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    Jarofix 2010

    Uploaded by

    Dev Ashish Gurjar
    Jarofix is the waste product that is obtained as a by product of hydrometallurgical extraction process of zinc metal. the document deals about the uses and properties of Jarofix

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Jarofix 2010

    Uploaded by

    Dev Ashish Gurjar
    153 views28 pages
    Jarofix is the waste product that is obtained as a by product of hydrometallurgical extraction process of zinc metal. the document deals about the uses and properties of Jarofix

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    © © All Rights Reserved

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    Jarofix is the waste product that is obtained as a by product of hydrometallurgical extraction process of zinc metal. the document deals about the uses and properties of Jarofix

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    153 views28 pages

    Jarofix 2010

    Uploaded by

    Dev Ashish Gurjar
    Jarofix is the waste product that is obtained as a by product of hydrometallurgical extraction process of zinc metal. the document deals about the uses and properties of Jarofix

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 28

    Xstrata Technology - Jarofix

    Hindustan January 2010

    History of Jarofix CEZ

    Imposed end to jarosite storage technology 1993 5 Years


    Research of all existing technologies 1993 - 1994
    Development of residue fixation technology at NTC 1995
    Testing and Pilot Plant - CEZ - Golder NTC 1996
    Production CEZ 1998
    Jarofix sale to Austurianna 2002
    Jarofix sale to Hindustan 2004
    Jarofix sale to Binani 2006
    Development package Jarosite Sulfur to Kokkola 2008
    Included in Xstrata Technology January 2009
    2

    Zinc Hydrometallurgical Process


    3 stage counter current leaching process
    Zinc oxide recovered in a neutral leach and a low acid leach
    Iron ferrites are then leached and precipitated in a third stage
    Iron is precipitated as a sodium jarosite in this stage
    In preparation for filtration, the jarosite is seeded
    This seeding gives a particle diameter mean near 9 microns

    Basic Information CEZ


    Annual zinc production capacity 280,000 tonnes
    Annual sulphuric acid production of 500,000
    500,000 tonnes of concentrate treated - 8 to 10 % iron
    Iron is precipitated as a sodium-jarosite
    Annual production of residue 160,000 tonnes

    Jarosite Particle Size Distribution

    120

    9
    8

    100

    Cumulative

    80

    Differential

    60
    4
    40

    Diff. Volume (%)

    Cum. Volume (%)

    2
    20
    1
    0
    0.1

    10

    0
    100

    Particle Diameter (microns)

    Selective Precipitation Circuit


    Used to remove circuit inerts such as Mn and Mg
    Used to maintain and modulate the water balance
    The liquid effluent is sent for further water treatment
    The gypsum solids generated are filtered with the jarosite

    Integrated Circuit

    Jarosite thickener

    Return to process

    Wash water
    To Jarofix

    Wash water
    Lime

    Selective precipitation circuit

    To plant effluent
    treatment system

    Repulp tank

    Jarofix Process Block Diagram


    Filtrate

    Slurry

    Leaching and
    Jarosite Precipitation

    S/L Separation

    Jarosite Filtration

    Solution

    Selective
    Precipitation
    pH 6 - 7

    Filtrate

    Residue

    residue

    Water Treatment
    pH 9.5

    Residue

    Fixation
    Residue

    Filtrate

    Residue

    Rain and effluents

    Disposal Area

    Jarosite Fixation
    Lime addition for pre-neutralization of contained solution
    Cement addition to the alkaline paste
    Requirements
    A well washed jarosite, gypsum, sulfur, cake
    A relatively small range of humidity
    A maximum temperature
    Short-term fluidity to transport
    Long term physical strength and chemical stability

    Jarofix Operation
    Lime
    Jarosite

    Lime Mixer

    Cement

    Transportation

    Cement Mixer

    Stockpile
    10

    Transportation Alternatives
    Liquid trucking CEZ current technique
    Solid trucking Austurianna current technique
    Paste trucking Hindustan current technique
    Liquid pumping Tested loop NTC Golder
    Liquid pumping Testing proposed Binani

    11

    Chemical and Physical Characterization


    Water Leaching Test TCLP 1311
    Method 1312
    BC Initial Test
    Dynamic Leach Test
    Unconfined Compressive Strength
    Hydraulic Conductivity

    12

    Chemical Characterization Details


    A sample of Jarofix residue taken from a fully controlled normal operation (pH) will pass
    tests (1311) designed to allow material to be placed in a mixed residue environment. As
    in any other sample, we consider that the water of hydration be removed from the sample
    before starting the test. However, we have always recommended that Jarofix be stored
    independently of any other residue. This is because there will always be minor upsets to
    a zinc process that could make the residue vulnerable to leaching in a mixed residue
    storage situation. Once the logic has been accepted that the material is stored in a very
    thick independant area with engineered filling drainage and engineered final surface
    drainage we have usually increased the pH target so that there is always a high level of
    available neutralization capacity from the cement and the lime. Government agencies
    must agree with this logic because it produces samples that at times do not pass the prescreening of the 1311 tests because of the excessive pH.

