1. HINDUSTAN ZINC LIMITED:Hindustan Zinc Ltd (HZL) is Indias leading zinc producer. A vertically integrated Mining & Smelting company, HZL, is currently gearing up to becoming a global lowest-cost producer. As a part of Vedanta Resources, a London listed metals and mining major with Aluminium. Copper and Zinc operations in UK. India and Australia. HZL takes advantage of its mineral resources and related core competencies and believes it has growth opportunities for increasing products and improving returns.

The Key features of the company are as: The only integrated Zinc producer in India Refined Zinc production capacity 411,000 tpa Refined Lead production capacity 85,000 tpa Ore treatment capacity 5.85 Mtpa

1.1 INTRODUCTION:Hindustan Zinc Limited was incorporated as a Government of India Enterprise under the ministry of Steel & Mines, Department of Mines, on January 10, 1966, after take-over of erstwhile Metal Corporation of India Limited, interalia, to own, manage& develop mining & smelting capacities for the important strategic zinc & Lead metals in the country with an operative lead smelter at Tundoo, Dhanbad & Mines at Zawar, Udaipur. Phasewise development of mines, commissioning of Smelters at Debari & Vishakhapatnam, capacity of HZL to produce lead & zinc reached to 79,000 MT of zinc & 30,000 MT of lead by 1990

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HINDUSTAN ZINC LIMITED 1.2 VISION:Be a world-class zinc company, creating value, leveraging mineral resources and related core competencies.

1.3 MISSION: Be a lowest cost Zinc Producer on a global scale, maintaining market leadership Produce half Million Tonnes/Year of Zinc by 2005 Be innovative, customer oriented and eco-friendly, maximizing stake-holder value The only integrated Zinc producer in India Refined Zinc production capacity 230,000 tpa Refined Lead production capacity 35,000 tpa Ore treatment capacity 4.6 Mtpa

Continuous operational improvements, meticulous planning, constant innovation, extensive R&D, technological upgradation and so much more - HZL has come a long way and grown into a multi-unit and multi-product company.

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1.4 HISTORY:Hindustan Zinc Ltd, was created from the erstwhile metal Corporation of India (MCI) on 10th January 1966 as a Public Sector Undertaking. In April 2002, the Government of India. disinvested its majority stake in HZL, and it became a part of the fast growing Sterlite group, Since then HZL as been growing from strength to strength HZL produces Zinc, Lead and other by-products including Sulphuric Acid, Silver and Cadmium. HZL achieved an all-time high with a record output of 2,61,226 tonnes Zinc and 6,14,938 tonnes of record production of Zinc concentrate during 2003-04. Today HZL is Indias leading base metal producer. HZL is a vertically intergrated Mining & Smelting company, gearing up to: Harnessing mining resources to help India achieve self-sufficiency in Zinc. Become a global leader in Zinc. Create value for all entities whether it is Customers, Investors or Employees.

Constant innovation, meticulous attention to detail, extensive investments in R&D and technology are the hallmarks of HZL making it a multi-unit and multi-product company.

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HZL Milestones at a glance:2002-03 Sterlite acquires 26% and management control in HZL from the Government of India in privatization. A further 20% is bought from market through open offer and 18.92% from Government of India under call option. 1991 Chanderiya Pyrometallurgical lead-zinc smelter and Rampura Agucha mine begin production. 1983 1977 1971 1968 Rajpura Dariba Mine starts production. Vizag zinc smelter and second set of Zawar mine facilities commissioned. First expansion of Zawar mine commissioned. Debari smelter commissioned.

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2.1 PHYSICAL AND CHEMICAL PROPERTIES OF ZINC:

Atomic number Atomic mass Electronegativity according to Pauling Density Melting point Boiling point Vanderwaals radius Ionic radius Isotopes Electronic shell Energy of first ionisation Energy of second ionisation Standard potential Discovered

30 65.37 g.mol -1 1.6 7.11 g.cm-3 at 20C 420 C 907 C 0.138 nm 0.074 nm (+2) 10 [ Ar ] 3d10 4s2 904.5 kJ.mol -1 1723 kJ.mol -1 - 0.763 V Andreas Marggraf in 1746

Zinc is a lustrous bluish-white metal. It is found in group IIb of the periodic table. It is brittle and crystalline at ordinary temperatures, but it becomes ductile and malleable when heated between 110C and 150C. It is a fairly reactive metal that will combine with oxygen and other nonmetals, and will react with dilute acids to release hydrogen.

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2.2 PHYSICAL AND CHEMICAL PROPERTIES OF LEAD:

Atomic number Atomic mass Electronegativity according to Pauling Density Melting point Boiling point Vanderwaals radius Ionic radius Isotopes Electronic shell Energy of first ionisation Energy of second ionisation Energy of third ionisation Energy of fourth ionisation Energy of fifth ionisation Discovered by

82 207.2 g.mol -1 1.8 11.34 g.cm-3 at 20C 327 C 1755 C 0.154 nm 0.132 nm (+2) ; 0.084 nm (+4) 13 [ Xe ] 4f14 5d10 6s2 6p2 715.4 kJ.mol -1 1450.0 kJ.mol -13080.7 kJ.mol -1 4082.3 kJ.mol -1 6608 kJ.mol -1 The ancients

Lead is a bluish-white lustrous metal. It is very soft, highly malleable, ductile, and a relatively poor conductor of electricity. It is very resistant to corrosion but tarnishes upon exposure to air. Lead isotopes are the end products of each of the three series of naturally occurring radioactive elements.

