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By J. Peter, S. E. James, J. L. Watson

A survey of operating zinc smelters and refineries throughout the world has been done in conjunction with the Lead-Zinc 2000 Symposium. This survey follows the examples set by the Japanese Mining Industry Association in 1985 and 1995. Questionnaires were sent to operating zinc plants that covered feed materials, process details, energy consumption and labor requirements. The voluntary responses to the survey were tabulated. Key operating parameters including feed grade, production capacity, quality of the intermediate products and quality of the final products have been compared for both hydrometallurgical and pyrometallurgical processes.

Jan 1, 2000

By A Kyllo a, D R. Swinbourne

Electric arc furnace (EAF) dusts contain significant quantities of zinc, found almost entirely as either zinc oxide or zinc ferrite. The dust has been classified as a hazardous waste due to the relative high lead, cadmium and hexavalent chromium contents. It is important that environmentally acceptable processes be developed to treat this waste. One possible process involves reacting the zinc compounds in the dust with metallic iron, thus avoiding zinc vapour reoxidation by CO2 as occurs in carbon reduction processes. It consists of two stages where the first is the reduction of iron oxides to iron and the second the reduction of zinc oxide to zinc vapour by the iron. In this work the effects of operating variables such as temperature, CO/CO2 ratio and pressure on the recovery of zinc from an industrial EAF dust obtained from the Smorgon Steel Mill were investigated. Zinc recoveries in the second stage were found to approach 100 per cent at 1000oC after about four hours in nitrogen but within 40 minutes if a low vacuum was used.

Jan 1, 2000

By D. Mishra

Electric arc furnace dust (EAFD) generated during the recycling of steel- scrap is classified as a hazardous waste for landfilling. This is because it contains leachable heavy metals such as zinc, lead,... Recovery of these metals could result in both resources conservation and resolving waste disposal problems. A study of the thermal reduction of a sample of EAFD was carried out in an inert gas atmosphere using coke as a reducing agent. Preferential volatilization of zinc and lead was achieved during the reduction process at about 800 "C. More than 96 % of both zinc and lead were removed from the dust and were recovered in the condensates. The treatment residue was essentially composed of iron oxides and almost free from heavy metals.

Jan 1, 2002

By Zdenek Kunicky

Kovohute Pribram is a plant recycling lead wastes, lead acid batteries in particular. Relevant new recycling technologies are being gradually developed. Outdated technology of smelting lead plates has been replaced by a new technology based on processing of entire batteries in a blast furnace according to the process developed by know-how of German Varta company. The classical Harris refining has been substituted by the oxygen refining. New technologies aimed at utilization of related wastes arising from refining lead bullion in Kovohute Pribram are being developed in house. At present, a new technology of utilization of spent battery acid for extracting zinc from various wastes has been developed. Zinc oxide dross from alkaline refining of lead bullion, during which residual zinc from the preceding vacuum de-zincing is removed as well as waste zinc galvanic sludges (a product of neutralizing precipitation of metals from industrial wastewaters with lime) were treated. In this study, the new developed technology yielding basic zinc carbonate - a valuable raw material for zinc electrowinning, is described together with the first experience of applying the developed method to processing zinc wastes on a pilot scale. Most of the equipment used in the past to regenerate alkali solutions originating from Harris refinery was utilized in the practical realization of this new technology.

Jan 1, 2008

By Xuemei Zheng, Aiyuan Ma, Jing Li, Jinhui Peng, Shaohua Yin, Libo Zhang

Zinc recovery from zinc oxide flue dust (ZOFD) by ultrasound enhanced neutral leaching process was investigated. In this study, the effects of leaching temperature, liquid/solid ratio, leaching time and ultrasound power were studied, and the conventional leaching experiments were also performed. The experimental results showed that the leaching time was greatly shortened and the leaching rate of zinc was effectively improved by the assistance of ultrasound. The optimum conditions of ultrasound-assisted leaching were determined as leaching time 20 min, temperature 35℃, and the liquid/solid ratio of 5. Under these conditions, the leaching rate of zinc was close to 80% as the ultrasound power of 540W, which was increased by 7% or so, in comparison with that of conventional leaching process.

