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Acid Plant Database  September 11, 2020

Owner Nyrstar

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Location Hoofdstraat 1
6024 AA Budel-Dorplein
The Netherlands
Background Formerly
- Budel Zink
1995 - Becomes a wholly owned subsidiary of Pasminco
- Zinifex Budel Zink
2007 -
Nystar announced that as of 31 August 2007 it had taken ownership of the zinc and lead smelting and alloying assests of Umicore and Zinifex, thereby formally launching the company and creating the world’s largest zinc producer.
Website www.nyrstar.com
Plant Budel Plant
Coordinates* 51º 14' 15" N, 5º 36' 8" E
Type of Plant Metallurgical
Gas Source Zinc
Lurgi Fluid Bed Roaster
Plant Capacity 1171 MTPD
SA/DA Original: 2/2 DA
Current: 3/2 DA - new single bed converter added in front of existing converter
Emissions SO2: 200 mg/Nm3
Status Operating
Year Built 1970's
Technology -
Contractor -
Remarks 1999 - October - Commissioning of plant incorporating NOx removal SCR
2020 - 4 New WESP's installed
Pictures   Nyrstar - Budel 2.jpg (20004 bytes)  Nyrstar - Budel 3.jpg (18911 bytes)  Nyrstar - Budel 4.jpg (8906 bytes) 
General The Budel zinc smelter is situated on a 200 hectare site at Budel Dorplein in the southeast of The Netherlands near the Belgian border and close to the majority of its customers in the major industrial centres of The Netherlands, Belgium, Germany, Luxembourg and northern France. Budel also owns approximately 550 hectares of adjacent land. The current electrolytic plant was commissioned in 1973, replacing the thermal zinc recovery operation that had existed on the site since 1892. The smelter uses RLE technology. The expansion of the plant was completed in 2006.

The Budel smelter is situated near Weert in the south east of the Netherlands, near the Belgian border and close to major European industrial centres in The Netherlands, Belgium, Germany, Luxemburg and northern France.  Approximately 80% of total product sales are delivered to customers within 300 kilometres of the plant.  The smelter was commissioned in 1973, uses conventional RLE technology and is one of Europe's most efficient zinc smelters in terms of its metallurgical performance.  It produced approximately 212,000 tonnes of zinc in 2003, however, after the planned expansion to 232,000 tonnes per year scheduled for 2004, it will be about the ninth largest zinc smelter in the world.
Budel produces SHG, CGG and cadmium and sulphuric acid by-products. With access to rail and canal transport in an area of good infrastructure, Budel is well located to supply European markets. It has strong brand recognition in a very competitive market.  Budel is a virtually solid waste-free zinc smelter, following a process conversion in 2000 which resulted in it becoming fully dependent on Century for its concentrate.
Budel's strategy is to expand its zinc capacity to 260,000 tonnes per year in 2006, whilst maximising the revenue from its existing capacity by increasing the proportion of high margin alloy products that it produces. As part of this strategy, Budel plans to enter the European EZDA market.
Budel will also seek to capture the value of the 550 hectares of nature reserve and industrial land that it owns adjacent to the site. Budel is working with a number of interested parties, including the city council of the municipality of Budel, to have some 100 hectares of this land re-zoned as industrial by the end of 2004.
In 2000, the Budel process was modified significantly to allow for the conversion to Century concentrates. The special nature of Century concentrates has provided a number of benefits, including higher recovery and lower energy requirements.
The modification also means that Budel's process is reliant on low iron concentrates. As part of its strategy of focusing on high margin alloy products, Budel commissioned new alloying facilities in 2001. This significantly increased its alloying capacity from 75,000 tonnes per year to 100,000 tonnes per year. The facility is able to produce CGG, Eutectic (5% aluminium) and special nickel/zinc alloys.
As part of its strategy of pursuing low cost capacity expansion opportunities, Budel is planning to de-bottleneck each area of the plant, which it expects will increase production capacity to 260,000 tonnes by 2006. The cost of the expansion is expected to be approximately US$340 per tonne of zinc metal capacity and as such, is substantially below the industry standard cost. The first stage will involve an increase to 232,000 tonnes during 2004 by expanding the capacity of the cell house.


