UNIVERSITY OF CAPE TOWN

DEPARTMENT OF CHEMICAL ENGINEERING

CHE3005W CHEMICAL ENGINEERING II – 2017
PROJECT 1: ELECTROLYTIC ZINC EXTRACTION PROCESS
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Task 1

Information search and qualitative evaluation of zinc extraction processes & Environmental
considerations for the tailings disposal section

Section 1

Task 1 of Project 1 is for you to review the process routes for zinc extraction from an ore body containing zinc
sulphide (sphalerite) and lead sulphide (galena). Discuss briefly the sources of zinc. Perform a brief search of
the properties of zinc metal and draw a neat table with all the key properties. Discuss the main uses of zinc
metal and indicate why it is attractive to use zinc for those applications.

You are required to review at least three process flowsheets. As part of the review make brief notes of the
many drivers for selection of each of the process flowsheets that you will review and the main stages involved
in the extraction after the ore is mined and enters the process plant. If you have reviewed more than three zinc
extraction flowsheets, select three and briefly discuss the functions of each key unit equipment in the flowsheet.

Without going into details provide a brief description of the environmental challenges posed by each process
flowsheet you have reviewed.

Compile a section in your report containing:

i. The sources of zinc
ii. The properties of zinc and the main uses of the metal.
iii. Using your drawing skills prepare and discuss three most common process flowsheets used for the extraction
of zinc metal. For each discuss the functions of the main process units.

Section 2

After dewatering in the thickener, the tailings are to be disposed of in a tailings storage facility (TSF). These
are often above-ground hill-type structures. If you’ve ever played with wet sand on the beach, you’ll know
how difficult it is to build a lasting structure (like a sand-castle). And indeed, in the history of mining, there
have been dozens of tragic disasters in which a tailings storage facility failed, burying surrounding landscapes,
and often also settlements, under tens of thousands of tons of mud. Research the history of the Merriespruit
tailings dam failure in South Africa and write a 300 word summary. Pay attention to particle size distribution
and moisture content of the tailings disposed there.

The remaining water contained in the tailings after thickening has one of three fates: it evaporates from the
TSF, it may seep into the ground (and ground-water) or it can be recovered for re-use from the dam that forms
on top of the TSF. New regulations for tailings disposal aim to minimise seepage, as this may pollute
groundwater. This is usually achieved by preparing one or several clay soil layers underneath the TSF. Look
up the permeability of compacted clay that may be used for such applications, and calculate the seepage flux
for a 15 cm thick layer. Give your estimate in litre per m2 per day. Also discuss how an assembly of layers
with vastly different permeabilities could be used to recover the percolating water.
Windblown dust is one of the significant environmental risks of TSFs. What fraction of the material that leaves
your thickener for disposal would be classified as PM10, and what fraction as PM2.5? Can you think of any
ways to minimise the risk of windblown dust causing pulmonary disease? Think of three interventions,
including at least one that would prevent the problem at source. Present your ideas in one page of writing –
including diagrams or sketches if appropriate.

If the thickener used for dewatering was a high rate thickener, what difference would you expect in the space
requirements on the plant and the impact on downstream tailings storage facility? Briefly discuss the
drawbacks of current tailings disposal methods on the environment. Give suggestions on how you can improve
the design of the solid-liquid separation techniques to minimise the environmental concerns. This can include
technologies that you think can help overcome the problems encountered in tailings disposal systems.

Report Specifications
Compile a section in your report containing well-structured responses to the issues raised in the paragraphs
above. Where calculations are required show all these clearly in the appendix and only main result in the main
body of the as well as reasons for the calculated solutions. Obtain the missing data from textbooks or sources
that have scientific integrity. Put all the references used in the report.

The section containing Section 2 of Task 1 should not exceed 4 pages.