Roasting

Hindustan Zinc Ltd.
Zinc Roasting Plant
Operating Manual Zinc Roasting Plant
Hindustan Zinc Ltd. Udaipur / India
Project No. I 76270-01 Document No. 03041
July 2003 ( Rev. 0 )
D:\Academics\ZINC\R3-HZL_Operating Manual Roasting_Rev0(11.08.03).doc / 1
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Hindustan Zinc Ltd. Zinc Roasting Plant Table of Contents

1 Introduction ___________________________________________________________________7
1.1 1.2 1.3 Preface __________________________________________________________________________ 7 Warning ________________________________________________________________________ 7 Special Equipment ________________________________________________________________ 8
Process Description _____________________________________________________________9

2.1 2.2 2.3 2.4 2.5 2.6 2.7 Concentrate Storage_______________________________________________________________ 9 Material Feeding System and Fluid Bed Furnace _______________________________________ 9 Calcine Discharging System _______________________________________________________ 11 Pneumatic Transport System ______________________________________________________ 13 Waste Heat Boiler _______________________________________________________________ 13 Hot Gas Cleaning ________________________________________________________________ 14 Fuel Oil Supply __________________________________________________________________ 15
Operating Instructions __________________________________________________________16

3.1 3.2
3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6
Assignment and Duties of Lurgi Metallurgie Supervision Personnel ______________________ 16 Services to be rendered by the Operator _____________________________________________ 16
Manning _____________________________________________________________________________ 16 Scope of duties for operating personal ______________________________________________________ 16 Maintenance Personnel _________________________________________________________________ 18 Consumables _________________________________________________________________________ 18 Tools _______________________________________________________________________________ 20 Plant Safety __________________________________________________________________________ 20
Function descriptions on the logic diagrams ________________________________________22

4.1 4.2 4.3 Transport equipment interlocking __________________________________________________ 22 Plant safety interlockings _________________________________________________________ 23 Interlockings with other plant sections ______________________________________________ 24
Trial Runs ____________________________________________________________________25

5.1 5.2 Introduction ____________________________________________________________________ 25 Roaster Plant ___________________________________________________________________ 25
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Hindustan Zinc Ltd. Zinc Roasting Plant

5.3 5.4 5.5 Waste Heat Boiler _______________________________________________________________ 26 Hot Gas Electrostatic-Precipitator __________________________________________________ 26 Calcine Handling ________________________________________________________________ 26
Preparations for start up ________________________________________________________27

6.1 6.2
6.2.1 6.2.2 6.2.3 6.2.4 6.2.5 6.2.6 6.2.7 6.2.8 6.2.9 6.2.10 6.2.11 6.2.12 6.2.13 6.2.14 6.2.15
Drying the Grate ________________________________________________________________ 27 Dry Firing of Roaster and Scalding of Waste Heat Boiler _______________________________ 27
Preparations __________________________________________________________________________ 28 Filling the Waste Heat Boiler_____________________________________________________________ 28 General Inspections ____________________________________________________________________ 31 Measuring the No-Load Resistance of Grate _________________________________________________ 31 Introducing the Bed Material _____________________________________________________________ 31 First and Second Day ___________________________________________________________________ 32 Third and Fourth Day___________________________________________________________________ 33 Fifth Day ____________________________________________________________________________ 34 Sixth Day ____________________________________________________________________________ 34 Seventh Day __________________________________________________________________________ 34 Eight and Ninth Day ___________________________________________________________________ 34 Tenth Day ___________________________________________________________________________ 35 Eleventh day _________________________________________________________________________ 36 Twelfth and Thirteenth Day ______________________________________________________________ 38 Fourteenth Day________________________________________________________________________ 39
Start-up of Roaster Plant (fifteenth day) ____________________________________________41

7.1 7.2
7.2.1 7.2.2 7.2.3 7.2.4 7.2.5 7.2.6 7.2.7
Preparations, Preconditions _______________________________________________________ 41 Heating to ZnS Ignition Temperature ______________________________________________ 41

Start-up Burners _______________________________________________________________________ 41 Temperature Increase by Discontinuous Turbulization (Air Surge) _______________________________ 41 Introducing and Ignition of Oil Lances _____________________________________________________ 41 Heating the Turbulent Layer to ZnS Ignition Temperature ______________________________________ 42 Operations at Calcine Handling System during Heating-up _____________________________________ 44 Preparations and Operations at Boiler during Heating-up _______________________________________ 44 Preparations at Hot Gas Electrostatic Precipitator _____________________________________________ 44
Running Operation _____________________________________________________________45

8.1
8.1.1 8.1.2
ZnS Feed _____________________________________________________________________ 45

Conditions for ZnS-Concentrate __________________________________________________________ 45 Screen analysis, size____________________________________________________________________ 47
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8.1.3 Slinger belts __________________________________________________________________________ 48
8.2
8.2.1 8.2.2 8.2.3 8.2.4 8.2.5
Roaster ________________________________________________________________________ 49
Temperatures in Roaster ________________________________________________________________ 49 Air Volume __________________________________________________________________________ 50 Conditions within Turbulent Layer ________________________________________________________ 51 Roaster Draught _______________________________________________________________________ 52 Sulphide and Sulphate Sulphur Content in Calcine total Mixture _________________________________ 52
8.3
8.3.1 8.3.2 8.3.3 8.3.4 8.3.5 8.3.6
Waste Heat Boiler _______________________________________________________________ 53

Temperatures _________________________________________________________________________ 53 Pressure Loss - Dust Behaviour ___________________________________________________________ 53 Steam Drum Water Level _______________________________________________________________ 53 Circulating Water Volume _______________________________________________________________ 54 Safety Valves _________________________________________________________________________ 54 Cleaning during Operation _______________________________________________________________ 55
8.4
8.4.1
Hot Gas Cleaning ________________________________________________________________ 55

Monitoring the operation of the hot gas electrostatic precipitator _________________________________ 56
8.5
Calcine transport ________________________________________________________________ 56
Mechanical Supervision, Maintenance, Lubrication __________________________________57

9.1 9.2 9.3 9.4 9.5 ZnS-Feed _______________________________________________________________________ 57 Roaster ________________________________________________________________________ 58 Waste Heat Boiler _______________________________________________________________ 58 Hot Gas Electrostatic Precipitator __________________________________________________ 59 Calcine Handling ________________________________________________________________ 59
10
10.1 10.2 10.3
Analytical Inspections _________________________________________________________60

ZnS-Feed _______________________________________________________________________ 60 Calcine _________________________________________________________________________ 60 Water __________________________________________________________________________ 61
Raw water ___________________________________________________________________________ 61
10.3.1
10.4 10.5
Roaster Gas _____________________________________________________________________ 65 Clean Gas Dust Content __________________________________________________________ 65
11
Shut-Down __________________________________________________________________66
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11.1
11.1.1 11.1.2 11.1.3 11.1.4
Normal Shut-Down ______________________________________________________________ 66

Roaster ______________________________________________________________________________ 66 Waste Heat Boiler _____________________________________________________________________ 66 Hot Gas Electrostatic Precipitator _________________________________________________________ 67 Calcine Handling ______________________________________________________________________ 67
11.2 11.3 11.4 11.5

11.5.1 11.5.2 11.5.3 11.5.4
Protective Measures for the Turbulent Layer _________________________________________ 68 Short Shut-Down ________________________________________________________________ 68 Emergency Shut-Down ___________________________________________________________ 68 Inspection during Shut-Down ______________________________________________________ 70
Roaster ______________________________________________________________________________ 70 Waste Heat Boiler _____________________________________________________________________ 70 Hot Gas Electrostatic Precipitator _________________________________________________________ 70 Calcine Handling ______________________________________________________________________ 70
12
12.1 12.2 12.3
Restarting __________________________________________________________________71
Restarting from Hot ______________________________________________________________ 71 Restarting after Shut-Down with Preheating System ___________________________________ 72 Start-Up with Elemental Sulphur ___________________________________________________ 73
13
13.1
Troubleshooting _____________________________________________________________76
Zinc Concentrate Feeding Problems ________________________________________________ 76
Blockage in the Feed Bin ________________________________________________________________ 76 Blockage of the Slinger Belt Inlet _________________________________________________________ 76 General Approach _____________________________________________________________________ 76
13.1.1 13.1.2 13.1.3
13.2
13.2.1 13.2.2
Electrical Power Failure __________________________________________________________ 77

Roaster Bed __________________________________________________________________________ 77 Boiler Emergency Operation _____________________________________________________________ 77
13.3
13.3.1 13.3.2
Low Pressure of Instrument Air ____________________________________________________ 78

Leakage in the Instrument Air System ______________________________________________________ 78 Low Pressure caused by Power Failure _____________________________________________________ 78
13.4
13.4.1 13.4.2 13.4.3
Cooling Problems ________________________________________________________________ 78

Boiler Chain Conveyor _________________________________________________________________ 78 Drum Cooler _________________________________________________________________________ 78 Failure Cooling Water __________________________________________________________________ 79
14
Start up procedure for roasting -, gas cleaning - and acid plant _______________________80
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1
1.1
Introduction
Preface
These instructions are to serve as the basis for plant operation, and to plant personnel in operating the plant. These instructions are to be considered as general guidelines only, since it is not feasible to describe all conditions and situations that may occur in the plant. The information contained herein are to be supplemented by the information of the individual manufacturers of equipment and other plant facilities. All operating data and parameters are to be considered preliminary since experience gained upon commissioning and start-up of the plant may call for modifications. The safety measures included are recommendations; they are not a substitute for the Owner's safety procedures. These operating instructions are a summary of all points that have proved essential in the start-up of such plants and are not a substitute for training of supervisory and operating personnel. In furnishing these instructions, Lurgi Metallurgie assumes no liability for damage caused to the equipment by Owner's personnel as a result of improper operation.
1.2
Warning
This plant and its component equipment constitute complex, sophisticated technology. Care has been taken to make sure that all equipment is safe to operate and maintain when used properly. Failure to use the equipment in strict accordance with the procedures and specifications presented in this manual may be dangerous and may lead to injury. Be certain to take all necessary measures to ensure that all users of the equipment are fully trained in the proper use of the equipment. All persons who will be using, maintaining or repairing the equipment should be required to study and understand the pertinent sections of this manual before use or should be otherwise instructed in accordance with the procedures and specifications set forth herein. Be sure that the plant will be operated according to the plant specification every time.
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1.3 Special Equipment
With regard to operation and maintenance of special equipment (e.g. blowers, heaters, pumps, heat exchangers, etc.) please see the separate manuals of the corresponding manufacturers as:
Item No.
Description
Name
Country
City
JF_01 G001 JF_01 G002 JF_01 G003-6 BB_01 E001 JL_01 G001 GA_01 E001 GC_01 G001 GC_01 G002 JL_01 G002 GC_01 Q001 GC_01 E001 HP_01 T001 JK_01 G003-4 JK_01 G005-6 HP_01 Q001 JK_01 G001-2 CH_01 V003 CH_01 G001-2 CH_01 Q001-8
Bin Discharge Belt Conveyor Table Feeder Slinger Belt Feeder Start-Up Burner Roasting Air Fan Waste Heat Boiler Boiler Chain Conveyor Inclined Chain Conveyor Cooling Air Blower Water-Cooled Rotary Valve Material Cooling Drum Ball Mill Fuller Type Pump Srew Type Compressor Dedusting Filter Chain Conveyor Hot-ESP Hot-ESP Chain Conveyor Rotary Valves
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2
2.1
Process Description
Concentrate Storage
Reference Drawing: PFD No. I 76270-01 00002 The zinc concentrate is delivered by trucks and is discharged into two underground bins. Several belt conveyors transport the concentrate from the underground bins to the concentrate storage hall. A Pay loader feeds the materials into two hoppers. By means of discharging and transport belt conveyors including an over-belt magnetic separator, a vibro screen and a hammer mill, the materials are transported to the concentrate feed bin. Dross material from the cathode melting and casting process will be added to the feed material before the vibro screen. For moistening of the concentrate several spraying nozzles are foreseen in the concentrate storage hall, as well as on the conveying belt before the concentrate feed bin.
2.2
Material Feeding System and Fluid Bed Furnace

Reference Drawing: PFD No. I 76270-01 00003 The roaster with a grate size of 123 square meters is designed to treat concentrates of varying compositions. The produced calcine has the following characteristics.
Sulphide sulphur in calcine Sulphate sulphur in calcine
approx. 0,3% of sulphide sulphur. approx. 1,8% of sulphate sulphur
Blended feed from the concentrate feed bin is discharged onto a discharge belt conveyor, which in turn discharges onto a rotary table feeder. The roaster is fed then by two slinger belts. The average particle size distribution of a standard concentrate feed mix is given below:
Size in m > 210 210 150 150 105 105 75 75 53 < 53
Weight-% 3 10 15 13 13 46
The loading level gate at the concentrate bin outlet, which changes the material loading level on the belt, coarsely controls the quantity of the feed flowing onto the discharge belt conveyor. The fine control occurs by means of the belt speed, which can be accelerated or slowed down by a remote-controlled gear drive. The coarse adjustment is made only once, during start-up, with fine adjustments being made as necessary during operation. The rotary table feeder supplies concentrates to the slinger belts, which directly feed into the roaster. The slinger belts provide a very soft, equal, and fine distribution of the concentrates in the bed area. It is particularly important to distribute the fine material over the surface of the fluid bed
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to prevent local material deposits and the development of gas zones of varying S0 2 concentration. For the initial charge of concentrates, the start-up burners and lances using fuel oil heat the roaster to ignition temperature. The grate itself is made of steel, lined with castable materials. The combustion air serves both as a carrier medium for the fluid bed and as a source of oxygen for the predominant reaction, which converts zinc sulphide to zinc oxide and sulphur dioxide. ZnS + 1.5 O2 -> ZnO + SO2 H = -446 kJ/mol
The fresh concentrate fed into the roaster by slinger belt thus meets a fluidized bed of finegrained roasted material at a temperature of 900C to 975 C consisting mainly of zinc oxide. The combustion air for the roasting process is provided by a high-pressure air fan, which is controlled between the following operating limits: Lower limit is the homogeneous fluidization of the bed in order to avoid separation of coarser size particles. The lower limit corresponds approx. to 70% of the design figure of roasting air or approx. 450 Nm/hm. Upper limit is the increasing in the roaster gas and the gas overload and the downstream components of the plant. The upper limit corresponds approx. to 105% of the design figure or approx. 700 Nm/hm. The reaction in the roaster is strongly exothermic, and the gases leave the roaster with a temperature of approximately 930C - 975C and with an S02 concentration of approximately 10,2% by volume, dry basis. A portion of the surplus reaction heat is absorbed by cooling coils installed in the fluid bed in the form of evaporator heating surfaces connected to the forced circulation system of the waste heat boiler, thus cooling the fluid bed by indirect heat transfer. The flexibility needed for the operation of treating concentrates with varying calorific values is provided by the combined direct/indirect cooling of the turbulent layer. A portion of the feed charged into the roaster agglomerates in the bottom of the fluid bed and would result in a continuously increasing pressure loss in the roaster if an appropriate quantity of material were not withdrawn. Bed material is withdrawn via:
The continuous roaster overflow. The purge device for coarse agglomerates.
The roaster overflow functions by gravity, and its barrier rim can be raised or lowered by the insertion of weir plates. The purge-discharging device is operated manually and withdraws the material from the grate level and thus prevents the accumulation of the coarser-sized particles. The operation frequency depends on the formation of coarse agglomerates, however as an indication and for 1st start-up the discharge should be operated once per shift. Further details on the operation will be given in the operating manual. The roaster has a cylindrical bed section, a conical intermediate section, a cylindrical enlarged top section, and a grate area of 123 square meters. The enlarged cylindrical section enables a complete roasting of even the finest calcine particles without the occurrence of a secondary combustion phenomenon. For process optimisation 10 secondary air nozzles are installed to be able to distribute additional roasting air above the bed. A slight draught is maintained at the roaster gas outlet to ensure the safety of the roaster operation.
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Before the first start-up, as well as for start-ups after extended shut-downs, the fluid bed furnace and the waste heat boiler have to be preheated. For this purpose, the roaster is equipped with a preheating unit for start-up purposes, which consists of 4 oil burners and 12 oil lances with accessories. The necessary combustion air is taken from the main roaster air fan and the start-up and cooling air fan.
2.3
Calcine Discharging System

