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Sulphuric Acid on the WebTM Technical Manual DKL Engineering, Inc.

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Acid Plant Database August 24, 2010

Owner Chelyabinsk Zinc Plant (CZP) OJSC

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Location 24 Sverdlovsky Trakt
Chelyabinsk 454008
Southern Urals
Russia
Background 1935 - Chelyabinsk Electrolytic Zinc Plant established, with annual capacity of 20,000 tonnes of zinc
1960 - CEZP's capacity increased to 70,000 tonnes
Website www.zinc.ru
Plant -
Coordinates* 55° 12' 48.5" N, 61° 22' 53" E
Type of Plant Metallurgical
Gas Source Zinc
Plant Capacity 240,000 MTPA
SA/DA DA
Status -
Year Built -
Technology -
Contractor -
Remarks The utilization of sulphur containing gases after zinc concentrate roasting is carried out at the sulphuric acid plant resulting in marketable sulphuric acid. The sulphuric acid plant has four sulphur containing gas treatment systems of total capacity 103 thousand Nm3/hour. At present the reconstruction of system No.5 of 40 thousand Nm3/hour design capacity is under way. SO2 concentration in the roasting off-gas is in the range of 8 – 9.5%. The process of oxidizing SO2 to SO3 is conducted in the double contacting scheme. The achieved contacting level is 99.8%. The use of "Begg Cousland", "KKK", "Alfa-Laval", "Haldor Topsoe" companies equipment allows to achieve SO2 content at the outlet to the atmosphere not more than 0.05%. Presently 1.5 t of sulphuric acid per 1 t of cathode zinc is produced.
Pictures Chelyabinsk Zinc 1.jpg (147365 bytes)  Chelyabinsk Zinc 2.jpg (119801 bytes)  Chelyabinsk Zinc 3.jpg (75014 bytes)  Chelyabinsk Zinc 4.jpg (43654 bytes)  Chelyabinsk-Zinc-5.bmp (3571174 bytes)
General Chelyabinsk Zinc Plant OJSC is a leading Russian zinc producer. The Company’s production facilities are among the most technologically advanced in the global zinc industry with potential smelter capacity of 200 thousand tones of zinc p.a. CZP is the biggest producer in Russia and CIS of Special High Grade zinc with a zinc content of not less than 99.995%; trade mark CZP SHG (Chelyabinsk Zinc Plant Special High Grade) is registered at the London Metals Exchange. The Company also produces a range of high value-added zinc alloys based on the SHG zinc and other metals, including aluminum, nickel and copper. It also sells by-products of the zinc production process, including cadmium, indium and sulfuric acid.   Chelyabinsk Zinc Plant is a fully integrated company, which mines and processes ore through to refined zinc to zinc alloys.  The company's market share is more than 60% of domestic and 2% of global market. 
References Kazanbayev, L.A. and Kozlov, P.A., “Development of Zinc Production at the Chelyabinsk Zinc Plant”, Lead & Zinc ’05, Proceedings of the International Symposium on Lead and Zinc Processing, Kyoto, Japan, October 17-19, 2005, Volume – I, pp. 405-418.
News April 28, 2009 - Russia's Chelyabinsk Zinc Plant said it produced 36.7 percent less zinc and zinc-based alloy in Q1 2009 than in the same period last year. Production cuts part of company's cost-cutting measures.

October 2, 2008 - Chelyabinsk Zinc Plant has completed implementation of a big investment project, having put the sulphuric acid system (Unit No.4) into operation upon its complete overhaul. The value of the project amounts to $35 mln.
It’s worth mentioning that five sulphuric acid systems are operating at the plant. Gaseous sulphur dioxide (SO2) is fed into such systems after zinc concentrate roasting stage. The principal aim of this production stage is to reclaim the produced gas, preventing its emission to the atmosphere.
State-of-the-art materials and technologies were used in the course of the construction of the sulphuric acid system, which made it possible to enhance the efficiency of SO2 reclamation process, reducing emissions of such gas to the atmosphere by 96.5 tn and emissions of sulphuric acid by 0.7 tons a year. Moreover, the equipment is capable of producing 100 thou. tn of improved sulphuric acid. In 2003, CZP implemented a similar project and put a new sulphuric acid system into operation.
“The new sulphuric acid system is an important environmental project. The equipment enables us to make the city’s air basin even cleaner. The system also makes it possible to produce sulphuric acid having better quality, which is highly demanded by industrial enterprises,” – commented Vsevolod Geikhman, CZP Director-General.
Overhaul of the system was started in 2006. It is planned to bring the equipment to the design capacity by the end of the year.

MTPD - Metric Tonne per Day           STPD - Short Ton per Day
MTPA - Metric Tonne per Annum      STPA - Short Ton per Annum
SA - Single Absorption
DA - Double Absorption 

* Coordinates can be used to locate plant on Google Earth