Lead is primarily extracted from lead sulfide ores, such as galena (PbS). These ores are typically mined using underground or open-pit mining methods, depending on the ore’s depth and location.
The extracted ore is crushed into small pieces, then a fine powder to facilitate further processing. The ground ore undergoes concentration to separate lead from other minerals, primarily through froth flotation. The ground ore is mixed with water and chemicals to create a slurry, which is aerated to form bubbles. Lead-containing minerals attach to the bubbles and rise to the surface, where they can be collected.
The concentrated lead ore is heated in the presence of air to oxidize sulfides to oxides and produce lead oxide (PbO) and sulfur dioxide (SO₂) gas.
The lead oxide is then smelted in a blast furnace or a rotary furnace:
01
Rotary Furnace
An alternative to the blast furnace, used for recycling lead from batteries and other scrap materials.
02
Blast Furnace
The lead oxide is mixed with coke (a carbon-rich material) and limestone (to remove impurities). The coke reduces the lead oxide to molten lead, and the limestone forms a slag that floats on top of the molten lead.
The molten lead from the smelting process contains impurities and must be refined:
01
Drossing
The molten lead is stirred and cooled, causing impurities to form a dross on the surface, which is then removed.
02
Electrolytic Refining
The lead is further purified by electrolysis, where impure lead acts as the anode and pure lead is deposited on the cathode.
02
Electrolytic Refining
The lead is further purified by electrolysis, where impure lead acts as the anode and pure lead is deposited on the cathode.
Zinc is primarily extracted from zinc sulfide ores, such as sphalerite (ZnS). These ores are typically mined using underground or open-pit mining methods, depending on the ore’s depth and location. The extracted ore is crushed into small pieces, then a fine powder to facilitate further processing.
The ground ore undergoes concentration to separate zinc from other minerals, primarily through froth flotation.
The concentrated zinc ore is heated in the presence of air to oxidize sulfides to oxides and produce zinc oxide (ZnO) and sulfur dioxide (SO₂) gas.
The zinc oxide is then leached to dissolve the zinc:
Sulfuric Acid Leaching
The zinc oxide is treated with sulfuric acid, producing zinc sulfate (ZnSO₄) in solution.
The zinc sulfate solution is purified to remove impurities:
Cementation
Impurities like copper, cadmium, and iron are removed by adding zinc dust, which precipitates these metals out of the solution.
The purified zinc sulfate solution undergoes electrolysis to produce high-purity zinc:
Electrowinning
Zinc ions are reduced and deposited on cathodes, producing high-purity zinc metal.
Knife Gate Valves are crucial in various stages of the lead & zinc extraction process, particularly in handling slurry, pulp, and other abrasive materials. Common areas you would find our Knife Gate Valves include:
• Provides reliability in slurry isolation across the entire plant:
o Concentration Plants: Flotation Cells, Cyclones, Thickeners, etc
o Heap Leach Plants
o SX/EW Plants
o Tailings Distribution Lines & Spigots
• Full body liner protects the valve body from slurry and leach solutions, increasing the life of the valve
• Rotable; easily refurbishable on site as the liner is replaceable
• Gate Options: 316 SS, 2205 Duplex, 2507 Super Duplex, Hastelloy C276, Hastelloy C22, etc
• Fully enclosed body does not discharge during operation, eliminating contamination of the surrounding environment
• Available in Class #150 and Class #300 ratings
• Meets MSS SP-135 Standards
• Successfully operate in:
o High Density Tailings
o Abrasive and turbulent slurries
• Features identical inlet and outlet seat rings that incorporate a soft primary seat and a hardened secondary seat to improve sealing and service life
o Seat Ring Options: Hardened Steel, Ceramic Lined, other anti-abrasion materials, etc to suit the process conditions
• Rotable; easily refurbishable on site
• Fully enclosed body does not discharge during operation, eliminating contamination of the surrounding environment
• Available in 10 bar or Class #150 ratings
• Body and Gate Options: 316 SS, DI, CS, 2205 Duplex, 2507 Super Duplex, Hastelloy C276, etc
• Features a soft primary seat and a metal secondary seat to improve sealing and service life
• Rotable; easily refurbishable on site
• Fully enclosed body does not discharge during operation, eliminating contamination of the surrounding environment
Browse our full range of knife gate valves for processing applications.
We understand the need to offer choices for our customers and offer a range of valves, price points and services.
Copyright © Hy-Performance Valves | All rights reserved
Simply request a product data sheet by placing your email address into the field below and clicking the submit button.
Unlock Efficiency with Our Valves!
Transform your mining operations with our state-of-the-art valves. Schedule a free demo to discover how our products can enhance efficiency and reliability. Simply enter your email, and one of our expert applications engineers will reach out to arrange a convenient time for your personalised demonstration.
