際際滷

際際滷Share a Scribd company logo

HZL

Download as PPTX, PDF
S
Sourabh Jain

This document provides an overview of an internship presentation at Hindustan Zinc Smelter Ltd. in Debari, Udaipur. It introduces the company and describes the key processes involved in zinc production including acid and roaster plants, leaching and purification, electrolysis, and melting and casting. It also summarizes the intern's project studying the operation and maintenance of the acid-roaster plant, outlining the basic processes within the plant such as roasting, gas cleaning, and sulfuric acid production.

1 of 24
Downloaded 13 times
Internship Presentation Hindustan Zinc Smelter Ltd. Debari Presented by:- Submitted To: - Dr. Rakesh Jain Dr. Gopal Agarwal
Introduction about the Company:- Hindustan Zinc Limited (HZL) is an integrated mining and producer of zinc , lead , silver and cadmium. On 10th January 1996 Hindustan Zinc Limited was declared as a Public Sector Undertaking. HZL is worlds lowest cost zinc producer. HZL operates worlds 3rd largest open pit mine and worlds largest zinc mine in Rampura Agucha, Rajasthan. HZL annually produces 10,00,000 tonnes of refined Zinc and Lead.
Business partners
Q. Why do we need Zinc? Galvanizing 50% Die Casting 17% Brass Bronze 17% Rolled Zinc 6% Chemicals 6% Others 4% Galvanizing Die Casting Brass Bronze Rolled Zinc Chemicals Others
HZL, Debari Udaipur Location situated at 14 km from udaipur Products :- high grade zinc , Cadmium and Sulphuric acid Raw material Suppliers : 1. Zawar mines (Udaipur) 2. Agucha Mines (Ajmer) 3. Dairba mines (Rajsamand) Basic Plants of the Process:- 1. Acid and Roaster plant 2. Leaching and purification 3. Zinc Electrolysis 4. Melting And cooling
Acid & Roaster Plant Roasting is a process of oxidizing zinc sulphide concentrates at high temperatures into an impure zinc oxide, called Zinc Calcine. ZnS + 3/2 O2 ZnO + SO2 Then ZnO is sent to Leaching process and SO2 is sent to Acid formation process. Acid plant conversion Reaction So2 + 1/2 O2 SO3 The formed SO3 is transferred to IAT and FAT for final acid formation
LEACHING AND PURIFICATION Leaching is dissolving the calcine in a solution of sulphuric acid to form zinc sulphate solution. ZnO + H2SO4 ZnSO4 + H2O The solid residues separated from the leaching process still contain substantial amount of zinc and some amount of lead, silver and other impurities Solids are leached with strong, often hot, sulphuric acid, dissolving most of the remaining zinc together with iron and other impurities. MeO + H2SO4 MeSO4 + H2O The solution removed are CdSO4, CuSO4 and CoSO4, for getting a pure ZnS04 solution. This is cleared solution is sent to filter press where the clear solution of ZnS04 is sent to zinc electrolysis segment along with Sulphuric Acid.
Electrolysis: - Electrolytic Cell:- This is the heart of the cell house. It is made up of reinforced concrete and is supported on electric isolator on one side of the cell and a PVC overflow box is integrated on the other. The cell has about 8 meters length 1.4 width and 2.5 meter height it cell contains 30 cathode and 31 anodes. Anode is made up of Lead Silver alloy and Cathode is made up of Aluminum. At Hindustan zinc limited cell house uses 35 megawatt of electricity the total used electricity by Hindustan zinc debari is 70 megawatt. Every 24 to 48 hours, each cell is shut down, the zinc-coated cathodes are removed and rinsed, and the zinc is mechanically stripped from the aluminum plates.
Melting and Casting :- Melting will be carried out in two identical electric induction furnaces.The furnaces will have melting rate of 22 tonnes per hour of zinc. After melting, zinc totes are formed which are further transferred to the open yard by lift trucks.
PROJECT Study Of Operation And Maintenance of Acid Roaster Plant