Reference Drawing: PFD No. I 76270-01 00004 The calcine is discharged at four points during normal operation: 1.) Roaster 2.) Waste heat boiler 3.) Cyclones 4.) Hot electrostatic precipitator The cyclone and precipitator dust is received relatively cold (300-350C) and sufficiently fine in size, whereas the calcine of the roaster and waste heat boiler requires primary cooling as well as grinding to the size required for leaching. This results in the following arrangement of the calcine handling. Roaster calcine and boiler dust are combined in a common chute and passed to a drum cooler. A water-cooled rotary valve provides the gas seal of the boiler chain conveyor. The cooling air blower cools the boiler chain conveyor. The material temperature at the drum cooler outlet is below 150C. The pre-cooled calcine is transferred into a ball mill via an inclined chain conveyor. This ball mill is designed to achieve the desired grain size, which is 90% below 0.075 mm and 70% below 0.050 mm for the total calcine. The finest dust precipitated in the hot gas ESP is combined with the mill discharge and transferred to the calcine silos via the pneumatic transport system. A bag filter is provided to capture fugitive dust from the calcine handling ventilation system. Furnace heating occurs prior to start-up of normal roasting operation with Zn-concentrate. Pre start-up activities contain basically: Grate drying Dry firing of roaster and waste heat boiler Cleaning of boiler Filling of boiler system Feeding of inert material (calcine) and heating up of system Feeding of Zn-concentrate
As combustion medium during the above described preheating diesel oil is used. The maximum flow of diesel oil amounts to 3000 kg/h. The composition of offgas during furnace heating is shown in below table:
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Component
Content in Vol-% (approx.)
SO2 H2O O2 N2 CO2 Total
0.2 10.3 1.9 74.0 13.6 100.0
Max. offgas volume: approx. 3200036000 Nm/h The total duration of 1st drying, boiler cleaning and preheating takes approx. 3 weeks. The duration of preheating after shut down of the roaster depends on the furnace temperature. If the furnace is cooled down to ambient temperature preheating and restart takes approx. 2-3 days. A detailed description of the start-up procedure will be given in the operating manual.
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2.4 Pneumatic Transport System
Reference Drawing: PFD No. I 76270-01 00005 The combined calcine from the ball mill, cyclones and hot-esp are transported via a chain conveyor to the calcine intermediate bin. Screw type compressors provide the air for the pneumatic transport pumps, which transport the calcine to the calcine silo. The calcine silo bin is equipped with a separate storage dedusting air fan.
2.5
Waste Heat Boiler

Reference Drawing: PFD No. I 76270-01 00006 and 00007 The hot dust laden gas stream leaving the roaster is drawn into the waste heat boiler under suction from the SO2 blower. The waste heat boiler is a horizontal-pass boiler, gas-tight welded, membrane wall-type, directly connected with the gas outlet flange of the roaster by means of a flexible fabric expansion joint. In the boiler, the dust-laden gases are cooled down from the roasting temperature to about 350C before entering the dust precipitation system. The waste heat boiler is a forced-circulation-type boiler for the production of superheated steam. The convection heating surfaces of superheaters and evaporators are combined in bundles in a suspended arrangement. The waste heat boiler is equipped with a membrane tubed settling (drop-out) chamber ahead of the front convection bundles. In the settling chamber, part of the dust carried along with the gas is separated. Since the waste heat boiler handles roasting gases having a very high dust content, a mechanical rapping device has to be provided. Pneumatic cylinders drive these rappers. Depending on the degree of fouling, the rappers can be actuated by a cylinder controller from a switching cabinet. The pneumatic cylinders are operated by compressed air, which can be taken from the plant air system. The gas-flow velocity through the tube banks was designed to be very low to avoid erosion. The tube banks can be easily removed for maintenance after the plant has been taken out of operation. The rapping device is automatically actuated at certain time intervals. The dust separating out in the boiler is collected in a chain conveyor and fed to the rotary drum cooler. The combined system of cooling coils in the roaster, superheated tube bundles, evaporator tube bundles, and membrane wall casing is designed for the maximum load of the boiler. The boiler produces steam in a forced circulation system and is equipped with two circulating pumps, one motor-driven and one turbine-driven. Each pump is capable of handling the maximum rating of the boiler continuously. The stand-by steam-driven circulating pump will start automatically when the electric power supply fails or when the flow of circulating water falls below a preset quantity. The water-steam mixture, produced in the forced circulation system, is separated in a steam drum by means of a demister. A pressure relief system is included to exhaust steam directly to the atmosphere via a noise damper in the event of curtailed steam usage in the leaching plant. The steam relief system is designed for the full waste heat boiler production of 49 metric tons per hour.
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The level-control valve installed in the incoming demineralized water line controls the feedwater tank level. The demineralized water is deaerated in the deaerator on top of the feedwater tank. Deaeration is accomplished by means of steam from the saturated steam line. The feedwater tank pressure is maintained by the pressure control valve. The deaerated feedwater is preheated and fed to the steam drum via the feedwater pumps, one motor-driven and one steam-driven. The steam drum level is controlled using a three-element control system. An additive preparation and dosing station for the boiler feedwater is included in the system. Cooled gases leaving the waste heat boiler flow into the hot electrostatic precipitator (ESP) for final dust removal.
2.6
Hot Gas Cleaning

Reference Drawing: PFD No. I 76270-01 00008 Hot gas cleaning comprising: two hot gas cyclones for roaster gas prededusting one single line three field hot ESP
Cyclones The cooled and dust loaded gas enters the two parallel cyclones for pre-dedusting with a temperature of approx. 350 C. The gas leaves the cyclones at the top whereas the dust is collected in the lower part of the cyclones and removed via rotary valves. Final dedusting of the hot gas is achieved in the hot ESP. Hot Gas Electrostatic Precipitator The gas leaving the cyclones enters a three field hot gas ESP. The ESP consists of the discharge electrodes, the collecting electrodes, gas distribution walls, casing, roof, hoppers, horizontal inlet and outlet nozzles, pressure relief system, rapping systems, sealing air . system for the insulators with electric heater and transformer rectifiers with control cabinet for the electrostatic fields. The precipitator is insulated. The collected dust is removed from the ESP via the chain conveyor and the rotary valves. Rapping systems are installed at the gas distribution plates in the inlet cone of the precipitator and at the discharge and collecting electrodes. At their bottom end, the collecting electrodes run through rapping bars, so that the rap is effected at the lower side end in the plate plane. A hammer shaft rotates at the end of each electrostatic field, lifting the rapping hammers which drop down in a free fall when the vertical position is exceeded. The acceleration amounts to more than 200 g (200 x 9,81 m/s2) at the total collecting electrode area. During start-up and shut-down the gas temperature in the precipitator can fall below the dew point. To prevent condensation on the insulator a heating system is installed. This heating system, consisting of a fan and a heater supplies hot air to all insulators. This hot air prevents the penetration of gases to the insulators and also will keep the insulators at a temperature
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above the dew point to prevent the formation of condensate, which could cause electrical flash-overs. Each discharge electrode system is supported by means of four high voltage insulators. The discharge electrodes are tightened in tubular frames, which are vertically arranged between the collecting electrodes. The high voltage insulators which support the discharge electrode systems are located within box-type roof beams on top of the electrostatic precipitator and a key-system is used to secure every door. By this way they are protected against accidental contact to personnel. Separate transformer-rectifier sets per each electrostatic field (= 3 fields = 3 units) are installed. The discharge electrode systems will be supplied with high voltage DC by modern transformer rectifier sets. Each transformer rectifier set will have its own cubicle for control and regulation. Such a transformer rectifier set (power pack) contains a high tension transformer and semi conductor rectifier pack. Both are installed in a steel vessel immersed in oil. The vessels of the power packs are located in the high voltage room below the hot gas electrostatic precipitator. The optimum values of the high voltage are controlled by a special low voltage control system. There is a high voltage switch on top of the T/R set for manual operation for disconnecting of high voltage supply and earthing of the discharge electrode system!
2.7
Fuel Oil Supply

Reference Drawing: PFD No. I 76270-01 00009 The fuel oil supply for heating up of the roasting and acid plant is provided by an fuel oil storage tank. The capacity of the tank with 100 m is designed for one start-up procedure from cold conditions.
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3
3.1
Operating Instructions
Assignment and Duties of Lurgi Metallurgie Supervision Personnel
Lurgi Metallurgie provides the personnel to supervise the commissioning. The number of personnel and the duration of their stay are governed by the agreements reached on conclusion of the contract. The commissioning or start-up of the plant covers the following sections: Preparations Dry firing of roaster Start-up and subsequent trail run of approximately 3 weeks Guarantee run
The duties of the supervision personnel are as follows: Supervision of the preparations for start-up and dry firing Familiarization of the operating personnel Supervision of start-up and process of plant during the start-up period. Supervision of the guarantee run to establish proof of the process guarantees.
3.2
3.2.1
Services to be rendered by the Operator

Manning
HZL is to provide qualified personnel in sufficient number to guarantee the safe operation of the plant in connection with sufficient supervision and maintenance. It is recommended that the operating personnel be selected and trained already several months prior to the commissioning, so that they are able to familiarize themselves with the conditions, equipment and other features of the plant already during the final phase of erection. 3.2.2 Scope of duties for operating personal
Operation The plant is operated and controlled from the central control room. The control room must be constantly manned for timely detection of failures. A proxy must be nominated in advance for the event that the assigned operator is forced to leave his post. Change-over of Shifts The personnel of a shift may leave the plant only after due change to the following shift. This take-over includes: Joint discussion of shift journals and reports; Report on all events of the shift concerned; Agreement on necessary repairs to be performed by the shop service.
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Operation Reports All important operating values agreed between supervision personnel and plant management are to be recorded at hourly intervals in a written form. This concerns the readings of instruments in the field as well as data taken from the DCS-screens. Shift Journal A shift journal is to be maintained with the following necessary entries: Time and nature of a fault; Functional tests; Irregularities during operation; Regeneration of the water treatment; Necessary maintenance work (mechanical/electrical); Quantity and nature of chemicals added to the feed water; Changes in operating values ordered by plant management or supervisor personnel.
The shift journal is to be maintained diligently because its entries must often serve as a source of information to determine the causes of failures. Analyses Journal The analyses (ZnS, calcine, boiler water and boiler feed water, superheated steam) prepared in the laboratory are entered in this journal, and any deviations from the standard values are to be reported to the plant management without delay. Inspections within Plant The operating personnel has to perform periodic plant inspections in order to detect any irregularities during operation as soon as possible. The operator shall checked hourly the material flow through the rotary gate valves by estimating the shell temperature of the chute underneath the equipment. All moving equipment is checked for any uncommon noise. The observations are to be reported to the control room. Report of Failures or Irregularities Upon detection of irregularities and failures, the operating personnel has to take immediate remedial action or to inform the plant superintendent in order to obtain a decision on how to proceed. Inspection of the Boiler Operation The operating personnel is to check once per shift whether the mechanical cleaning device of the boiler is functioning satisfactorily. The personnel are to satisfy themselves moreover whether any dust accretions are building up in the boiler, in the transfer piece between roaster and boiler or in the duct between boiler and hot ESP. Cleaning doors are provided in sufficient number at the boiler casing for the performance of the inspections. Dust cornices are removed by compressed air lances through the
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inspection doors. The control center must be notified and the draught at the roaster outlet must be increased before the doors are opened. Furthermore it is recommended that after a change of the concentrate quality these inspections shall be done more frequently until the new dust behavior is well known. 3.2.3 Maintenance Personnel
The plant management together with the head of the mechanics shop and electro shop must arrange for the following prior to starting the operation of the new roaster plant: 3.2.4 Personnel assignment during the start-up period (24 hour operation where necessary) Maintenance of a stand-by crew over 24 hours for instant elimination of failures or breakdowns. Daily lubrication of equipment within the plant according to a fixed schedule. Consumables
All required consumables are to be provided by the plant according to the following listing. Lubricants Oils and greases vendors specifications for the initial filling of gearings. Fuel Oil for Roaster Start-Up Specification: Type: Hu: Viscosity: Appearance: light fuel oil (diesel oil) 9400 kcal/kg 350 Centistokes at t = 20C (required) clear, colourless
The oil quantity depends on the number of burners and oil lances installed. For a roaster with a capacity of 954 TPD ZnS-concentrates and a grate area of 123 sq.m. 4 shell burners and 12 oil lances are used. The burners have an oil consumption of each 300 kg/h. The throughput of the oil lances is max. 150 kg/h oil per lance. The oil storage tank is to be kept full at all times. Roaster Filling Prior to start-up - but after drying of the grate and measuring the no-load resistance (item 4.2.4.1) the roaster is to be filled with the material for the auxilliary turbulent layer. This material consists of roasted zinc sulfide (ZnO).
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Requirements: Size in m > 1000 1000 500 500 150 150 75 <75 Weight-% 10 20 50 15 5
The grain size distribution is from an average bed material which has been used for start up of several fluid bed roasters for ZnS. The maximum size of the bed material is not to exceed 3 mm = 1/8". As during start-up there will always be some dust loss, it is necessary to have a reserve of at least 50 % of bed material. Quantity : per m grate surface Bulk weight: (in case of roaster calcine) (in case of dust from flash furnace) Sulphide sulphur content: preferably 0.8 m 2.2 - 2.4 t/m 1.6 - 1.8 t/ m 0.2 - 0.6% 0.4%
A stock of bed material in sufficient quantity is to be maintained at all times during the subsequent operation. Elemental Sulphur A stock of 6 t of elemental sulphur as "starting aid" is recommended for the final phase of the heat-up or to accelerate the ZnS-ignition. Specification: "lump sulphur" Size: less than 50 mm, dry Chemicals For boiler scalding: Tri-sodium phosphate: NaOH (solid): Hydrazine: (per scalding action) approx. 5 kg/m boiler filling approx. 1 - 1.5 kg/m boiler filling approx. 0.5 l /m boiler filling Note: The hydrazine is supplied as diamide in 15% solution.
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3.2.5
Tools
One tool chest with most important sizes of keys, screw drivers and pliers, to be held in readiness under lock and key in the control center. Hammers - of various sizes - and chisels should also be available. Required for the event of disturbances in the roaster operation and for cleaning the bottom roaster outlets and burner ports are: 3 rods, each 3/4" diameter, length : 2, 3 and 5 m, the rods to be pointed at the front end. 2 pipes (compressed air lances) outside, dia. 3/4", length of lances: 3 and 5 m 2 compressed air hoses, length : 10 and 20 m; the hose must be capable of withstanding a pressure of 7 atm.g. For the boiler inspection: 1 scraper, shaft length approx. 3 - 4 m 2 lances, each 3/4" outside dia., and each with 8 m connecting hose. Flash lights in sufficient number (at least 3), plus spare batteries 1 hand torch 24 V, with 50 m cable and cable drum. 3.2.6 Plant Safety
First aid instructions and safety regulations must be displayed in the control centre. The telephone numbers for: Emergency physician Fire Department Nearest Hospital must be made known. Dangerous points in the plant are to be identified by caution signs. Signs stating that drives are being remote controlled and may start automatically after the end of the starting signal are to be installed in the area of the conveyor systems. At least one fire extinguisher is to be available on each platform.
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The following must be available in the control centre: Stretcher with blanket First aid box with dressings and bandages, splints and medicaments against burns Rinsing vessel against chemical burns of the eye Oxygen equipment Fire extinguisher :
The following items are to be issued to the operating personnel Dust goggles, Dust masks,
Face masks with filter cartridge for SO2 absorption, protective clothing, gloves. Important: To be observed in addition are the general accident prevention regulations or special regulations in force for the plant.
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4 Function descriptions on the logic diagrams
The interlocking system comprises 3 different groups of interlockings: 1. Transport equipment interlockings 2. Plant safety interlockings 3. Interlockings with other plant sections Important: A start up warning signal ( acoustic ) has to be selected for the start of all machinery started from the control room. Only after completion of the preset warning time, e.g. 30 seconds, the drives can be started within the next three minutes. For the complete interlocking description please refer to the function charts, document no.: I 76270-01-00453
4.1
Transport equipment interlocking
Zinc concentrate transport to feed bins Belt conveyors should preferably be started from the control room. The concentrate transport line will be stopped by: a. b. By manual stopping from the control room By any actuation of the safety switches or motor protections.
a: The stopping sequence of the conveyors is opposite to the start up sequence, i.e. the first conveyor in the conveyor line stops first and, controlled by timer setting, the conveyor closest to the feed bin stops last. b: The affected conveyor and all upstream equipment will stop immediately, the downstream conveyors will continue in operation. Zinc concentrate feeding system The zinc concentrate feeding system with the exception of the slinger belts can only be started with the roasting air blower in remote control operation. The slinger belts can be started only in local operation but will not start the upstream equipment automatically. The table feeder will be started from the control room and will automatically start the belt conveyor. For stopping the feed to the roaster, only the table feeder is stopped from the control room, which automatically stops belt conveyor. In case of failure of one transport equipment, all upstream equipment is stopped immediately. Failure of one slinger belt will also stop all upstream equipment, the other slinger belt remains in operation.
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Calcine transport system (for pneumatic transport see also detailed vendor instructions) The chain conveyors of the hot precipitator will stop the roasting air blower after 6 hours out of operation.
4.2
Plant safety interlockings
Roasting air blower The roasting air blower can only be started (locally or interlocked) when its vane control is closed. After start up, the vane control can be opened. Additionally, the roasting air blower can only be started when : the boiler drum level is above LL and the circulating water flow to the boiler is above minimum flow set point the boiler drum level reaches LL the boiler circulating flow drops below minimum set point interlocks with other plant sections actuate
The roasting air blower will be stopped automatically when one of the following conditions occur : -
Preheating burners The preheating burners are equipped with a separate control panel which contains the safety elements (see manufacturers instructions). The burners can only be ignited when the boiler circulating flow is above minimum set point. Fuel oil lances The fuel oil lances introduced into the roaster during the last stage of preheating to start-up can only be fed with fuel under the following conditions: roasting air blower in operation minimum air flow ( approx. 15,000 Nm3/h ) adjusted a minimum of 4 bed thermocouples indicate a temperature above 400 C
Draft limitation A pressure measurement installed at the outlet of the hot electrostatic precipitator will stop the roasting air blower and the main SO2 -blower in case of excess draft at this point, in order to protect the hot electrostatic precipitator. Boiler circulating pump ( turbine driven ) The turbine driven circulating pump will start automatically in case of power failure and also when the circulating water flow drops below the preset value.
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4.3 Interlockings with other plant sections
Blowers The roasting air blower, start up blower and the main SO2 - blower can be started independently from each other. Under preheating conditions, the roasting air blower and the start up blower are interlocked after start-up. In interlocked operating condition, each blower will stop the other blower when it is stopped manually or due to actuation of any individual interlock or safety device. In normal operation, the roasting air blower and the main SO2 - blower are interlocked after start-up. Like in preheating conditions, each blower will stop the other two blowers when it is stopped manually or due to actuation of any individual interlock or safety device. The start-up sequence for the blowers is described within the start-up procedure in chapter 14 of this operating manual.
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5
5.1
Trial Runs
Introduction
The trial runs serve as functional test of the completely installed conveyors, equipment and fans. Included in the dry runs is the mechanical supervision of the equipment and the check-up of the electrical interlocking and the functional test of the Digital Control System (DCS) in the control room. All dry runs are fist performed without load. When high voltage motors are set up in the plant, it is necessary to check the direction of rotation before each high voltage motor is connected. For this purpose the coupling of motor/equipment must be disengaged, so that the motor starts without load. The insulation value is to be determined prior to making the connection. This value is to be higher than 500 Megohms. The connection can be made only after proof of this value has been given. The initial switching at the high voltage motors is, as a matter of principle, to be performed in the presence of an engineer from the manufacturer, and possibly also in the presence of an engineer from the switch gear manufacturer. The connection of belt conveyors, chain conveyors, fans and the other equipment is to be preceded by thorough cleaning of feed bin, ash hopper, chutes, casings and conveyors, from which all foreign matter is to be removed. To prevent accidents the erection and operating personnel are to receive timely notification of the time scheduled for dry runs.
5.2
Roaster Plant
Fans Conveyors Pumps.
A 24 hour trial run is prescribed for:
Bearing temperatures, correct direction of rotation and flawlessness are the subjects of the check-up during this trial run. The trial run of an item of equipment is to be discontinued on occurrence of a failure, which is then to be remedied. 1 - 2 hours after connecting the fans, it will be noted that the bearing temperature rises to 80C. This temperature must drop again to 30 50C after another 3 - 4 hours. Where this temperature decrease should not occur, the trial run must be interrupted and both bearings must be opened. Any excess grease is to be removed and the bearing must be completely cleaned if necessary. The fan supplier must be informed if the failure cannot be eliminated by these measures. The following steps are necessary prior to making the connection in order to protect the fans against overload. Roasting air fan Open the manhole door at the transition roaster/boiler. On reaching the full fan rotational speed with closed guide vane slowly open the throttle valve in the roaster air pressure line and adjust for approx. 50% of the normal air flow by means of the guide vane. Cooling air fan Open the manhole doors above roaster grate and the flap in the combustion air duct to the burners. Check, whether the air lines at the burners are open. Start fan and operate it with normal load.
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5.3 Waste Heat Boiler
The trial run extends to the circulating pump. Before this, fill the boiler with treated water (see item 4.2.2). A trial run of the feed pump and turbines will only be possible at the beginning of drying when the steam is available with sufficient pressure and in sufficient quantity, and when an adequate quantity is also withdrawn from the feed pump.
5.4
Hot Gas Electrostatic-Precipitator
Please refer to operational manual of the hot-esp supplier. Notice that the chain conveyor and the rotary valves are part of the calcine handling system.
5.5
Calcine Handling
Trial runs of all chain conveyors, rotary valves, cooling drum, ball mill, bucket elevator for 24 hours. At that time thoroughly grease the conveyor bearings until the grease runs out at the axles.
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6
6.1
Preparations for start up

