.
3. Maton Rock Phosphate Mine(Udaipur) :

Maton mine has been developed to meet rock-phosphate requirements for the super-phosphate
&phosphoric acid plant at Debari.
4.Rampura Agucha Mining Complex:

The prestigious Rampura Agucha Open Cast Mining Complex is Asia’s richest &largest lead –
zinc deposit.. It is situated in Tehsil Hurda, District Bhilwara in Raj.
The discovery of a world class diposie of 60.6 million tones at Rampura Agucha, containing 15.4
% metal has dramatically altered the prospect of not only reducing the cost of production of zinc
and lead, but also the expansion of HZL’s production capacity resilting in increasing the demand
satisfaction up to 82 %for zinc and 61%for lead.
5. Sargipali Mine (Orissa)
6. Agnigundala Lead Mine (Guntur, A.P.)
(B) Smelters in Operation :

1. Debari Zinc Smelter, Distt. Udaipur (Raj.)
2. Vizag Zinc-Lead Smelter(A.P.)
3. Tundoo Lead Smelter (Dhanbad), Bihar
4. Chanderiya Lead-Zinc Smelter

CHAPTER 7 PYRO PLANT
SMELTING
PYRO METALLURGY HYDRO METALLURGY
SINTERING ROASTING
DCDA-H2SO4
IMPERIL SMELTING LEACHING
REFINING PURIFICATION
AUSMELT
ELECTROLYSIS
Zn REFINING Pb REFINING
MELTING &CASTING
PW &SHG
Zn&Cd Metal Pb&Ag,CuSO4 as
as By Product By Product
HG&SHG
.PROCESS OF HZL

Z in c L e a d S in te r S O2 G a s G as S u lp h u ric S u lp h u ric
C o n c en tra te s P la n t C le a n in g A c id P la n t A c id
H G P D u st
F in e s Lead
Sinter
P W Z in c
B riq u e tte s IS F Z in c IS F Z in c Z in c
C o ke IS F P la n t Z in c
V a p o u r C o n d e n se r S e p a ra tio n R e fin e ry
S H G Z in c
Bullion
Lead
Slag
S u lp h u r C opper L ead R e fin e d

D ro s si n g R e fin e ry L ead
S ilv e r P y ro
P la n t S ilv e r
C opper C op per
R e c o v e ry S u lp h a te
PROCESS FLOW DIAGRAM PYRO PLANT

CHAPTER 8 SINTER PLANT
EXTERIOR VIEW OF SINTER PLANT

RMH
Bins Common Mixing Conditioning
Belt Drum Drum
Conveyer
Sinter
Machine
Return Fines Bins
Cooling
Drum
Sinter
To ISF Breaker
Smooth Roll
Crusher
Corrugate Classifier Spike

d Roll Roll
Crusher Crusher
PROCESS FLOW CHART OF SINTER PLANT

HZL’s CLZS zinc and lead production begins with zinc and lead concentrates wherein zinc and
lead are present as sulphides is imported from its own captive mines in India. Concentrates is
received in trucks and stored in a Raw Material House. From the Raw Material House, it is
transported to Bins in Sinter Plant by a well controlled belt conveyor system, where along with
certain other necessary ingredients like fluxes, secondary materials and water it is mixed in a
prefixed proportion and fed to sintering machine. Sintering serves the dual purpose of converting
the sulphides into oxides and agglomerates the product into porous, high strength lumps called
sinter.
In the sintering process the sulphides of lead and zinc react with oxygen of air to form SO2 gas:
ZnS + 3O 2 
→2 ZnO + 2SO 2
PbS + 3O 2 → 2 PbO + 2 SO 2
The sinter plant has following main sections:

1. Raw Material Handling Plant (RMH)
2. Charge Proportioning and Conditioning System
3. Sinter Machine
4. Sinter and Return Fines Handling (Crusher Plant)
5. Gas Cleaning (Acid Plant)
6. Slurry Handling
1. RMH (Raw Material Handling):
The raw material from mines is first dumped in a yard then it comes in RMH Plant through Belt
Conveyor. The unloading system of belt conveyors takes the material to the respective bay through
a tripper conveyor. *The tripper conveyor is like a belt, which is mounted on the head pulley and is
driven by a gear coupling (spiral helical gear, the gear box is SCN 180 where S→Spur gear,
C→Triple state, 180→code for size and other specifications). With the tripper conveyor Take-up
Pulley Arrangement (automatically adjustable system) is there, which prevents breaking of belt due
to stretching while working. This arrangement is perpendicular to the tripper conveyor and head
pulley arrangement. *
*From the belt conveyor raw material is transferred to the respective bay via Shuttle Conveyor.
Water spraying is done with the help of Fly-Over, so that the powder form of material doesn’t
scatter here and there. *
From the bay the material is fed into the hoppers using Pay Loaders. Hopper transfers the material
on the belt conveyor, which carries the material to the Sinter building. *Impact idlers are used in
driving this belt conveyor to absorb sudden shocks. Some magnetic separators are put in between
the way to separate the magnetic impurities present in the raw materials.
The basic raw material used in the industry is as follows:
1. Zn Concentrate
2. Pb concentrate
3. Lime Stone

4. Ferous Oxide
5. Calcium Oxide
6. Silicon Oxide
7. Sulphur
2. Charge Proportioning and Conditioning System:
The raw materials can be made to pass through a disintegrator and then through hammer mill to
break the oversized particles. Now the material comes on the shuttle conveyor via a belt conveyor.
Raw material is transferred to the respective bin via Shuttle Conveyor.
Here we have kept 13 storage bins.
6 for Zinc concentrate (cap.→50 cu.m.)

4 for Lead concentrate (cap.→50 cu.m.)
1 for bulk concentrate (cap.→50 cu.m.)
1 for iron flux (cap.→50 cu.m.)
2 for limestone (cap.→50 cu.m.)
1 for spare dross (cap.→25 cu.m.)
2 for return fines (cap.→25 cu.m.)
All bins are equipped with Vibrators and Shock Cannons to prevent blockage, provide uniform
charging and separate out the undersized particles.
The feed basically contains:

1. Return fine
2. Ventilation dust
3. Rich gas dust
4. Bag house dust
5. Blue powder
6. Leach residue from Copper dross leaching
7. Leach residue from Cadmium plant
8. Sludge from lead refinery
The raw material from the bins comes on a belt conveyor that moves on the rollers. This system is
called Weigh Feeder because a rod is attached among the rollers to sense the material load in tones
per hour. The speed of all weigh feeder bins is 6 times lesser than the speed of the feeder of return
fines bin due to the 6 times more requirement of return fines in sinter machine. Generally the ratio
between the crude charge and return fines is in the range of 1:3 to 1:5. In order to have a sulphur of
6% in the feed to sinter machine.
From weigh conveyors the charge comes on the collecting belt, common to all bins. From this belt
the charge is fed to mixing drums. The mixing drum is a cylinder in which the charge is mixed with
the moisture, 2 to 4% water is added for that.

