zinc debari report

7/24/2019 Zinc Debari Report

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PREFACEPractical training is a way to implement theoretical knowledge to practical use to

become a successful engineer. It is necessary to have a sound practical knowledgebecause it is only way by which one can acquire prociency & skill to work successfully

dierent industries.

It is proven fact that bookish knowledge is not sucient because things are not as ideal

in practical eld as they should be.

industan !inc "td. is one of the best e#amples to understand the production process &

productivity in particular of !inc.

$his report is an attempt made to study the overall production system & related action

of !inc %melter 'ebari a unit a !". It is engaged in production of high grade (inc

metal & other by products vi(. )d sulphuric acid etc. since *+,- by adopting ydroetallurgical technology.

)ompany ProleVedanta

/edanta is an "%01listed diversied 2$%0 *33 metals and mining company and India4s

largest non1ferrous metals and mining company based on revenues. Its business is

principally located in India one of the fastest growing large economies in the world.

In addition they have additional assets and operations in !ambia and 5ustralia. $hey

are primarily engaged in copper (inc aluminium and iron businesses and are alsodeveloping a commercial power generation business.

2ounder of this recognition is r. 5nil 5garwal who is chairman of this group a simple

person without any special degree in management eld but have a great e#perience in

this eld and a sharp sight of the future conditions and requirement.

industan !inc "imited

industan !inc "imited was incorporated from the erstwhile etal )orporation of India

on *3 6anuary *+,, as a Public %ector 7ndertaking.

In 5pril 8338 %terlite 9pportunities and /entures "imited :%9/"; made an open oer for

acquisition of shares of the company< consequent to the disinvestment of =overnment

of India>s :=9I; stake of 8,? including management control to %9/" and acquired

additional 83? of shares from public pursuant to the %0@I Aegulations *++B. In 5ugust

833C %9/" acquired additional shares to the e#tent of *-.+8? of the paid up capital

from =9I in e#ercise of Dcall optionD clause in the share holder>s agreement between

=9I and %9/". Eith the above additional acquisition %9/">s stake in the company has

gone up to ,F.+8?. $hus =9I>s stake in the company now stands at 8+.GF?.

industan !inc "td. operates smelters using

H Aoast "each 0lectro1Einning :A"0;

H ydrometallurgical :'ebari /i(ag and )handeriya %melters;

H I%P pyrometallurgical :)handeriya "ead !inc %melter; and


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H 5usmelt :)handeriya "ead %melter; process routes.

!inc %melter 'ebari17daipur

"ocation *F km from 7daipur AaJasthan India

ydrometallurgical !inc %melter )ommissioned in *+,- Aoast "each 0lectrowining

$echnology with )onversion Process =one through a series of debottlenecking --333

tonnes per annum of !inc

)aptive Power =eneration 8+ E '= )aptive Power Plant commissioned in 833C

)ertications @0%$F )ertied Integrated %ystems I%9 +33*K8333 I%9 *F33*K833F

9%5% *-33*K*+++ %5 -333K833*

)overed 5rea :a; 88.,G

$otal Plant 5rea :a; *8,

Products Aange

:a; igh =rade !inc :=; :8G kgs; & 6umbo :,33 kgs;

:b; )admium Pencils :*G3 gms;

L %ulphuric 5cid M +-? concentration

5wards & Aecognitions

:a; International %afety 5wardK 833, by @ritish %afety )ouncil 7N

:b; A9%P5 =old 5ward for prevention of accidents9perating )apacity :Per Oear;

!n K -3333$

5cid K *C3333$

)d K 8G3$

!inc dust K C,3$

Eork force -B, os.

anagerial & 0ngineering %ta -F os.

%upervisory & $echnical %ta G- os.

"abour B8+ os.

:a; %killed *GFos.

:b; %emi1%killed GGGos.

L 7nskilled 8G3os.Aaw aterial %uppliesK1

:a; !awar ines

:b; 5gucha ines

L AaJpura 'ariba ines

Product @uyersK1

:a; $ata

:b; @hel

L %teel )ompanies

Process )ollaboratorsK1

:a; Nrebs Penorrova 2rance "eaching Purication 0lectrolysis

:b; "urgi =@ and =ermany Aoaster and gas clearingL 5uto Numpu 2inland A$P Eartsila Plant

:d; I.%.). 5""9O 7.N. !inc dust plant 5llen Power Plant


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!inc :!n;

Introduction!inc is a metallic chemical element with the symbol !n and atomic number C3. Innonscientic conte#t it is sometimes called spelter. )ommercially pure (inc is known as

%pecial igh =rade often abbreviated %= and is ++.++G? pure.