Drying the Grate
Preparations A gas burner or a fan-forced heater of suitable capacity is needed for grate drying. The heat is introduced to the grate from the wind box. For this purpose it is necessary to either remove the bottom cone of the wind box or to open the wind box manhole. At the resulting openings it will be possible either to attach a gas booster burner or to introduce the hot air from a fan. The energy required for grate drying ranges from 200 2000 MJ/h, depending on roaster size. Hardening A hardening or setting time of 48 hours is to be allowed after the introduction of the ceramic grate. Before drying begins, open the manhole door in the transfer piece roaster/boiler to release the flue gas.
Dry firing procedure First start with moderate firing: Temperature approx. 40C, measured underneath the grate. This temperature is to be maintained for 24 hours. By intensified heating, then increase the firing to 125C final temperature within 48 hours. This temperature is to be maintained constant for 48 hours. The wind box manhole is to be closed, or the auxiliary cone reattached, on completion of the grate drying. The manhole doors in the roaster transition must likewise be closed again. Approximately 120 hours are required for grate drying, including the setting time.
6.2
Dry Firing of Roaster and Scalding of Waste Heat Boiler
The dry firing of roaster and boiler is practically one single action. The drying period of the roaster and of the boiler lasts approx. 3 weeks. In order to prevent the moisture of the roaster from condensing in the cold waste heat boiler at the beginning of the dry firing, open the manhole at the roaster transition and blow the flue gas into the atmosphere during the first three days. The boiler scalding is carried out approx. 8 - 10 days after the beginning of the drying period. Until that time the temperature at the roaster outlet has not risen above 400C. As the turbine of the stand-by circulating pump is not yet ready for operation, there is as yet no danger for the cooling elements and evaporator bundles of the boiler within this temperature range in case of a sudden power failure and breakdown of the circulation. The waste heat boiler must be filled with treated feed water prior to the ignition of the first burner at the roaster. After 6 days of dry-firing the roaster, the temperature is increased above the limit of 400C. At this time the latest the stand-by turbine driven circulation pump has to be ready for emergency operation, even though the steam supply line to this unit is not yet blown out.
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6.2.1 Preparations
The feed water treatment plant is to be taken into operation by client. Where an outside source of steam is available, the deaerator is to be put into operation and the feed water tank is to be filled with demineralized hot water. Where no outside steam is available, it is necessary to add an appropriate amount of chemicals for deaeration. The fuel oil tank is to be filled. A date for refilling - possibly also on Sundays and holidays - is to be negotiated with the contract dealer. Chemicals are to be placed in readiness for boiler waterside cleaning. An emergency service (fitter and electrician) is to be maintained on call. A shift plan is to be drawn up for the operating personnel. Sufficient bed material must stand ready for roaster filling. The measuring equipment is to be checked and taken into service: Switch on the paper feed at the recorders. Adjust the time clock. Switch super-heated steam temperature controller to "manual" and open entirely, i.e. the total steam volume arising during the dry firing passes through the attemperator of the drum. Set feed water control valve to "manual".
Check the oil levels at all gear boxes and couplings . Start the cooling water (low rate) at boiler pumps and chain conveyors.
6.2.2 -
Filling the Waste Heat Boiler Drain valves at feed water pumps Shut-off and by-pass valves at feed water control valve in the feed water pressure line Shut-off valve preceding the continuous demineralization at the steam drum Sludge valve at boiler steam drum and drain valve Dewatering valves of evaporator and cooling elements of roaster and all circulating lines Vent valves at evaporators
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The following valves must be closed:

Shut-off valves in feed water lines of turbine driven feed water pump, at suction and pressure side Steam shut-off valve on superheated steam line to steam condensing system, respectively steam turbine Dewatering and drain valves at circulating pumps Shut-off valves at pressure side of circulating pumps Shut-off valves at pressure side of circulating pumps Shut-off valves on steam supply line to the turbines of circulating and feed pumps, and Shut-off and by-pass valve to overflow controller
Also please observe the separate Operating Instructions of the boiler manufacturer and its subsuppliers. The following valves must be open: Supply valve on feed water suction line to electric feed pump Valve on minimum rate line of feed pumps Shut-off valve at steam drum water level: direct indication Shut-off valve at steam drum water level: remote indication Steam drum ventilation Shut-off valves at suction side of circulating pumps All pressure gauge shut-off valves All shut-off valves on instrument lines All shut-off valves on sampling lines Vent valve of superheater Start-up valve of superheater (1/3 open) all water drains at steam side of turbines and circulating pump Also please observe the separate Operating Instructions of the boiler manufacturer and its subsupppliers. Filling the boiler drum and evaporator system The filling of the La Mont system can be started after the valves have been set as described before. Start the electric feed pump. Fully open the by-pass valve to feed water controller and adjust water flow (100% design value) with the shut-off valve at the pressure side of the feed water pump. Maintain contact with the control room over the intercom. Fill the boiler drum to maximum level. Please observe also the Operations Instructions of the boiler maker and its sub-suppliers.
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Starting the circulating pump Notify the control room before starting the pump. It is switched on shortly before reaching the maximum drum water level. Preparations prior to start up: Check oil level at bearing block Open the cooling water inlet at main stuffing box Open the cooling water inlet at advance stuffing box Open the cooling water inlet at pump supporting frame
After the circulating pump is switched on, open the valve in the circulating pressure line until the normal circulating rate is reached. A rapid decline of the drum water level will be noticed immediately after the pump has been connected. The boiler feed pump remains in operation. Once the minimum drum water level has been reached, the circulating pump is switched off for a short period until the boiling water level has returned to the maximum value. Restart the circulating pump. It will be noted that after two or three repetitions of this procedure, the drum water level will no longer decline but rise to maximum value with the circulating pump in operation. The feed water pump is switched off and the circulating pump remains in operation when the La Mont system has been filled in this manner. Oil pressure, noiseless run and bearing temperatures of the circulating pump are now to be checked and the values are to be recorded. Please see also Operating Instructions of the boiler maker and its sub-suppliers. Supervision of electric circulating pump The inspections must be performed periodically every hour: The lubrication oil at the bearing block is to be monitored at the oil level window. The oil pressure at the bearing block is between 0.4 and 0.8 bar g with the pump running and with the oil warmed by the operation. The cooling water (oil cooler and stuffing box cooling are connected in series) shall have an even flow. With a temperature of max. 45, the flow rate is to be regulated accordingly. Main and advance stuffing box must always be slightly dripping for packing ring lubrication. Bearing temperatures are permitted to 80C max. The plate-type oil filter is cleaned by repeated turning of the handle. The smooth run of the pump is to be monitored by ear. The differential pressure between suction and pressure side of the pump is to be held under constant surveillance; normal are approx. 3-4 bar g. The current intake of the circulating pump is not to exceed the permitted normal value.
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Also please observe the separate Operating Instructions of the boiler maker and its sub-suppliers. 6.2.3 General Inspections
After filling of the boiler, check the La Mont system for leakages. Fill the boiler of rapping mechanism and release water at the drain as necessary. Fill all sand seals in the area of calcine handling. Close all throttle valves on the air and gas lines. Check whether all manhole doors at roaster and boiler are closed. 6.2.4 Measuring the No-Load Resistance of Grate
This measurement is performed before the bed material is charged. For this purpose: Close the flaps in the gas duct to the Sulphuric Acid Plant. Open the louvre type damper after the hot gas precipitator completely. Start the wet gas cleaning plant in line (start acid pumps, fans) Start the start-up fan. Adjust a draught at roaster outlet of 0,1 to - 1 mbar by opening the flap of the start-up fan. Start roasting air fan. Re-adjust roaster draught. Slowly open throttle valve in roaster air line. Slowly open the guide vane until the air volume subsequently applied in operation has been reached; simultaneously: re-adjust draught at roaster outlet. Note the windbox air pressure, the power consumption of the roasting air fan and the roasting air volume in the different stages and document the readings in the shift journal. Then adjust maximum permitted air volume and record maximum value. Then turn back guide vane and throttle valve to original positions. Re-adjust draught at roaster outlet with the flap of the start-up fan accordingly (close the flap). Check the roaster tuyeres again for any blockage.
6.2.5
Introducing the Bed Material
Feeding Device The bed material will be introduced into the roaster from the bin for start-up material in the ZnSfeeding system via the rotary table feeder and the slinger belts.
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Procedure Open the flap of the start-up fan on suction side by 2 - 3 turns. An air volume of approx. 350 Nm/hm. of grate surface and hour is adjusted by opening the throttle valve in the roaster air line and opening the guide vane of the roasting air blower. Re-adjust draught at roaster outlet with the flap of the start-up fan. Slowly charge bed material into the roaster by way of the described feeding device. Adjust material quantity to obtain a bed height of 20 cm above the grate. Compensate bed losses at the sixth day to get again the 20 cm level and introduce another 20 cm at the seventh day in the manner described. Maintain turbulizing air volume until the end of the filling operation. When the mentioned bed height has been reached, increase air volume to 520 Nm/hm grate area and hour and maintain for approx. 1 minute. During the filling operation, switch on the calcine handling system and discharge the dust. This polluted dust can later be added to the ZnS-feed in order to thus utilize the zinc contained in the dust.
This is followed by checking whether the introduced turbulent layer is even. The following causes may be responsible if this should not be the case: a) b) c) Material demixing Blockage of the nozzles The material charged had become moist during storage Re a: Eliminate material demixing by aerating the zones concerned with the aid of compressed air lances. Introduce the lances through existing openings in bed height or through manhole doors. Open manhole in wind box and clean the nozzles from below underneath the material accumulations by means of approx. 5 mm thick welding wires. Allow moist zones to dry, turbulize again if necessary clean nozzles as described under b) in the zones concerned
Re b:
Re c: -
Close the guide vane of the roasting air fan and stop it. Shut the throttle valve in roaster air line. Stop the start-up fan. Stop the acid pumps and fans in the wet gas cleaning plant. Before dry firing period starts, please open one or two manhole doors above roaster grate and the manhole doors at roaster transition to boiler. First and Second Day Make sure that the waste heat boiler circulation pump is in operation.
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6.2.6 -
Igniting the first Oil Burner

