Calcimin Company is the largest plant for production of zinc ingot from the ore. Calcimin Company was established in 1964 in the field of industry and mines and for the purpose of production of baked zinc concentrates, raw zinc concentrates, lead concentrate, zinc ingot, lead ingot and zamak ingot.

Zinc and Lead Ingot Production Process
Calcimin contains two concentrate and ingot plants each containing different sections. A part of the ore is transferred by use of a tele-cabin line with 28 km length from Angouran mine to the Calcimin Plant.

Crushing: The crushers of this section use the feed with 8 cm dimension and crush them into 1.5 cm size through different screens.

Heavy Media: there is another equipment named classifier in the next stage of concentrate plant which sorts the minerals based on their gravity i.e. it separates the ore with higher specific weight, which contains more zinc and  lead grade, from the ores of low zinc and lead content (dump). The high grade ore is then entered into equipment named hemicyclon which acts like classifier and separates the mineral from dump. Then the mineral is transferred into crushers. The mineral is enriched in this section and then transferred to rod and ball mills.

Floatation:The ore, after passing through the above stages, is become a fine-particle material and transferred into floatation bonkers. The separation of lead from zinc is carried out in this section. The suds making materials are injected into the tanks and the lead is connected to suds and then separated by use of mixer. The separated lead is transferred to lead storage by means of water and the zinc is settled in the
botom of the tank and then transferred to the next stage.

Filtration: The mineral after passing the floatation stage is transferred to filtration station in which the ore is dehydrated and transferred to the next state. The zinc grade of the ore after this state is about 15-20 percent.

Calcination: The ore, after dehydration, is fed to calcination furnace section for upgrading. The dehydrated zinc ore is fed into a 10-story furnace and baked there. The concentrate then is discharged into bunkers for promotion of grade. The furnace temperature is 120 to 1200 °C. When the baked concentrate is exited from the bottom of the furnace water is added to it for cooling and prevention from destruction of conveyor and then is transferred to storage by use of a conveyor belt.

Zinc Ingot Production Process: The most important zinc production methods used in the world are pyrometallurgy and hydrometallurgy which the latter is used in Iran. This method has four stages: dissolution (leaching), solution filtration, electrolysis and smelting and casting.

Dissolution (Leach): The ore is dissolved in sulfuric acid of pH ≈ 1 (120 gr/l). The product is then transferred to filtration unit. The major part of the mineral has been dissolved in dissolution phase and only a little non-dissolved ore is transferred to the dump site. During the dissolution phase water is added into sulfuric acid and the ore is added to the solution afterwards. The dissolution process is taken place in a boiler at 200 to 300 °C.

Filtration: After dissolution by acid the acid is neutralized by alkaline (lime) and the impurities are settled into the solution. The most important impurity of the ore is silicon, and there are some other elements like cadmium, iron and other elements. After this phase a little amount of impurities remain in the product and are separated in the next stage. The product of this stage has the minimum amount of impurity and is then transferred to electrolysis section.

Electrolysis: The filtered solution after separation of impurities is called electrolyte. The electrolyte is introduced to the electrolysis section for separation of Zinc. In this section the zinc sulfate is decomposed and the pure zinc is settled on the cathode. The zinc is then transferred to the casting unit for ingot production.

Smelting and Casting: The zinc layer produced in the electrolysis stage is transferred to the smelting and is formed as ingot by casting. The reduction furnace for zinc ingot production works at 500 °C. Then the ingot is discharged into moulds containing Calcimin Company’s mark and after separation of slug the ingots are bundled as 36 ingot bundles with about 1 MT weight and stored in the storage.

Dandi Basic Zinc Sulfate (BZS) Project
The object of this project is production of zinc hydroxide of 20% grade by utilizing basic zinc sulfate process to provide the needed feed for Calcimin Zinc Ingot Plant by use of wastes stored in the plant side with the aim to promote green industry and protection of the environment.
The annual production capacity of this plant is 400,000 ton dried leach cake which in turn produces 105,000 ton dried zinc hydroxide of 20% grade by utilization of BZS process.
The initial estimated investment in the plant is 225 billion Rials and the capital return period will be 8 months.

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