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

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Sulphuric Acid Plant Specifications
 

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Acid Plant Database January 30, 2009

Owner Nyrstar NV

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Background Formerly
- Jersey Minere Zinc Company
- Savage Zinc, Inc.
- Pasminco
- Zinifex
2007 -
Nystar today 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.
Location P.O. Box 1104
1800 Zinc Plant Road
Clarksville, Tennessee
USA  37041-1104
Website www.nyrstar.com
Plant Clarksville
Coordinates* 36º 31' 0" N, 87º 24' 21" W
Type of Plant Metallurgical
Gas Source Zinc
Plant Capacity 456 MTPD
SA/DA 2/2 DA
Status Operating
Year Built 1978
Technology Outotec (Lurgi)
Contractor Lurgi
Remarks Mercury removal system
Pictures   Nyrstar - Clarksville 2.jpg (10771 bytes)
General The Clarksville zinc refinery is located four kilometres southwest of Clarksville, Tennessee, beside the Cumberland River. The operation is sited on 1,400 acres of freehold land of which 120 acres (49 hectares) is occupied by the plant and the auxiliary operations. The land surrounding the plant supports farming, forestry and wetlands.
Clarksville is a relatively modern electrolytic zinc smelter which uses RLE technology. The plant was commissioned in 1978.
Clarksville is located within 900 kilometres of the United States’ industrial heartland, including Chicago and Detroit.

Clarksville smelter is located four kilometres southwest of Clarksville, Tennessee in the United States. It was commissioned in 1978 by Union Miniere SA, making it one of the newest zinc smelters in the world. The facility is surrounded by over 1,400 acres of land owned by Zinifex. It is ideally situated within one days delivery distance from many of the US's major zinc consumers. It is within 800 kilometres of Chicago, Detroit and much of the US industrial heartland. This provides Clarksville with a location advantage, which contributes to its realisation of a premium over the LME price for its zinc products. Clarksville is the smallest of Zinifex's smelters, producing approximately 110,000 tonnes of SHG and CGG zinc metal per year. It also produces cadmium and sulphuric acid. Clarksville is accessible by barge, rail and road for feedstock and product handling.

Clarksville's strategy focuses on consolidating its current competitive strengths. This will potentially involve expanding its capacity by 36,000 tonnes per year, reducing unit cash costs, entering selected US zinc alloy markets to increase proportion of premium margin products sold and securing medium term concentrate supplies and shortening its current concentrate supply chain.

Operations

Historically, Clarksville smelter sourced the majority of its concentrates from the nearby Gordonsville and Clinch Valley mines. As a result of the closing of Gordonsville in 2003 and the closing of Clinch Valley in 2004, Clarksville now obtains all of its concentrates from Central and South America, Ireland, Australia, including 19% from Century. Clarksville has successfully processed concentrate containing up to 30% Century content.

Zinifex plans to expand Clarksville's capacity to 154,000 tonnes in three stages. The first stage, scheduled for 2006, will involve increasing roaster throughput capacity to 130,000 tonnes and is expected to cost pproximately US$1.5 million. Subsequent stages to expand capacity to 143,000 and 154,000 tonnes will address cell house constraints.

Zinc Production

Zinc production in 2003 was around 110,000 tonnes and represented 30% of total US domestic zinc production. As part of its strategy, Zinifex is considering entry to the high value zinc alloy market in the US, a move Zinifex believes will increase Clarksville's overall margin.

The smelter also produces approximately 145,000 tonnes per year of sulphuric acid which is marketed through an 80% owned subsidiary, Taylor Chemical Inc.

Minor additional revenues are derived from the sale of cadmium.

Environmental Management

In July 2003, the US Environmental Protection Agency's Office of Solid Waste confirmed that by-products and wastes generated by Clarksville are done so from beneficiation activities and are therefore exempt from certain Resource Conservation and Recovery Act (RCRA) regulations.

This is a positive outcome for Clarksville, as it means that the materials currently stored on-site can be treated as solid waste rather than hazardous waste, with no immediate additional storage or disposal requirements.

Capital Expenditure

Over the next two years to 2005, Zinifex expects to spend US$6.5 million on capital expenditure. The plan includes replacements of relatively small plant items, as well as environmental expenditures.

News 2008-12-15 - Nyrstar NV today announced that it will be reducing production at its Clarksville, USA plant by about 40% to reflect current market conditions.  The reduction takes effect in early January and is expected to last for six months, reducing Clarksville's production by approximately 25,000 tonnes of zinc. The action at Clarksville follows Nyrstar's decision to temporarily suspend production at its Balen plant and reduce production at Budel by 28% through to mid 2009.  Total production cuts at Nyrstar now amount to approximately 190,000 tonnes for the first half of 2009, in addition to the 35,000 tonnes reduction in 2008.

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