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MDMW-Zinc&Lead06

MDMW-Zinc&Lead06

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Published by miningnova
Main purposes of these studies are to increase the recovery of Zinc metal in refineries and moreover to undertake new methods and techniques. These studies categorized as: Conventional methods of mineral processing, Modern techniques such as SX and recovering the residuals in tailing and very low grade ore.
Main purposes of these studies are to increase the recovery of Zinc metal in refineries and moreover to undertake new methods and techniques. These studies categorized as: Conventional methods of mineral processing, Modern techniques such as SX and recovering the residuals in tailing and very low grade ore.

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Published by: miningnova on Jul 07, 2009
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05/11/2014

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Iran Zinc mines Development Company: Industry Overview and…
147 
Iran Zinc Mines Development Company: IndustryOverview and R&D Center Research Activities
 A. Rashtchi*, D. Moradkhani** and H.A. Ghanbari 
*Mineral Processing Leadership, **Managing DirectorAssociated Professor,R&D Center, Iran Zinc Mines Development CompanyFaculty of Engineering, Zanjan University
ABSTRACT:
Ever since the establishment of Iran Zinc Mines Development Company in 1996, it has played asignificant role in promoting positive potentials for the Zinc metal industry in Iran. For the reason that theAngouran ore has a distinct nature, and as one of largest nonsolfide reserve in the world, any other contemporarytechniques failed to process the suitable minerals efficiently. Research and development center in IZMDC pursues efficient and feasible approach to the processing and recovering the Zinc and Lead minerals. Main purposes of these studies are to increase the recovery of Zinc metal in refineries and moreover to undertake newmethods and techniques.
 
These studies categorized as: Conventional methods of mineral processing, Moderntechniques such as SX and recovering the residuals in tailing and very low grade ore.
1. BRIEF BACKGROUND1.1Company
Ever since the establishment of Iran Zinc MinesDevelopment Company in 1996, it has played asignificant role in promoting positive potentialsfor the Zinc metal industry in Iran.Company's contribution to Iran's overallZinc and Lead metal production constitutes 85%and 95% respectively. This make companylargest producer of zinc in Middle East.Subsidiaries of IZMDC consist of largest Iranlead and zinc mineral processing plant (CalciminCo.) in Dandi Zanjan province and 100,000 toncapacity calcination plant in Zanjan (Zangan zincindustry Co.) and also seven zinc refinery plantas below:
30,000tpy Bafgh Smelting Co. plant
20,000tpy Calcimin Co. Qeshm plant
12,000tpy Calcimin Co. Bandar Abbas plant
18,000tpy Calcimin Co. Dandi plant
12,000tpy Calcimin Co. Zanjan plant
15,000tpy National Iran Lead and zinc Co. plant
18,000tpy Faravary Mavad Maadani Co. plantIn addition there is a 30,000t Lead smelting plant in National Lead and Zinc Co. site. There isan intense intention to build a 100,000t capacity plant in cooperation of consortium Iranian andEuropean companies, is in progress. This plantdesigned to recover 94% of zinc content of feedore and 84% of lead.
1.2Angouran Mine
Angouran mine is the most important ore supplyfor Iran lead and zinc industry. More than 80% of zinc product in Iran is dependent to excavatedore from this mine that is mostly oxide ore. Thismine cosidered as non sulphide lead and zincreserve carrying >16 Mt 26% Zn and 4%Pb.Location of the deposit is about 120 Km NWZanjan in Zagross montains.Ore body hosted by complex consists of marbels and schists overlayed by sedimentaryand volcanic sequence. Complex ore bodyconsisists of an oxid cap, underlyed by a mixedsulphid-oxid body, then downwarded into Zn-Pbsulphide ore (Approximate
 
grade
:
Pb < 3%, Zn> 40%)The upper level of the ore body aredominated by smithsonite-rich ore. Other phasesare composed of carbonated oreand supergenweatherd ore. In this phase minerals are Zn–richclays, mimetite,smithsonite,hydroxy and oxide of Fe and Mn, calcite, hydrozicite and hemi-morphite. Beneth of the ore body is limited tofootwal schist; proximity to fottwall schistmixture of oxid and sulphide ore is present. Main
 
