Extraction of zinc

Presented By:-
Patel Ashik (170130121032)
Patel Manan (170130121038)
Patel Umang (170130121039)
Patel Yash (170130121040)
Pipalva Manthan (170130121041)

Metallurgy Engineering
Government Engineering College
Sec- 28, Gandhinagar.
Topics To be covered…
 Introduction
• General.
• Sources of Zinc.
• Properties of Zinc.
• Applications
 Extraction of Zinc
• Pyro-Metallurgical Extraction process.
• Hydro-Metallurgical Extraction process.
• Imperial Smelting Process.
 Production of Zinc in India
 Global Trends of Zinc
 Introduction
Introduction
• Zinc is a chemical element with the symbol Zn.
• Atomic number 30.
• It is 1st element of group 12 of the periodic table.
• Appearance:- silver-gray
• Zinc is slightly brittle at room temperature.
• Discovery:- Indian Metallurgist (Before 1000 B.C.)
• Crystal structure:- Hexagonal close-packed (H.C.P)
• Magnetic type:- diamagnetic
Sr No Ore Name Chemical Image Physical
Composition Appearance

1) Sphalerite Zns Streak:-brownish

white, pale yellow

2) Zincite Zno Streak:-Yellowish

orange

3) Calamine Zn2(OH)2Sio3 Streak :- brownish

4) Smithstone Znco3 Streak :- White

5) Franklinite Zno(Fe,Mn)2O3 Streak :- black

 Properties Of Zinc
• Density :- 7.10 g/cm3
• Tensile Strength :- 37 MPa
• Modulus of elasticity :- 96.5 GPa
• Hardness(VHN) :- 30
• Thermal Conductivity :- 112.2 W/mK
• Melting point:- 692.68 K ​(419.53 °C, ​787.15 °F)
• Boiling point:- 1180 K ​(907 °C, ​1665 °F)
• It exhibits good malleability and ductility at higher temperatures.
• Zinc is fair conductor of electricity.
 Applications
• Galvanization of iron
• Architectural
• Automotive
• Cathode in batteries
• Toys
• Pigments, activator and catalyst
• Pharmaceuticals
• Brass, bronze and other alloys
 Extraction of Zinc
• Zinc ores are often low grade.
• Both pyro metallurgical and hydrometallurgical techniques are currently being
employed in extraction of zinc.
• Pyro metallurgical route is best suited for very high grade ores.

Processes of Zinc Extraction

Name of Process Year of commercial adoption
 Horizontal Retort  1800
 Vertical retort  1930
 Electrothermic  1936
 Electrolytic  1915
 Imperial Smelting  1950
• The principal processes by which zinc is extracted from its ores can be
categorized under pyro metallurgical processes and hydrometallurgical
processes.

Pyro-metallurgical processes Hydro-metallurgical processes

 Horizontal Retort  Roasting , Leaching , Electro winning
 Vertical retort  Pressure Leaching
 Electro-Thermal  Electrolytic
 Imperial smelting

Presently about 15 – 20%of the world’s zinc production comes from

Pyro-metallurgical route.
Extraction of Zinc by Reduction of ZnO by carbon
Ore
Retort Residue
Grinding Coke Distillation, (Pb, Fe, Cu)
Rock, Pb, Cu Concentrates 1200-1400℃
Flotation

Zn Vapour Zno Powder

Zn Concentrate (50-60% Zn)

Roasting (800℃) 𝑆𝑂2 , Pb, Cd Condenser (450℃)

Zn Calcine (1-4% S) Liquid Zn

Sintering, Vacuum Distillation

Pb, Cd , 𝑆𝑂2 Pb, Cd
1200-1400℃

ZnO Agglomerate Pure Zn

Zns + 1.5𝑂2 ZnO + SO2
ZnO + CO Zn(g) + CO2
 Difference between vertical and horizontal retort reduction

