Gpi Tanks XL builds two 1,089 m³ duplex reaction tanks on-site for zinc producer Nyrstar
Nyrstar in Budel is the largest zinc producer in Europe. Large reaction tanks, also known as SIHAL tanks, are essential in the production process for extracting zinc from raw materials. When two out of the three SIHAL tanks had to be taken out of service due to leakage, the continuity of production came under serious pressure. Nyrstar turned to Gpi Tanks XL with a request to supply two new 1,089 m³ duplex tanks.
Murat Sozer, Senior Project Engineer at Nyrstar, was involved throughout the project. He explains how the request came about: “It became critical when two of the three tanks were out of service. If the third tank had also failed, the entire production process would have come to a standstill. To prevent this, we submitted a request to Gpi Tanks XL for two new reaction vessels.”
“Gpi could deliver quickly, and we knew what to expect from them”
Choosing Gpi
Murat elaborates on the decision: “We approached several suppliers. Gpi was already familiar to us, as they had supplied tanks before. With the risk of the last tank failing, short lead times were crucial. Gpi could deliver quickly, and we knew what to expect from them, so the choice was easily made.”
The assignment
Part of the production process involves leaching and purifying zinc from insoluble compounds. Nyrstar carries out this process in special reaction tanks, operating under high temperatures and with highly concentrated sulfuric acid. Gpi Tanks XL was commissioned to design and deliver two 1,089 m³ tanks capable of withstanding these extreme conditions.
The right material choice was essential: “We researched which materials were most suitable for our process medium at 98°C and high concentrations of sulfuric acid. Duplex turned out to be the best choice, and Gpi was able to realize this,” Murat explains. The tanks – 12 meters high and 11 meters in diameter – were constructed from duplex stainless steel 2205, insulated with mineral wool, and finished with bolted stainless steel plates. In addition, the vessels were equipped with heat exchangers, steam and condensate circuits, valves, and fittings.
“There was smooth cooperation between the engineering teams”
Design and on-site construction
Murat looks back positively on the design phase: “In the initial phase, we carefully defined what we needed. During the process, there was smooth cooperation between the engineering teams of Nyrstar and Gpi. Both parties took responsibility in the right areas, which made the collaboration efficient and trouble-free.”
After the engineering process, the tanks were built directly on-site at Nyrstar in Budel.
“The assembly went very well. The Gpi team on-site was professional, worked with precision, and paid close attention to detail. Agreements were met as promised,” Murat says enthusiastically about the construction phase.
The result
Since May, one of the new tanks has been operational, giving the company security once again. Murat explains: “The risk of the entire plant eventually shutting down has now been eliminated. The end result meets our expectations, and we are very satisfied. The second tank will soon be put into operation as well. With these tanks, production is secured again for the next 20 to 25 years.”
“We look back on a very successful collaboration with Gpi”
Collaboration
“We look back on a very successful collaboration with Gpi. Everything went smoothly, and we had no issues at all. Agreements were clearly communicated and kept. The fact that we had worked with Gpi before was definitely an advantage. It’s reassuring when you know what to expect.”