148
 
Mineral Processing Technology (MPT 2007)
composition of sulphide-oxide ore aresmithsonite,arsenopyrite, galena, pyrite andquartz (Approximate Grade: Pb > 5 , Zn > %33).
Diagram 1:
Ore Classification of angouran mine
Mineralized schist consists of smithsonite,cerussite and Clay mineral (Approximate Grade:Pb > %1, Zn < % 13). In regards to these data;Angouran ore could be categorized as shown in(Diagram 1).
2. INDUSTRY'S PROCESS2.1 Mineral Processing
There are 2 plant involving in concentrationwithin company; Calcimin complex and ZanganZinc Calcination plant.Due to distinct nature of Angouran mine ore,several methods are in use in order to consumethe excavated ore. Most of the Pb low grade oreis used directly in refinery plants (FaravariMavad Madani plant). Calcimin plant usesreverse flotation method to facilitateconcentration of the zinc from accompanyinglead and gangue minerals. This plant has acapacity of 25,000 tpy lead concentrate and270,000 tpy zinc concenterate.Process in this plant is divided to two lines:low grade and high grade. High grade oretreatment begins by grinding the high gradecrushed ore, which is transported via ropeway,with rodmill and ball mill.Lead concenterate is being concentrated by flotation process in a battery of rougher, scavenger and cleaneflotation cells. The lead tailing after lead flotationconsists of 33-40% Zn and 15-25% silica; whichis treated az zinc concentrate. Recovery of leadconcentrate is 75-85% with grade of 54-60% Pb.Both concentrates are dewatered in seperatethickners and filtered in vaccum filters, beltfilters and filter press are used to reduce themoisture. The coars zinc concentrate from beltfilter is sent to calcination plant for enrichment of zinc from 35 to 50-55% by heating it up to800
o
C.The fine zinc concentrate from filter pressis sent to zinc refinery plant in Zanjan and Dandi.The low grade ore which contains about 15-22% zinc,is washed and subjected to heavymedia seperation, after separating 0-2 mmmaterials. Heavy media enriches the materialwhich leads to increase in zinc grad materials to28-35% and afterward it is sent to plant for furthur treatment, while the tailing whichcontains 8-9% Zn tailed in the tailing dam inorder to recycl the water.Zangan Zinc Calcination plant maintain heattreatment on carbonated ore with the purpose of increasing the grade. İn this plant after crushingand miling the ore which contains 22-30% Zn,direct heat calcination in furnace increases theconcentrate grade to 27-40%.
2.2 Hydro Metallurgy
Hydrometallurgy plants subordinated to IZMDCmainly utilizes three kinds of ore in the beginning of their process. Faravary MavadMadani consumes raw ore material excavatedfrom mine while other plants feed by raw or calcined concentrate obtained from Calcimine plant and Zangan Zinc Calcination plant.Process in these plants (Diagram 2) beginswith leaching the feed by sulfuric acid thencontamination is removed and filtered in order to purify the electrolyte. Electro winning proceduretakes place in separate cells using Pb-Ag-Caanodes and Aluminum cathodes. Produced zincmetal grad varies from 99.95 to 99.98. OnlyBafgh smelting plant is capable of producingSHG 99.99 zinc ingot.
AngouranAngouranOre bodyOre body
SulfideOreMixOreCarbonateOreHard
 
CarbonateBrecciatedCarbonate SoftCarbonate Very lowGradeCalamine 
 
Iran Zinc mines Development Company: Industry Overview and…
149
Diagram 2:
Process in Hydrometallurgical plants
3. RESIDUALS AND TAILING
Angouran mine ore contains variety of other elements which most of them are valuable toextract and also harmful to the environment(Table 1) if being released. Hence recoveringsome of these elements which are peresentedmostly in taling and filter cake residuals is one of the key researchs being conducted in IZMDC.
Table 1:
element in hydrometallurgical plantResiduals
 Abundance Residuals Element 
8-25%Leach filter cakePb4-10%Leach filter cakeZn11-17%Purification filter cakeCd3-5%Purification filter cake Ni1-2%Purification filter cakeCoUp to 40%Purification filter cakeZnUp to 1000ppmPurification filter cakeGeUp to 100ppmPurification filter cakeIn
Three major processes are designed andadopted to recover the named elements fromresiduals:
3.1 Recovery of Zn from Leach Filter Cake
Recovering the Zn in the form of basic zincsulfate is sugested in many industrial prescriptions.This process because of highamount of Cl and F in this residual , faces lots of difficulties. Most of the technical problomes inthis area solved and also techniques aredeveloped to produce thebasic zinc sulfate (BZS)with grade of 22% Zn.
3.2 Recovery of Zn, Ni and Cd from LeachFilter Cake
As shown in (Diagram 3) this process beginswith leaching and then each of elements isrecovered by solvent extraction (SX) methods. İnthis techinque residuals will be cobalt salt andsome amount of zinc sulfate.
Diagram 3:
Recovery of Ni, Cd and Zn
Sulfuric
MineralRaw zinc
TailingLeadRaw ore
Calcinat
CalcinedConcenttrate
Leachin
Neutralizing
Decontamination
Water Additive
RecycledAdditive
Leach
ResidualscontainingCo, Cd, Ni
Electrowinnin
Recycledelectroltes
Zinc MetalNeutralizing
Residuals containingCo, Ni, Zn and CdLeaching
Water AdditivesSulfuric Acid
Recycled
L
CdElectrowinning
Cd
SX first StageElectrowinning
Zn
 SX SecondStageElectrowinning
 NiRecycled Electrolyte

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