Inspect burner casing. Insert smallest nozzle supplied. Start the cooling air fan against the closed damper in the combustion air line. In the beginning of the dry firing the gas leaves the roaster through the manhole doors. When the temperature is increased the gas is directed through the gas cleaning and cooling plant thus avoiding any danger to the operation personnel. Remove the safety cap from the burner casing. Swing burner into position, start oil pump and adjust oil pressure. Open the damper in the combustion air line to roaster and adjust an air pressure at the burner of approx. 30 mbars. Make sure that this pressure is obtained with the primary air handle in position 2 to 3. Open the ball valves in the oil line to the solenoid valves. Switch on the local burner control panel. For the dry firing of the roaster refractory it is necessary to vent the flue gas through the open manholes of the roaster. This operation is not allowed for normal plant operation so there is a process interlocking. In normal plant operation the flue gas shall flow to the waste heat boiler, the gas cleaning and cooling plant to be finally vented to atmosphere by the start up blower. The interlocking conditions are explained in detail in chapter 2. In this special operation a jumper has to be installed to start the burner without the process interlocking. Do not forget to remove this jumper as soon as the interlocking are fulfilled what is necessary at higher gas temperatures. Inspect oil admission. Push the button BURNER ON on the control panel. The burner will ignite after a short flushing time.
The burner is designed for a rated capacity of 100 to 300 kg/h. In cold condition the lower limit can not be reached. At first run oil burner with higher oil volume to ensure complete oil combustion, when burner bricks are cold. After about half an hour, reduce oil volume until proper combustion is assured. 6.2.7 Adjust gas outlet temperature at roaster outlet as low as possible with the minimum oil flow at the first burner (200 C). Interrupt firing on irregularities or occurring vibrations, and disconnect cooling air fan for repair purposes. Diligently record the course of drying process in the shift journal. Third and Fourth Day Take the wet gas cleaning plant in operation (start acid pumps, fans). Check, if louvre type damper is fully open.
Start-up of Start-up Fan
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Start the start-up fan with closed inlet damper, adjust draught at roaster outlet (-0,1 to 1 mbar) with the inlet damper of the start-up fan. Inspect and hourly record bearing temperatures at fan and motor. Check smooth run of fan. In case of failure, switch off the fan and take remedial action. Increase the gas temperature at roaster outlet from 200 to 400C by closing the openings at the roaster. During the time it will be necessary to start the start-up fan and to adjust a slight draught at the roaster outlet. When the start-up fan is running perfectly, open the flap slowly, close manhole doors at transition roaster/boiler and determine roaster draught, which is to be approx. 0 mm WG at roaster outlet. Regulate any deviations with the flap of the start-up fan. Try whether doors at outlet boiler can be closed, or whether the draught is too high when the doors are closed. In this case open the doors to a narrow crack and secure. Connect insulator heating of precipitator for protection of Al203- insulators. Fifth Day
6.2.8
The scalding of the boiler is started at the fourth day by sucking the flue gas through the boiler. For details please refer to the boiler-manufactures instructions. 6.2.9 6.2.10 Hold the temperature at roaster outlet at 400 C maximum. Sixth Day Make sure that the boilers turbine driven circulation pump is ready for emergency operation in case of power failure. The drum water level is to be observed and the water evaporated in the meantime to be replaced. For procedure refer to item 4.2.2 The drum ventilation is to be closed and the start-up valve is to be opened so that the steam generated by the intensified firing flows through the super heater, which is thus being cooled. Increase the temperature at the roaster gas outlet to 500 C. Seventh Day
Maintain the temperature of 500 C for one day. This temperature is necessary for driving out the crystalline water of the roaster refractory lining. After this day the dry-firing of the roaster is completed. 6.2.11 Eight and Ninth Day
Waterside Cleaning of Waste Heat Boiler In parallel to the dry-firing of the roaster the waterside cleaning of the boiler takes place. It is performed starting at the third day. The La Mont system shall be under operating pressure only after scalding of the boiler, i.e. cleaning the pipe interior from dirt, oil and grease remnants and scale by etching and grease-dissolving chemicals. Running the La Mont system under pressure makes it possible to start up the turbo drives of the stand-by pumps, which is a pre-condition for the application of higher temperatures at the roaster outlet (>400 C).
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The boiling out procedure can be repeated several times until the out-running water shows hardly any dark discoloration. Then remove the boiler filling entirely, rinse the whole system remove and clean all nozzles and valves with seals. This work is performed under the guidance of the boiler start-up engineer. A period of minimum 3 days is to be anticipated for the boiler cleaning. Preparations for boiling out The preparations have to be done with ambient pressure in the steam drum. Prepare chemicals as described in the boiler manufacturers instructions. Stop the circulation pump. Cautiously open the manhole of the steam drum and fill the dissolved chemicals through the open manhole. 6.2.12 Close the manhole. Close all vents and drains. Close start-up valve. Switch on the boiler circulation. Tenth Day
Boiling out Operate one or two oil burners, depending on the temperature requirements. When the pressure in the steam drum rises, the boiling out procedure starts. After 24 h blow down the steam drum for the first time in order to remove any debris from cleaning the waste heat boiler system. Blow down the system frequently following the instructions of the commissioning personnel of the boiler manufacturer. Slowly increase the boiler pressure. When the flue gas reaches a temperature of 400 C, make sure that the turbine driven circulation pump is ready for operation. Open the 3-way-mixing valve to cool the super-heater bundles and adjust the steam pressure with the start-up valve. Prior to the last blow down, boiling out shall be made with approx. of the operating pressure, however, the water level should not drop below the low level mark. Do not exceed a steam pressure of 15 bar.
Water Exchange / Emptying the Boiler Stop firing with the start-up burners. Cool down the whole boiler system to avoid any damage during the flushing procedure. The cooling air fan and the start-up fan can be used for this operation. Open all doors at the boiler following the instructions of the start-up personnel of the boiler manufacturer. Fully open sludge valve of drum and drain out the dirty water via the flashing tank. Constantly replenish feed water from feed water tank. After boiling out the whole boiler content is to be discharged and the boiler is to be rinsed at least
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two times with demineralized water. The mesh filters in the suction piping have to be cleaned, the fine screen has to be removed. If it is not practicable to discharge the whole boiler content, the continuous water outlet and feed are to be adjusted in such a way that the water is exchanged but only with the direct water level indicator being visible in the lower sight range. Rinsing shall be stopped as soon as the p-value is 1.
The boiling out with alkaline can in no case be considered harmless and not dangerous. It must be done with great care. In no case may any residue of alkaline solution, which may evaporate later, be retained in any parts of the boiler. This applies especially to materials such as austenites, being subject to stress corrosion.
6.2.13
Eleventh day
Inspect once more the hot precipitator in mechanical and electrical terms. Tightly close inspection doors at boiler and precipitator. Heating up the roaster and boiler is started from the twelfth day. The boiler is set under full pressure.
Start of intensified firing Start start-up fan and cooling air fan, each at closed flap. Then ignite one burner as described before. - The louvre type damper is fully open. - The turbine driven circulation pump is ready for operation. Raise the roaster outlet temperature to 500 C in the course of 10 hours. For this purpose operate the second burner if necessary. With the cooling air fans the necessary air load is provided via the two operating burners, via the third burner and through the oil lances.
Start-up of Feed Water Controller Manual operation: Open the shut-off valves upstream and downstream of feed water control valve and close bypass valve if not yet done. Set controller in the control room to "manual" and slowly regulate design value to 50% or 0 depending on dial graduation. These positions correspond with the mean drum water level. Check the water level at the drum for agreement with the indication of the three-term controller in the control room.
Automatic operation: This setting is only possible when sufficient steam is being produced after the rated pressure has been reached, so that a favourable control range of the feed water control valve prevails. After these conditions have been met, turn the switch to "automatic". The control system must now hunt according to the steam and feed water flow rate.
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- Adjust design value to 50% as soon as possible. Start-up of Turbo Circulating Pump Preparations The preparations are started when the super heated steam has a pressure of approx. 20 bar(g). The operation will be possible even at lower pressure. 1. 2. 3. 4. 5. Inspect oil level in bearing block. Open cooling water inlet main stuffing box. Open cooling water inlet advance stuffing box. Open cooling water inlet pomp supporting frame. Check whether the outrunning cooling water is freely emerging into the drain line.
Preparations for turbine start-up 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Inspect oil level at turbine. Switch on the gear type oil pump to produce the necessary control oil pressure. Open the shut-off valve on the super heated steam feed line. Open drain on super heated steam line. Open shut-off valve preceding the turbine. Open control valve by turning the hand wheel counter-clockwise to the stop, and then by 90 clockwise to avoid locking. Turn hand wheel of rotational speed adjustment on initial start-up counter-clockwise to the stop. Check whether emergency release button is depressed. Turn on the cooling water for oil cooler. Check whether the outrunning water is freely emerging in the drain line. Inspection of the automatic starting unit: Disconnect gear-type oil pump and turn hand wheel of rotational speed adjustment slowly clockwise. Turbine must now start at low rotational speed (the separate operating instructions of suppliers have to be followed)
Turbine start-up by automatic starting unit 1. 2. 3. 4. Interlock the gear type oil pump with the driving motor of electric pump. Turn hand wheel of control valve counter-clockwise to the stop, depress emergency release button and then turn hand wheel clockwise almost to the stop. Manually disconnect electric pump. Turbo pump must now run automatically. The automatic rotational speed control must be adjusted at the first start-up. This is done by means of a small hand wheel near the speedometer. The final position can be determined only after the rated pressure of the boiler has been reached. After the rated pressure of the boiler is available, repeat the procedure until - after several starts - the turbine reaches automatically its rated speed.
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Inspection of Turbo Pump in Operation The inspections are to be performed periodically every 30 minutes. To be inspected are: The rotational speed (the speed setting is to be readjusted in case of deviations). The oil temperature : Maximum value 70C, normal value approx. 40C Cooling water must be regulated accordingly. The control oil pressure: Normal approx. 10 bar g. The lubrication oil pressure: minimum 0.5 bar g. The exhaust heat pressure: Normal 0.5 bar g. (only where exhaust steam is used for feed water deaeration). Oil plate filter: Clean by repeated turning the handle. Normal 1 - 2 bar g.
For details please refer to the manufacturers instructions. Shut Down of Turbo Pump The turbo pump may normally be shut down only if the electric pump has previously been started. 1. Shut down the turbine by turning the hand wheel of control valve clockwise to the stop. The turbine can in case of emergency also be shut down immediately by pulling the emergency release button of the beam-spring speed controller. After the turbine has come to a halt, turn the hand wheel of control valve counterclockwise to the stop. Depress the emergency release button again if the turbine has been shut-down by pulling the emergency release button. Check whether the electric interlock of the turbine control oil pump with E-pump driving motor is switched on. Open the valve on the preheating line to maintain the temperature of turbo pump casing.
2.
3. 4.
6.2.14 -
Twelfth and Thirteenth Day Raise the temperature at roaster outlet to 500C to 700C. Blow out the steam line to the steam condensing system or the turbo generator respectively as soon as the steam quantity and the pressure are sufficient for this operation. Charge additional bed material (up to 70 cm above grate) in the described manner and distribute by an air surge with normal air volume (520 Nm/hm). Adjust boiler pressure to 30 - 35 bar g and hold. Fill ZnS-feed bin and calibrate discharge belt for adjustment of normal ZnS throughput. Determine and record the indicator reading of instrument in the control room on reaching the normal throughput rate. Turbulize bed content approx. 1 minute every 2 hours as described.
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If during heating up any sintering effect occurs in the roaster bed especially on the bed surface, it might be necessary to turbulize the bed more frequently. Blowing out the steam line Flow blowing out the line a steam quantity of a least 2/3 of the maximum quantity is necessary. A steam pressure close to the nominal pressure makes sure that a steam velocity in the line of about 40 m/s is achieved. If the steam quantity for blowing out produced by heating with the start-up burners only is not sufficient, it is necessary to install the oil lances in addition to the burners. The operation of the oil lances is described in details in chapter 5. The procedure takes a time of about 5 to 15 minutes of blowing out the steam and about 3 to 4 hours of cooling down the line. This is necessary in order to remove all dirt or scale from the walls of the steel pipe due to different thermal expansion. This procedure is repeated 4 to 5 times. Then a copper plate is installed at the outlet of the line, to check if there are sill coming particles out of the line during blowing out. Continue the operation until no longer any particles can be detected on the copper plate. Reinstall the line to the following equipment. Reinstall the steam control valve, if it had to be removed for the blowing out procedure. The steam line is now ready for operation.
Belt calibration Procedure Install a temporary discharge chute between the rotary table discharge and the rejection grid in the floor of the slinger belts location . Start the belt conveyor. Adjust belt loading to 20 cm height by means of the floating level gate at bin outlet. Start and run rotary table feeder for 5 minutes. Stop feeder and tray conveyor simultaneously. Reject already discharged material. Start feeder and tray conveyor simultaneously and stop and weigh the material quantity discharged within 5 minutes. Repeat test until three reliable values are received at normal load. Fourteenth Day
6.2.15 -
Maintain the roaster outlet temperature at 600 - 700C. Replace bed material losses. Prepare succeeding contact plant for roaster gas take-over. Connect boiler to steam condensing system respectively steam turbine on trial basis. This connection can be maintained provided that stable conditions result at sufficient steam production. Depending on the demineralized water plant capacity it might be necessary to make the above mentioned connection at an earlier point in time to ensure an adequate supply of boiler feed water.
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Connecting the boiler to the steam condensing system, respectively steam turbine Adjust boiler pressure to rated value by means of start-up valve. Notify control centre about imminent take-over. Start overflow controller according to manufacturers instructions. Open shut-off valves upstream and downstream of controller, leave by-pass valve closed. After the controller functions properly, slowly open the shut-off valve on the super heater steam line at super heater outlet, drain the steam line from any condensate. Upon reaching the rated pressure, the controller will slowly open and the steam flows into the condensing system, respectively steam turbine. Slowly close start-up valve. Check the operation of the condenser (main or auxiliary condenser) and of the condensate pumps. Check the operation of the condensate water level control loop and optimize the control function if necessary.
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7
7.1
Start-up of Roaster Plant (fifteenth day)

Preparations, Preconditions
The complete calcine handling system is to be started. The insulator heating of the hot electrostatic precipitator is in operation. The hot electrostatic precipitator is to be started. The waste heat boiler is connected to the steam condensing system and the stem turbine respectively. The feed water tank is completely filled with deaerated demineralized water. The water treatment plant is fully operational. The gas clearing plant is completely in operation. The acid plant is able to accept roasting gas. All start-up burners are in operation.
7.2
7.2.1
Heating to ZnS Ignition Temperature