The sketch of the mixing drum and its drive is somewhat like this-
input Mixing drum discharge
Small Small
Motor drum drum
Bearings
MIXING DRUM
In its mechanism the motor drives the smaller drums, which drive the mixing drum. The spherical
roller bearings are provided so that no rubbing occurs. The charging and discharging is through a V-
belt arrangement. In the mixing drum some intermediate cones are provided so that slipping of
charge does not occur. When the charge gets stuck in between the cones then the charge find time to
mix with the moisture.
From mixing drum the charge goes to the conditioning drum, where further water is added. The
difference between the mixing and the conditioning drum is that the no. of cones in the latter one is
more. The conditioning drum maintains the amount of moisture (approx. 6%) in the charge in the
sinter machine feed. In this drum lumps of charge are formed and thus size of fines is increased. The
mechanism of this same as that of the mixing drum.
3. Sinter machine:
The updraft sinter machine has an area of 120 m 2 and 109 pallets each measuring 3m*1m in size.
There are 444 grate bars in a pallet.
To drive the sinter machine, is used a motor and a gear box system. The drive gear is flexible and it
is hanged at one side of machine. It is made flexible and movable because the machine is very long,
so there are jerks in some conditions. So to withstand it drive gear box is made flexible and thus the
drive does not get damaged.
The specifications of drive gearbox are-

Supplier – M/S-CITROEN MESSIAN DURAND FRANCE
Type – 71 HAA-165-500F-H3C20
Input Ratio –128/18*76/3*40.078 = 7219.90
Input Speed – n1 – 1500rpm
Output Sped – n2 – 0.207-27rpm
Motor (kW) – 75

Above the sinter machine the main and ignition layer bins are located. Through ignition bin charge
is passed on the pallets to form the ignition layer, the thickness of which is generally adjusted to
give 30mm height. The ignition layer is fired by 2 burners operating on LSHS (low sulphur heavy
stack) to get about 1000°C hood temperature.
The ignition gases are drawn by the ignition waste gas fan through the wind box and conveyed to
recirculating gas fan. Dust and spillage are removed in a solid separator. The ignition wind box, is
equipped with two screw conveyors which are to seal and discharge the sinter machine dust
collecting through.
Heat 1000°C
Ignition layer
30mm layer
Heat drawn from bottom
IGNITION LAYER IN BINS
On the 1000°C burnt ignition layer, is formed the main layer 360mm in all (30mm ignition
layer+330mm fresh charge). The 330mm layer comes from main layer hopper which is located
above the sinter machine. The burnt 30mm layer of charge with air now heats the 330mm layer of
fresh charge.
330mm
Main layer
360mm
30mm
Ignition layer
Air+ O2
LAYER FORMATION IN BINS

To supply O2, there are 3 fresh air fans and one recirculating fan supplying fresh air and recirculates
to 17 wind boxes of the sinter machine. The gases above the both updraft windboxes are low in SO 2,

extremely humid and at low temperature. These gases are mixed with the hot gases from the
discharge and of the sinter machine and recirculated to the last 3 windboxes at the discharge end of
the sinter machine. There are 5 Cyclones for dust removal og ventilation air and recirculating gases
in order to avoid any dust build up in the ducts and also to avoid wear of the fans.
The SO2 gas is sucked from the top and the duct is situated in the mid of the sinter machine.
The reaction is as follows-
ZnS + O 2 → ZnO + SO 2 ↑
The maximum of SO2 is sucked at mid and the remaining from the back of sinter machine with hot
gases. The SO2 from mid is sent to Wet Gas Cleaning Plant (WGC) through a HGP with the help of
booster blower.
The specifications of the plant are as follows:

Effective updraft are a of the sinter m/c 120 m2,
Width of the pallet 3.0 m
Capacity (Dry basis) Sinter material 4600tons per day
Specific Sulphur burning rate 1.6 tons per square meter per day
Sinter Production 1080 tons per day
Sulphur content of mixture <1%
SO2 content of the gases >5%
Moisture Content <7%
Bulk density of the crude charge 2.5 tons per cubic meter (Avg.)
The ignition chamber contains the horizontally arranged oil burners. Oxidation reaction produce
such heat that local melting at contact surface takes place between single grains as a result of that
they agglomerate into lumps. The temperature at the outlet of the sinter machine is around 800◦ C.
4. Sinter and Return Fines Handling (Crusher Plant):
Because the sinter from sinter machine is in the form of very big size lumps, which cannot be
directly fed to furnace, and it needs to be broken in the size of approximately 65 to 130mm. This
sizing is done in the Crusher Plant. Also, as the major part of the input to sinter plant is the return
fines and for that the fines are prepared in the Crusher Plant.
Now the agglomerated material is directly fed to the claw crusher or Sinter Breaker that is placed
just after the sinter machine. This crusher helps in reducing the size of sinter upto 300mm. And the
temperature at this stage is approximately 500°C.
Now the sinter is sent to the Spike Roll Crusher that gives the size of sinter as 130mm. Before this
crusher a Vibro-Feeder is provided to give uniform charging to crusher.
Finally the material goes in the Rose Roll Classifier. The sinter of size less than 65mm and greater
than 65mm is classified in this classifier. The sinter of size 65 to 130mm comes to Production Bin,
which is the input for ISF Plant.
The –65mm sinter (i.e. the size is less than 65mm) passes through another circuit so that proper size
of fines can be fed to the sinter input in the form of return fines. The size should be approximately
6mm for proper permeability is achieved.

The size of returns is reduced upto 25mm in the Corrugated Roll Crusher. Further the size is
reduced in the Smooth Roll Crusher to 6 to 13mm, which is the required size of return fines. At this
stage the temperature is approximately 300°C that is further reduced to 90°C in the Cooling Tower
or Cooling Drum. Thus formed fines are the feed for the sinter plant.
The material, which is agglomerated in the sinter machine, is mainly rich in ZnO and PbO, which
are now; send to the ISF plant to feed it to the furnace. The reaction-taking place in the plant is as
follows:
2 PbS + O 2 → 2 PbO 2
ZnO + O 2 → 2ZnO
These are sent to ISF to reduce it to Zn and Pb.