HZL
Raw Material Section Zinc is delivered by trucks and stored in two underground bins. From several belt conveyors that ore is transport to two hoppers . With the help of magnetic separator the material is transported into feed bins. Here many nozzles are spraying water to add moisture to it. Then finally using belt conveyors and rotary table feeder .The roaster is fed.
Roaster Plant Roasting is a process of oxidizing zinc sulphide concentrates at high temperature into impure zinc oxide. Zinc Suphide Sulphur DioxideCalcine
Parts of Roaster Plant: - 1. Waste Heat Boiler The hot gas stream leaving the roaster is drawn into the waste heat boiler under suction from the SO2 blower. The waste heat boiler is a horizontal- pass boiler , directly connected with the gas outlet flange of the roaster. The boiler produces steam in a forced circulation system and the dust-laden gases are cooled down from the roasting temperature to about 350属C
2. Cyclone: - The cooled and dust loaded gas enters the two parallel cyclones for pre- dedusting with a temperature of approx. 350 属C. The gas leaves the cyclones at the top whereas the dust is collected in the lower part of the cyclones and removed via rotary valves. Final dedusting of the hot gas is achieved in the hot ESP.
Gas Cleaning Plant: - 3. Hot gas precipitator After passing through Cyclone the gas passed through hot gas precipitator to remove the fine particles of calcine by the application of electric field. 4. QuenchingTower: - In the quench tower, the hot gas is cooled by the evaporation of water.The heat of the incoming gas (Temperature: > 300属C) is used for the evaporation of water that is sprayed into the QuenchTower.
6. Packed gas cooling tower The cooling in the quench tower does result in Addition of moisture to SO2 gas . Removal of water vapour is done in a packed gas cooling tower.The gas enters the tower from the bottom and flows upwardly through the packing. 7. Wet Gas Precipitate Final removal of dust and aerosols will be carried out in the wet electrostatic precipitator system. Here 2 parallel arrangement are present , so that the SO2 could me more clean
In order to achieve an upgraded quality of Sulphuric Acid(H2SO4), the Gas Cleaning Plant is equipped with a system for removal of excess MercuryVapour(Hg). 8. Mercury Removal: - 諮駒2 + 諮 諮2 駒2 諮駒2 + 駒2 2諮駒2 Calomel MercuryChloride
BASIC OPERATION OF ACID PLANT 1. DryingTower :- Gases are passed through drying tower from bottom to remove the moisture by spraying Sulphuric Acid from top. By the use of concentration analyser, the concentration of circulating acid is maintained in IAT(Initial AbsorptionTower) and FAT(Final Absorption tower). 2. SO2 Blower : - It is used to circulate SO2 bearing gases by the use of heat exchangers and mixers. It is assembled with an electric motor to transport the gas from gas cleaning plant via Sulphuric Acid Plant.
3. Converter Group and Preheater: - In Catalytic converter , conversion of so2 to so3 take place at 450c Preheater is use to heat the catalyst and heat exchangers to increase efficiency of plant. It is also used to preheat SO2 gas at startup. SulphurTrioxide
4. AbsorptionTower: - After convertor group and preheater , the gas is then flows in absorption tower, where the final reaction takes place. The SO3 reacts with H2SO4 to make H2SO4 and then this H2S2O7 is converted into final H2SO4. This is how the sulphuric acid produced at HZL, Debari ,Udaipur
Conclusion In my 45 days training I learnt How the processes are going on in an Industry The Smelting Zinc from Zinc ore. The process making of Sulphuric Acid H2SO4. Also learn the inside process of Leaching , electrolysis , melting etc.
References Plant Operating Manuals Zinc Smelter Debari, Udaipur www.google.com www.wikipedia.org www.vedantaresources.in
Thank You!