Jan 1, 2015

By G. Diáz

A basic technology coping with a wide range of secondary zinc sources has been developed. The process combines an electrowinning stage, a solvent-extraction unit and a leaching procedure. The acidity generated in zinc electrowinning, transferred by the organic solvent to the aqueous raffinate, is reused to leach the zinc secondary materials. The basic process recovering zinc is described in detail. The route recovering other valuable metals such as copper, cadmium and lead associated with zinc is also described. This non-ferrous metals recovery route is advisable for either ecological and/or economical reasons. Main results of an experimental program aiming at the demonstration of the suitability of the process for several feed materials are summarized. Waelz oxides, galvanizing ashes and EAFD coming from different sources were tested in laboratory and continuous pilot plant campaigns. High zinc recovery, low reagents and utilities consumption, and effluents meeting environmental regulation were confirmed. The paper also includes the main results of a feasibility study of an industrial "base case". A mixed raw material and Spanish EAFD and 20,000 ta of zinc ingots production were chosen. The SGH zinc recovery from secondary raw material by means of the clean, safe and profitable Modified Zincex Process has been demonstrated. This reliable technology is ready for industrial application.

Jan 1, 1995

By W. -D. Schneider, B. Schwab

Like all metals, zinc can be recycled theoretically without end. To demonstrate environmentally friendly use of zinc, it is necessary to increase the recycling rate. In this regard, the Imperial Smelting Process developed in the forties and fifties in the United Kingdom has become more and more important. This unique process combined with a sinter plant, hot briquetting, and direct injection through the ISP furnace tuyeres offers ideal possibilities to recycle all kinds of zinc and lead bearing materials. Possible secondary materials include Electric Arc Furnace (EAF) dust, zinc-containing sludges and even zinc/carbon batteries. This high temperature process also destroys all organic materials, like dioxin, and can be seen as a sink for many harmful substances.

Jan 1, 2000

Paper withdrawn from publication September 8,1977, after book was printed. Pages 258.272 are therefore omitted.

Jan 1, 1977

By Leland Wemple

PREVIOUS to 1915, zinc refining had not become a general practice among the zinc smelters in the United States. Such refining as had been carried on was confined chiefly to remelting very high-leaded zinc, such as third-draw metal from the retort furnaces, and slab dross, and hard spelter from galvanizing pots. In this remelting operation, the lead and iron were settled out and the refined spelter obtained graded fifth class, i.e., Prime Western. Owing to the presence of lead in most zinc ores, the bulk of the spelter produced by direct smelting is of this Prime Western grade. Careful selection of ores of low lead content gave purer grades of spelter, i.e., Brass Special and Intermediate; and smelters which could secure ores carrying practically no lead produced high-grade spelter. Thus, in general, the grade of spelter produced by any smelter was pre-determined by the purity of the ore it could obtain. The needs of the warring nations of Europe for enormous quantities of cartridge and other high-grade brass resulted in such a demand for the purer grades of spelter that the available supply of lead-free and low-lead ores could not produce the quantity required. Prime Western grades went begging, so to speak, while high grades sold at times from 5 to 15 c. per pound over the Prime Western market. The great demand, coupled with the wide market margin, which permitted the inherent costs and losses, resulted in the conversion of the lower grades into higher grades by processes of refining. These conditions also accentuated the development and size of the electrolytic plants, which were being worked out at the time this increased demand for pure grade of metal occurred. The electrolytic process, where available, produces a higher grade of spelter from impure ores than does the fire process; a large portion of those impurities in the ore, which by the distillation process would be carried into the spelter, are removed in the leaching of the ores and the purification of the solutions. The refining process, adopted at a number of smelters for the purpose of converting low-grade spelter into "grades suitable for brash was that of redistillation.

Jan 11, 1917

E. G. SPILSBURY, New York, N. Y.-I would like to ask Mr. Wemple what is the total loss in redistillation; not merely the weight of the lead removed, but also the loss clue to rehandling of a large amount of blue powder, and that clue to the final remelting in the tank furnace? LELAND E. WEMPLE.-The loss of zinc by redistillation, on the first operation, is approximately 5 per cent. This loss does not cover the lead

Jan 4, 1918

By Francis P. Sinn

IN the zinc smelting industry the year 1947 seems to have been one of putting one's house in order rather than one of any material technical development or radical change in operating conditions. Labor generally has been in better supply but several plants report a scarcity of skilled workmen. Some plants continue to operate on the basis of a six-day week and will probably continue to do so until labor is more plentiful. Only one plant is known to have operated on a curtailed basis because of labor shortage, but here the difficulty was lack of proper housing facilities. Necessary materials and equipment for much-needed maintenance and modernization have been in short supply so these programs have often been delayed. Laborsaving devices of the "Payloader" type have been more generally used for handling materials. Slab zinc production was discontinued during the last months of the year at Danville, 111. and at Langeloth, Pa. Both of these plants used the Hegeler type of furnaces fired with producer gas. It is understood that the rolling mill and possibly the acid plant at Danville will continue to operate. At Langeloth acid will be produced from