!inc is found in the earth4s crust primarily as (inc sulde :!n%;. !inc :!n; is a metallic

element of he#agonal close1packed :hcp; crystal structure and a density of B.*C grams

per cubic centimeter. It has only moderate hardness and can be made ductile and easily

worked at temperatures slightly above the ambient. In solid form it is grayish white

owing to the formation of an o#ide lm on its surface but when freshly cast or cut it has

a bright silvery appearance. It4s most important use as a protective coating for iron

known as galvani(ing derives from two of its outstanding characteristicsK it is highly

resistant to corrosion and in contact with iron it provides sacricial protection by

corroding in place of the iron.

!inc ores typically may contain from C to ** percent (inc along with cadmium copper

lead silver and iron. @eneciation or the concentration of the (inc in the recovered

ore is accomplished at or near the mine by crushing grinding and Qotation process.

9nce concentrated the (inc ore is transferred to smelters for the production of (inc or

(inc o#ide. $he primary product of most (inc companies is slab (inc which is produced

in G gradesK special high grade high grade intermediate brass special and prime

western. $he primary smelters also produce sulfuric acid as a byproduct.

Eith its low melting point of F83R ) :B--R 2; unalloyed (inc has poor engineering

properties but in alloyed form the metal is used e#tensively. $he addition of up to FG

percent (inc to copper forms the series of brass alloys while with additions of

aluminum (inc forms commercially signicant pressure die1casting and gravity1casting

alloys. Primary uses for (inc include galvani(ing of all forms of steel as a constituent ofbrass for electrical conductors vulcani(ation of rubber and in primers and paints. ost

of these applications are highly dependent upon (inc4s resistance to corrosion and its

light weight characteristics. $he annual production volume has remained constant since

the *+-3s. India is a leading e#porter of (inc concentrates as well as the world4s largest

importer of rened (inc.

Properties of !inc :metallic; at 8+CN

*. 'ensity B*F3Ng.SmC

8. elting Point ,+CN

C. %pecic "atent eat of 2usion *3 6S Ng

F. %pecic heat capacity C-G 6SNgSN

G. "inear e#pansivity C*SN

,. $hermal conductivity *** ESmSkB. 0lectric %ensitivity G.+ ohm Tmeter

-. $emp. )oecient of resistance F3Sk

+. $ensile %trength *G3 pa

*3. 0longation G3?

**. Ooung4 modulus **3 =pa

*8. Passion4s Aatio 3.8G


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Zinc Smelting

!inc smelting is the process of recovering and rening (inc metal out of (inc1containingfeed material such as (inc1containing concentrates or (inc o#ides. $his is the process of

converting (inc concentrates :ores that contain (inc; into pure (inc.

$he most common (inc concentrate processed is (inc sulde which is obtained by

concentrating sphalerite using the froth Qotation method. %econdary :recycled; (inc

material such as (inc o#ide is also processed with the (inc sulde. 5ppro#imately C3?

of all (inc produced is from recycled sources.

=lobally two main (inc1smelting processes are in useK

:a; Pyrometallurgical process run at high temperatures to produce liquid (inc.

:b; ydrometallurgical or electrolytic process using aqueous solution in combination

with electrolysis to produce a solid (inc deposit.

$he vast maJority of (inc smelting plants in the western world use the electrolytic

process also called the Aoast1"each10lectrowin :4A"04; process since it has various

advantages over the pyrometallurgical process :overall more energy1ecient higher

recovery rates easier to automate hence higher productivity etc.;.

In the most common hydrometallurgical process for (inc manufacturing the ore is

leached with sulfuric acid to e#tract the !inc. $hese processes can operate at

atmospheric pressure or as pressure leach circuits. !inc is recovered from solution by

electrowinning a process similar to electrolytic rening. $he process most commonly

used for low1grade deposits is heap leaching. Imperial smelting is also used for (inc

ores.


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Zinc Smelter Debari

!inc %melter 'ebari have following main plants

Fig.-1 Plants at Zinc Smelter Debari

=eneral Process 9verview

$he electrolytic (inc smelting process can be divided into a number of generic

sequential process steps as presented in the general Qow sheet set out below.

In %ummary the Process %equence isK

%tep *K Aeceipt of feed materials :concentrates and secondary feed materials such as

(inc o#ides; and storage

zinc debari report

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