CHAPTER 9 ACID PLANT
ACID PLANT

The acid plant used for manufacturing the sulphuric acid is a traditional plant based on contact
process for manufacturing the sulphuric acid. In the plant we have used following instruments in
some fixed numbers as:
Absorption Towers (3):

1. In the gas coming from the gas cleaning plant contains a significant amount of water
which is to be removed before it is allowed to enter to the catalyst chamber because water
may destroy the catalyst. For that we must dehydrate it using a dehydrating agent. And
the dehydrating agent frequently available in the plant is the Sulphuric acid itself. We
pass the concentrated acid through the tower to absorb the water vapors in the gas. After
passing through the tower the acid become dilute which is mixed with the concentrated
acid coming from the other two absorption towers to maintain the concentration.
2. The second absorption column is used to convert the SO3 into Sulphuric acid. A spray of
the some dilute sulphuric acid made from the top of the column and we are getting the
concentrated acid from the bottom of the plant.
3. The third absorption column is used to convert the remaining SO3 into the Sulphuric
acidusing the same method.The acid coming out of the last tower is approximately 98%
pure. This acid is mixed with the acid coming from the other two towers to maintain the
concentration. The amount of acid of each concentration getting mixed with one another
is controlled from the control room
Reactors (1):
The reactor used in the sulphuric acid plant is contain a known weight of the catalyst Vanedium
PentaOxide. The Sulphur Dioxide entering into the reactor get converted into the Sulphur
Trioxide. The temperature at which the reaction is fastest is 450-620°C . So temperature from the
control room is maintained between these limits. As the reaction is exothermic the temperature is
maintained automatically inside the reaction vessel around the desired value. This is
accomplished by taking out some amount of gas out of the column after each catalyst bed. When
the gas is brought out first two times it is just cooled using the heat exchangers. But when gas is
brought out after next two catalyst beds it is first through the heat exchangers and then through
the absorption columns.
Heat Exchangers(6):
In plant we have total 6 heat exchangers which are being used to cool the gases coming from the
reactor (On tube side). These heat exchangers are arranged in such a way that proper usage of the
heat generated in the plant can be done.

O2
Absorption
Tower 1
Cooler Heat
Exchanger
Simplified Diagram Of Sulphuric Acid Plant In Plant
Reactor
Absorption
Tower 2
Absorption
Tower 3
To Storing
Tank

Specifications
Parameters Content
Total Acidity (as H2SO4) 98.00% min
Residue on ignition 0.050% max
Iron Content (as Fe) 0.005% max
Lead Content (as Pb) 0.002% max
Arsenic content (as As) 0.003 % max
Bulk density 1.840
End Uses
Sulphuric Acid is the bulk commodity chemical used by almost all the industries. It is the basic
building molecule for chemical industry; used for different applications. The major consuming
end use segments are:
• Fertilizer (Phosphatic Fertilizers: DAP & SSP)

• Detergent
• Dyes & Dyes Intermediates
• Organic & Inorganic Chemicals
• Textiles
• Petrochemicals
• Refineries
• Pharmaceuticals
• Explosives
• Pulp & Paper
• Rayon
• Alum Manufacturing
• Sugar Refining
• Metal Pickling
• Electrolysis
EFFLUENT TREATMENT PLANT
The Effluent Treatment Plant can be divided into 5 sections

1. Cadmium Removal
2. Cyanide Destruction
3. Fluoride Precipitation
4. Heavy Metals Removal
5. Lime Slurry Make-up

1. Cadmium Removal:
The Cadmium plant produces the effluent containing 40% cadmium. Therefore this
Cadmium is precipitated before entering the main effluent treatment plant. The effluents
are first mixed with 10% w/w slurry & pH is maintained at 11.5. The solids are taken to a
sludge tank, which also collects sludge from the main plant. The over flow from the
thickener flows into the primary reaction tank for the precipitation of the remaining
heavy metals.
2. Cyanide Destruction:
Blow down from the ISF gas washing system is received into an agitated tank, where the
pH is adjusted with a lime slurry. The pH is maintained at about 8. The effluent is
pumped to a cascade tower prior to which the effluent is chlorinated with a vacuum
ejector chlorine dosing system, at a rate of 0.825 kg/hr. The cyanide decomposes during
aeration in the cascade tower,; the effluent is then pumped to the r treated effluent tank.
The treated effluent is then pumped to the ISF gas washing system at a rate of 10 gm cu.
M/hr. The excess treated effluent is channeled to the evaporation lagoons.
eaction tanks to precipitate heavy metals.
The clarified treated effluent overflowing from the thickener gravitates to a
Cl2 (0.825 kg/hr)
ISF Effluent Cascade Tower
a+b Tank Chlorinator
For Precipitation Cascade

of Heavy Metals Sump Tank
3. Fluoride Precipitation:
Effluent from the gas cleaning plant is the main source of fluoride ion. In order to reduce the
level of fluoride to an acceptable level in final effluent this stream is treated with milk of
lime slurry to precipitate fluoride to 8 mg/l.

The fluoride bearing stream is fed to agitated reaction tank where it is mixed with milk of lime
from the ring main & the pH controlled at approximately neutral (pH 6-8). The resulting gypsum
& calcium fluoride are filtered out on a plate & frame filter pres. A standby press is provided.
The coke is manually discharged &dumped. The filtrate is pumped to the main effluent stream
pH 6.8 Fluoride Reaction Tank

For precipitation of Heavy a Filter Press
Metals
Fluoride Cake & Gypsum
precipitation of HeavyManually Removed
Heavy Metals Removal:
Effluent arising from the following sources are routed to either the primary or secondary reaction
tank :
Sinter plant (Blue Powder Filtrate) Gas Cleaning Copper Recovery, Water Treatment, Boiler
Blow Down (Launder &Power Generation), & Soft Water Circuit.
In addition, intermittent wash-downs from the Acid Plant, Sinter Plant & Raw Material
Handling &Intermittent arising from the Precious Metal Plant.
The reaction vessel also receives the cadmium plant effluent & ISF gas washing effluent
mentioned previously. The majority of heavy metals are precipitated in two reaction tanks by
treatment with lime slurry & continuous agitation at a pH of 8.0& 10.5 respectively in first &
second tank. The effluent & precipitated solids are taken to a 30metre diameter thickener.
The overflow from the thickener gravitates to the third reaction vessel where the pH is adjusted
to 9 by the addition of sulfuric acid (98%w/w). The underflow from the thickener is pumped to a
sludge tank, which also receives cadmium sludge. This vessel is agitated to maintain the solids in
suspension. The liquor in the third reaction vessel precipitates gypsum as the pH is lowered. This
liquor is pumped for final clarification to a thickener where any solids removed are pumped to
the sludge vessel mentioned above.
The sludge collected in the sludge tank is pumped as a slurry, to the Blue Powder Thickener
where it is further thickened & returned to the sinter plant.

