Apparatus for direct smelting of zinc bearing compounds to produce metallic zinc

Apparatus for producing lead and zinc from concentrates of zinc and lead sulfides or oxides, consisting of:

• (a) a source of zinc ore and/or lead ore concentrates, iron bearing and carbon containing materials;
• metallic iron fines and iron oxide fines;
• carbonaceous reductant;
• fluxing agent;
• and a binder;
• (b) a mixer for forming a mixture from said concentrates and other materials;
• (c) means communicating with said mixer for forming agglomerates from said mixture;
• (d) a melting furnace;
• (e) a heater communicating with said mixer for preheating the mixture and producing a preheated charge to said melting furnace;
• (f) a pressure sealed feed system communicating with said agglomerating means and said melting furnace for introducing said agglomerates to said melting furnace;
• (g) a pressure sealed chamber surrounding said melting furnace;
• (h) means for maintaining, a reducing atmosphere within said melting furnace;
• (i) means for vaporizing lead and zinc in the melting furnace;
• (j) means for removing the lead and zinc from the melting furnace in vaporized form;
• (k) water-cooled condenser means for cooling and condensing the metal vapors to liquid metal;
• (l) tapping means communicating with said condenser for removing the liquid metal;
• (m) means for separating the zinc and lead and recovering the lead and zinc metal separately;
• (n) a cooler-scrubber communicating with said melting furnace for cleaning and cooling the off-gases removed from said melting furnace;
• (o) a gas turbine communicating with said cooler-scrubber for receiving and utilizing the cleaned and cooled off-gases as combustion fuel;
• and
• (p) a generator associated with and driven by said gas turbine.

Apparatus for producing lead and zinc from concentrates of zinc and lead sulfides or oxides, consisting of:

• (a) a source of zinc ore and/or lead ore concentrates, iron bearing and carbon containing materials;
• metallic iron fines and iron oxide fines;
• carbonaceous reductant;
• fluxing agent;
• and a binder;
• (b) a mixer for forming a mixture from said concentrates and other materials;
• (c) means communicating with said mixer for forming agglomerates from said mixture;
• (d) a melting furnace;
• (e) a pressure sealed feed system communicating with said agglomerating means and said melting furnace for introducing said agglomerates to said melting furnace;
• (f) a pressure sealed chamber surrounding said melting furnace;
• (g) means for maintaining a reducing atmosphere within said melting furnace;
• (h) means for vaporizing lead and zinc in the melting furnace;
• (I) means for removing the lead and zinc from the melting furnace in vaporized form;
• (j) water-cooled condenser means for cooling and condensing the metal vapors to liquid metal;
• (k) tapping means communicating with said condenser for removing the liquid metal;
• (l) means for separating the zinc and lead and recovering the lead and zinc metal separately;
• (m) a cooler-scrubber communicating with said melting furnace for cleaning and cooling the off-gases removed from said melting furnace;
• (n) a gas turbine communicating with said cooler-scrubber for receiving and utilizing the cleaned and cooled off-gases as combustion fuel;
• (o) a generator associated with and driven by said gas turbine;
• and
• (p) a waste heat boiler associated with said gas turbine for recovering the sensible heat contained in off-gas exiting said gas turbine, and producing steam.

Apparatus for producing lead and zinc from concentrates of zinc and lead sulfides or oxides, consisting of:

• (a) a source of zinc ore and/or lead ore concentrates, iron bearing and carbon containing materials;
• metallic iron flues and iron oxide fines;
• carbonaceous reductant;
• fluxing agent;
• and a binder;
• (b) a mixer for forming a mixture from said concentrates and other materials;
• (c) means communicating with said mixer for forming agglomerates from said mixture;
• (d) a melting furnace;
• (e) a pressure sealed feed system communicating with said agglomerating means and said melting furnace for introducing said agglomerates to said melting furnace;
• (f) a pressure sealed chamber surrounding said melting furnace;
• (g) means for maintaining a reducing atmosphere within said melting furnace;
• (h) means for vaporizing lead and zinc in the melting furnace;
• (l) means for removing the lead and zinc from the melting furnace in vaporized form;
• (j) water-cooled condenser means for cooling and condensing the metal vapors to liquid metal;
• (k) tapping means communicating with said condenser for removing the liquid metal;
• (l) means for separating the zinc and lead and recovering the lead and zinc metal separately;
• (m) a cooler-scrubber communicating with said melting furnace for cleaning and cooling the off gases removed from said melting furnace;
• (n) a gas turbine communicating with said cooler-scrubber for receiving and utilizing the cleaned and cooled off-gases as combustion fuel;
• (o) a generator associated with and driven by said gas turbine;
• (p) a waste heat boiler associated with said gas turbine for recovering the sensible heat contained in off-gas exiting said gas turbine, and producing steam;
• (q) a steam turbine associated with said waste heat boiler adapted to be driven by the steam from said waste heat boiler, and an associated generator adapted to be driven by said steam turbine for producing additional electricity.