Start-up Burners
If the burners were equipped with smaller start-up nozzles, exchange them to the normal size nozzles. Adjust the burners to their maximum performance of approx. 300 l/h each. 7.2.2 Temperature Increase by Discontinuous Turbulization (Air Surge)
The bed temperature is to be 400 C before the oil lances are introduced and ignited. The temperature is reached by heating the bed surface by means of the start-up burners and by hourly turbulizing (air surge lasting approx. 1 minute), whereby the superficially heated material is mixed with the lower and colder zones. Procedure Start the roasting air fan. Open the throttle valve in the roaster air line. Re-adjust the draught at the roaster outlet by moving the flap of the start-up fan. The louver type damper shall be fully open. Open the guide vane to the angle at witch the normal air volume is reached. Re-adjust roaster draught accordingly at any time. Record the indicator reading in % of the position revertive signal transmitter for convenient locating of the desired settings for the following turbulizing action. Maintain the turbulizing air volume (520 Nm/hm) for about ten seconds. Then simultaneously close the guide vane and adjust the roaster draught until the initial value is reached at a quiescent layer.
7.2.3
Introducing and Ignition of Oil Lances All shell burners are in operation, the turbulent layer has a temperature of 400 C. There are 8 thermocouples located in the roaster bed. In the interlocking all of the eight thermocouples have to show a temperature above 400C. Otherwise the solenoid valve of the lances oil supply does not open.
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The lance openings are properly adjusted the flexible air line is connected, the air gates are closed. Open the guide vane of the roasting air fan 13.600 Nm3/h is reached. Re-adjust the roaster draught. Check whether all ball valves at the oil lances are closed. Fully open the shut-off valve in the oil supply line (solenoid valve can be opened from control room). Introduce one lance after the other into the associated casings. Immediately open the air gates in order to avoid a blockage on the lance nozzle. Also open the valve at the oil inlet to the nozzle connection line and the ball valve at the oil lance. Check the oil pressure in front of the pressure reducing station. It should stay in the range of 21 to 26 bar. Check whether the oil mists have ignited by watching the roaster temperatures. Re-adjust the roaster pressure at any time. Now record the air volume indicated in the DCS as well as the roaster draught and the roaster temperatures. until an air volume of
7.2.4
Heating the Turbulent Layer to ZnS Ignition Temperature
This is done by moderate continuous turbulizing (bubbling) with the aid of all burners and lances. Procedure for roasting area Inject a roasting volume of approx. 220 Nm3/hm. Inspect through the sight glasses or an inspection port at the material inlet or calcine outlet whether the turbulizing motion of the bed is as desired: The bed shall bubble evenly at all points, but the appearance of fountains shall be avoided. If necessary, slightly increase or reduce the roasting air volume. Adjust the draught at the roaster outlet to approx. 0.1 mbar. Now observe the rise of the bed temperatures (8 measuring points) and roaster temperatures. It is recommended to prepare a small table to record temperatures air volume bed resistance roaster draught every five minutes. This table shall later be transferred into the shift journal for purposes of comparison. At the low turbulizing air volume, it is impossible to avoid any demixing in the turbulent layer. By demixing a phenomenon is described that separates the coarser particles in the lower areas from the fine particles in the higher areas of the fluidized layer. In a demixed fluidized bed is low. During heating up the bed temperature in the top areas of the fluidized layer increases much faster than in its lower areas.
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A short air surge is therefore introduced about every 30 minutes for equalization of the bed. The temperature increase shall average to 20 - 30 C every five minutes. In case of any deviations, the air volume can be slightly varied upwards or downwards referring to 220 Nm/hm The slinger belts are switched on starting at an average temperature of 700 C. Inspect and correct the belt run if necessary. Push the rotating slinger belts near the still closed roaster inlet ports. Switch the mode selector switch of the concentrate conveying system to Normal Operation. Charge the table feeder via the discharge belt conveyor so that ZnS can be charged immediately upon reaching the ignition temperature. For the initial start up, the bed temperature should at least at three measuring points be higher than 880 C in order to have a sufficient temperature reserve. Subsequent start are then possible at 800 C. Already during preheating the following areas shall be prepared or in operation: The acid plant for gas take-over, the steam condensing station, respectively the steam turbine for steam take-over. Open slowly damper in gas route from gas cleaning to sulfuric acid plant. Slowly close the inlet damper of the start-up fan always watching the pressure at outlet roaster. Start feeding concentrate - Open the inlet ports (slinger belts are already in operation) - Start the feeding sequence from the control room. - Locate one field operator at the discharge conveyor underneath the day bin to check the right tension of the rubber belt. If necessary readjust the belt tension. 4. 5. 6. Slowly increase the roasting air flow, always recording the roaster temperatures. When the temperatures are coming up, start to remove the oil lances one after the other. In parallel switch off one after the other start-up burner and remove them from their operation position. Adjust for the following values upon completion of the gas route switchover: Air volume through grate: Bed temperature: Roaster head: Roaster draught: Bed pressure: 7. 8. 450 Nm3/hm 950 C 20 C 900 96 C 10 C - 0.1 ... 0.2 mbar 160 ... 180 mbar
Procedure with gas cleaning and acid area (please see also chapter 14) 1. 2. 3.
As soon as the desired bed pressure is reached, open the roaster overflow. The poking device should be manually operated once per shift.
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7.2.5 Operations at Calcine Handling System during Heating-up Turn on the cooling water at all equipment; give a certain amount of air from the cooling air fan to the boiler conveyor for cooling. Start the calcine conveying system using the group switch in the DCS. Choose to start with the top mounted fan of the calcine silo, thus starting the silo, and with the baghouse filter of the ball mill. By the group switch the whole calcine conveying system is started sequentially. Check the warm-up of all chutes at the boiler, the electrostatic precipitator and the rotary gate valves. Chutes which remain cold will show material build-up. Remove these immediately and clean the chutes.
7.2.6
Preparations and Operations at Boiler during Heating-up
Heating-up the roaster by the significantly higher heat evolved (up to 60 % of normal operation) constitutes practically the start-up for the boiler. The connection of the boiler to the steam condensing system, respectively steam turbine has already been described in chapter 4. If the boiler has not yet been connected, it is now necessary to make this connection to the steam condensing system/steam turbine. The following operations are still required after the boiler has been connected to the steam system: Close all vent valves, open the drum drain to approx. 5 10 %. Close all other drain valves. Inspect and start all control elements at the deaerator to have now deaerated water available with 105 C. Start the rapping device.
7.2.7
Preparations at Hot Gas Electrostatic Precipitator
Start the dust discharge system by the group switch for the chain conveyor and all rotary valves. For further instruction please refer to operational manual of the hot-esp supplier .
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8
8.1
8.1.1
Running Operation
ZnS Feed
Conditions for ZnS-Concentrate
Moisture Content The optimum moisture content of the concentrate charged to the roaster ranges between 7 and 10%. The process engineering calculation for the running procedure is tuned to this value. Deviations require a minor variation of the water rate injected into the roaster additionally. Fluctuations of 3% in the moisture content (limit: 5% minimum and 12% maximum) are permissible with regard to the operational safety of the plant. Fluctuations beyond this limit, however, would affect the course of the roasting process. The following phenomena will be observed if the moisture content in the concentrate is less than 5% : An increase of the roaster outlet temperature to values above 1000C. Fine dusts (size below 80m) are possibly still burning in the region of the first evaporator bundle in the Waste Heat Boiler. This results in excessive heat transfer in the evaporator and in the superheaters, the water circulation may decline and appearances of overheating may occur. There is the danger of pipe rupture in case of overheating within the tube bundles. The formation of hard crusts at evaporator pipes may occur. This is due to dusts with a high magnetite content which can no longer be completely shaken down by the rapping mechanism. There will be high dust emissions on the concentrate conveyors.
Recommended remedial actions are the following: Mix the dry concentrate batches with concentrate of higher moisture content. Increase the humidity using a sprinkler system in the storage area or by spraying water onto the concentrate on the belt conveyors
At concentrate moistures of 7 - 10%, the combustion occurs almost entirely in the turbulent layer. Bed and gas outlet temperature are either equal or differ only by an average of 20C. The portion of the calcine discharged from the turbulent layer ranges between 10 and 30% of the total calcine quantity. The prerequisites for a smooth running process are thus available. Exceeding a moisture content of 10% will primarily lead to conveyor problems due to increased pollution and accretion at the charring equipment. The increased moisture content affects the process as follows: Decline of the bed temperature and possibly also a minor increase of the bed temperature. Increasing bed discharge quantity. More frequent occurrence of lumps in the turbulent layer, possibly even connection with a coarsening of the bed. Danger of bridge formation in the ZnS-feed bin.
Roasting very moist ZnS will thus impede the roaster operation and requires increased attention and intensified supervision by the operating personnel.
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Temporary short fluctuations in the ZnS-concentrate moisture are to be avoided. They affect the discharging accuracy of the bin discharge conveyor and the discharge capacity. Such load variations cause temperature fluctuations in the roaster, which represent an aggravation of the roaster service due to constant readjustment of the ZnS-quantity. Particular care is therefore required when ZnS-feed is reaccepted from the storage. Largely dried batches are to be mixed with moister material. This mixing can be accomplished in the simple manner of discharging alternatively a bucket with dry and then a bucket with moist material over the belt route to the ZnS-feed bin, where the mixing will then occur. The better way of mixing is to mix the feed material already in the storage area using a payloader and then to feed this premixed material to the underground hoppers. When the concentrate is transported to the day bin, on every change of the belt conveyors the mixing is accomplished. Lumping If there is a long time interval between flotation and processing of the concentrate, there will be a gradual sulphation partly beginning during transportation but mainly during the storage. This oxidation is slow, but becomes evident by heating in the interior of the dump. On unloading the ZnS in the storage, and especially at high piling, there occurs a pelletizing affect which forms lumps which, during prolonged storage, will harden due to the mentioned sulphate formation. Lumps above 25 mm diameter are therefore separated and recrushed as they pass through the screening and crushing plant. The percentage of lumps between 2 and 25 mm in the so-called undersize is not to exceed approx. 10%. Otherwise the screen size is to be changed to 20 mm. In the turbulent layer there is only a slow decomposition of the lumps. An excess submission will therefore lead to demixing, despite the periodic function of the lower bed outlet (poking device) and, over a prolonged period (more than 24 hours), it will result in serious disturbances to the roaster operation. Content of Sulphur, iron, copper, lead, SiO2, CaO and MgO Sulphur, iron The varying contents of sulphur and iron have the affect of a changed calorific value on the proper course of the process. ZnS with much sulphur and iron requires therefore an increased cooling surface. The means of installing an additional cooling element has been provided in order to be sufficiently flexible in operation. Copper ZnS with a copper content of up to 1.0% still permits the application of roasting temperatures up to 950C. It is nevertheless recommended to test the optimum roasting temperature as soon as possible after commissioning.
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Lead Contents of up to 1% permit the application of temperatures up to 960C in the turbulent layer. Contents of up to 2.5% still enable roasting at 950C. At higher lead contents, the bed temperature has to be decreased to below 900C to avoid a coarsening in size during the operation. Decreasing the roasting temperature, however, is already of influence in the residual sulphide sulphur content. In order to achieve the target of the sulphide and sulphate sulphur contents also with lead-rich ZnS, it is customary to mix lead-rich ZnS above 6% with lead-poor ZnS to obtain an average content of 5% Pb. It will then be possible to apply temperatures of approx. 880 to max. 900C in the turbulent layer and still obtain reasonable sulphur contents in the calcine. SiO2 The SiO2 content in the ZnS-feed must be kept under constant surveillance. SiO2 contents of up to 1.5% have had no negative effect in lead and copper-poor ZnS (less than 0.2%). Roasting temperatures up to 950C were possible. Lead contents of up to 3% at a simultaneous SiO2 content of approx. 2% may cause a bed coarsening in the 950C temperature range. The roasting temperature in this case should be lowered to about 900C, in order to maintain a stabilized roaster operation and in order to master the accretions in the waste heat boiler. Silicic acid in combination with copper may also present an interference and necessitate a limitation of the turbulent layer temperature to 920C maximum. CaO/MgO Both elements are 100% transferred into the corresponding sulphate during the roasting process. ZnS with CaO and MgO content are therefore always producing a calcine with high SO4- sulphur. CaO in the appropriate quantitative ratio with FeO and SiO2 can form a readily melting eutectic mixture. With ZnS meeting this condition in terms of their CaO, FeO and SiO2 content, the temperatures should be maintained at around 925C in the turbulent layer. An application of higher temperatures is basically possible, but will at 950 960C result in an almost doubled sulphide sulphur content in the calcine. It is suspected that the surface of the turbulent layer particles and of the fly dust begins to soften, and that this causes inclusions of freshly charged or partly roasted ZnS. 8.1.2 Screen analysis, size
The ZnS roasted until now in standard stationary fluid bed roasters can be divided into three categories ZnS with coarse grinding ZnS with normal grinding ZnS with extremely fine grinding degree.
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This is demonstrated by the examples of the following table: Category coarse (Cartagena) m + 160 - 160 to 100 - 100 to 80 - 80 to 50 - 50 % 38.85 16.1 6.05 15 24 20.8 54.6 1 Category medium 2 Category 3
(Geco, Monteponi, (Roseberr/Tas.) (Timmins) Broken Hill)
% 11.6 13.0
% 1.1 2.1 5.6 15.4 75.8
0.1 0.5 6.1 93.3
Coarse ZnS tend towards bed build-up and combustion in the turbulent layer. This effect is even promoted by a moisture content of 7 - 8%. On roasting coarse grained ZnS, the temperature of the turbulent layer ranges as a rule above the roaster head temperature. ZnS of category 2 has similar tendencies as those of category 1. With the normal moisture content it will be found that bed and head temperature are almost equal and will never deviate from each other by more than 20 K. Extremely fine ground ZnS require some attention in processing. With the usual 8% moisture content, the combustion still occurs primarily in the turbulent layer, so that the head temperature ranges about 50 K above the layer temperature. The bed build-up, however, is low - amounting to only approx. 10% in most cases. The roast process becomes difficult to manage when this fine ZnS with low moisture content of e.g. 5 7% is charged. The result is a significant rise of the gas outlet temperature to more than 1000 C. As this temperature shall not to be exceeded, it is recommended to decrease the throughput together with the roaster air volume. Increasing the ZnS-moisture to 8 - 9% by subsequent water addition will only be successful if the water addition occurs homogeneously and if there is sufficient time for the moisture absorption in the feed. Local conditions will permit this only in exceptional cases. Usually it will only be possible to arrange for the water addition in the storage yard or along the conveyor route to the ZnS discharge bin. This irrigation has to be discontinuous, however, because of the changing belt load and water repellant properties of dry ZnS which frequently lead to smudged belts. 8.1.3 Slinger belts
For normal operation two slinger belts shall be used in parallel. Each slinger belt is designed to charge the full concentrate feed load to the roaster. In case of a mechanical failure of one of the two sets it is
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possible to continue operation without interruption. The field operator has to close the gate in the chute underneath the rotary table feeder and has to readjust the knife gate on top of the rotary table. During the operation with only one slinger belt the roaster is loaded unsymmetrical. This leads to an uneven gas distribution with areas of high SO2- an low O2 concentration and other areas vice versa. On a long term basis this might lead to operation problems on the subsequent plant areas: uneven temperature distribution in the roasting gas thermocouples showing the local temperature do not represent the intermediate temperature higher possibility of building sulphates in the roasting gas dust handling problems possible
For further details concerning the slinger belts, please refer to chapter 7.
8.2
8.2.1
Roaster
Temperatures in Roaster
Turbulent Layer The recommended temperature range is between 900 and 970C with 950C being the most favourable level. To maintain this temperature the turbulent layer is cooled indirectly by the surface of the cooling coils and directly by injection of a minor quantity of water. The cooling surface, distributed over various registers, is during commissioning adjusted to the most favourable value and remains unchanged thereafter. The detailed temperature adjustment is performed by varying the minor injection water volume. The water feed is adjusted manually. A temperature control by varying the ZnS-feed is not proposed. The ZnS rate corresponding with normal operation remains constant. A variation in the feed rate will only be made when there is a change in the ZnS moisture. There are 8 thermocouples installed in the turbulent layer. These thermocouples are placed in a staggered arrangement to each other with four elements protruding from the grate approx. 200 mm vertically into the turbulent layer. The others are immersed horizontally into the layer at approx. 300 mm distance from the grate. The bed temperature is the mean value of the indications from all thermocouples in the turbulent layer, whereby the values should not vary among each other by more than 20C. Wider deviations would mean: Defective thermo-couple - or inhomogenous turbulent layer. Reasons for an inhomogeneous turbulent layer could be: Insufficient air volume Excessive portion of lumps in the ZnS-feed Accidental increase of bed pressure beyond maximum value Coarsening of bed
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Remedies against inhomogenity of turbulent Layer If a beginning temperature deviation is recognized early enough as a sign for inhomogenity, it will be possible to normalize the turbulent layer by the following steps: Increase the air volume by 10 ...15% and simultaneously reduce the bed pressure to 140 150 mbar. Remove either one or two weirs at the overflow and operate the bottom outlet more frequently by shortening the cycle between two operations of the mechanical stoking device. Increasing the turbulizing air volume on reducing the bed pressure means that the turbulent layer is loosened, so that zones of varying turbulence are mixed with each other. A sample for screen analysis is to be withdrawn from the roaster discharge (overflow and bottom outlet) and the grain fraction is to be compared with previous values. Increased air volume and reduced bed pressure are to be maintained until the original grain specter is reached again. It is imperative to determine the cause of the inhomogenity. If the portion of lumps is too high in the ZnS-feed it may be necessary to instal a 15 mm grid on the vibro screen. If the grain coarsening is due to thermic influences (superficial sintering), drop the bed temperature by increasing the injection water volume. Investigate whether cooling surface should be increased.
Roaster Outlet Temperature In normal operation, the roaster head temperature will adjust to 950 1000C. There is no means of regulating the roaster outlet temperature. Where the permitted maximum temperature of 1000C is exceeded for the mentioned reasons, it will be necessary to try to lower the temperature either by increasing the cooling water quantity of the spray nozzles or, if this measure alone does not help, by reducing the throughput. 8.2.2 Air Volume Primary air: recorded by air volume meter and adjustable to desired value by means of the guide vane preceding the roasting air fan. Secondary air: Necessarily introduced by slinger belts and its volume cannot be precisely determined. Indirect but only approximate registration is possible by means of SO2 concentration at roaster outlet.
The air volume admitted to the roaster consists of two components:
Both air components combined form the combustion air supplied into the process. We are concerned only with the primary air, however, which is measurable. An air volume of 550 Nm3/hm is injected in normal operation in order to maintain a homogeneous layer. This figure constitutes an optimum value. The minimum value possible in continuous operation ranges at 450 Nm3/hm. This value is adjusted at underload. Going below this specified value in continuous operation may cause demixing and failures in the roaster operation. The mentioned air loads apply for the normal bed pressure of 160...180 mbar.
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8.2.3 Conditions within Turbulent Layer
Grain size The grain size distribution of the turbulent layer will result automatically. Of influence in this respect are: Air volume Bed temperature Fineness of ZnS-concentrate Water content Frequency of actuating the bottom drain
The following table shows examples of grain specters in a homogeneous turbulent layer:
1 m +500 -500 to + 320 -320 to + 160 -160 to + 100 -100 to + 80 - 80

Cartagena concentrate
2
Paragsha concetrate
3
Mixture: Mcot/Timmins
8.25 14.05 47.65 23.75 4.85 1.45
14.57 10.18 65.54 0.42 2.71 6.58
15.6 % 5.2 % 40.0 % 17.6 % 16.8 % 4.8 %
Hards lumps running in the ZnS-feed are slowly crushed by the erosive effect of the turbulent layer. They are to be constantly removed through the bottom outlet (poking device). Bed Height and its Adjustment Bed height or bed pressure is the pressure lost by the primary air as it passes through roaster nozzle grate and the turbulent layer. It is measured in mbar as wind box intake pressure. In normal operation its value is approx. 160...180 mbar. The wind box intake pressure depends on the air quantity and on the height of the turbulent layer. The height of the turbulent layer is adjusted by the weir elements installed in the roaster overflow. When the quality of the concentrate is changed, it may happen that with unchanged roasting conditions the wind box pressure changes. This is a normal effect when the density of the bed changes. Experience gained from many roasting plants gives a time in the range of 1 to 2 weeks until the bed has stabilized and the wind box pressure does not change anymore due to this effect. Overflow The roaster overflow remains constantly opened. Its manner of functioning can be compared with a weir. The shut-off gate following the overflow casing remains still closed during preheating. It is
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opened after the normal bed pressure has been obtained, accretions have to be poked off manually and the final bed height is adjusted to the desired value by insertion of one or two plates of heatresistant steel. This adjustment then remains constant. Bottom Outlet It is periodically opened by the mechanical stoking device once per shift. The purpose of this apparatus is the removal of coarse size at grate level normally not discharged by the usual overflow. The functioning of this discharge contributes essentially to the stability of operation. The stoking device does not constitute a control element for the bed height. 8.2.4 Roaster Draught
The roaster draught is to be adjusted to 0.1...-0.2 mbar. As a matter of principle the roaster draught is to be regulated with the aid of the louvre flap, so that gas bursts at the inlet ports are no longer detectable. Any unauthorized increase of the roaster draught causes increased air inleakage and thus a higher rate of reaction from SO2 to SO3 and finally to sulphates due to a higher oxygen content in the roasting gas.
8.2.5
Sulphide and Sulphate Sulphur Content in Calcine total Mixture
With consideration for the electrolysis, it is to be endeavored to hold the sulphide and sulphate sulphur content as low as possible, and the highest possible roasting temperatures are therefore to be applied. Sulphide Sulphur Sulphide sulphur contents of between 0.1 and 0.3% are already received in the temperature range of 920 950C. A temperature increase to above 950C will in most instances not bring any significant decrease in sulphide sulphur content. With some types of concentrates (Raibl and Paragsha) starting at 940C there was even an increase in the sulphide sulphur content, whereas the minimum of approx. 0.15 to 0.20% was found in the range of 920 930C. It is therefore recommended to fix the most favourable turbulent layer temperature also via the sulphide sulphur content in the calcine, among others. SO4- Sulphur The sulphate sulphur content in the total mixture of the calcine ranges mostly between 1.6 and 2.2%. Storage-aged ZnS-concentrate will often bring already a considerable SO4-quantity into the roasting process as a result of the sulphate formation which has already occurred during storage, but these zinc sulphates will be noticeably decomposed at temperatures above 900C. The formation of sulphates in the roasting plant takes place in the roasting gas. Free oxygen in the gas reacts partly with SO2 thus forming SO3. With calcine particles in the gas containing magnesium and calcium the SO3 is partly captured building magnesium suphate and gypsum compounds. At the
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temperatures present in the waste heat boiler and in the hot gas electrostatic precipitator it can be assumed that all the magnesium and calcium will be transferred into its sulphate compound. A similar reaction takes place in presence of lead or copper in the calcine. But these elements usually do not react completely to the sulphate modification. Using the Jarosite process for leaching the calcine, a sulfate sulfur content of 2% does not effect the process as SO4 ions are consumed.
8.3
8.3.1
Waste Heat Boiler