Lime Slurry LimeSlurry FeSO4
pH 8 Primary pH 10.5Secondary Heavy Metal

a Reaction Reaction Thickener I
Tank Tank
Overflow
Heavy Metal Tertiary Heavy Metal Overflow for
pH 10.5 I
Thickener pH 9 Reaction Tank pH 9 KK
Thickener Recirculation
245 m3/hr
Underflow Underflow
Sludge Tank
Blue
Cd sluPowder
Thickener
5. Lime Slurry Make-up:
Lime of 80%CaO crude, received in 40 kg bags is transported by hand from the storage area to
the lime mixing tank at a rate about 1.1 tonnes/hr. The bags are split open on a grid over the tank
& mixed with treated recycled effluent water. The lime slurry is pumped via a transfer pump to a
head tank, which supplies two sets of pumps feeding lime slurry (10% w/w) to the cadmium
plant & effluent treatment plant ring mains
Overflow Cd Effluent
a+b+c Cd sludge Thickener
Mixing Tank
Underflow
For
Precipitat
Sludge
ion of
Tank
Heavy
Metal

CHAPTER 10 ISF PLANT
The imperial smelting blast furnace is designed to simultaneously produce molten zinc and lead
by smelting prepared raw materials with preheated coke and preheated blast air.
The prepared, agglomerated raw material (sinter) is fed to the top of a vertical shaft furnace
together with the heated coke. Air is blown into the bottom of the shaft and the chemical reaction
between this air and the coke produces carbon monoxide and generate heat to smelt the metallic
oxide in the charge into the elemental metal. Molten lead falls into the bottom of the furnace
from where it is tapped together with slag of a molten gangue material. At the temperature of
operation, metallic zinc is formed as a vapor and rises up the furnace shaft with the furnace
gases. These zinc containing gases pass through a furnace off take into the condenser containing
molten lead. Here zinc is condensed to a liquid by shock cooling, the gases with a spray of finely
divided droplets of lead generated by rotors immersed in the lead. After absorbing condensed
zinc, this lead is pumped out of the condenser into a adjacent cooling launder where it is cooled
by tube banks immersed in the launder from above. At the end of the launder the zincy lead is
treated with flux and flows into a separation bath where, at the cool temperature of 440 deg cent.,
zinc separates as a molten layer on the top of lead. Zinc continuously overflows via a V- notch
into a adjacent liquation bath whilst the main lead stream passes from the separation bath under
the underflow weir and then into a return launder leading back into the condenser.
The liquation bath is small bath in which any final separation of lead and iron from the zinc can
occur before the zinc overflows to the final holding bath. Here it is allowed to accumulate before
being tapped for casting or further treatment in zinc refinery.
The waste gases leaves the condenser after zinc is condensed from them are passed into a gas
cleaning system where they are cooled and cleaned of particulate matter. These gases contain
carbon monoxide and have a low calorific value. After cleaning calorific value is utilized in
preheating the furnace blast air and in preheating the coke; any remaining excess gases is used in
the site power plant boilers.

Coke
LCV gas
Coke
Preheater
Sinter+Hot Coke
Gas
Cleaning
Section Cowper
Hot Gas
Stove
Zinc Vapour
BP Thickener
In ETP
Imperial
Smelting
Lead
Furnace
Pump Sump
Separ Liquati-
CoolingLaunderng -ation on Bath
Launder Bath
Hot Air Hot Air
Holding
Furnace
Slag to Yard
Force Hearth
Furnace
Furnace Zinc
to ZRP
Lead Bullion
to LRP

FURNACE
The ISF consists of three sections-the upper section ( or furnace shaft) which contains furnace
gases off take, and intermediate section with a shower cooled casing and the lowest section- the
furnace hearth. All three section are joined together to give a gas tight construction in which the
charged is smelted.
The sinter and coke are fed into the shaft though two sets of charging gears situated in the
furnace roof and blast air enters through tuyeres set in the lower portion of shower cooled casing.
Lead and slag are tapped from the furnace hearth and furnace gas and zinc vapor leaves the shaft
through furnace off take which is set in one side above the top level of charge
CONDENSER:
Zinc condenser is essentially a refractory lined steel tank containing molten lead with a gas
above through which furnace off gases are passed. Furnace gas enters the gas space from the
furnace off take and flow through the lead spray in three condensation stages before leaving the
condenser through the vertical off take stack at the rear. The condenser has a shallow inverted
arch refractory floor and a demountable shallow arch roof formed from cast iron and mild steel
tiles. It is divided into three sections by vertical steel baffles to form three distinct condensation
stages. In each stage steel baffles are there to form three distinct condensation stages. In each
stage vertical rotor units are suspended from above with the rotors immersed below the normal
lead level. The rotors are designed to throw the spray of lead droplets into gas space in order to
condense zinc vapor contained in the furnace off takes.
The condenser gas off take is a regular refractory lined stack fitted with internal liner plates. The
gas pass up the stack before leaving through a doubly inclined cross over duct leaving to the gas
washing tower. The off take stack is provided with doors in prder to provide facility for cleaning.
LEAD COOLING AND METAL SEPERATION SYSTEM
Hot lead delivered from the condenser lead pumps is cooled so that dissolved zinc separates as a
second liquid phase and floats of the lead from where it can be removed by physical separation.
Cooled lead reduced in zinc contents is returned to the condenser so that it can condense more
zinc from the furnace gases.
The metal separation system consists of two connected baths between the cooling launder and
the return launder to the condenser, and two baths which form a side stream route for the zinc
output metal.
As lead enters the flux bath about 20 kg per hour of ammonium chloride pellets are added from
the hooper and feeder system. This flux is added to minimize turbulence and the oxidation of
zinc. The lead enters into a section from which it flows out over a submerged baffle, this
arrangement being adopted to ensure that the ammonium chloride is thoroughly mixed into the

lead and that dross is brought to the surface. The flux bath is roofed and the point of flux
addition is hooded for ventilation purpose. Lead flows out of the bath via an underflow weir to
prevent dross carry over to the separation bath.
From the liquation bath zinc overflows to the zinc holding bath which is a surge bath allowing
zinc metal output to accumulate before being tapped into ladles or moulds from transfer to zinc
refinery. This bath also provides a facility for reheating molten zinc to between 480 to 520 deg
cent.which is temperature required for further handling.
At the separation bath, zinc overflows the V-notch and falls into the liquation bath. The purpose
of this small bath is to provide facility for removal of impurity from zinc to maintain the grade of
zinc passing to the zinc refinery. Iron is removed in the hard metal which gradually forms a layer
under the zinc as is cools. Lead carry over and settle in this bath and may be tapped and removed
from time to time for return to cooling launder as lead ingot.
All the baths of the metal separation system are of a refractory lined metal casing construction,
have removable refractory lined roof tiles and are fitted with a burner and cleaning rods. In the
sides of the bath, refractory tapping blocks allow metal to be drained out when required. All
baths are provided with ventilation ducts which passes through the roof tiles and ventilation
hoods are provided over the dross discharge areas.
GAS WASHING PLANT AND LCV DISTRIBUTION SYSTEM
Introduction
The purpose of these systems is to cool the condenser off gas, to remove particulate matter and
to produce and deliver a clean, low calorific value gas suitable for burning in coke preheaters,
cowper stoves and power generation plant. The particulate matter, containing zinc and lead
oxides and other fine particles carries over from the furnace(blue powder) is washed out of the
gas and collects as a slurry for subsequent thickening and return to sinter plant.
Gas cleaning is accompanished by a preliminary cleaning and conditioning operation in a
unpacked co current spray tower, followed by scrubbing in a special high speed irrigated fan
known as disintegrator. Water droplets are then remove from the gas in a cyclonic separation and
the gas pressure is booted for distribution to the gas consumers.
The dirty liquor drains to a dredge tank from which it is collected for pumping to a thickener.
This tank is 15m long and run under the three units, gas washing tower, disintegrator and
moisture separator. It serves both as water seal and as a slurry collection tank for each unit.
LCV GAS DISTRIBUTION
The function of this system is to distribute the cleaned LCV gas from the outlet of the moisture
separator to the three major consumers, or to release from the system via the flare stack at
periods of low consumption.