Jan 1, 1948

By C. G. Maier

The fundamental chemistry of zinc smelting, especially that part dealing with the chemical reduction of the zinc-oxide content of a roasted zinc ore, has been discussed by metallurgists in some detail, but, in the light of present knowledge, unsatisfactorily. A considerable portion of the information available has been qualitative, or quantitative in a sense that could not be interpreted chemically. A number of attempts to elucidate the physical chemistry of zinc oxide reduction have been based upon unsubstantiated and, as is now known, incorrect equilibrium data. To write upon the chemistry of zinc smelting at this time, when electrolytic methods for the production of zinc metal from ore are becoming increasingly widespread, may seem a belated effort. So, for example, C. A. Hansen,3 in the communicated discussion of an article by the author,4 writes as follows:

Jan 1, 1930

By R. Reed von Gal

The majority of zinc strip produced in the world today is cast on the Hazelett twiri-belt continuous casting machine. Ten of these machines are currently operating worldwide, and one machine is under construction for the People's Republic of China. The caster, which was first patented in 1947, was originally developed for aluminum and copper alloy casting. In the early 1960s, the design was expanded into zinc casting and within ten years the industry had essentially converted from casting and rolling ingots to twin-belt continuous casting with in-line rolling. The casting process employs two parallel, moving. water-cooled belts as the major mold surfaces. Together with two strings of side dam blocks, the design offers a four-sided moving mold which produces a continuous strip or bar. This paper will cover a bit of, the history, as well as the current technology surrounding this high production process for zinc strip production.

Jan 1, 1990

By A. C. Mollison

In November of 1983 a fire inside the autoclave caused the curtailment of operation of the Kidd Creek pressure leaching facility. Subsequent repairs and recommissioning of the autoclave in 1984 allowed Kidd Creek to increase its production of zinc as originally planned. This paper describes the operation of this process from 1984 to 1988 and details major mechanical work carried out on the vessel in 1.988:

Jan 1, 1990

By George C. Stone

WHEN George C. Stone, a Director of the Institute, and so well known to our Members in connection with the Institute's many activities was abroad in 1.919, he secured an interesting collection of these coins, which appeared in Zinc, a publication by the New Jersey Zinc Co. Regarding this collection of coin, Mr. Stone says: "During the war, all gold and most of the silver disappeared, making small change very scarce. As the French Government was fully occupied by the war, it allowed various Chambers of Commerce and other bodies to issue money, both paper and coins. Many of the latter were made of zinc, and I secured several while in Paris. We had all heard of the Belgian and German zinc coins, but I imagine few knew how many different kinds there were. The accompanying plates show both sides of those I got. I took all that the dealer had; but he said that there were a number of others in existence. The coins in the bottom line were issued by the Germans in Belgium during the war and all are still in common use. The first two in the next to the bottom line are German. All of the others were issued by Chambers of Commerce or corporations. A few have been nickel plated; these look and wear much better than the others. "Coins" made of pasteboard were also issued by similar bodies, also notes.