Temperatures
The gas inlet temperature to the boiler equals the gas temperature at the roaster outlet, as both units are immediately connected to each other. The gas outlet temperature from the boiler is fixed to 350 C, in view of the operational safety of the succeeding deduster unit, and must on all accounts be maintained. The automatic temperature control maintains the super heated steam temperature at the value desired in operation. 8.3.2 Pressure Loss - Dust Behaviour
The heating surface suspended in the boiler block represents a hurdle for the dust-loaden gas. The power required for the flow through the open cross-section of the bundles is evidenced by a pressure. This pressure loss is 1...1,5 mbar for a properly serviced boiler. The pressure loss is received from the difference in the draught meter indication at the boiler outlet and roaster outlet. A portion of the dust-loaden flue dust is precipitated at the heating surfaces, another portion adheres to the pipe walls and is shaken down by the rapping mechanism. Failure or improper functioning of the boiler rapping mechanism results in increasing dust accretions which will more and more fill out the open cross-section of the gas space. The result is an increasing pressure loss in the boiler. The tolerable maximum value is 2 mbar. This is the ultimate value at which the plant must be shut down to determine and eliminate the cause of the increasing pollution. Substantial accretions are an indication of a high formation of sulfates due to: a) b) c) High oxygen content in the roasting gas High content of Mg, Ca, Pb, Du in the concentrate High rate of very fine particles in the concentrate.
The weight of the dust accretions constitutes a load on pipes and pipe attachments. Polluted bundles require increased rapping forces and will thus result in increased wear to the rapping mechanism. Periodic manual inspections of the boiler interior by the personnel are therefore recommended.
8.3.3
Steam Drum Water Level
The alarm system (visible and audible) responds when the water level rises to 60 % (high level) or drops to 30 %(low level). If the water level rises above 60 % up to 80 % (high-high level), the alarm system responds again and the feed water pump/feed water turbine is stopped automatically. At reaching the lowest water level of20 %, the boiler system is protected against damage by dripping the main blowers (roasting air blower, SO2-blower) automatically. The whole plant is then shut-down. The
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drum water levels are visually indicated in the boiler drum symbol in the DCS-system in the control room. The water level shall oscillate about the operating water level of the direct indicator. If there is any doubt about secure function of the water level indicator, it shall be blown through according to the instructions of the manufacturer. Do not blow through for too long time to avoid damages of the mica. We should like to point out that the remote indicator is merely an auxiliary device. In case of doubt, only the direct water level indicators shall prevail. 8.3.4 Circulating Water Volume
The volume of the circulating water is 950 t/h for normal operation. If the volume declines to about 85% of this value, an alarm will be sounded in the control room and a signal lamp lights simultaneously in the circulation pressure line at the DCS-System. If the circulation volume is dropped to 75% of the rated volume, the turbine driven pump will be switched on automatically via a second alarm contact of the circulation flow meter. In parallel the roasting air fan is switched off which is interlocked to the SO2 blower. This means an emergency shutdown of the plant. A change of the circulating flow rate at the cooling coils without an alternation in operation may be attributed to a disturbance of the circulating pump itself or a changing of the fluidized bed conditions or a leakage of the cooling coils resp. evaporator bundles. In case of any failure of the electric circulation pump the turbine driven circulation pump has to start immediately. This is done automatically by stopping the control oil pump. That will open the inlet valve of the steam supply to the turbine driven pump. By this arrangement a sufficient circulation is achieved in any case. When the turbine driven pump starts, the operator has to check whether the normal circulation volume is achieved. In the pump room the operator has to check the pump and turbine for proper operation. Make sure that the equipment is cooled by gland water and record all pressures and temperatures of the now operating machines.
8.3.5
Safety Valves
The boiler drum is equipped with two spring loaded safety valves. These valves open when the highest permissible operating pressure is reached, and do not prevent a further pressure increase. Another safety valve is located at the super heated steam line and opens earlier than the drum safety valve when the boiler pressure increases beyond the normal value. The devices to prevent excess of the maximum allowable operating pressure (safety valves) shall be checked regularly. Unauthorized changes in the devices or their loads are forbidden. They shall by no means be overloaded or inactivated. The only competent person for making changes in the adjustment is an expert from the engineering department of the surveying authorities. The steam pressure shall not go beyond the red mark indicating the maximum allowable operating pressure on the gauge. If the steam pressure exceeds the maximum allowable operating pressure, the heat input will be throttled down. If doing so the safety valves do not react, these must be inspected immediately.
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Should it not be possible to eliminate the disturbance, the heating must be stopped at once and the principal informed of it. 8.3.6 Cleaning during Operation
Gasside Cleaning The boiler is inspected once per week by opening the cleaning and inspection doors at the boiler block, beginning at the transition from roaster to boiler and ending at the dust hopper. The appropriate aid is an air lance, the procedure of manual boiler clean-out is as follows: Notify control room to have roaster draught increased. Commence the cycle of cleaning at transition from roaster to boiler. This door is the first to be opened. First determine thickness and nature of accretions. Then connect the lance connecting hose to the nearest compressed air outlet and open the tap valve approx. 1/3. Introduce the lance and blow off the dust accumulation. Tightly close the door after cleaning is finished. Clean the dust hopper walls at both boiler longitudinal sides from above. Never clean any hot dust build-up from below as the material can come down in an avalanche. Remember that fine dust can behave like a fluid, especially at higher temperatures. When cleaning any dust build-up always make sure that the area below the place is evacuated so that the downcoming dust cannot harm people. Inspect the condition and the aligning of bundles. Poorly cleaned bundles indicate insufficient functioning of the rapping device. If necessary, open the doors on both sides of the hopper one after the other and remove any dust build-ups using the air lance. Then tightly close the doors.
Recommendation: Statistically record the clean-up period, the frequency and the thickness of accretions depending on the roaster throughput, the concentrate analysis and the roasting gas temperature.. A change in the concentrate feed may require a different frequency of manual cleaning the waste heat boiler. Waterside Cleaning, Blow down The steam boiler shall be blown down at regular intervals and be demineralized in accordance with the boiler water analyses taking into consideration the height of the water level.
8.4
Hot Gas Cleaning
It is the operators' responsibility to monitor and control the equipment associated with the hot gas cleaning plant to ensure that the dust contained in the gas stream will be removed in a manner that will assure minimal downtime and a clean gas supply to the wet gas cleaning system. The operation of the hot gas cleaning plant must be coordinated with the roaster operation and the acid plant operations. The following points should be observed:
the hot gas cyclones including dust discharge and rotary valves. the sealing air system for the support insulators
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the electrostatic precipitator rapping system. the transformer/rectifier sets. the dust discharge and conveying system including rotary valves. Start and stop equipment in accordance with the established procedures. Inspect equipment in accordance with the established routine inspections and, when necessary, submit maintenance work orders for repair of equipment. Clean up the area as required to maintain high housekeeping standards.
8.4.1 Monitoring the operation of the hot gas electrostatic precipitator Ensure that the sealing air system is operating properly. Caution: A low sealing air temperature or pressure to the insulators may result in fouling or damage to the electrode insulators. The sealing air system should be operating for at least 8 hours prior to starting the high voltage. Monitor the current drawn by the electrostatic precipitators. Note: A decrease in the normal operating current may indicate that there is an accumulation of material on the discharge electrodes. Monitor and record the gas temperature at ESP inlet. Note: The gas temperature at the inlet should be 350 C (min 320C). For reasons of the material properties the maximum temperature of 390 C must not be exceeded. Control the operation of the rotary valves and chain conveyor. The control is necessary to prevent dust accumulation and blockages. Control the operation of the driving motors of the rapping mechanism. Note: The rapping motors for the gas distribution plates in the gas inlet and for the collecting electrodes are running on a timer controlled on-off cycle. Please refer to operating manual of the hot-esp manufacturer.
8.5
Calcine transport
The calcine transport system should be inspected in regularly intervals for any irregularities. For information about maintenance work please refer to chapter 7.
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9 Mechanical Supervision, Maintenance, Lubrication
The plant is to be supervised constantly during operation. The operating personnel is to make inspection rounds every 30 minutes. This is necessary for an early detection of changes in the plant which might lead to failures. All events are to be notified into the shift journal. The plant is to be maintained and kept clean. Any necessary repairs are to be carried out without delay. All equipment is to be lubricated once per day according to the lubrication instructions supplied, or several times per day according to special instructions. Oil and grease fillings are to be replaced regularly according to the manufactures instructions. Improper maintenance causes forfeiture of the guarantee claims.
9.1
Belts
ZnS-Feed
The rubber belt of the bin discharge belt is to be inspected daily for proper condition. Supporting and reversing rollers are to be inspected regularly for accretions, which are to be removed. Check the belt tension and readjust it as necessary. Inspect the rubber belt for true run and adjust by means of the tensioning device if necessary. During the first start-up of the plant it is necessary to check all the rubber belts in the plant more frequently, as the belts may change the position on the rollers due to elongation of the rubber material. This elongation will decrease after several days of operation. Constant inspections are also required for the slinger belts. Adjust belt run by means of tensioning device. The rubber belt service life is decisively influenced by the feed purity, i.e. the more foreign material or hard lumps are in the feed the shorter the service life of the belt. Slinger Belt Replacement Precondition: One slinger belt is in operation. Due to a long operation time of the rubber belt the belt shall be replaced. Procedure: During this procedure the material feed is not interrupted. Raise the roaster draught to -1 mbar. Open the gates at the second material inlet and clean the inlet port. Switch on the second slinger belt and bring it into position. Remove the gate underneath the second table feeder dumping point and clean the chute. Let down and secure the second table feeder scraper Pull up the other table feeder scraper. The feed of concentrate now goes to the second slinger belt. The first slinger belt operates without load. Insert the gate underneath the first table feeder dumping point. Close the gate at the first inlet port. Pull back the old slinger belt. Switch off the old slinger belt.
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Bin-Chute The concentrate feed bin shall be emptied once a month and material accretions in the corners shall be scraped off. Examine the rubber strips above the discharge belt for proper condition. Inspect all transfer chutes, especially the discharge chute above the slinger belts, and carefully clean them.
9.2
Roaster
The mechanical inspection extends to checking the bearing temperatures of the fans and to the regular functioning of the poking device at the bottom outlet. The roaster overflow is to be inspected once per shift and is to be cleaned if necessary.
9.3
Waste Heat Boiler
Steam Drum Water Level Inspection of lighting. Compare water level at drum with water level indicator of the controller in control room. The drum level must not decline below the minimum water level. Over-feeding the drum is also to be prevented in order to rule out that water will be swept into the super heater. Super heated Steam Temperature The super heated steam temperature indicator in the DCS is to be compared with the direct indication (mercury thermometer). The direct indication may differ from the control panel value by approx. 10 15C. Steam Pressure Outlet Boiler The value of the remote indication in the control room is to be checked with the direct pressure indication on the boiler drum or at the super heater outlet. Both values are to differ by less than 1 bar(g). Circulating Pumps The pumps are to be inspected as described in the previous section. Once a fortnight the turbo circulation pump must be put in to operation manually to make sure, that it will operate when needed. This should be recorded in the shift book. Valves It is to be assured that all flange connections and stuffing boxes may are tight. Sludge Drain The sludge drain of the filter on the circulating pumps is to be opened briefly once per day. The continuous sludge drain of the boiler drum is to be adjusted to a value of approx. 3%. Any deviating values are to be determined according to the analyses of the boiler water.
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9.4 Hot Gas Electrostatic Precipitator
The dust discharge devices like chain conveyor, rotary gate feeders and chutes are to be inspected. For further inspections please refer to the operating manual of gas cleaning section BA.
9.5
Calcine Handling
Chain Conveyors Open the inspection doors once per day and inspect the condition of conveyor chain. Check the grease filling of the bearings and replace insufficient grease filling during the next regular lubrication. Inspect gearing and motor once a week for proper anchoring. Inspect the shaft seal and repack if necessary. Replacement of a shearing pin First determine the cause of fouling - mostly congested outlet chute or chain jammed by foreign matter. If necessary, dismantle the cover and remove any foreign matter. Straighten any twisted chain links by heating with welding torch. In case of congested chute, remove accretions first. Remove the coupling guard at motor and secure motor electrically against accidental connection. Then turn motor by hand until the shear pin halves in cam and sprocket are positioned above each other. Remove both parts of the shear pin, insert new shear pin and secure with clamps. Unlock the drive Now switch on the driving motor for one or two seconds and run the conveyor intermittently idling. Caution: The succeeding section must not be overloaded. Arrange for pauses if necessary. Interlock the drive when conveyor is free again and take the calcine route into operation.
Cooling Drum Inspections of the bearings and the rollers are to be performed daily. Grease the rollers daily. Inspect chutes for wear. Ball Mill Check the bearings cooling and the bearing seals. Remove some balls every three months and determine the abrasion. Replenish the stock if required by refilling of fresh balls. Bag Filter Inspect the cleaning mechanism and the rotary gate feeder in the discharge chute. Check the condition of the bags once a month. Replace all defective bags.
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10 Analytical Inspections
The analysis results are to be recorded daily in the appropriate analysis book.
10.1
ZnS-Feed
An hourly sample from the discharge belt conveyor underneath the day bin is to be withdrawn in the closed container held ready for this purpose. This container is forwarded to the laboratory and the individual samples are mixed and united to the so-called total sample. The following elements are to be analysed: Once a day: Once a week: Once a month: Moisture content S, Fe, Zn, Pb, Cu. S, Fe, Zn, Screen analysis Pb, Cu, MgO, CaO, Cl, F
For the screen analysis the grain fractions shall be divided as follows: + - 160 - 100 - 80 to to to + + + 160 100 80 50 50 m m m m m
During the first start-up of the plant it is useful to do the analysis more frequently in order to adjust the operation variables to the optimum point. The required frequency will be determined by the commissioning team. Relevant analysis methods are used for the determination of the mentioned elements. Reference can be made to the following literature: "Analyse der Metalle" Vol.II, Operational analyses, 2nd Edition 1961, Publisher: Springer-Verlag: Part 1 pp. 1 - 726, part 2 - pp. 727 - 1568. A translation of the analysis procedures is attached in the annex.
10.2
Calcine
An hourly sample of the calcine total mixture is withdrawn in normal operation, most appropriately at the collecting chain conveyor behind the ball mill discharge. Mixing and further treatment of the withdrawn individual samples are described under 8.1. Once per day the following analyses are to be made:
Sulphide sulphur The recommended analysis method: according to Eberius.
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This acknowledged method has enabled the determination of non-roasted sulphide sulphur and gives absolutely reliable results. Sulphate sulphur The recommended analysis method is the soda extraction method. A detailed description is given in the Annex. Grain Size Analysis of Roaster Bed A screen analysis of the roaster bed should be carried out once per week. The grain fractions shall be divided as follows: + -500 -320 -160 -100 to to to to + + + + 500 320 160 100 80 80 m m m m m m
Cl and F Distribution If concentrate is roasted with elevated content of chlorine and fluorine, the distribution of these elements in the dust is to be tested once a week. The investigations should appropriately be extended to cover also the washing acid in the cold part of the downstream gas cleaning plant.
10.3
10.3.1
Water
Raw water
The layout of the feed water treatment plant is based on a certain water analysis. It is known from actual experience that the content of anions and cations in the water are subjected to constant fluctuations. These fluctuations have a direct influence on the service life of anion and cation filters. The analytical control of a properly managed boiler operation must therefore begin with the constant surveillance of raw water and feed water treatment plant:
Sampling - Location: - Tank: Inlet into the feed water treatment plant White used. polyethylene bottles or glass bottles with plug shall be
The vessels must be absolutely clean. They must be thoroughly cleaned before and after use. As a matter of principle, use only polyethylene bottles for demineralization plants.
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- Quantity: For complete analyses, at least 2 l or as arranged with the laboratory.
- Procedure: Prior to sampling let water drain out at the sampling point for approx. 5 minutes to ensure that the samples are withdrawn the normal water flow. Stagnant water may lead to falsified values and often still contain dissolved foreign matter from fittings and piping. Analyses Once a month the raw water is to be tested for the following constituents: Total hardness as CaCO3 Calcium hardness as CaCO3 Magnesium hardness as MgCO3 Chloride as Cl Sulphate as SO4 Nitrate as NO Iron, Fe Manganese, Mn Silica, SiO2 Chlorine as Cl2 Conductivity in S/cm KMnO4 consumption Raw Water Hardness Already the determination of raw water hardness is indicative for the fluctuations in the water analysis. The method of analysis described in the following can be performed without difficulties by the operating personnel, according to prior agreement with the laboratory. The necessary instruments and chemicals are to be requested from the laboratory. Procedure for Hardness Test 100 ml of water are measured off in the graduated cylinder and filled into the Erlenmeyer flask. Added to 100 ml of water is a buffer tablet, which in addition to the buffet substance contains the indicator and 1 ml of 25% ammonia from the graduated pipette. The solution turns red in the presence of alkaline earth ions. Complexometric titration solution is added from the micro-burette until the colour turns to green. When using the titriplex solution B together with 100 ml of water, the number of ml of solution consumed until the colour change from red to green will directly equal the hardness in d (degrees Deutsch). Required Equipment and Chemicals: 1 Erlenmeyer flask 300 ml 1 Graduated pipette 10 ml 1 Graduated cylinder 100 ml
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1 Micro-burette 2 ml for titriplex solution with stand titriplex solution B (Merck) indicator-buffer tablets (Merck) ammonia solution 25%. The hardness is either indicated in d of German hardness or in milli-equivalent per liter. The following hints are added to facilitate the conversion: 1 1 1 2.8 Derivation of mval/l: 1 val = 1 equivalent = 1 mol / valence The milli-equivalent is 1000, a customary unit of measurement for water examination. Boiler Feed Water / Dosing of Chemicals Where completely demineralized water with a pH value of less than 8 is available than 8 is available, it will be necessary to raise the pH value to 8.5 - 9 by a dosing of chemicals. A suitable piston dosing pump with preparation tank will be furnished for this purpose. The feeding occurs mostly in the line to the feed water tank or to the feed water pumps. To be added are: NaOH or Na3PO4 or hydrazine. As a matter of principle, dose only the absolutely necessary quantity to maintain the purity of the treated feed water as far as possible. NaOH raises the pH value to a higher, hydrazine to a lesser degree. When residual hardness is suspected in the treated water, it will be bound as calcium phosphate by using Na3PO4. The quantity of the chemicals to be dosed will be determined on commissioning and must be varied from case to case according to the analysis results. Boiler Water Requirements according to VGB (extract): The pH value of the boiler water should not exceed 10.5. Normal values: 9.5 - 10. Sampling Location: Socket at outlet cooler sampling. The boiler water withdrawn here comes from the bottom outlet of the continuous drum sludge drain. The sampling valve must be constantly opened for adjustment of a low boiler water flow. Vessel: Polyethylene bottles. d d d d = = = = 0.357 mval/l (CaO/CaCO3) 10 mg CaO/l 17.8 mg CaCO3/l 1 mval/l
Tests to be performed The following analyses are important for proper boiler supervision: pH value
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p value m value conductivity residual hardness as Ca residual hardness as Mg dissolved solids SiO2 P2O5 (in mval/l) (ppm) (ppm) (ppm) (in mval/l) (mval/l) (mval/l) (microsiemens/cm)
The analyses are to be performed at least once a day. As the determinations of the pH value, of the p value and of the m value are not difficult, it will be possible to have the operating personnel perform the analyses twice per shift. A suitable analysis apparatus can readily be set up in the control centre under the guidance of the laboratory. The operating personnel will be appropriately instructed for the initial analyses by a laboratory technician from the plant laboratory. Evaluation of Analyses The evaluation of the analysis results and the decision concerning changes in the quantity of boiler elutriation and chemical dosing are matters concerning the operating procedure. It is recommended that the boiler elutriation be constantly opened in the ratio 1 - 3%. The sampling valve is to be fully opened once daily for flushing of the sludge drain line. The following is a guide for the evaluation of analysis results, as important conclusions on the boiler water composition can be drawn from the ratio of p and m values: Ca(OH)2, CaCO3 and alkaline earth hydrogen carbonate are not present if there is no affirmed evidence of hardness. Prevailing conditions: a) p = m (English p = T, T is needed for m) Only hydroxides are present in the water. p . 40 = ppm NaOH b) 2 p m (English p = 1/2 T) Carbonates as well as hydroxides are present in the water. (2 p - m) . 40 = ppm NaOH (m - p) c) . 106 = ppm Na2CO3 2 p = m (English p = 1/2 T) Only carbonates are present. p . 106 = ppm Na2CO3 d) 2 p m (English p 1/2 T) Carbonates as well as bicarbonates are present. p . 106 = ppm Na2CO3 (m - 2 p) . 84 e) p = O, m
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= ppm NaHCO3

