Presentation on roaster and acid plant (hindustan zinc ltd)

Company profile
HZL was created from MCI in 1966. In 2002, sterlite acquired 26% stack. Chanderiya lead zinc smelter has annual capacity of 100000 tpa zinc. HZL has total capacity of 232000 tpa from its 3 plants in India. It is largest zinc producing company in Asia.

Main products
Zinc mainly used galvanizing Lead mainly used in batteries

By products
Sulphuric acid used in making fertilisers Silver photo films cadmium- alkaline batteries

Extraction of zinc from zinc sulfide occurs in three sections

Roaster and acid plant Leaching and purification plant Cell house

Roaster It has following parts

Furnace Waste heat recovery boiler Cyclone separator Hot gas precipitator Drum cooler

Raw material handling section flowsheet

Underground bin Magnetic separator screens

Hammer mill

Concentration storage bin

Roaster day bin

Table feeder

Slinger machine

Ball mill

Drum cooler

furnace

Horizontal chain conveyer

boiler

Silos (2)
Hot gas precipitator cyclone

Sulphuric acid plant

There are four main process criteria. Gas drying and water balance Energy (heat) balance. Conversion of SO2 to SO3 . required O2/SO2 ratio

Physical properties of acid

It is colourless,water white ,viscous liquid,with MP 10 C,BP 280 C. It may be mixed with water in any proportion. Density increases with increase in concentration at fixed temperature. Physical properties will depend on SO3 concentration.

Chemical properties
Sulphuric acid is chemically and thermally very stable. Known hydrates are H2SO4 x H2O,H2SO4 x2H2O, and H2SO4 x 6H2O . Pure sulphuric acid is dissociated to only a small extent in accordance with equations . 2 H2SO4 = H3SO4+ + HSO42H2SO4 = H3O+ + HS2O7-

Wet gas cleaning

This is achieved by application of multistage process.
Quenching tower Packed gas cooling tower Wet electrostatic precipitator

Wet gas cleaning flowsheet

Vapor SO2 Weak acid water SO2 Wet electrostatic precipitator

Quenching tower

Packed gas cooling tower Acid 96.5%

Hot SO2

Drying tower
SO2
blower

Converter system
It is tower with four catalyst beds. Inbuilt cooling tubes are provided. Catalyst is alkali vanadium pentaoxide with cesium salt promoter. Four heat exchangers are provided to cool or heat the gaseous stream.

FAT
economiser 270 c 180 c

Stack SO2 < 200ppm

HE 4
410 c

HE 1

400 c 425 c 433 c Catalytic converter 443 c

HE 2

400 c

I A T 98.5%

165 c

HE 3B

HE 3A

Thank you