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Sulphuric Acid on the WebTM Technical Manual DKL Engineering, Inc.

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Sulphuric Acid on the Web

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Acid Plant Database  November 21, 2024

Owner Korea Zinc Company Limited

Location Onsan
South Korea
Background  A subsidiary of Young Poong, Corporation Young-Poong-Logo2.gif (3546 bytes) 
Website www.koreazinc.co.kr
Plant -
Coordinates* 35° 25' 46" N, 129° 20' 43" E
Type of Plant Metallurgical
Gas Source Zinc Roaster
Plant Capacity 1,000,000 MTPA
SA/DA -
Status Operating
Year Built -
Technology -
Contractor -
Remarks Products:
98% H2SO4
25% Oleum
Liquid SO3
Ultrapure Sulphuric Acid: 280,000 tons per year
Pictures Korea-Zinc-Onsan-1.JPG (179170 bytes)  Korea Zinc - Onsan 3.gif (9875 bytes) 
General Onsan Refinery operates the refining facilities for both zinc and lead. The refinery adopts the zinc residue-processing technology that maximizes the recovery of valuable metals from zinc residue and changes the slag environmentally sustainable. Also constructing zinc refinery and lead refinery together in one plant has generated the synergy effects such as higher recovery ratio of valuable metals, use of various-types of raw materials, and lower waste discharge.

Onsan Refinery, characterized as 'Custom Smelter', is able to process various kinds of zinc ores, successfully commercializing innovative technologies such as Direct Leaching Process, QSL process, and TSL process. Direct Leaching Process is a refining technology that directly dissolves the zinc from zinc concentrates in a special leaching process and thereby eliminating the need for traditional roasting and sulfuric acid plants. Presently, Korea Zinc is the only company that uses this process commercially in the world.

QSL process is a process that produces lead bullion through oxidization and deoxidization by dissolving lead concentrate. It is zinc-refining technology that helps save energy and prevent pollution by using only one furnace instead of two. It is an excellent process in that it can process a variety of materials, and uses coal as a power of source, which is rather cheap.

Zinc fuming is a process that recovers valuable metals like zinc, lead, and copper from zinc residue. This process contributes to minimizing environmental contamination by making clean slag, which has much less toxic materials than iron residue and is recycled as construction materials and/or raw material for cement. In addition, this process makes it possible to dispose the residue at the company's discretion; thus, not only it solves the lack of enough lot for pond, which is required for storage of the residue, but it also produces a lot of steam by recovering wasted heat in the process of production.

The Top Submerged Lance (TSL) technology has been designed to solve the disposal problem of residues generated during the refining process, the problem that almost every refinery in the world has in common. This technology recovers valuable metals from by-products generated at the nonferrous metals refining process and turns the residue into environmentally stable insoluble slag by inserting combustible materials like coal and oxygen and causing turbulence, using Lance, which is installed in the upper parts of Smelting Furnace and Fuming Furnace. In a nutshell, this technology has a great advantage in that it processes environmentally instable matters into environmentally stable wastes and recycles them. These efforts for environment paid off as the company was awarded Environmental New Technology by the Ministry of Environment in September 2002.

