PbZn 2020: The 9th International Symposium on Lead and Zinc Processing: Primary Zinc II
Sponsored by: The Mining and Materails Processing Institute of Japan, Nonferrous Metals Society of China, GDMB: The Society for Mining, Metallurgy Resourcce and Environmental Technology, Metallurgy & Materials Society of the Canadian Institute of Mining, Metallurgy & Petroleum, TMS Extraction and Processing Division, TMS: Hydrometallurgy and Electrometallurgy Committee, TMS: Process Technology and Modeling Committee, TMS: Pyrometallurgy Committee, TMS: Recycling and Environmental Technologies Committee
Program Organizers: Andreas Siegmund, LanMetCon LLC; Shafiq Alam, University of Saskatchewan; Joseph Grogan, Gopher Resource; Ulrich Kerney, Recylex; Cheng Liu, China Enfi Engineering Corporation; Etsuro Shibata, Tohoku University
Tuesday 11:00 AM
February 25, 2020
Room: 15A
Location: San Diego Convention Ctr
Session Chair: Andreas Siegmund, LanMetCon LLC
11:00 AM
Resource Efficiency Evaluation of Pyrometallurgical Solutions to Minimize Iron-rich Residues in the Roast-leach-electrowinning Process: Alejandro Abadias Llamas1; Neill Bartie2; Magdalena Heibeck2; Michael Stelter1; Markus Reuter2; 1TU Bergakademie Freiberg; 2Helmholtz Institute Freiberg for Resource Technology
The Roast-Leach-Electrowinning process generates considerable quantities of iron-rich precipitates that must be landfilled, potentially causing a problem for the zinc smelters as well as negatively affecting society and the environment. The integration of pyrometallurgical flowsheets into existing Roast-Leach-Electrowinning plants is evaluated in this paper. Ten different cases, including Direct Zinc Smelting, ferrite fuming or pyrometallurgical treatment of iron-rich residue, are assessed to find the most resource efficient and environmentally friendly solution to minimize the hydrometallurgical precipitates of the electrolytic process for the zinc production. The simulation-based methodology used provides indicators to evaluate the material recovery and losses, residue production, resource consumption, exergy destruction and environmental impacts, which are used to find the best alternative that improves the resource efficiency and the environmental impact of the Roast-Leach-Electrowinning process. Furthermore, the social, environmental and economic impacts associated to the different alternatives are discussed based on the indicators provided by the simulation.
11:20 AM
Zinc Plant Expansion and Modification for Increased Metals Recovery: Björn Saxen1; Florentino Estrada2; Maciej Wrobel1; Marko Lahtinen1; 1Outotec; 2Met-Mex Peñoles
Met-Mex Peñoles recently increased its zinc production capacity by 120000 ton per annum at Torreón plant in Mexico. The expansion was based on Outotec atmospheric direct concentrate leaching (DL) technology integrated to the calcine leaching circuit. Also new solution purification and electrowinning sections were added for the increased capacity. As a continuation to the expansion, there is an ongoing project aiming at improving recovery of silver and lead by new flowsheet modifications and technology from Outotec. A pure jarosite process minimizing metal losses to iron residue will be introduced in the leaching circuit. Sulfur cake from iron reduction step of pure jarosite process will be recycled to the fluidized bed roasting through a new feed pre-treatment system (FPS). Expected additional benefits of PFS are reduced dust entrainment and more homogeneous temperature distribution in roaster. This paper presents results and observations from the DL expansion and describes the new flowsheet.
11:40 AM
Experience with Digital Process Optimization of Zinc Roasting Plants: Robert Schiemann1; Steffen Haus1; Marcus Runkel1; Jörg Hammerschmidt1; 1Outotec
Operation of today’s zinc roasting plants is becoming more and more challenging due to declining concentrate qualities. This results in unstable process conditions in the furnace of the roasting plant which can harm product quality. Operating a zinc roasting furnace in desirable operating conditions is subject to many factors such as feed, air as oxygen flow as well as water addition at different positions. Operating the roaster in a stable and profitable operating window requires careful, regular and anticipatory adjustment of these parameters. To support the operation of such plants, Outotec has developed and commissioned the Pretium Roaster Optimizer, a system that continuously leverages embedded process know-how to operate the roaster in an optimal way for high process efficiency, a consistently high product quality and improved economical KPIs.This article gives a short review on how Outotec applies modern advanced automation and optimization methods to improve metallurgical process plant operations.
12:00 PM
Bulk Zn / Pb Concentrate Treatment with the Albion Process™ at Nordenham Zinc Refinery: Paul Voigt1; 1Glencore Technology
In 2011, Glencore integrated an Albion Process™ direct leaching plant for the processing of bulk zinc / lead concentrate into the Nordenham Zinc Refinery Roast-Leach-Electrowin (RLE) flowsheet. The Albion Process™ is an atmospheric oxidative leaching process comprising mechanical and chemical liberation steps. Mechanical liberation is achieved by ultra-fine grinding of the concentrate which occurs at the mine site. Chemical liberation is achieved by sulphide oxidation through the supersonic injection of oxygen into a series of Albion Process™ leach reactors. The implementation of the Albion Process™ served two purposes: The first was to implement a process that could treat McArthur River Mine bulk zinc / lead concentrate at existing Glencore metallurgical assets. The second purpose was to overcome plant bottlenecks (roaster and acid plant) and fully utilize processing plant capacity. This paper describes the process that was implemented and the operating performance since 2011.