Jan 1, 1920

By M. Maeda, H. Sasaki

"Precious metals such as platinum, palladium, and rhodium are commonly used for automotive catalyst converters. To recover these metals with lower environmental load and cost, exposure to zinc vapor was proposed as a pretreatment prior to acid leaching. Alloying with zinc is expected to enhance dissolution of precious metals and reduce the amount of toxic chemical agents required for the leaching. This study examined the effect of the alloying pretreatment using model catalysts. Catalysts were immersed in leaching solutions for a predefined time with or without zinc vapor pretreatment, and the amount of dissolved metals was then evaluated. INTRODUCTIONAutomotive catalysts account for large portions of the world consumption of platinum (Pt), palladium (Pd), and rhodium (Rh) (Butler, J., 2011). Because of their limited production and high prices, recovery of the precious metals from spent catalysts is obviously an important issue. A representative structure of an automotive catalytic converter can be described as a monolithic ceramic support with a honeycomb structure which is coated with porous oxides such as those of aluminum (Al2O3), cerium (CeO2), and zirconium (ZrO2) (Heck & Farrauto, 2001; Matsumoto & Shinjoh, 2007). Small particles of precious metals, originally several nanometers or less, adhere to the oxides.Typical recovery processes for precious metals from scraps are shown in Figure 1 (a)-(c) (Habashi, 1997; Yoo, 1998; Shibata & Okuda, 2002). Precious metals can be recovered by using non-ferrous smelters as Figure 1 (a) shows. Smelted along with metals such as copper (Cu), precious metals and ceramics in the scraps are absorbed into the metal phase and slag phase, respectively. Because the metals separate from Cu as anode slime in successive electro-refining, such a process can recover precious metals as co-products of Cu. However, in order to prevent negative effects on the principal process, a specialized procedure is needed. Figure 1 (b) is a specialized approach in which scraps are melted at elevated temperature with Cu called the Rose process. Here Cu works as a collector metal, and the absorbed precious metals are then concentrated by oxidation of Cu. Such a process can separate precious metals from ceramics constituting catalyst converters. Smelting at high temperature, however, requires extensive equipment as well as a high amount of energy. On the other hand, hydrometallurgical processes may be effective to separate precious metals from ceramics into an aqueous solution, because chemical agents can act on these metals selectively (Figure 1 (c)). Leaching of precious metals, however, requires strong acid and oxidizing agents because of their corrosion resistance; this makes liquid waste disposal and the large environmental load controversial. To solve the problem, a metal vapor pretreatment was proposed (Okabe, Yamamoto, Kayanuma, & Maeda, 2003a, 2003b; Kayanuma, Okabe, Mitsuda, & Maeda., 2004; Kayanuma, Okabe, & Maeda, 2004; Itoh, Kayanuma, Miyake, Kimura, & Maeda, 2005). A flow diagram of the process using zinc (Zn) vapor is shown by Fig. 1(d). Exposed to Zn vapor, precious metals are expected to form alloys which dissolve more easily than pure precious metals, thus reducing the use of chemical agents and environmental load involved with successive leaching. In previous research (Sasaki, Miyaki, & Maeda, 2010; Sasaki & Maeda, 2010, 2012), dissolutions of precious metal alloys formed by Zn vapor treatment were examined in hydrochloric acid (HCl) using an electrochemical method, and it was confirmed that these metals dissolved at higher rates from the alloys than from their pure states (Figure 2). In this study, the availability of the alloying pretreatment was demonstrated by testing on model catalysts in leaching solutions."

Jan 1, 2012

By Y. Hayashi, A. Fuwa

To analyze zinc vaporization kinetics of zinc smelting slag in the ISP furnace, reduction reaction rate of zinc oxide from ZnO-FeOx-CaO-SiO2 slag system with CO-CO2-Ar gas mixtures has been measured by a therm o-gravim etric apparatus at various ZnO content, Pco, and temperature. The reduction rate was measured under a chemical reaction control in the initial three minutes where surface zinc content can be assumed constant. Through the reaction rate dependency analysis on ZnO contents, Pco and temperature, discussion has been made on its reaction mechanistic information in terms of rate coefficient, adsorption/desorption mechanism and activation energy.

Jan 1, 2008

By Dan Slyter

This paper prov ides comparisons be­tween Merrill-Crowe and Carbon Adsorption pl Rnts 11sed for Pree ious Metal Heap Leach Operations. During the first stage of mine devel­opement, the question arises as to type of gold recovery circuit to be employed, Car­bon or Zinc. Several important factors to consider in answering this question are: Au/Ag ratio Solution grades Daily plant production Plant throughput required Plant gold inventories

Jan 1, 1992

By GUY C. RIDDELL

ZINC, manganese, and aluminum received attention at the two nonferrous metallurgy sessions at the Annual Meeting. L.P. Davidson, general superintendent of the rebuilt Monsanto zinc plant, described its operation, which reflects Polish practice and is really a combination of electrolytic, Waelz, and retort procedure. Briefly, it embraces leaching of roasted concentrate with sulphuric acid, electrolysis of sulphate solution using Tainton lead-silver anodes with ?goulac? added to the electrolyte, treatment of tailing in Waelz kilns, and retorting of the recovered zinc oxide, casting furnace dross and residues. Recovery is good, equipment and maintenance costs low. Ferrate zinc that might be lost in the electrolytic process appears to be recovered as oxide in the Waelz treatment.

Jan 1, 1942

By Adolf Mikula

Lead-tin solders are commonly used in electronic packaging due to their unique combination of electrical, chemical, physical, thermal and mechanical properties. Since it is known that lead and lead containing alloys cause great environmental concern and health hazards it is necessary to replace lead in solder materials. Besides the environmental concerns new technologies in electronic packaging require new and improved solders. In most cases the new solders will consist of ternary or quarternary alloy systems, the main component will be tin or indium and the second element could be bismuth, silver, copper and gold and to improve certain properties a third element will be added. For a third element zinc, nickel, antimony and aluminum can be considered. This report will concentrate on solders containing zinc as an environmental safe element.

Jan 1, 2003