Zinc Direct Leaching
August 27, 2008
Bjrn Saxn
2
Leaching
A key step in the production chain of
zinc metal
Zinc from solid particles is dissolved in
a liquid
Zinc
ore Leaching
Metallic
zinc
Zind Direct Leaching, August 27, 2008
3
Two options for Zinc
treatment of Zinc concentrate
concentrate
SO2
H2SO4 Roasting
plant
Direct Elemental
Calcine leaching sulphur
Sulphuric Acid leaching
Iron removal
Solution
purification
Electrowinning Metallic
Zind Direct Leaching, August 27, 2008
zinc
4
Why atmospheric direct leaching?
It is proven and available technology for zinc production with
excellent performance
It gives a possibility to increase the capacity in small steps and a
possibility to avoid production of additional sulphuric acid
It is an economical and practical way to start zinc production and to
avoid roaster investment
Combined with a roaster plant, the direct leaching process enables
the zinc producer to use a wider selection of raw materials or
specially difficult or low-grade raw materials
Very flexible technology for different iron precipitation processes
Compared to pressure leaching
Low operation costs with reliable operation
Low need for maintenance
Zind Direct Leaching, August 27, 2008
5
Reference list of Outotec atmospheric direct
leaching
Company Country Capacity Start up year
t/y
New Boliden Finland 50.000 1998
New Boliden Finland 50.000 2001
New Boliden Norway 50.000 2004
Zhuzhou Smelter China 130.000 2008
Zind Direct Leaching, August 27, 2008
6
Kokkola zinc plant, Finland
Currently the worlds fifth largest zinc producer
One of the most cost-efficient plants in the world
by Outotec technology
Transferred from Outokumpu to New Boliden
Jan. 2004
Annual production capacity 300 000 t Zinc
The Kokkola zinc plant
employs 640 people.
Zind Direct Leaching, August 27, 2008
7
Odda zinc plant, Norway
Outokumpu acquired Norzink AS in Q2 2001.
Norzink is one of the worlds most profitable and
cost-efficient zinc producers by Outotec
technology.
Transferred from Outokumpu to New Boliden
Jan. 2004
Annual production capacity:
150 000 t Zinc
The Odda plant employs
350 people.
Zind Direct Leaching, August 27, 2008
8
Calcine
Spent MnO2
Neutral leaching
Flocculant Pre-neutralization
NEUTRAL
Flocculant
Neutral leaching
SOLUTION
thickener Pre-neutralisation
thickener
Integration Na 2SO 4
of direct Hot acid leaching Zinc
concentrate MnO 2
leaching to
Jarosite precipitation
Flocculant
Flocculant
an existing
HAL Thickener
Concentrate Jarosite
Oxygen
pulping thickener
H2SO 4
zinc Super hot acid
leaching Direct concentrate
leaching
Flocculant
Water
production Flocculant
Pb/Ag thickener
Leach
residue Belt filter
process Water
Flotation
Jarosite cake
Belt filter
Elemental
sulphur
Lead-Silver cake
Zind Direct Leaching, August 27, 2008
9
Direct Leaching Area Layout View
Concentrate Low Acid Leach High Acid Leach
Slurrying Reactors (4 pcs) Reactors (4 pcs)
Reactors
Slurry
(2 pcs)
Thickener
(Grinding)
Outotec
TankCell
System
(Flotation)
Low
Zind Acid Leach
Direct Leaching, August 27, Thickener
2008 High Acid Leach Thickener
10
Outotec atmospheric direct leaching reactors
installed in Odda, Norway
Zind Direct Leaching, August 27, 2008
11
Schematic Presentation of Flows in Direct
Leaching Reactor
Efficient
mixing
Low power
consumption
Good
oxygen
dispersion
Oxygen
Zind Direct Leaching, August 27, 2008
12
Raw materials
The atmospheric direct leaching process is
highly flexible for various zinc raw materials
Laboratory tests with excellent leaching
results with
Zinc content 8 60 %
Iron content 1 - 23 %
Carbon 16,5 %
SiO2 15 %
Copper 0,003 4,6 %
Carbonate 16 %
Zind Direct Leaching, August 27, 2008
13
Zinc recovery is a function of
Concentrate composition, mineralogy, particle size
Temperature, acidity, iron content
Oxidation of iron (= Performance of the reactor)
Retention time 100
90
Recoveries 80
Recovery / %
in leaching 70
tests of
60
different
concentrates 50
40
0 6 12 18 24
Time / h
Zind Direct Leaching, August 27, 2008
14
Recovery %
90
91
92
93
94
95
96
97
98
99
100
1.7.1998
30.9.1998
30.12.1998
1.4.1999
Zind Direct Leaching, August 27, 2008
Kokkola plant
1.7.1999
30.9.1999
31.12.1999
31.3.2000
1.7.2000
30.9.2000
30.12.2000
1.4.2001
1.7.2001
30.9.2001
31.12.2001
1.4.2002
2.7.2002
1.10.2002
31.12.2002
2.4.2003
2.7.2003
1.10.2003
Zn extraction recovery in direct leaching at
15
Benefits of atmospheric direct leaching plant
Simple reactor construction,
reduced maintenance costs
Easy process control (acidity
and iron control)
No scale build-up problems
Very flexible process, which
allows various methods for iron
removal
High Zn recovery
Low power consumption
High plant availability
Little or no heating needed
Low investment
No explosion risk
No molten sulphur
No SO2 emission
Zind Direct Leaching, August 27, 2008