Only bicarbonates are present. m . 84 = ppm NaHCO3 m . 28 = ppm CaHCO3 as CaO Not present: NaOH, Na2 CO3 Analyses Methods Reference is made to the relevant literature. Silicic acid, phosphates and also residual hardness are today determined by calorimetric means.
10.4
Roaster Gas
The SO2 and O2 concentration in the gas at hot gas electrostatic precipitator outlet is measured continuously during operation. Although this sampling point is a long way away from the roaster, and although the gas is already diluted, the sampling is done at this point where clean roaster gas prevails and the danger of blocking the sampling line and of falsifying the analysis results is very low.
10.5
Clean Gas Dust Content
The determination of the clean gas dust content requires extensive preparations and special equipment, arranged by the laboratory of Lurgi Umwelt GmbH and made available to the supervisory personnel. For more information refer to operation manual of gas cleaning section BA.
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11
11.1
Shut-Down
Normal Shut-Down
Inform everybody whom it may concern about the imminent shut-down. Especially the acid plant and gas cleaning plant operators and the operators of the turbo-generator area have to be informed.
11.1.1
Roaster Stop the injection water supply to the roaster. Stop the ZnS-feeder to the roaster by switching off the rotary table feeder group switch. The slinger belts are still rotating. Close the material inlet ports to the roaster. Switch off the automatic poking device and shut off the roaster overflow. Pull back and then switch off the slinger belts. The pressure control at the roaster outlet is still in automatic operation and will readjust the pressure. Continue the roasting process for several minutes until the SO2 indicator in the sulfuric acid plant drops to zero. As soon as the SO2 level in the plant is low enough to match the local environmental regulations, start the start-up fan. Open carefully the start-up damper in front of the start-up fan. Close the butterfly flap in the gas duct to the mercury absorption tower. This will separate the acid plant from the rest of the plant. The operation mode is now in the preheating interlocking conditions. The roasting air fan is interlocked with the start-up fan. For details referring to the further operation of the SO2-blower please see the operating manual of Sulfuric Acid Plant. Open the louvre type damper complete and adjust the roaster outlet pressure at any time if necessary with the start-up damper. Cool down the roaster bed to a temperature of approx. 600 C by constantly fluidizing. Shut down the roasting air fan, when the above mentioned temperature is reached. After approx. 1...2 h shut down the calcine handling system using the group switch. Stop the rapping devices. Stop the high tension on hot ESP and wet ESPs. The pumps in the wet gascleaning plant and the flushing fans of hot and wet ESPs stay in operation unless this equipment shall be inspected during shut down.
11.1.2
Waste Heat Boiler
Disconnect the boiler from steam system when the steam production comes down in order to avoid overheating of the superheater bundles. For this purpose:
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Open start-up valve approximately half way, the overflow controller is still in operation and the hand valve on the super heated steam line is open. The additional steam withdrawal via the start-up line causes the boiler pressure to drop, so that the overflow controller begins to close. Then close the manual shut-off valve on the superheated steam line and adjust the steam temperature at superheater to approx. 30 40 K below design value by means of the start-up valve. Instead of using the start-up valve, the steam withdrawal can also be accomplished by operating the turbo circulating pump. The steam volume withdrawn from the turbine assures sufficient super heater cooling. The rapping mechanism can be switched off about 1 h after the air supply to roaster has been stopped. The superheated steam temperature control is to be switched to manual operation. The pressure in the boiler is not to decline faster than 0.5 bar(g). per minute. The steam drum vent valve is opened by approximately 3 turns after the boiler pressure has dropped to 0 bar g. When the boiler is shut down, the feed water volume will decrease to a very minor residual value as the cooling increases. A rising water level will be observed as this value is beyond the valve control characteristic. The automatic control is therefore shut down and the re-supply is made intermittently according to the evaporation losses. Circulation Shut-Down The circulating pump can be shut down only after the boiler is without pressure. The pipe wall temperature of the heating surfaces must not exceed 350C on disconnection of the circulating pump. To be on the safe side at that point in time the temperature in the roaster shall in no area be above 400C. Otherwise the circulation pump has to stay in operation. 11.1.3 Hot Gas Electrostatic Precipitator When no further dust is to be expected, electrically disconnect the plant and secure against unauthorized reconnection. Operate the rappers for a few more hours after roaster shut-down. Keep the dust conveyor equipment in operation during short shut-downs; run them during prolonged shut-downs until the rappers are switched off. For short shut-downs keep the insulator flushing and heating in operation; for prolonged shut-downs, start the insulator heating in time, i.e. 8 hours before restarting.
11.1.4
Calcine Handling Run the entire calcine handling system for at least one additional hour. Operate the rapping mechanism of the waste heat boiler for approx. 1...2 hours after shut-down, in order to shake down any accretions or scale which has loosened in the meantime. The cooling water at running equipment is not shut off - not even when this equipment is switched off after about 1...2 hours. The same applies for the air cooling of the boiler chain conveyor. Empty the conveyor route and switch off the calcine handling system.
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11.2
Protective Measures for the Turbulent Layer
The dormant layer resting on the grate and formed of ZnO begins to densify after a certain time. This action is known as "fritting" or agglomeration. When it occurs the turbulizing air will not be able to produce a homogeneous turbulent layer on restarting. There are two possibilities : The development of channels above the nozzles with air entering into the furnace space practically without pressure loss: The indicator at the control panel shows a very low bed pressure (e.g. 60...80 mbar at nominal air flow). The bed forms a solid cake which blocks the passage of air: The indication of the instrument at the control panel then shows a bed pressure of at least more than 200 mbar WG at nominal air flow.
This comprimation can also occur already during the preheating period on reaching temperatures above 700C combined with an unexpected interruption of the preheating action. In order to prevent aggolmeration of the bed content, it is therefore necessary to determine by means of a shut-down the period of time in which a comprimation of the bed content does not yet occur. This period ranges from 15 - 30 minutes according to our experience. Some Canadian ZnS-concentrates which permitted shut-down periods up to 4 hours and more have been an exception until now. An agglomerated turbulent layer can be aerated by manually inserting compressed air lances through the openings at the roaster to blow the bed content free from various points at the roaster periphery. In most cases it will be possible to loosen 90% of the bed content enough to enable restarting, and the not yet loosened crusts decrepitate automatically when the operating temperature is reached.
11.3
Short Shut-Down
(Duration 1 - 2 hours) The procedure for a short shut-down highly depends on the analysis and the behavior of the concentrate. The following information refers to the concentrate specified in the contract with a maximum lead content of 1.69%wt. In general follow the instructions given in chapter 9.1 except for the following changes. After the SO2 level in the plant came down to the level matching the local environmental regulations, check the temperature in the roaster. If the temperature is still high above 800 C. Proceed like described in 9.1 and cool down the roaster bed to a temperature of approx. 800C.
The temperature of the bed is 800C or below: Shut down the roasting air fan. After approx. 15 - 30 minutes (see 9.2), turbulize the bed for approx. 60 seconds with normal air volume. Repeat this turbulization periodically at 30 - 60 minutes untill a temperature of 600 C is reached.
11.4
Emergency Shut-Down
In most cases the emergency shut-down will take place automatically by interlock.
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Some examples are: Failure of the SO2 blower. Failure of the roasting air fan. Water level in the steam drum is below the low level. Insufficient boiler water circulation. Failure of the sulfuric acid pumps in the absorption area. Power failure.
But there are as well some operating conditions, where the operating personnel has to decide whether to shut down. In these cases an alarm will sound in the control room: Problems to feed the concentrate like blockages or slinger belt failure. Roaster temperatures above 1000C. Problems at the calcine handling system. Problems on the cooling of equipment like the cooling water supply or the cooling air fan. Problems on baghouses with high dust emission over a long period of time.
For an emergency shut-down use this procedure: Switch off the concentrate feed group. Close the roaster inlet ports. Shut down the roasting air fan.
In case of an emergency when personal injury is involved: Shut down the roasting air fan.
When during shut down the roaster inlet ports are still open, hat gas can leave the roaster and can ignite the slinger belts. This minor damage can be tolerated if personal injury can be avoided. However, the operating personnel has to decide which way to proceed in any case of emergency. The most important piece of equipment, during emergency shut-down as well as during a scheduled shut-down, that has to be protected against damage is first the waste heat boiler and second the roaster bed (refer to 9.1.2 and 9.2).
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11.5
11.5.1
Inspection during Shut-Down

Roaster Prepare the start-up burners for restarting (refer to chapter 4.) Clean the burner nozzle and the inlet cone in the roaster brick lining. Try to avoid that hard lumps fall onto the bed surface. Clean the roaster sight glasses. Clean the roaster overflow box and insert the gate at the overflow. Inspect all chutes in the ZnS feeding area and jar off accretions if necessary. Inspect the slinger belts, open the cleaning doors, inspect and clean the interior casing if necessary. Open the inspection doors at the transition from roaster to boiler and jar off dust accretions if necessary. Determine all equipment deficiencies in the plant and report them to the workshop. The observations are to be recorded in the shift journal.
11.5.2
Waste Heat Boiler All access doors are to be opened. Inspect the bundles, intermediate walls, and remove any dust accretions. Inspect expansion joints in boiler area, remove pollution in these joints where possible. The calcine hopper of the boiler must also be inspected. Remove accretions which have formed in the corners. Inspect the condition of the heating surfaces. Deficiencies at control devices and accessories logged in the shift journal and reported to the workshop may now be rectified.
11.5.3
Hot Gas Electrostatic Precipitator
Safety Measures when working at the Precipitator during Shut-Down Strictly observe the statutory safety and accident prevention regulations described in the operating manual of the hot-esp manufacturer. 11.5.4 Calcine Handling Open the inspection doors at all conveyors and the bucket elevator and inspect all chains for true run and tension. Inspect all drives and the tension of drive chains and readjust as necessary. Replenish the ball filling of the ball mill. Perform all necessary repair and maintenance works.
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12
12.1
Restarting
Restarting from Hot
The most simple way of restarting the plant is to start with a hot bed, at a bed temperature of above 800C. At this temperature the Zn-concentrate most likely will ignite. The start-up procedure can be supported by the addition of elemental sulfur. Depending on the quality of the Zn-concentrate it is possible to start directly from even lower temperatures. After some years of operation the plant operator will be able to determine the minimum start-up temperature of the different ore types to be roasted. If the start-up fails, the start-up burners have to be installed again, what ends up in a time loss. The start-up procedure described hereunder has the advantage that SO2 gas inside the plant is not vented to the atmosphere but is converted to sulfuric acid. This procedure shall be used for example after a short shut down due to a power failure. 1. The waste heat boiler has to be ready for operation. The boiler rapping device has to be restated. 2. Notify all operators involved about the imminent start-up, as there are: - waste heat boiler (with steam condensing system) operators - turbo generator operators - gas cleaning operators - sulfuric acid plant operators 3. Check whether - The start-up valve on the superheated steam line is open by 7 to 9 % - The flaps in the gas ducts are open - The pressure control loop of the gas pressure at the roaster outlet is in manual operation and the louvre type damper is open by 100 %. - The cooling air fan is in operation. - The rapping devices of the hot gas electrostatic precipitator are in operation. - The calcine handling system is in operation. - The gas cleaning plant and the sulfuric acid plant are ready to take over gas. 4. Start the high tension on the electrostatic precipitators. Make sure that the wet ESPs have been flushed before. 5. Switch on the slinger belts and bring them into position in front of the closed inlet gates. 6. Start the SO2 blower and the roasting air blower, both against the closed inlet vane dampers. 7. Adjust the inlet vane controller of the SO2 blower to create a draught at the roaster outlet of 0...-4 mbar. Open the throttle valve in the roasting air duct and open the inlet vane damper of the roasting air fan. Open both vane dampers accordingly step by step until the full fluidizing air quantity is achieved. Always watch the roaster draught. 8. When the roaster bed is fluidized the steam production will increase. Make sure that the feed water pump is in operation and set the feed water controller to automatic operation. Try to switch over from blowing out the steam at the start-up valve to using the auxiliary condenser as soon as possible. In any case, watch the superheated steam temperature
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and adjust the saturated steam flow through the superheaters to avoid excessive temperatures. 9. Open the gates at the material inlet ports of the roaster and start the concentrate feed group. Watch the roaster bed temperatures. First the temperatures will drop as cold feed material enters the bed. After a few minutes the temperature decrease will slow down, then stabilize and finally the temperature will move up. If this does not happen, the starting temperature was too low and the start-up procedure has to be interrupted. For a new restart the preheating system has to be used as described later. 10. Restart was not successful but temperatures in roaster bed and acid plant converter are sill high: Start feeding elemental sulfur in addition to the concentrate feed as described in 10.3. 11. Restart has to be interrupted: Continue fluidizing the roaster bed until the SO2-content in the roasting gas goes to zero. A restart using the preheating system with a not dead roasted bed content may create problems, as there are elevated SO2 emissions and possibly sintering effects in the roaster bed during start-up with burners and lances. 12. Restart has been successful: Open the roaster overflow by removing the blind plate in the discharge cute. Restart the poking device. Adjust the roasting temperature by starting the water injection if necessary.
12.2
Restarting after Shut-Down with Preheating System
This procedure is very similar to the initial start-up as described in chapter 4 The final steps are the same as outlined in 10.1. 1. Prepare the waste heat boiler for the start-up. Fill the boiler referring to chapter 4 and start the circulation. 2. Notify all operators involved about the imminent start-up, as there are: - waste heat boiler (with steam condensing steam) operators - turbo generator operators - gas cleaning operators - sulfuric acid plant operators 3. Check whether: - The pumps in the wet gas cleaning plant are in operation. - The flushing air blowers and heaters of the hot and wet ESPs are in operation. - The start-up valve on the superheated steam line is open by 7 to 9 %. This is necessary to ensure a certain steam flow through the superheater bundles and to have a right temperature indication. - The pressure control loop of the gas pressure at the roaster outlet is in manual operation and the louvre type damper is open by 100 %. - The throttle flap in the roasting air duct is closed. - The damper in front of the start-up fan is closed. 4. Start the start-up burners:
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- Start the start-up fan with closed inlet damper and adjust a draught of about 1 mbar at the roaster outlet. Make sure that the inlet damper is open by about 5 %. - Start the cooling air fan. - Start at least one field of the hot ESP and one wet ESP (after flushing). - Switch on the oil pump, open the gates in the combustion air line and ignite the start-up burner according to item chapter 4. - At any time during preheating adjust the roaster outlet pressure to about 1 mbar using the inlet damper of the start-up fan. - Use as many burners as necessary to achieve a maximum temperature increase of 100 C per hour in the roaster top. - Maintain a roaster gas temperature of 800 to 900 C maximum and try to transfer the heat from the gas into the bed by frequently turning the bed as described in the following. 5. Slowly increase the pressure of the waste heat boiler by adjusting the start-up Valve. For details please refer to the operation manual of the boiler manufacturer. 6. Fluidize the bed depending on the temperature profile of the bed every 10 to 60 minutes in order to equalize the bed temperatures. - Start the rapping devices of the hot ESP. - Start the roasting air fan, open the throttle flap in the roasting air duct completely and turn around the bed by injecting air of a sufficient quantity to equalize the temperatures (550 Nm3/hm). - During the procedure always try to maintain a roaster draught of 1 mbar by adjusting the inlet damper of the start-up fan. - Shut down the roasting air fan and close the throttle valve. 7. As soon as a bed temperature safely above 400 C is reached, the bed heating can be continue by using the oil lances as described in chapter 5.2.3 and 5.2.4 (heating the turbulent layer to ZnS ignition temperature). - Start the complete calcine handling system.
12.3
Start-Up with Elemental Sulphur
A roaster is started with sulphur only in exceptional cases to save time for preheating or to accelerate the preheating when there has been a considerable decline in temperatures within the contact plant. The elemental sulphur is usually charged with the slinger belts in order to achieve the best possible loose and even distribution over the bed. On the other hand, there occurs a certain commination of the lumps when the sulphur is accelerated in the quickly running slinger belt and the arising very fine and easily igniting dusts will cause danger of explosion. It is therefore necessary to take appropriate safety measures. The following equipment has to be available: Fire extinguisher Water hose.
The sulphur is charged manually via the rotary table feeder. Bin discharge belt and feeder must therefore be unlocked before the sulfur is charged.
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For a start-up with elemental sulphur the bed temperature shall be above 400 C and the start-up burners shall be in operation. The preparations are similar to those described in 10.1. 1. The waste heat boiler has to be ready for operation. The boiler rapping device has to be restarted. 2. Notify all operators involved about the imminent start-up, as there are: - waste heat boiler (with steam condensing system) operators - turbo generator operators - gas cleaning operators - sulfuric acid plant operators 3. Check whether: - The start-up valve on the superheated steam line is open by 7 to 9 %. - The flaps in the gas ducts are open - The pressure control loop o f the gas pressure at the roaster outlet is in manual operation and the louvre type damper is open by 100 %. - The cooling air fan is in operation. - The rapping devices of the hot gas electrostatic precipitator are in operation. - The calcine handling system is in operation. - The gas cleaning plant and the sulfuric acid plant are ready to take over gas. 4. Start the high tension on the electrostatic precipitators. Make sure that the wet ESPs have been flushed before. 5. Switch on the slinger belts and bring them into position in front of the closed inlet gates. 6. Start the SO2 blower and the roasting air blower, both against the closed inlet vane dampers. 7. Adjust the inlet vane controller of the SO2 blower to create a draught at the roaster outlet of 0...-4 mbar. Open the throttle valve in the roasting air duct and open the inlet vane damper of the roasting air fan. Open both vane dampers accordingly step by step until a fluidizing air volume of approx. 400 Nm3/hm2 is reached. Always watch the roaster draught. 8. Feed the sulphur slowly but continuously so that no unburned sulphur vapours will enter the scrubbing tower. Unburned sulplhur in the gas would condensate and clog pipelines and pumps in the area of the scrubbing and cooling plant. 9. Supervise the SO2 concentration in the sulfuric acid plant, which is to receive sufficient gas during the preheating of the roaster and not to be blown cold. 10. When the roaster bed is fluidized the steam production will increase. Make sure that the feed water pump is in operation and set the feed water controller to automatic operation. Try to switch over from blowing out the steam at the start-up valve to using the auxiliary condensor as soon as possible. In any case, watch the superheated steam temperature and adjust the saturated steam flow through the superheaters to avoid excessive temperatures. 11. At 750C in the turbulent layer, slowly start with the ZnS-feed. Continue feeding sulphur manually and at the same time at lowest speed of the discharge belt charge the zinc concentrate together with elemental sulphur. Increase the air volume to the nominal capacity starting at 780C.
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12. On slow but constant temperature increase, the elemental sulphur feed can be discontinued after the temperature has exceeded 800C. The plant is now in operation, the roaster draught can be adjusted to the usual set point of 0.1...-0.2 mbar at the roaster outlet. Run the plant up to operating temperature as described in previous section. Adjust the discharge belt speed to normal value. 13. Open the roaster overflow by removing the blind plate in the discharge chute. 14. Restart the poking device. 15. Adjust the roasting temperature by starting the water injection if necessary
Comment: In many cases elemental sulphur is used to support a start-up from hat, when the bed temperatures are very close to the ignition point of the concentrate and there is the danger that during the start-up procedure the temperature might drop below this point. Another advantage of the start-up with elemental sulfur addition is, that the Converter in the acid plant receives SO2 rich gas very fast. This helps the converter temperatures to come up fast and ensures high conversion rates even in the start-up phase.
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13 Troubleshooting
The structure of this chapter is according to the different consumables: Failure of Zinc Concentrate Electrical Power Supply Instrument Air Cooling Water or Cooling Air
13.1
13.1.1
Zinc Concentrate Feeding Problems