The gas booster fan is used to control the pressure in zinc condenser and the gas washing system
and to deliver gas at the required pressure into the LCV gas header main for supply to cowper
stoves, the coke preheaters and the boilers of the power generation plant.
DREDGE TANK AND BLUE POWDER DISPOSAL
The dredge tank forms a reception tank for the drain from the component of the gas washing
system, and also acts as a water seal for all the down comers. Scrubbing water drain into the tank
carrying with all solids scrubs from the condenser gas. The heavier solid particles settles to the
bottom of the tank while the major part of the liquor carries away the smaller suspended particles
and flows over a weir on the side of the tank into a line leading to a blue powder pump tank.
At the blue powder slurry pump tank two slurry pumps, one operating and one stand by, pumps
the blue powder suspension onto a high level open launder leading to blue powder thickener.
Pumps also discharge liquor from the blue powder sump and the blue powder slurry tank to the
launder. Lump material from the lump bunker is moved to the sinter plant

CHAPTER 11 ZRP
This Plant is also known as

1) Zinc and Cadmium Refinery
2) Zinc Refluxing Plant
Objective of refining
The I.S.F. zinc is not suitable for zinc’s prime user i.e. galvanizers due to
1) High cadmium percentage
2) Occasional high arsenic
Hence zinc produced from I.S.F. needs a suitable refining to become of economic industrial use.
The process followed in CLZS is by distillation in “new jersey type distillation columns
The Plant
Zinc refinery is situated east of I.S.F. the basic engineering is given by mechim-engineering of
Belgium and process by novellas-godault of France. Main construction is done by TATA DAVY
LTD.
Some Special Features:
1. Since the main refining is done in columns consisting of superimposed silicon-carbide

trays, the trays can’t take thermal shock, so the process can’t be stopped more than 2-3
minutes. Only after the life (2 to 3 yr) of the columns finishes can be stopped. So the
equipments which are responsible for feeding and heating must run 24hr/day.
2. Due to above reasons, there are some conditions before start up. Otherwise huge
expenditure & time will be taken to rebuilt the trays consisting columns.
Properties used in refining metals:

Zn Pb Cd As
Melting point 419.5c 327 320. 616
9
Boiling point 907c 1740 767 815
Specific gravity 7.14 11.40 8.65 5.73
Atomic no. 30 82 48 33
Atomic weight 65.37 207.1 112. 74.92
9 4

Furnace Zinc from ISF

Caustics Sodium
Storage Feeding Soda Nitra
Furnace Furnace
Cadmium
treatment
Furnace
Cadium
Baby Metal
Column 99.99min
Lead
Cadium
Column
Column
SHG Storage
Liquation Furnace Furnace
PW Storage Hard Zinc+Liquid

Furance Lead to ISF Casting Machine
Casting Machine
PW SHG SHG Zinc

Zinc(98.65min) Jumbo99.99min 99.99 min
FLOW CHART OF ZRP

MAIN PROCESS WISE UNITS:
1. I.S.F. ZINC HANDLING UNIT

2. EMERGENCY CASTING UNIT
3. MAIN WORKING UNIT
4. CASTING AREA
5. RECUPERATOR UNIT
6. CADMIUM REFINERY
7. L.P.G. AIR MIXING UNIT
8. OIL HANDLING STATION
9. BLOWER HOUSE AND BURNER
10. FUME EXTRACTION SYSTEM
11. BUILDING VENTILATION
12. STORES
PROCESS DESCRIPTION
The I.S.F. Zinc is feed to the storage f/c through tilting device or by the loading door in form of
1.1T ingots. This Zn by gravity goes to the feeding furnace. In emergency 1 zinc pump is used or
ladles are tilted in the feeding f/c directly. The feeding furnace through the needle valve and float
valve feeds the I.S.F. Zinc to the lead columns in requite amount and temp. The lead columns
which have 59 trays each are having two parts up to the 30th tray. It is having a combustion
chamber around it and is known as the boiling part. The top portion above the 34th tray (feed
tray) is insulated, it is the refluxing part. Only during the start up this top part of lead columns
are electrically heated. If we consider the column erected by superimposition the trays, has got 8
types of trays. The top tray is different as it is connected to the condensers by a mass-rack
(electro-fused silica) cross over the bottom tray, the feed tray, the tray above feed tray. The 30th
tray is having double opening and extra electric coils around it. 33rd tray is having different outer
shape. All the rest trays are of 2 types:
1. flat type: located in the reflux part
2. w-type: located in the bottom part(boiling part)
If we consider the composition of I.S.F. Zn and see the action of combustion chamber which is
having 8 burners in each column drawing 10% of total combustion air from the burner and the
rest 90% preheated air from recuperator, we find that full cadmium, half Zn vaporizes and full
lead and half Zn comes down. The top product is condensed in condensers of each lead column
and then again in hot condition they are fed to cadmium columns. Feed system is same as lead
columns. Here the number of trays are 56 only and 2 columns are there ( rest everything is same
for cadmium columns) . this feed is known as Zn-Cd alloy. The bottom products of lead columns
are collected through sump which has an air lock type overflow system. This is Pb-Zn alloy
having extra lead. This Pb is separated in liquation f/c. some hard Zn also comes and rest Zn
having only the minimum lead comes out as G.O.B. Zinc i.e. good ordinary brand or prime
western (PW) zinc. The top Zn-Cd alloy is separated in cadmium columns. The bottom product
of this is very high grade Zinc known as special high grade zinc (SHG).