    13

    Liner Considerations
    At CEZ an agreement was reached with the Canadian government that Jarofix at CEZ would not
    require a lower liner nor an upper liner before re-vegetation. The agreement was reached by reviewing
    the environmental conditions in Canada, the hydrological parameters of the proposed storage site, the
    results of chemical and physical tests, hydraulic conductivity of Jarofix and the final proposed shape
    of the strorage site.
    A short term bottom liner would have been required if there was a risk of contaminating the ground
    water before the Jarofix sealed the ground itself. We have opted for a liner in our operation in Spain
    but consider the thick layer of very low hydraulic conductivity Jarofix as being the protection for the
    environment for the centuries to come.
    The upper liner under the vegetation is not required for the vegetation as can be seen in our Photo
    Annexes. We have found that we can get vegetation to grow on fairly steep but controlled slopes
    without a plastic liner. Slopes must be reduced if a liner is required despite their not being a real logic
    for an upper liner. Again, we were required to place an upper liner below the vegetation in Spain. We
    have been required to repair one problem areas on our outer profile probably due to effects from
    freezing during the winter. This work is also included in the Photo Annexes.

    14

    Environmental Monitoring
    Sampling of current production
    Leaching tests
    Physical caracterization

    Sampling of cured Jarofix at site


    Leaching tests
    Physical caracterization

    Effluent monitoring

    15

    TCLP 1311 and TCLP 1312 Test Results

    TCLP 1311
    Al

    As

    Be

    Cd

    Co

    Mn

    Ni

    Pb

    Zn

    Year

    (mg/L)

    (mg/L)

    (mg/L)

    (mg/L)

    (mg/L)

    (mg/L)

    (mg/L)

    (mg/L)

    (mg/L)

    2000

    <0.1-0.2

    0.02-0.06

    <0.01

    <0.005

    0.09

    0.02-0.03

    <0.01

    <0.05

    0.01-0.03

    2001

    <0.1-0.2

    0.03-0.04

    <0.01

    <0.005-0.006

    0.09-0.10

    0.05-0.20

    <0.01

    <0.05

    <0.01-0.12

    Al

    As

    Be

    Cd

    Co

    Mn

    Ni

    Pb

    Zn

    Year

    (mg/L)

    (mg/L)

    (mg/L)

    (mg/L)

    (mg/L)

    (mg/L)

    (mg/L)

    (mg/L)

    (mg/L)

    2000

    0.1-0.3

    <0.01-0.03

    <0.01

    <0.005

    <0.02-0.04

    <0.01-0.02

    <0.01

    <0.05

    0.01-0.03

    2001

    0.2-0.3

    0.01-0.03

    <0.01

    <0.005

    0.03-0.04

    0.01

    <0.01

    <0.05

    <0.01

    TCLP 1312

    16

    Disposal Area at the End of Construction

    17

    Jarofix Impoundment - August 2000

    18

    Jarofix Impoundment - Access Road

    19

    Jarofix Impoundment - Unloading Point

    20

    21

    22

    Jarofix Impoundment - Dike Construct

    23

    Jarofix Impoundment Jarosite dikes

    24

    Progressive development concept- year 5

    25

    Jarfix stacking at the end of year 25

    26

    Conclusions
    Jarosite residue can be engineered for filtration

    Selective precipitation can also be engineered for filtration

    Good filtration technology increases metal recovery

    Jarofix is major breakthrough in the zinc industry


    Jarofix residue is chemically and physically stable
    Progressive revegetation is feasible and economical

    27

    Technology Recognition
    Falconbridge Innovation Award (2003)
    (Award presented at the 42nd Conference Metallurgist of the Canadian
    Institute of Mining and Metallurgy (CIM) Vancouver 2003)

    Teck-Cominco Environmental Award (2008)


    (Award presented to Gary Monteith at the 47th Conference Metallurgist of
    the Canadian Institute of Mining and Metallurgy (CIM) Winnipeg
    2008)

    28

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