Zinc Direct Leaching

August 27, 2008

Bjrn Saxn
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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

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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
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zinc
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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

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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

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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.

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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.
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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
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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
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Outotec atmospheric direct leaching reactors

installed in Odda, Norway

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Schematic Presentation of Flows in Direct

Leaching Reactor

Efficient
mixing
Low power
consumption
Good
oxygen
dispersion

Oxygen

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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 %
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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
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Recovery %

90
91
92
93
94
95
96
97
98
99
100
1.7.1998
30.9.1998
30.12.1998
1.4.1999

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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
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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
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