• Vertical retorts are usually made • Horizontal retort are usually

of silicon carbide. made of clay.
• Vertical retort can yield 7-10 • Horizontal retort can yield 50 kg
tons of Zinc per day. of Zinc per day.
Hydrometallurgical Extraction Process For Zinc
is based on Following scheme
• Dissolution of the Zinc calcine in sulphuric acid.
• Precipitation of cadmium by adding Zinc dust to the leach solution, i.e.
Cementation.(some Co and Cu are also removed.)
• Precipitation of Cobalt from leach solution by adding α -nitroso- Β -naphthol.
• Adjustment of the pH of the leach solution to about 5.3 to hydrolyze Al and Fe
and addition of MnO2 to oxidize Fe trivalent state.
• Electrolysis of the purified leach solution using a cell with a Pb-Ag anode and Al
cathode.
 Hydro-Metallurgical Extraction of Zinc
Concentrate

α-nitroso Filtrate
Roasting (800℃) Precipitate
Β-napthol
(mainly Cd)

Calcination Cd Recovery
Precipitated Solution
Underflow for cobalt
recovery of Mixing 𝐻2 𝑆𝑂4
precious metals Cd
Electrolysis

Overflow

Cementation Zn Dust 𝐻2 𝑆𝑂4 Zinc ( 99.95%)

(recirculation)

Filtration
Imperial smelting process (ISP)
• Contribution in total Zinc Production :
Currently about 8-10% of the world’s primary Zinc production are through
the imperial smelting process(ISP).

• Working :
The ISP is similar to blast furnace process except that it is operated with
hot top whereby preventing reoxidation of Zinc vapors. The Process
consists of basic 2 operations namely ; sintering and blast furnace smelting
of sintered lumps to extract lead and zinc simultaneously.

• Reaction:
C + 0.5O2 = CO
C + O2 = CO2
CO2 + C = 2CO
ZnO + CO = Zn + CO2
 Merits of ISP
• It is possible to simultaneously smelt low grade complex mixed
charges of Zinc and lead ores and concentrates in order to recover
both Zinc and lead.
• Since the overall efficiency is higher, the recovery of Zinc becomes
less expensive.
• A wide variety of furnace sizes are available, the trend being
towards units with larger capacities at lower operational costs.
• The furnace function is fully automated.
• The mechanism is highly robust.
 Demerits of ISP
• Labor intensive process.
• Process requires mix of Zinc and lead concentrates.
• It is present demand scenario does not call for addition of
lead smelting capacity in the country.
• Because of high temperature involved in maintainability of
the plant.
• Low plant availability.
Ore Treatment in Debari Hydro-metallurgical process of zinc
This process involves the following
basic steps:-
• The treatment of ores to obtain a
concentrate rich in zinc.
• The roasting of the concentrates to
convert the zinc into a soluble form.
• The treatment of the roasted
concentrates to form a zinc sulphate
solution.
• The purification of the zinc sulphate
solution by precipitation of impurities.
• The removal of zinc from the purified
solution by electrolysis.
• The melting of zinc sheets to form
ingots.
Global Trends of Zinc
Top zinc output countries 2014
Rank Country Tonnes
1 China 5,000,000
2 Australia 1,500,000
3 Peru 1,300,000
4 India 820,000
5 United States 700,000
6 Mexico 700,000

Percentage of zinc output in 2006 by countries

 Major Mines of Zinc in India
Mine Ore Capacity (Million
Tonnes per Year)
Zawar Mines, Zinc – Lead 1.20
District Udaipur
Rajasthan Two major industries of Zinc in India
Rajpura – Dariba, Zinc – Lead 0.90  Hindustan Zinc Limited
District Rajsamand, (Rajasthan)
Rajasthan • Capacity:- 45,000 Tonnes
Sindesar – Khurad Zinc – Lead 3.00  Cominco-Binani (Kerala)
Mine, • Capacity:- 20,000 Tonnes
District Rajsamand,
Rajasthan
Rampura – Agucha, Zinc – Lead 6.15
District Bhilwara,
Rajasthan
Kayad Zinc - Lead 1.00
District Ajmer,
Rajasthan