An integrated hydrometallurgical process was used for the zinc leaching and purification from a zinc ore containing 9.75 wt% zinc. The zinc minerals in the ore were hemimorphite, willemite, and calcophanite. Main gangue minerals were quartz, goethite, hematite, and calcite. Central composite design (CCD) method was used to design leaching experiments and the optimum conditions were found as follows: 30% of solid fraction, 22.05% sulphuric acid concentration, and the leaching temperature of 45 °C. The PLS containing 35.07 g/L zinc, 3.16 g/L iron, and 4.58 g/L manganese impurities was produced. A special purification process including Fe precipitation and Zn solvent extraction was implemented. The results showed that after precipitation of iron, Zn extraction of 88.5% was obtained with the 2 stages extraction system composed of 30 vol% D2EHPA as extractant. The overall Zn recovery from the ore was 71.44%. Therefore, an appropriate solution containing 16.6 g/L Zn, 0.05 g/L Fe, and 0.11 g/L Mn was prepared for the electro-winning unit without using the roasting and calcination steps (conventional method), which result in environmental pollution.

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