The top product after condensation becomes Cd-Zn enriched alloy and is casted in moulds to be
sent to Cd refinery. The SHG & GOB are casted in separate casting m/c.
Main difference between lead and cadmium columns:
1) The feed tray is 34th for lead columns & 36th for cadmium columns.
2) After the 36th tray cadmium columns are having baffles inside the trays.
3) There are no electrical heating systems for cadmium column top portion, it unlike lead
columns behave as condenser also.
4) Total no. of trays for LC is 59 & CC is 56 each.
5) Condenser size is small for cadmium columns.
Both types of columns have attached recuperator system for energy conservation. The I.S.F. Zn
is stored to ensure a constant feed but in case this 1.1T ingot stock fails, we have recirculation
facility of GOB zinc through 4T shaft way using one demag monorail hoist. 0.5T shaft way is
also there for bringing ingots to the top floor. Weighing m/c is used to weigh the ingots before
charging. Some Zinc from cadmium refinery comes in form of 0.5T ingots to be melted in
storage f/c. the lead from liq. f/c is sent to lead refinery and hard zinc to I.S.F.. All other dross is
also sent back to I.S.F.
PROCESS PARAMETERS
A) Storage furnace
1. bath area: 18 square meter

2. free metal: 70 T
3. fixed metal: 40T
4. total metal: 110T
5. metal content: I.S.F. Zinc
6. metal flow: 286T/Day (same as feed)
208T/Day (when ingots are used)
7. metal feeding temp.: 480 – 520^c
8. bath temp.: 550
9. burners each of: 400000 kcal/h
(Triple fired i.e. L.D.O/LSHS/LPG)

B) Feeding furnace
1. bath area: 6.6 square meter

2. metal flow: 286T/day
3. metal content: I.S.F. Zn
4. metal feeding temp.: 550
5. bath temp.: 55-670
6. feeding quantity: 282T/day
7. burners one of: 600000 kcal/h
B) Lead columns(LC,LC2,LC3,LC6)
1. combustion chamber: 14 square meter

3. top flow (vapors): 38T/day
4. bottom flow: 57T/day
5. top outlet temp.: 850/950
6. incoming temp.: 550/670
7. bottom outlet temp.: 750/850
8. condenser capacity: 1square meter/ton of Zn condensed
(Natural induced air type)
9. expected life: 2.5 yrs
10. burners 8 each: 250000kcal/h
(Triple fired)
C) Cadmium columns (CC4 & CC5)

1. metal flow: 57.5T/day
2. metal content: top: Zn-Cd alloy enriched
Bottom: SHG Zn
Feed: Cd-Zn alloy
3. top outlet flow: 2.5-3T/DAY
4. bottom outlet flow: 54.5-55T/day
5. top outlet temp.: 850/950
6. bottom outlet temp.: 750/850T/day
7. incoming feed temp: 550/670T/day
8. combustion chamber: 14 cubic meter
9. burners (triple fired): 8 no. each 200000kcal/h

D) Liquation furnace:
2. free metal capacity: 103T
3. minimum metal capacity: 25T
5. metal content: Pb-Zn alloy
6. metal feeding temp.: 430/450
7. bath temp.(reheating part): 480/540
8. burners each having: 200000kcal/h
E) GOB holding f/c:

1. bath area: 26 square meter
3. minimum metal capacity: 25T
4. metal capacity(total): 128T
6. metal content: GOB Zn
8. bath temp.: 475/540
9. burners(2 no.): 400000kcal/h
F) SHG holding furnace:

3. fixed metal capacity: 17T
4. total metal capacity: 88T
5. metal flow input: 120T/day
6. metal content: SHG Zn
8. bath temp.: 475/540
9. metal flow(outlet): 120T/day24h/day
10. burners (2 no.): 400000kcal/hr

CHAPTER 12 LRP
OPERATION IN LEAD REFINERY
Lead refinery can be subdivided into two sub sections for ease of understanding
1. Copper drossing area
2. MTM Refined lead production area
COPPER DROSSING AREA
In this area the copper is removed from ISF bullion in two stages.
The area consists of five kettles, each of 100 MT capacities, out of which two are enmarked
for first stage of copper drossing, or hot drossing and others are used for second stage of
copper remove, or cold drossing. In fifth kettle, lead bullion from the Ausmelt Plant is
charged.
HOT DROSSING
ISF lead ladle is received in lead refinery by means of 15/8 MT E.O.T. crane. The ladle is
placed on a hydraulically operated ladle tipper which raises the ladle to pour molten lead into
hot drossing kettle. The kettles are provided with hoods with opening for stirrer and
dedrosser. The hot drossing kettle is filled up to capacity and temperature of the bath is
brought down to 450 deg. Cent with the stirrer running. As the temperature goes down,
solubility of copper in lead decreases resulting in separation copper from the bath. The
copper so separated forms a dross on the surface of the bath owing to its high melting point
and low specific gravity then the bath. A little quantity of saw dust is added into the bath to
make the dross dry. The dross is then removed from the kettle by means of a mechanical
dedrosser and is taken into skips. The copper dross is then transferred to copper recovery
plant for recovery of copper.
COLD DROSSING
The bath is then transferred to either of the two cold drossing kettles. Here temperature is
brought down to 330 deg cent and a calculated amount of sulphur is added depending upon
copper content of the bath. Sulphur reacts with copper to form copper sulphide which floats
on the surface of the bath. This dross is removed manually into skips and is recharged into
hot drossing kettle. Copper after cold drossing is around 200 gpt. The Decopperised lead is
then transferred to MTM refined lead production area for further treatment.

LEAD\SILVER REFINARY FLOW CHART
SawDust Sulphar Copper Drossing Copper DrossCRP CuSO4 Soln
De-Arsenic ArsenicDrossto
Caustic Soda Sinter Plant
De-silversitation Zn-AgCrust
Z
in
c
VaccumDe-zincing Liquation Furance

Z
in
c
w
d
eG
ra
o
L
Caustic Soda AntimonyRemoval Vaccum Retort Furance

Sodium Nitrate
Final Refining Oxygen

BBOC
Antimony Nitrogen
Dross
CastingMachine Pyro Ag
(98.5%min.)
RefinedLead
>99.99%

MTM REFINED LEAD PRODUCTION AREA
DEARSENATING
Decopperised bullion is received in 150 MT capacity dearsenating kettles via a transfer pipe. The
temperature of the bath si raised to 459 deg cent and 100 kg of caustic soda is added and which
react to form sodium arsenate and which in the form of dross floats over the surface of the bath.
Once dross is formed, it is removed by mechanical deedrosser into skips. The dross is then sent
for treatment into rotary furnace. Dearsenate bath is pumped into desilverization kettle.
DESILVERIZATION
Desilverization is carried out in two stages, each kettle of 180 MT capacities.
Dearsenated lead is received into first stage desilverization kettle at 450 deg cent. The kettle has
a lead of Pb-Zn-Ag alloy from the previous charge. Poor silver zinc crust from previous batch of
second stage of desilverization and low grade metal from liquation kettle in silver recovery area
are added into this bath. The bath is thoroughly homogenized with the help of a mixer. Zinc and
silver present in the bath forms intermetallic compound which floats on the surface of the bath in
the form of crust. The crust, called rich crust is skimmed of f by means of perforated crane
skimmer and cast into moulds for treatment in silver refinery. Once crust have been removed a
calculated amount of zinc is added to the bath depending upon its silver content, zinc is melted,
bath is homogenized and the bath is pumped into second stage desilverization little. When the
bath is received into second stage de-Ag kettle the little already contains a crust bridge across the
kettle with the central opening in it. Upon receiving the metal, thorough mixing is done and the
crust bridge is homogenized with the bath. At 450 deg cent again a crust formation is there e
which is lean is silver. The crust is skimmed off into the moulds for charging into De-Ag first
stage kettle in succeeding charge. After removal of crust bath is allowed to cool with central
mixer running at very slow speed. As the bath cools down, solubility of bath zinc and silver
comes down and these elements separate from the bath and come to the top in the form of crust.
As the crust melting point is higher then the bath, the crust solidify over the bath. The kettle is
cooled to 325 deg cent, at this temperature mixture is removed and the pump is placed in the
central opening of the solidify crust and the bath is transferred to next kettle for dezincing.
VACUUM DEZINCING
This kettle is of 150 MT capacities and has a water cooled rim over it. In this kettle temperature
is raised to 590 deg cent and a vacuum dome is placed over the kettle. On the underneath of the
dome there is a solid rubber ring which sits over water cooled rim to make the system vacuum
proof. For dezincing vacuum pump is started. At this vacuum zinc in the bath get vaporized and
get deposited over the bottom of the water cooled dome. The operation is carried over in two

