EPC Turnkey Solutions for Zinc Processing Plants

Zinc ore is an important mineral resource used to extract zinc, which is widely applied in the production of galvanized steel, batteries, and alloys. Global zinc ore resources are mainly distributed in countries such as Australia, China, Peru, and Mexico.

With the continued mining and processing of zinc ore, the global average zinc grade has decreased from 7.2% in 2000 to 4.8%.

In addition, zinc processing plants are also facing challenges such as stricter environmental regulations and increasing difficulties in energy consumption control.

Xinhai Mining provides EPC turnkey solutions for zinc processing plants. Our full-process services mainly include the following aspects.

01Design of Ore Dressing Process for Zinc Processing Plant

1. Ore Dressing Test

Xinhai Mining never applies a one-size-fits-all ore dressing scheme. When we receive ore samples from customers, we first conduct comprehensive beneficiation tests.

We use X-ray fluorescence spectroscopy (XRF) to perform elemental analysis and quickly quantify major elements (Zn, Pb, Fe, S) as well as harmful elements (As, Cd).

X-ray diffraction (XRD) is used for phase analysis to determine the proportions of sphalerite, smithsonite, quartz, and other minerals.

We also apply scanning electron microscopy with energy-dispersive spectroscopy (SEM-EDS) for micro-area analysis to identify the occurrence states of zinc-bearing minerals.

2. Customized Ore Dressing Scheme

Xinhai Mining firmly believes that no two mines in the world are exactly the same. Therefore, we offer fully customized ore dressing solutions tailored to each customer.

Based on the beneficiation test results, the optimal process route is selected, and a personalized scheme is finalized.

Different types of zinc ore require different processing methods. Below are three typical zinc ore beneficiation solutions:

High-sulfur zinc ore – Priority flotation

After crushing and grinding, the ore enters the flotation system for sulfur suppression and zinc flotation. Through roughing, cleaning, and scavenging, zinc concentrate is produced. The tailings are desulfurized and then dewatered.

This process is applied at the Neves-Corvo zinc mine in Canada.

Zinc oxide ore – Sulfidation-flotation

The raw ore is first crushed, ground, and deslimed, then subjected to sulfidation. Afterward, the slurry enters the flotation system where amine collectors are added to extract zinc concentrate. The concentrate is dewatered, and the tailings are neutralized before disposal.

This process is used at the Skorpion zinc mine in Namibia.

Mixed ore – Gravity separation + flotation + leaching

Mixed zinc ore requires a combined beneficiation approach. After crushing and grinding, gangue minerals like quartz, calcite, and feldspar are removed via gravity separation. The remainder is processed in the flotation system, leveraging floatability differences. Residual gangue minerals that cannot be separated are treated with leaching.

This solution is adopted in the Huize mining area in China.

3. Tailings Recovery Enhancement Technology

Xinhai Mining has achieved significant progress in improving the recovery rate of zinc tailings. This includes the development of new flotation reagents, adoption of microbubble flotation technology, the design of new spiral chutes and other gravity separation equipment, and the use of high-gradient magnetic separators for recovering weakly magnetic minerals. These technologies have effectively increased the recovery rate of tailings.

02Zinc Processing Plant Equipment

1. Crushing and Grinding Equipment

The first step in zinc ore processing is to crush and grind large pieces of ore into fine particles. This stage requires crushing equipment such as jaw crushers and cone crushers, and grinding equipment such as ball mills and rod mills.

Xinhai’s energy-saving ball mill features a novel structural design, high grinding efficiency, large output, and reduces energy consumption by 20% compared to traditional ball mills.

2. Sorting Equipment

Depending on the beneficiation process used, the sorting equipment mainly includes flotation machines, spiral chutes, and high-gradient magnetic separators.

The XCF-KYF combined flotation unit enables an efficient closed-loop process of roughing, scavenging, and cleaning, thereby improving concentrate grade and recovery rate.

3. Dewatering Equipment

The selected zinc concentrate needs to be dewatered using equipment such as thickeners, filters, and filter presses.

Xinhai Mining’s high-efficiency deep cone thickener offers excellent sedimentation performance and strong processing capacity, with unit throughput 30%–50% higher than that of conventional thickeners.

4. Auxiliary Equipment

In addition to the core equipment above, zinc ore processing plants also require auxiliary equipment, including feeders, conveying equipment (belt conveyors, slurry pumps), agitation tanks, and automated control systems.

03Zinc Processing Plant Operation Management

Once the zinc processing plant is officially put into operation, applying scientific and reasonable operation management strategies can help achieve the expected mineral recovery rate and concentrate grade.

Xinhai provides customers with an intelligent monitoring system that continuously tracks equipment operating status and collects real-time operational data from the plant. Through a 3D visualization digital twin platform, the production process can be clearly understood and efficiently monitored.

04Technical Highlights of the Zinc Processing Plant

Xinhai Mining offers integrated EPCM+O services, which combine engineering design, procurement, construction management, and operation services to deliver a one-stop solution for the entire project life cycle—from construction to operation.

Compared with traditional models, the EPCM+O model shortens the construction period, accelerates production ramp-up, reduces operating costs per ton of ore by 15.5%, improves overall equipment efficiency by 8%, and lowers tailings treatment costs by 21%.

Conclusion

Xinhai Mining has extensive expertise in zinc ore beneficiation and smelting. We have successfully completed over 50 zinc ore processing projects in more than 20 countries and regions across Asia, Africa, South America, and more. These projects cover the comprehensive recovery of sulfide ores, oxide ores, and complex polymetallic ores.

We welcome you to explore our successful cases studies, including the  Tibet zinc case, the Malaysia lead-zinc case, and the Iran lead-zinc case.