Objectives

On completion of this lesson you would be able to know

• Blast furnace used for production of Zinc.

• Blast furnace method of production of Zinc.

• Charge preparation for Blast furnace.

• Products of Blast furnace.

1
 Recap

• Horizontal retort process

• Vertical retort process

• Electrothermic production of Zinc in different electrical

furnaces and splash condensation of Zinc.

2
 Introduction

• In this process ZnO is reduced by carbon to produce zinc.

• The reduction is carried out in an imperial smelting blast

furnace.

• Zinc evolved in the form of vapour and is condensed by

using molten lead.

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 ADVANTAGES

• It is possible to simultaneously smelt low-grade complex

mixed charges of zinc and lead ores and concentrates in

order to recover both zinc and lead.

• Since the overall thermal efficiency is higher, the

recovery of zinc becomes less expensive

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• A wide variety of furnace sizes are available, the trend

being towards larger capacities at lower operational costs.

• The funance operation is fully automated.

• The mechanism is highly robust, i.e., it can withstand

frequent shut-downs and restart.

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Fig.1: Imperial Smelting Blast Furnace

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 Blast Furnace Charge

• Preheated coke (8000C).

• Preheated sinter (8000C).

• Preheated air (5500C – 7500C).

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 Zinc Blast furnace details

• The furnace is of square cross section, which is operated

at 10000C.

• It consists of a water jacketed brick lined shaft.

• Feed arrangement at the top of the furnace operates

under a positive pressure.

• Blast furnace uses preheated air between 5500C and

7500C.
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• Air is supplied through water cooled tuyers.
• Use of preheated air reduces Zinc percentage passing
into the slag.
• Preheated coke and sinter are introduced through
double bell charge system.
• The furnaces gases generated during reduction pass
upwards through the charge and are evenly divided
between two condensers.

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 Fig-2 Condensers
• The condensers very rapidly
cool the furnace gases result
is condensation of Zinc in
gases.
• Condensers help in dissolving
condensed Zinc in molten
Lead.
• Each condenser consists of
Bath of molten Lead.
• Retorts in condensers
capable of generating an
intense spray of Lead
droplets.
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• Condensers are immersed into the molten Lead bath.

• When the furnace gases pass through the spray, they

subjected to shock cooling which minimizes re-oxidation

of Zinc by CO2.

• Result is that Zinc vapours either goes directly in to

solution with the Lead or forms liquid Zinc.

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 Zinc Separation

• The Zinc containing Lead is continuously pumped out

from the furnace at a temperature of 5500C into water
cooled launders.
• It is cooled to a temperature of about 4400C.
• During cooling Lead is saturated with Zinc.
• Excess Zinc emerges from the lead and floats in the
form of a rivulets on the surface of Lead because of less
density.
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• Zinc is separated and the Lead is continuously returned

to the condensers.

• The Zinc is collected in a holding tank and treated with

metallic sodium to remove arsenic.

• At this stage the metal is high grade and ready for

casting.

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Chemistry of Blast furnace smelting

• C + 1/2O2 = CO

• C + O2 = CO2

• CO2 + C = 2CO

• Zn O + CO = Zn + CO2

• Pb O + CO = Pb + CO2

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 Products of Zinc Blast furnace

• Zinc vapours (collected at top and condensed ).

• Lead in the sinter reduced to Lead metal flows down to

the bottom of the furnace .

• Slag ( tapped from bottom ).

• Lead bullion ( tapped from the bottom ).

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• Lead bullion contains copper, silver, gold, and impurities .

• Slag and bullion are separated by density difference.

• Bullion is usually cast into one ton ingots for subsequent

refining.

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 Summary

• Zinc Blast furnace is of a square cross section which is

operated at 10000C.

• Feed arrangement at the top of the furnace operates

under a positive pressure.

• Blast furnace uses preheated air between 5500C and

7500C.

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• The furnace gases generated during reduction pass
upward through the charge and are evenly divided
between two condensers.
• The condensers very rapidly cool the furnace gases
result is condensation of Zinc in gases.
• Each condenser consists of bath of molten Lead.
• When the furnace gases pass through the spray they are
subjected to shock cooling.

18
 Quiz

1.The temperature maintained in Zinc Blast furnace is

a) 8000C

b) 10000C

c) 15000C

d) 7000C

19
 Quiz

2. Feed arrangement at the top of the furnace operates under

a) positive pressure

b) negative pressure

c) atmospheric pressure

d) none

20
 Quiz

3. Zinc blast furnace uses air in

a) cold condition

b) pressurized condition

c) preheated condition

d) none

21
 Quiz

4.Sinter is preheated to

a) 5000C

b) 3000C

c) 9000C

d) 8000C

22
 Frequently Asked Questions

• Write the Zinc production in Blast furnace

• Write the construction of Zinc Blast furnace

• Explain the condensation of Zinc vapours from the Blast

furnace

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THANK YOU

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