As mentioned above, Korea Zinc takes advantage of the world best technologies to recover the most valuable metals, discharges the least wastes and uses various materials including the recycled ones. All in all, Korea Zinc becomes and will maintain its presence as the world most competitive refinery.
References -
News November 18, 2024 - Young Poong’s bid to buy Korea Zinc has been met with concerns that the takeover of the world’s largest zinc smelter could erode its position in the global markets and cause high-tech supply disruptions.  Industry watchers have cast doubt over the ability of Young Poong and private equity firm MBK Partners to run Korea Zinc, which exerts negotiation power in setting global zinc prices.  “Based on Korea Zinc’s track record in the zinc smelting market, which has been built on trust over a long period of time, we are creating a global standard that will continue to lead the market,” a Korea Zinc official said.  Since the late 2000s, Korea Zinc has set the benchmark treatment charge for zinc, the fee a smelter earns for converting mined concentrates into metal.  The annual benchmark treatment charges are renewed through contracts at the beginning of every year and used as a reference point to other smelting and mining firms in the world.  “Negotiation power in this market can be built through long-term know-how, and it is virtually impossible to approach it in the short term without a business understanding,” an industry source said.  What makes Korea Zinc a benchmark price setter is its status as the world's biggest zinc smelting company in terms of output capacity, ahead of Belgium's Nyrstar and Switzerland-based Glencore.  It is also the world’s largest buyer of zinc concentrates with an annual purchase of 1.4 million tons when combined with its Australian subsidiary SMC.  Concerns have been raised that Korea's national security and industrial competitiveness could be weakened if the alliance of Young Poong and MBK put the zinc smelter up for sale after their acquisition. Korea Zinc and a US think tank have accused MBK of having strong ties with Chinese capital.  On Monday, the Korean government decided to designate Korea Zinc's technology for producing lithium-ion battery material as a core national technology.  The decision could thwart Young Poong's plans for Korea Zinc, because it is reliant on the help of MBK, which is thought to be eyeing a second sale. Companies recognized as having national core technologies can be acquired by foreign companies only with government approval.  To fend off the takeover, Choi Yoon-beom, chairman of Korea Zinc, has been stressing the firm’s role in the production and supply of rare minerals used for high-tech and defense industries.  “Korea Zinc holds significance in establishing a stable supply chain, as some rare minerals are only produced by a few countries,” he said.  It produces bismuth and antimony and occupies more than 60 percent of the domestic market.  China has reportedly taken measures to ban exports of antimony and related metals since Sept. 15 for national security reasons. Antimony is a strategic metal used in military applications, with China accounting for 48 percent of global production.  As Donald Trump won a second term in the White House, the trade war between China and the US is highly expected to intensify to shake up the global supply chain of rare minerals.  “Despite China's export controls on antimony, Korea Zinc is putting a lot of effort into maintaining a stable supply chain,” a company official said.  Another group warily watching the dispute over Korea Zinc’s management rights is the country’s chip manufacturers, as the zinc smelter also plays a crucial role in supplying them with sulfuric acid.  “As the difficulty of semiconductor products and processes increases, any outlier in sulfuric acid quality is likely to cause serious damage to semiconductor production and quality control,” a major chip manufacturer said in a letter to Korea Zinc to ensure a stable supply of sulfuric acid.  Sulfuric acid is an essential material that acts like a cleaning agent by removing fine impurities on the wafer surface, a thin disk of semiconductor substance.  High-purity sulfuric acid is mainly used as it affects semiconductor performance and yield.  Korea Zinc’s Onsan smelter in Ulsan produces the most high-purity sulfuric acid in Korea. As of last year, the Onsan plant produced about 230,000 tons of sulfuric acid for semiconductors out of 1.4 million tons of sulfuric acid it produced.  The company supplies about 65 percent of the sulfuric acid used in Korea's semiconductor industry, approximately 240,000 tons out of 380,000 tons annually.  Some 95 percent of sulfuric acid for semiconductors produced by Korea Zinc is supplied to Samsung Electronics and SK hynix, the world's top two memory chip makers.  “A prolonged dispute over management rights of Korea Zinc could lead to supply chain risks such as disruption in sulfuric acid supply, which could also affect product competitiveness,” an official at a chip maker said on a condition of anonymity.