Budel currently produces CGG and SHG zinc metal in addition to the industrial alloy it is now able to produce.
Budel also produces cadmium metal and over 320,000 tonnes of high-quality Sulphuric acid, sold to a majority of customers located within a 150 kilometre radius of the plant.
In addition, it produces approximately 81,000 wet tonnes of Budel Leach Product (BLP) per year that is sold to secondary European smelters that recover lead and precious metals. Classification of BLP as a saleable product is essential to the continued operation of Budel and to ensure this, Zinifex often blends high concentrates with silver lead into its feedstock.

Environmental Management

Budel has ISO 14001 certification for its site environmental management system in addition to ISO 9001:2000 certification for its quality management system.
Budel has been a virtually solid waste-free zinc smelter following its conversion in 2000 to Century concentrates. This conversion enabled the site to comply with environmental commitments made to the Dutch authorities to cease production of solid waste material, namely jarosite.
A second biological waste water treatment plant, commissioned in 1999, allowed Budel to cease production of its other solid waste, gypsum.
Budel has an agreement with the Province of Noord-Brabant for completion of capping of its historic jarosite and gypsum ponds by December 2005 prior to handing over responsibility of the area to the provincial authorities.
The agreement also included an obligation to pay the province an amount to cover the costs relating to the ongoing maintenance of the ponds after handover. Discussions with the Province are underway to determine the amount of the after care fund. The outcome should be concluded by the end of 2004.

Capital Expenditure

Over the two years to 2005, Zinifex expects to spend 25.2 million on capital expenditure. A campaign shut-down for mid-calendar 2004 will cost approximately 3.6 million.   Major growth projects include expansion of Budel's capacity to 260,000 tonnes per year in 2006 which is expected to cost 9.3 million.

References Van Driel, J., Giesen, B., Berryman, A., Sampat, S., Enevoldsen, S. and Jensen-Holm, H., "Budel Zink Sets a New Standard for NOx Reduction in an Acid Plant", Sulfide Smelting 2002, Proceedings of a Symposium sponsored by the Extraction and Processing Division (EPD) of TMS, Seattle, Washington, February 17-21, 2002, pp. 73-84
News 2019 - Trafigura Group Pte Ltd., a market leader in the global commodities industry, recently became the majority owner of the operating business of Nyrstar, a global multi-metals business.  “The closure of this capital restructuring is excellent news for both Trafigura and Nyrstar,” said Jeremy Weir, executive chairman and chief executive officer of Trafigura. “Nyrstar is a significant global business that has been built on strong foundations. The macro economic environment is positive for zinc concentrate and refined zinc metal markets on a forward looking basis, and Nyrstar will be very complementary to our existing trading activities. As an independently operated company within the Group and with its restructured and strengthened balance sheet, there is now the opportunity for Nyrstar to realise its full potential.”  Daniel Vanin has been appointed Chief Executive Officer of the operating business of Nyrstar.  With 40 years in the industry, he brings extensive international mine and smelting development experience, alongside strong management skills to the role.  “I’ve already visited almost every Nyrstar operation around the world.  I’ve been impressed by the fundamental strength of the assets, by the depth of technical knowledge of the teams and by their passion for the work that they do.  I’ve seen many opportunities and solutions that could be implemented quickly.  We will also be able to draw on Trafigura’s technical, economic, and other commercial expertise,” said Vanin.  Over the next few months, a new headquarters will be established at Nyrstar’s operations at Budel, in the Netherlands.  Members of Zurich-based staff whose roles are affected have already been informed of these plans, with the employee consultation process having taken place during July. 

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