Zinc Smelter Debari
Overview
Debari Smelter primarily produces High-Grade (HG) zinc while also recovering cadmium as a by-product. With a zinc production capacity of 88,000 MT per annum, it achieved 82,517 MT of zinc in the financial year ending March 2023. The smelter’s journey began with an initial capacity of 18,000 tonnes per annum of zinc. Over the years, it has undergone significant expansion, growing fivefold to its current production capacity. The Debari Zinc Smelter adopts Roast Leach Electro-winning Technology in its Hydro metallurgical zinc smelter, featuring two Roasting facilities, a Leaching and Purification section, Electrolysis, and Melting-Casting sections. Additionally, it generates surplus calcine, an intermediate product supplied to other Hydro metallurgical zinc smelters.
Key Facts
- Location : 13 kms north of Udaipur, Rajasthan, India
- Technology : Roast Leach Electro-winning Technology
- Products : High Grade (HG) zinc
- Annual Product Capacity : 88,000 tonnes per annum
- Certifications : ISO 9001:2015, ISO 14001:2015, ISO 45001:2018, ISO 50001:2018
Background Information
About 13 km from Udaipur, Rajasthan, Zinc Smelter Debari was commissioned in the year 1968 with an initial production capacity of 18,000 tonnes per annum of Zinc.
Process Description
Roast Leach Electro-Winning (RLE):
The hydrometallurgical smelting process utilizes Roasting, Leaching, and Electrowinning (RLE). Initially, zinc concentrate undergoes Roasting, with resulting gases cleaned and sent to the Sulphuric Acid plant. The roaster’s primary output, Calcine, is directed to the Leaching plant, yielding Zinc Sulphate solution. After Purification via a hot process, this solution undergoes Electrolysis to create Zinc cathodes, later cast into Ingots.
Pyrometallurgical-Klin process:
Walez kiln, volatilization process in the solid state, it is the pyrometallurgical processing of Zinc Leach residue. It is a high-temperature method used to extract raw Zinc Oxide powder from waste slag/cake. The raw materials are subjected to intense heat in a specialized kiln or furnace, causing them to melt, react, and separate into valuable metal alloys and slag.
