Nyrstar - Balen

Acid Plant Database September 10, 2011

Owner	Nyrstar NV
Location	Zinkstraat 1 B-2490 – Balen Belgium
Background	Formerly - Ste Vieille Montagne - Umicore formed as a result of the merger between Metallurgie Hoboken-Overpelt, SGM and Vieille Montagne 2007 - Nystar today announced that as of 31 August 2007 it had taken ownership of the zinc and lead smelting and alloying assests of Umicore and Zinifex, thereby formally launching the company and creating the world’s largest zinc producer.
Website	www.nyrstar.com
Plant	Plant No. 1	No. 4 Roaster Plant No. 2
Coordinates*	51º 12' 3" N, 5º 13' 3" E	51º 12' 3" N, 5º 13' 58" E
Type of Plant	Metallurgical	Metallurgical
Gas Source	Zinc Lurgi Roaster	Zinc Lurgi Roaster
Plant Capacity	770 MTPD	-
SA/DA	3/1 DA	SA
Emissions	-	SO₂: < 600 ppm with ZnO scrubber
Status	Operating	-
Year Built	-	-
Technology	Chemetics	-
Contractor	Chemetics	-
Remarks	-	2002 - ZnO tailgas scrubber using Dynawave technology. Byproduct ZnSO₄ sent to leaching plant. Cost €1.8 million
Pictures
General	The Balen smelter is located on a 244 hectare site in the northeast of Belgium near the city of Mol, approximately 80 kilometres east of Antwerp. Since 1910 the plant has gradually moved to integrated zinc-lead smelting. The main production process has changed over time from electrolyte zinc production (1930s), to fluidised bed roasting (1950s and 1960s) and to the treatment of residues by an iron removal process (goethite) around 1973. In 1985, Balen began using what was then the largest roasting facility in the world. The Western regional office is based at the Balen plant and covers Europe, the Middle East, Africa and the Americas. The Balen office is also the Nyrstar's registered address.
References	Geenan, C., Aït Maamar, R. and Eusèbe, C., “Main Developments in Umicore Zinc Smelting”, Lead & Zinc ’05, Proceedings of the International Symposium on Lead and Zinc Processing, Kyoto, Japan, October 17-19, 2005, Volume – I, pp. 247-263.
News	2008-11-26 - Nyrstar NV today informed its Belgian works councils that it will temporarily suspend production and initiate a care and maintenance program at its Balen smelter due to adverse economic circumstances. The program, which will take place before year end, is necessary to address the significant and sudden decline in customer demand and reduce the accumulation of surplus zinc stocks in the market. The suspension will also minimise losses at the plant which have been caused by the prevailing low zinc price, falling 58% from its 2008 peak, combined with Balen's high energy and production costs. Balen currently has the highest labour cost across the Nyrstar Group and its energy cost has increased by more than 50% in the last 12 months. The suspension is anticipated to continue until mid 2009, but will be reviewed over the coming months. This equates to a reduction of approximately 25,000 tonnes of zinc in 2008 and a further 130,000 tonnes in the first half of 2009. Nyrstar has previously announced that it is reducing production at its Budel plant by 28% for the remainder of 2008, and this reduced level of production will now be maintained through mid 2009. For Budel, this equates to a reduction of approximately 10,000 tonnes of zinc in 2008 and a further 35,000 tonnes in the first half of 2009. The care and maintenance program at Balen will help to ensure the plant is maintained in a ready condition, enabling it to return to production when economic conditions improve. The adjoining site at Overpelt will continue to operate at a reduced five-day week, producing die-cast alloys and providing washed zinc oxides for the Group.

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


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