Blockage in the Feed Bin
In case of bridges in the bin, it is necessary to restore the material flow by rapping against the bin walls. The decline of the bed temperature must possibly be maintained by intermediate feed of elemental sulphur (also refer to chapter 10). If the discharge belt is damaged, it has to be considered to shut down the plant as described in chapter 9 13.1.2 Blockage of the Slinger Belt Inlet
If the slinger belt inlet is clogged as a result of insufficient attention by the operating personnel, resulting in material backwash in the table feeder, this congestion can be removed as follows: Stop the rotary table feeder. Slowly clear the feeder discharge by stoking with a wooden pole of about 0.5 m length at the running slinger belt. Run the rotary table feeder intermittently for approx. 5 10 seconds and slowly remove the congestion this way. Clean the chute once more. Then run the plant as normal. Follow up with an inspection of the moisture in the feed material, because congestions at the feeder outlet are mostly the result of moisture fluctuations.
13.1.3
General Approach 1 2 Try to stay at high temperatures in the roaster bed to avoid any start-up troubles as soon as concentrate feed is back. Make sure that agglomeration or sintering does not occur in the bed.
In case of any feeding problems the following guidelines are useful:
Both items are very important. The second one highly depends on the chemical and physical behaviour of the concentrate. For example if you have a very good concentrate with a low tendency of sintering you are able to reduce the roasting air volume, thus increasing the SO2-content, reducing the temperature drop of the bed and reducing the temperature drop on the converter.
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If you realize that you cannot solve the feeding problems in a short time, you have to cool down your bed and blow the SO2 ladden gas to the sulphuric acid plant in order to avoid SO2 emissions during the following start-up through the start-up stack. In general a bed temperature of 600 - 700 C is seen as uncritical and should be achieved after blowing cold the bed.
13.2
13.2.1
Electrical Power Failure

Roaster Bed
In case of an electrical power failure all equipment immediately trips except for those items connected to the UPS (Uninterrupted Powers Supply). In the roaster the most dangerous fact is that the roaster bed is hot at operation temperature and contains a high amount of sulphur from the concentrate not yet dead roasted. There is a potential of sintering the bed material within a short time. Again the time frame for sintering the bed highly depands on the roasting behaviour of the concentrate. After a shut-down from full prcess temperature the roaster bed should be fluidized as soon as possible, practically within the first 10 to 15 minutes. If the electrical power failure lasts longer than this time, the fluidizing procedure has to be performed using emergency power from the diesel generator. The fluidizing procedure is described in detail in chapter .... 13.2.2 Boiler Emergency Operation
The most important piece of equipment during an electrical power failure is the waste heat boiler. The electrical circulation pump and the electrical feed water pump trip and the turbine driven stand-by pump will start immediately. As the cooling water pumps trip too, cooling water comes from the emergency water tank. If the power failure lasts longer than about 15 min. the instrument air pressure might drop below a point were the feed water control valve and the steam transforming station in the condenser area shut down automatically. For details please refer to the manufacturers operation manual. Operate the waste heat boiler as follows: 1 2 3 4 Control the drum pressure by the start-up valve (with power supply of the UPS) from the control room. Control the water level in the steam drum in manual operation using the bypass line at the feed water control valve. Close the blow down valve and the sample coolers in order to minimize the water losses. Control the pressure of the dearator in manual operation in the field.
As soon as the power is gone the steam production drops very fast. Heat is conserved in the roaster bed and will produce steam over a longer period of time, enough to drive the turbo circulation pump.
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When the roaster bed is fluidized again the steam production rises very fast. Make sure that during this operation the water level in the steam drum always stays in the desired range.
13.3
Low Pressure of Instrument Air
There are two possibilities of having low pressure on the instrument air system. The first one is a leakage somewhere in the system or failure of the compressors, the second one is a longer failure of electrical power supply. The instrument air system is equipped with a receiver, a pressure vessel with a capacity of approx. 15 min. of normal instrument air consumption. 13.3.1 Leakage in the Instrument Air System
If there is some severe damage in the system we recommend to shut down the plant. For the scheduled shut down procedure please refer to chapter 9. 13.3.2 Low Pressure caused by Power Failure
In case of a power failure the plant is automatically shut down anyway. But after a short time the roaster bed has to be fluidized. For this procedure some valves have to be operated manually in the field. 1 2 3 The pressure in the waste heat boiler is controlled manually from the control room using the start-up valve. The water level in the steam drum is controlled manually in the field by operating the bypass valve of the feedwater control valve, always watching the water level. Water level and pressure in the feedwater tank are controlled manually by operating the bypass valves.
Always make sure that before the feedwater control valve or the bypass is opened, the turbine driven feedwater pump is in operation. This pump has to be started manually in the pump house.
13.4
13.4.1
Cooling Problems
Boiler Chain Conveyor
During operation the boiler chain conveyor has to be cooled by air supplied form the cooling air blower. In case of a failure the chain conveyor has a very short emergency operation time. If it is not possible to restore the cooling within approx. 1 min, the chain conveyor has to be stopped and, as a consequence, the plant has to be shut down as described in chapter 9. 13.4.2 Drum Cooler
In case of a too low cooling water flow on the drum cooler, the outlet temperature will increase immediately. The hot calcine might destroy the whole calcine handling system. Shut down the calcine handling system immediately. Close the roaster overflow and try to restore the cooling water flow. If this is not possible, shut down the plant as described in chapter 9.
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13.4.3 Failure Cooling Water
Cooling Water is used for cooling the following equipment: Process Water for cooling the roaster by water injection Ball Mill cooling Rotary Valve below chain conveyor Drum Cooler and Chain Conveyor Sample Coolers of Waste Heat Boiler Oil Cooler of SO2-Blower Electric Motor of SO2-Blower
In case of a failure of the whole system the stand by pump has to be started immediately within of maximum 1 min. If this is not possible it is required to shut down the plant by emergency shut down as described in chapter 9.
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14 Start up procedure for roasting -, gas cleaning - and acid plant
This procedure is an extract of chapter five Start up of roaster plant. It should give a brief overview of all three plant sections on how to start up. The operators should use it as a guideline for the first start up. 1. Approx. 4 days before starting the concentrate feed, the acid plant needs to start with the preheating of the converter (pre-heater in operation). During the preheating phase the SO2blower is controlled manually and the air valve is completely open. 2. Waste heat boiler is ready for start up. (Circulation pump and Feed water pump are in operation) 3. Close valve between primary air duct and secondary air duct (should be closed always) and open valve after cooling air blower to secondary air duct. Reduce valve opening at cooling air duct to boiler chain conveyor to provide burners with enough air. 4. Start the start up blower with flap. 5. Start intermediate gas blower with closed throttle valve. 6. Start cooling air blower. 7. Oil pressure for burner operation is minimum 5 bar. Air pressure for burner ignition should be 50 mbar and in normal operation about 100 mbar. Adjust oil throughput of all three burners to the same level depending on the gas outlet temperature of the roaster. Control the oil pressure of each burner (approx. 1.0 bar). 8. Start calcine transport system. 9. Start Hot-ESP. (Air blower needs to be in operation 8 h in advance) 10. Once an hour it is necessary to fluidize the roaster bed for 1-2 minutes with the roasting air blower. Open primary air valve at the wind box. Start roasting air blower with closed valve. Increase the roasting air flow to 38.000 Nm/h and fluidize the roaster bed for 20 seconds. Then reduce the air flow slowly to zero. During fluidization control the pressure of roaster and hot-esp outlet. The pressure limits for roaster and hot-esp are 2 / -16 mbar. Re-adjust the draught at the roaster outlet by moving the flap of the start up fan. 11. The oil lances can be installed, if all bed temperatures are above 400C and the oil pressure is at a minimum of 25 bar. Check whether all ball valves at the oil lances are closed. 12. All man holes of the roaster and boiler must be closed. 13. Start roasting air blower and fluidize the bed as described under point 10 with 38.000 Nm/h. The roasting air blower stays in operation with an air flow of 13.000 Nm/h. Switch interlock switch to preheating mode. 14. The shutt off valves for the oil lances are opened from the control room. Then the ball valves of each oil lance are opened one after the other. 15. The inlet temperature of catalyst bed 1 is > 420C and the temperatures in beds 2 - 4 are > 400C. Stop the pre-heater and the SO2-blower approx. 2 3 h before starting the concentrate feed and close the bypass to the intermediate absorber. Then open the flap in the gas duct to the intermediate absorber completely. 16. Start pre-heater and SO2-blower. 17. Start the slinger belts and bring them in position, if the roaster bed temperature is > 800C. The roaster inlet ports at the slinger belts stay closed until the concentrate feed is started. 18. Flush the two wetesp one after the other. 19. Prepare boiler for concentrate feed. (control manually) 20. Open slowly damper in gas route from gas cleaning to acid plant. 21. Close damper before start-up blower and stop the blower. Then re-adjust the draught at the roaster outlet by closing the damper for additional air to the acid plant. (roaster outlet pressure 1 mbar) 22. Start the two wet-esp one after the other. 23. Open roaster inlet ports for concentrate feed. Start concentrate feeding system with 8 t/h. Set roasting air to 31.000 Nm/h.
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24. Set roasting air and concentrate feed in the following steps to 100% capacity (each step must be coordinated with the boiler and acid plant): 11t/h 33.000 Nm/h, 14t/h 35.000 Nm/h, 16t/h 38.000 Nm/h 25. Switch off the roaster burners, if the roaster outlet temperature increases again after a slight decrease. 26. Close the electric valve for the oil lances, if one of the roaster bed temperatures increases again after a slight decrease. 27. Remove the oil lances, if the roaster bed temperatures are stabile. 28. Open the flap between the cooling air blower and the boiler chain conveyor completely. Set the flap for the burners until the air pressure indicates approx. 50 mbar. 29. Step by step open the gas flap after the heat exchanger IV and close the gas flap to the preheater according to the temperatures in converter and the SO2 content in the gas. The pressure difference will decrease. 30. If the pressure difference is lower than a minimum the pre-heater will switch off automatically. Then the converter is in normal operation.
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Roasting

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Hindustan Zinc Ltd.

Zinc Roasting Plant

Operating Manual Zinc Roasting Plant

Hindustan Zinc Ltd. Udaipur / India

Project No. I 76270-01 Document No. 03041

July 2003 ( Rev. 0 )

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Hindustan Zinc Ltd. Zinc Roasting Plant Table of Contents

Process Description _____________________________________________________________9

Operating Instructions __________________________________________________________16

Function descriptions on the logic diagrams ________________________________________22

Trial Runs ____________________________________________________________________25

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Hindustan Zinc Ltd. Zinc Roasting Plant

Preparations for start up ________________________________________________________27

Start-up of Roaster Plant (fifteenth day) ____________________________________________41

Preparations, Preconditions _______________________________________________________ 41 Heating to ZnS Ignition Temperature ______________________________________________ 41

Running Operation _____________________________________________________________45

ZnS Feed _____________________________________________________________________ 45

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Hindustan Zinc Ltd. Zinc Roasting Plant

Waste Heat Boiler _______________________________________________________________ 53

Hot Gas Cleaning ________________________________________________________________ 55

Calcine transport ________________________________________________________________ 56

Mechanical Supervision, Maintenance, Lubrication __________________________________57

Analytical Inspections _________________________________________________________60

Roaster Gas _____________________________________________________________________ 65 Clean Gas Dust Content __________________________________________________________ 65

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Hindustan Zinc Ltd. Zinc Roasting Plant

Normal Shut-Down ______________________________________________________________ 66

11.2 11.3 11.4 11.5

13.1.1 13.1.2 13.1.3

Electrical Power Failure __________________________________________________________ 77

Low Pressure of Instrument Air ____________________________________________________ 78

Cooling Problems ________________________________________________________________ 78

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Hindustan Zinc Ltd. Zinc Roasting Plant

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Hindustan Zinc Ltd. Zinc Roasting Plant

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Hindustan Zinc Ltd. Zinc Roasting Plant

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Hindustan Zinc Ltd. Zinc Roasting Plant

Material Feeding System and Fluid Bed Furnace

Sulphide sulphur in calcine Sulphate sulphur in calcine

approx. 0,3% of sulphide sulphur. approx. 1,8% of sulphate sulphur

Size in m > 210 210 150 150 105 105 75 75 53 < 53

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Hindustan Zinc Ltd. Zinc Roasting Plant

Hindustan Zinc Ltd. Zinc Roasting Plant

Calcine Discharging System

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Hindustan Zinc Ltd. Zinc Roasting Plant

Content in Vol-% (approx.)

SO2 H2O O2 N2 CO2 Total

0.2 10.3 1.9 74.0 13.6 100.0

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Hindustan Zinc Ltd. Zinc Roasting Plant

Waste Heat Boiler

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Hindustan Zinc Ltd. Zinc Roasting Plant

Hot Gas Cleaning

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Preparations, Preconditions _________ 41 Heating to ZnS Ignition Temperature 41

Roaster Gas ___________ 65 Clean Gas Dust Content 65