More Related Content

HZL

  • 1. Internship Presentation Hindustan Zinc Smelter Ltd. Debari Presented by:- Submitted To: - Dr. Rakesh Jain Dr. Gopal Agarwal
  • 2. Introduction about the Company:- Hindustan Zinc Limited (HZL) is an integrated mining and producer of zinc , lead , silver and cadmium. On 10th January 1996 Hindustan Zinc Limited was declared as a Public Sector Undertaking. HZL is worlds lowest cost zinc producer. HZL operates worlds 3rd largest open pit mine and worlds largest zinc mine in Rampura Agucha, Rajasthan. HZL annually produces 10,00,000 tonnes of refined Zinc and Lead.
  • 4. Q. Why do we need Zinc? Galvanizing 50% Die Casting 17% Brass Bronze 17% Rolled Zinc 6% Chemicals 6% Others 4% Galvanizing Die Casting Brass Bronze Rolled Zinc Chemicals Others
  • 5. HZL, Debari Udaipur Location situated at 14 km from udaipur Products :- high grade zinc , Cadmium and Sulphuric acid Raw material Suppliers : 1. Zawar mines (Udaipur) 2. Agucha Mines (Ajmer) 3. Dairba mines (Rajsamand) Basic Plants of the Process:- 1. Acid and Roaster plant 2. Leaching and purification 3. Zinc Electrolysis 4. Melting And cooling
  • 6. Acid & Roaster Plant Roasting is a process of oxidizing zinc sulphide concentrates at high temperatures into an impure zinc oxide, called Zinc Calcine. ZnS + 3/2 O2 ZnO + SO2 Then ZnO is sent to Leaching process and SO2 is sent to Acid formation process. Acid plant conversion Reaction So2 + 1/2 O2 SO3 The formed SO3 is transferred to IAT and FAT for final acid formation
  • 7. LEACHING AND PURIFICATION Leaching is dissolving the calcine in a solution of sulphuric acid to form zinc sulphate solution. ZnO + H2SO4 ZnSO4 + H2O The solid residues separated from the leaching process still contain substantial amount of zinc and some amount of lead, silver and other impurities Solids are leached with strong, often hot, sulphuric acid, dissolving most of the remaining zinc together with iron and other impurities. MeO + H2SO4 MeSO4 + H2O The solution removed are CdSO4, CuSO4 and CoSO4, for getting a pure ZnS04 solution. This is cleared solution is sent to filter press where the clear solution of ZnS04 is sent to zinc electrolysis segment along with Sulphuric Acid.
  • 8. Electrolysis: - Electrolytic Cell:- This is the heart of the cell house. It is made up of reinforced concrete and is supported on electric isolator on one side of the cell and a PVC overflow box is integrated on the other. The cell has about 8 meters length 1.4 width and 2.5 meter height it cell contains 30 cathode and 31 anodes. Anode is made up of Lead Silver alloy and Cathode is made up of Aluminum. At Hindustan zinc limited cell house uses 35 megawatt of electricity the total used electricity by Hindustan zinc debari is 70 megawatt. Every 24 to 48 hours, each cell is shut down, the zinc-coated cathodes are removed and rinsed, and the zinc is mechanically stripped from the aluminum plates.
  • 9. Melting and Casting :- Melting will be carried out in two identical electric induction furnaces.The furnaces will have melting rate of 22 tonnes per hour of zinc. After melting, zinc totes are formed which are further transferred to the open yard by lift trucks.
  • 10. PROJECT Study Of Operation And Maintenance of Acid Roaster Plant
  • 12. Raw Material Section Zinc is delivered by trucks and stored in two underground bins. From several belt conveyors that ore is transport to two hoppers . With the help of magnetic separator the material is transported into feed bins. Here many nozzles are spraying water to add moisture to it. Then finally using belt conveyors and rotary table feeder .The roaster is fed.
  • 13. Roaster Plant Roasting is a process of oxidizing zinc sulphide concentrates at high temperature into impure zinc oxide. Zinc Suphide Sulphur DioxideCalcine
  • 14. Parts of Roaster Plant: - 1. Waste Heat Boiler The hot gas stream leaving the roaster is drawn into the waste heat boiler under suction from the SO2 blower. The waste heat boiler is a horizontal- pass boiler , directly connected with the gas outlet flange of the roaster. The boiler produces steam in a forced circulation system and the dust-laden gases are cooled down from the roasting temperature to about 350属C
  • 15. 2. Cyclone: - The cooled and dust loaded gas enters the two parallel cyclones for pre- dedusting with a temperature of approx. 350 属C. The gas leaves the cyclones at the top whereas the dust is collected in the lower part of the cyclones and removed via rotary valves. Final dedusting of the hot gas is achieved in the hot ESP.
  • 16. Gas Cleaning Plant: - 3. Hot gas precipitator After passing through Cyclone the gas passed through hot gas precipitator to remove the fine particles of calcine by the application of electric field. 4. QuenchingTower: - In the quench tower, the hot gas is cooled by the evaporation of water.The heat of the incoming gas (Temperature: > 300属C) is used for the evaporation of water that is sprayed into the QuenchTower.
  • 17. 6. Packed gas cooling tower The cooling in the quench tower does result in Addition of moisture to SO2 gas . Removal of water vapour is done in a packed gas cooling tower.The gas enters the tower from the bottom and flows upwardly through the packing. 7. Wet Gas Precipitate Final removal of dust and aerosols will be carried out in the wet electrostatic precipitator system. Here 2 parallel arrangement are present , so that the SO2 could me more clean
  • 18. In order to achieve an upgraded quality of Sulphuric Acid(H2SO4), the Gas Cleaning Plant is equipped with a system for removal of excess MercuryVapour(Hg). 8. Mercury Removal: - 諮駒2 + 諮 諮2 駒2 諮駒2 + 駒2 2諮駒2 Calomel MercuryChloride
  • 19. BASIC OPERATION OF ACID PLANT 1. DryingTower :- Gases are passed through drying tower from bottom to remove the moisture by spraying Sulphuric Acid from top. By the use of concentration analyser, the concentration of circulating acid is maintained in IAT(Initial AbsorptionTower) and FAT(Final Absorption tower). 2. SO2 Blower : - It is used to circulate SO2 bearing gases by the use of heat exchangers and mixers. It is assembled with an electric motor to transport the gas from gas cleaning plant via Sulphuric Acid Plant.
  • 20. 3. Converter Group and Preheater: - In Catalytic converter , conversion of so2 to so3 take place at 450c Preheater is use to heat the catalyst and heat exchangers to increase efficiency of plant. It is also used to preheat SO2 gas at startup. SulphurTrioxide
  • 21. 4. AbsorptionTower: - After convertor group and preheater , the gas is then flows in absorption tower, where the final reaction takes place. The SO3 reacts with H2SO4 to make H2SO4 and then this H2S2O7 is converted into final H2SO4. This is how the sulphuric acid produced at HZL, Debari ,Udaipur
  • 22. Conclusion In my 45 days training I learnt How the processes are going on in an Industry The Smelting Zinc from Zinc ore. The process making of Sulphuric Acid H2SO4. Also learn the inside process of Leaching , electrolysis , melting etc.
  • 23. References Plant Operating Manuals Zinc Smelter Debari, Udaipur www.google.com www.wikipedia.org www.vedantaresources.in