stages of four hours each. At the end of the operation the dome is lifted away and zinc deposited
is scrapped off. The dezinced bath is then transferred to first stage.
SOFTENING
The dezinced bath is received in 150 MT capacities for the removal of antimony. The removal of
antimony is cooled softening. Here in addition to antimony residual zinc, arsenic etc are also
removed.
In this kettle caustic soda and sodium nitrate are added at a temperature of 440 deg cent. All the
impurities get oxidized and floats in the form of dross. This dross is removed by mechanical
dedrosser and sent for the treatment in rotary furnace. Then this lead is transferred for casting. In
casting condenser kettles are there in which lead condenses. Condenser lead is consumed by ISF
plant.

The Imperial Smelting Furnace used in the production of lead and zinc produces by-product
drosses from the ISF bullion floor which are rich in copper and lead. These drosses are treated in
copper recovery plant by a process developed by Imperial Smelting Processes Limited. Drosses
receiver from the copper drossing kettles are ground and screened and over sized material which
are predominantly lead, returned to kettles.
The drosses are treated in a stirred batch leach reactor by an aerated of ammonia liquor and
carbon dioxide. Copper is dissolved and removed as cupra ammonium carbonate. After leaching,
the slurry is filtered in a filter press and the leachant passed to leachant tank. Lead is present as a
mixture of lead oxide and lead carbonate in the filter cake, the lead content being approximately
70% on a dry weight bases. The filter cake is slurried and returned as approx 50 % w/w slurry to
the sinter plant.
Leachant is further filtered before treatment by solvent extraction to recover the copper. Copper
is extracted with LIX 54, a copper specific diketone liquid ion exchange reagent in hydrocarbon
diluents, in two stages of mixture settler. The depleted aqueous phase or raffinate, containing
approx 1.5 g/l copper recycled to leaching circuit for reuse in leach reactor.
The loaded organic is washed with dilute sulphuric acid to remove impurities before being
stripes with depleted electrolyte to remove copper. The copper enriched strong electrolyte passes
to electro winning section in which cathode copper is produced by electrolysis of the acid copper
sulphate solution.
SOME PARAMETER OF MILLING:
Temperature of feed 70 deg cent (max)

Temperature of product 60 deg cent (max)
Size of feed 80 % - 5 mm
Product size 80 % - 75 micron
Ball mill capacity 2 tonnes per hour
Mill running time 15 hrs/day
DROSS MILLING:
The function of dross milling circuit is to grind back hoe dross to 80 % finer than 75 micron.
Simultaneously as much metallic lead as possible is rejected to return to drossing kettle. Dross is
received as back hoe dross for milling and also as fine dross from the drossing section bag house.
GRINDING CIRCUIT
The mill is a hardinge conical ball mill, air swept in close circuit with double cone separator and
vibrating screen. The mill has an overflow discharge into an air stream,. Coarse metallic fails to
be transported by the air stream and will drop out into a drag link conveyer.
The ground material carried up by the air stream is classified in the double cone separator. The
coarse fraction is screened on a double deck vibrating screen. Coarse dross is recycled to the mill
through a air lock. The cyclone overflow returns with the main air stream to the mill. The
cyclone underflow forms part of the ground dross product. A bleed form the exhauster fan
delivery is fed to the mill bag filter. Dust recovered from this unit is also fed to the ground dross

product. The mill feed is controlled automatically to maintain the correct mill load by an audio
signal from the mill.
FINE DROSS HANDELING

All fine dross, consisting of ground dross, bag house dross and dross from the hygiene bag filter,
is also fed to the ground dross storage bin. Ground dross and hygiene bag filter dross are fed
directly into the ground dross bin. Dross is discharged from the ground dross bin by a rotator
feeder into a bell hooper resting on a rail mounter trolley. A forced seal is made to prevent egress
dust during loading. The rotatory wall is operated by a timer to enable a reasonable consistent
volume of dross to be loaded into the bell hooper. The bell hooper is pulled clear of the storage
bin by a winch. The copper leach crane, fitted with a crane weigher, is used to transport the bell
hopper in between the dross milling section and leach reactor. Nine transfers of fine dross to the
leaching section are done per day. The copper recovery plant is divided into following plant area
Area K2 Dross Milling

Area K3 Leaching
Area K5 Solvent Extraction
Area K6 Electro winning
Area K3 Leaching
The leach reactor extracts copper from the dross produce in decopperising kettle. In leaching fine
dross is leached with CO2, H2O and ammonia to form cupra ammonia carbonate which contain
copper approx 10 gpl
The designed criteria:

Dross treated 9369 t/a
Copper production 2100 t/a
Copper content in dross 32.2 %
Leach efficiency 90 %
Batch leach time 4 hrs approx.
Batch dross quantity 3.25 t
Leaches per day 9
A typical feed stock dry analysis
Copper 32.3 %
Lead 50 %
Zinc 3.5 %
Arsenic 1.3 %
Antimony 2.4 %
Tin 0.3 %
Silver 0.1 %
Bismuth 0.025 %
Gold 7.25 g/t
Sulphur 1.3 %