October 7, 2024
- The hostile takeover bid led by MBK Partners and Young Poong is raising concerns about the potential threats it poses to the global semiconductor supply chain.  Korea Zinc, a leading supplier of semiconductor sulfuric acid, plays a crucial role in providing the key material to semiconductor giants such as Samsung Electronics and SK Hynix.  A successful takeover could not only jeopardize the timely delivery of high-quality sulfuric acid, but it could also undermine efforts to build a secure, China-free semiconductor supply chain.  The semiconductor sulfuric acid market in South Korea currently stands at approximately 380,000 tons per year, with Korea Zinc supplying 240,000 tons and LS MnM Inc. providing 140,000 tons. Samsung Electronics and SK Hynix, which together account for over 98% of the total consumption, rely on this essential material for cleaning semiconductor wafers—a critical process that directly impacts production yield and quality.  Due to the stringent quality and timely delivery requirements, importing semiconductor sulfuric acid is limited, and Korea Zinc and LS MnM remain the only domestic producers. Korea Zinc’s current production capacity is 280,000 tons per year and additional expansions currently underway are expected to increase this capacity to 320,000 tons upon completion in 2026. Semiconductor sulfuric acid is one of the key strategic materials for Korea Zinc's current management, with long-term plans to exceed production by 500,000 tons annually.  The sulfuric acid used in semiconductor processing must be extremely pure, requiring specialized expertise and rigorous process controls. Samsung and SK Hynix regularly conduct detailed audits of their suppliers’ production processes and impose strict standards before approving the material for their manufacturing lines.  Any disruption in the supply or quality of this critical material could halt production at major semiconductor factories, including Samsung’s facilities in Pyeongtaek, Hwaseong, and Giheung, as well as SK Hynix’s plants in Icheon, Cheongju, and Wuxi. Continuous communication between Korea Zinc and its customers is essential for ensuring supply chain stability and addressing any technical issues that may arise.  The ongoing management dispute between Korea Zinc and MBK Partners is being closely monitored by Samsung and SK Hynix, both of whom recognize the vital role of Korea Zinc’s products. Industry experts are concerned that a private equity takeover, driven by short-term financial objectives, might jeopardize the long-term investments necessary to maintain and expand Korea Zinc’s production capacity.  This concern is particularly acute as South Korea undergoes significant semiconductor fab expansions. SK Hynix is investing KRW 122 trillion in new fabs in Yongin's Wonsam-myeon, set for completion by 2027, while Samsung has committed KRW 360 trillion to a new fab in Namsa-myeon in Yongin city, with construction slated to begin in 2031. Once these projects are completed, the domestic demand for semiconductor sulfuric acid is expected to exceed 1 million tons annually.  Given the technical expertise required to produce semiconductor sulfuric acid, a high-precision foundational material, only a few specialized plants, like those operated by Korea Zinc which has secured advanced contamination control technologies, can meet the strict quality standards. Imported alternatives pose significant risks related to quality control and supply reliability, underscoring the importance of Korea Zinc’s production capabilities.  The global semiconductor supply chain could also face broader repercussions. Industry sources have expressed concerns that if Korea Zinc were acquired by Chinese companies, they could prioritize supplying Chinese semiconductor manufacturers, potentially disrupting the flow of this essential material to Korean companies and affecting the U.S., a key competitor to China in the global AI race.  As semiconductors remain South Korea’s largest export, Korea Zinc’s advanced technology, commitment to quality, and sustained investment in production capacity are essential for maintaining a stable and secure supply chain for this critical material.

June 28, 2016
- About a thousand liters of sulfuric acid leaked from the construction site of a smelter factory in the country's industrial city of Ulsan Tuesday, injuring six workers, firefighters said.  The incident took place at around 9:15 a.m. at a factory owned by Korea Zinc Inc., the country's largest zinc smelter, some 414 kilometers southeast of Seoul.  The chemical at some 70 percent concentration leaked as six workers were disassembling pipes for maintenance. All six are suffering from burns, with three of them in critical condition, authorities said.  Firefighters said they are investigating whether there is any secondary damage from the accident.  Earlier in the day, about a ton of waste chemicals comprised of hydrochloric acid, nitric acid, hydrofluoric acid and water spilled out of a tank due to chemical reactions in Gumi, 261 kilometers southeast of Seoul.  The firefighters completed cleanup of the spilled chemicals at around 5:30 a.m., about three hours after the incident was first reported.  They said no harmful chemical substances were detected near the site of the accident. 

April 20, 2009 - GEA Bischoff received an order for 1 horizontal dry electrostatic precipitator from Korea Zinc Co. Ltd. The off-gases from a new lead smelter in Onsan, South Korea will be cleaned.  With this contract Korea Zinc Co. Ltd. continuous the longtime cooperation with GEA Bischoff, who since the year 1993 supplied 11 dry and 20 wet precipitators as well as various other gas cleaning equipment to this client.

November 26, 2008 - Ausmelt Limited (AET) has signed a Licensing Agreement with Korea Zinc Co. Ltd (Korea Zinc) for the construction of two new Top Submerged Lance (TSL) technology furnaces for lead smelting.  The two new furnaces will be built at Korea Zinc.s production facilities in Onsan, Korea. They will recover lead from up to 70,000 tonnes per annum of lead-bearing materials, including lead secondaries.

MTPD - Metric Tonne per Day           STPD - Short Ton per Day
MTPA - Metric Tonne per Annum      STPA - Short Ton per Annum
SA - Single Absorption
DA - Double Absorption
 

* Coordinates can be used to locate plant on Google Earth