Copper is extracted by reaction with raffinate (ammonia carbonate solution) returned from
solvent extraction plant.
A typical raffinate analysis is:
Copper 1.5 g/l
Ammonia 30 g/l approx
Carbon dioxide 20-30 g/l
Ammonia Recovery
It is essential for environmental, health and economic factors to minimize the loss of ammonia
and maximize the recovery for reuse in the process.
The ammonia recovery plant:
1. Provide ventilation for all areas in which ammonia bearing solution are handled
2. Recovers ammonia from the ventilation gases by scrubbing.
3. Recovers ammonia from the wash section for recycling
4. Produce an effluent suitable for disposal to the site effluent facility
5. Maintain in plant conditions below the TLV.
All ammonia bearing gas stream are scrubbed with water to produce a acceptable stack
discharge. The mildly ammoniacal water is then used for the final washing of the filter cake
before passing to the wash storage tank.
Ammonia bearing gases are streamed are scrubbed with water to produce a stack discharge not
greater than 25 ppm ammonia. Absorber water is used for the final washing of the filter cake in
order to maximize the water utilization.
All the ammonia bearing liquid streams, including bleed stream from the LIX wash and
electrolyte circuit are collected in the wash storage tank. The composite wash is treated by the
solvent extraction to remove any copper present prior to neutralization with caustic soda in the
caustic soda treatment tower where the pH is raised to 11 to liberate ammonia.
Solvent Extraction
The solvent extraction plant process 12.5 m3/hr of leachate (cupra ammonium carbonate
solution) containing approximately 30 gm/l Cu+2. Copper is transferred from the leachate to the
barren electrolyte by proprietary copper specific ion exchange reagent LIX 54 diluted with
Escaid 100 ion exchange diluents.
A typical leachate analysis is :
Copper 30 g/l
Ammonia 30 g/l
Carbon dioxide 23-30 g/l

APPLICATIONS OF Zn , Pb AND PRINCIPAL BY PRODUCTS
Some of the common uses of these metals are given below:
ZINC: The main uses of Zn are in galvanizing for protection of steel against corrosion, alloy
making (brass, bronze and bearing metals) dry cell batteries, die castings for automobiles parts,
business machines & toys. Oxides & sulphides of Zinc are widely used in paints &rubber
industries. Zinc dust is used for metal coating &as reducing agent for many chemical processes.
Zinc sulphate is used as an important micronutrient for soils.
LEAD: The main uses of lead are for storage batteries in transportation, ammunition, in defense,
lead protection for cables, chemical equipment, pigments &paints. Lead is also used in bearing
& soldering alloys, type metals, fusible alloys, in sound & vibration insulations, shield against
X-ray & nuclear radiations & as ballast weight.
CADMIUM: Cadmium is used for pigments, electro-plating steel for improved corrosion
resistance, solders, brazing &bearing alloys, rechargeable batteries &nuclear control rods. It is
also used for plastic stabilizers and semiconductor materials.
SILVER: The important industrial uses of silver are in photography, electrical switches,
batteries, stabilizers & in bearing alloys .Silver is extensively used for jewelry & coinage.
TUNGSTEN: Tungsten has become indispensable in strategic & industrial uses particularly in
defense armaments. It is mainly used in tungsten carbide tools, electrical bulbs &other electronic
applications, alloy making, chemical etc.
COBALT: It is used in manufacture of magnets, high speed steel & as a binding agent for the
manufacture of cutting tools, mining drills etc. This metal is also used in super alloys for
industrial &air-craft gas turbine engines. Its non-metallic applications are pigment in paints,
ground coat in porcelain enameling, and coloring agent in glass & essential ingredient in some
catalysts.
SULPHURIC ACID: It is a basic chemical required for manufacture of chemicals & fertilizers.
PHOSPHORIC ACID: It is mainly used in the manufacture of complex phosphatic fertilizers,

detergent, food preservatives & as pickling agent.
These metals have amazingly wide spread use in our day to day life also. Be it a ball point pen or
a fountain pen, a small tea-spoon to a big water heating boiler & all other utensils for boiling &
cooking , dry cells for torches , radio transistors, tape recorders, calculators, watches & many
other electrical & electronic gadgets ; wet batteries for cars & other automobiles, G.I. sheets ,
pipes, pesticides , fertilizers & many other things which come into use in our daily life, have zinc
&lead component or their alloys along with other metals.

MISCELLANEOUS PICTURES OF PLANT
FINISHED BRICK OF ZINC

CAM FOLLOWER MECHANISM
CONVEYOR AT ZRP PACKAGED ZINC READY TO SELL

TOPPLER MACHINE TO TOPPLE RAIL BOGIES

HZL Chanderiya Pyro Training Report

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Kunal Gupta M.B.M.

Engineering College, Jodhpur

LOCATION OF HZL PLANTS IN INDIA

M.B.M. Engineering College, Jodhpur 1

Continuous operational improvements, meticulous planning, constant innovation, extensive

HZL is a vertically integrated Mining & Smelting company, gearing up to:

M.B.M. Engineering College, Jodhpur 2

HINDUSTAN ZINC (CHANDERIYA PLANT)

Location: 120km east of Udaipur, Rajasthan

Capacity: 669,000 tpa of refined Zinc

PRODUCTS CAPACITY (TPA)

REFINED ZINC 70000

M.B.M. Engineering College, Jodhpur 3

CHAPTER 2 SAFETY DEPARTMENT

The main reasons for accidents in form of unwanted acts are:

Some unsafe conditions which motivate accidents are:

M.B.M. Engineering College, Jodhpur 4

CHAPTER 3 ABBREVATIONS USED

ABBREVATION: FULL NAME:

M.B.M. Engineering College, Jodhpur 5

CHAPTER 4 LIST OF FLOW CHARTS

FIG NO: FIG NAME:

M.B.M. Engineering College, Jodhpur 6

CHAPTER 5 LIST OF TABLES

TABLE: TABLE NAME:

M.B.M. Engineering College, Jodhpur 7

CHAPTERS 6 LIST OF DIAGRAMS

M.B.M. Engineering College, Jodhpur 8

SOURCES OF RAW MATERIALS

(A) Mines in Operation :

3. Maton Rock Phosphate Mine(Udaipur) :

4.Rampura Agucha Mining Complex:

5. Sargipali Mine (Orissa)

6. Agnigundala Lead Mine (Guntur, A.P.)

(B) Smelters in Operation :

M.B.M. Engineering College, Jodhpur 9

CHAPTER 7 PYRO PLANT

PYRO METALLURGY HYDRO METALLURGY

IMPERIL SMELTING LEACHING

M.B.M. Engineering College, Jodhpur 10

S u lp h u r C opper L ead R e fin e d

PROCESS FLOW DIAGRAM PYRO PLANT

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CHAPTER 8 SINTER PLANT

EXTERIOR VIEW OF SINTER PLANT

M.B.M. Engineering College, Jodhpur 12

Corrugate Classifier Spike

PROCESS FLOW CHART OF SINTER PLANT

M.B.M. Engineering College, Jodhpur 13

The sinter plant has following main sections:

1. RMH (Raw Material Handling):

M.B.M. Engineering College, Jodhpur 14

2. Charge Proportioning and Conditioning System:

6 for Zinc concentrate (cap.→50 cu.m.)

The feed basically contains:

M.B.M. Engineering College, Jodhpur 15

input Mixing drum discharge

The specifications of drive gearbox are-

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Heat drawn from bottom

IGNITION LAYER IN BINS

LAYER FORMATION IN BINS