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3.1 USES OF ZINC:Zinc is the fourth most common metal in use, trailing only iron, aluminium, and copper in annual production

Zinc is used to galvanize steel to prevent corrosion Zinc is used to Parkerize steel to prevent rust and corrosion Zinc is used in alloys such as brass, nickelled silver, typewriter metal, various soldering formulas and German silver

Zinc is the primary metal used in making American cents since 1982 Zinc is used in die casting notably in the automobile industry Zinc is used as part of the containers of batteries. The most widespread such use is as the anode in alkaline batteries

Zinc is used as the anode or fuel of the zinc-air battery/fuel cell providing the basis of the theorised zinc economy

Zinc is used as a sacrificial anode on boats and ships that use cathodic protection to prevent corrosion of metals that are exposed to sea water

Zinc is used in contemporary pipe organ building as a substitute for the classic lead/tin alloy in pipes sounding the lowest (pedal) tones, as it is tonally almost indistinguishable from lead/tin at those pitches, and has the added advantages of being much more economical and lighter in weight. Even the best organ builders use zinc in this capacity.

Zinc oxide is used as a white pigment in watercolours or paints, and as an activator in the rubber industry. As an over-the-counter ointment, it is applied as a thin coating on the exposed skin of the face or nose to prevent dehydration of the area of skin. It can protect against sunburn in the summer and windburn in the winter. Applied thinly to a baby's 7

diaper area (perineum) with each diaper change, it can protect against rash. As determined in the Age-Related Eye Disease Study, it is part of an effective treatment for age-related macular degeneration in some cases

Zinc chloride is used as a deodorant and can also be used as a wood preservative Zinc sulfide is used in luminescent pigments such as on the hands of clocks and other items that glow in the dark.

Zinc methyl (Zn(CH3)2) is used in a number of organic syntheses. Zinc stearate is a lubricative plastic additive. Lotions made of calamine, a mix of Zn-(hydroxy-)carbonates and silicates, are used to treat skin rash.

Zinc metal is included in most single tablet over-the-counter daily vitamin and mineral supplements. It is believed to possess anti-oxidant properties, which protect against premature aging of the skin and muscles of the body. In larger amounts, taken as zinc alone in other proprietaries, it is believed by some to speed up the healing process after an injury. Preparations include zinc acetate and zinc gluconate.

Zinc gluconate glycine and zinc acetate are also used in throat lozenges or tablets to reduce the duration and the severity of cold symptoms.

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3.2 USES OF LEAD:The following uses for lead are gathered from a number of sources as well as from anecdotal comments. I'd be delighted to receive corrections as well as additional referenced uses (please use the feedback mechanism to add uses).

the metal and the dioxide are used in storage batteries cable covering, plumbing, ammunition manufacture of PbEt4 - an antiknock compound in petrol. Environmental concern with lead poisoning, (and cheaper unleaded petrol prices) is slowly resulting in less use of lead in petrol

the metal is very effective as a sound absorber a radiation shield around X-ray equipment and nuclear reactors used extensively in paints, although recently the use of lead in paints has been drastically curtailed to eliminate or reduce health hazards the oxide is used in producing fine "crystal glass" and "flint glass" with a high refractive index for achromatic lenses solder used by the Romans for plumbing (the decline of the Roman empire is attributed to lead in the water supply!) used to contain corrosive liquids alloying cable covering ammunition shield against X-rays oxide used to produce crystal glass insecticides

4. UNITS:9

4.1 Mines in Operation:

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4.1.1. Zawar Group of Mines:Zawar group of mines (Mochia, Balaria, Zawar Mala & Baroi) is situated in the Girwa Tehsil of Udaipur District of Rajasthan at a distance of about 35 kms from Udaipur, amidst a valley of Arawali hills.

4.1.2. Rajpura-Dariba Mines:The multi=-metal Rajpura-Dariba Mines, which is located about 85km away from Udaipur (Raj.) has demonstrated ore reserve of about 16.4 million tones having metal content of about 6.9% zinc & 2.2% lead.

4.1.3. Maton Rock Phosphate Mine (Udaipur):Maton mine has been developed to meet rock-phosphate requirements for the super-phosphate & phosphoric acid plant at Debari.

4.4.4. Rampura Agucha Mining Complex:The prestigious Rampura Agucha Open Cast Mining Complex is Asias richest & largest lead zinc deposit.. It is situated in Tehsil Hurda, District Bhilwara in Raj. The discovery of a world class diposie of 60.6 million tones at Rampura Agucha, containing 15.4% metal has dramatically altered the prospect of not only reducing the cost of production of zinc and lead, but also the expansion of HZLs production capacity resilting in increasing the demand satisfaction upto 82% for zinc and 61% for lead.

4.1.5. Sargipali Mine (Orissa) 4.1.6. Agnigundala Lead Mine (Guntur, A.P.)

4.2 Smelters in Operation :11

1. Debari Zinc Smelter, Distt. Udaipur (Raj.) 2. Vizag Zinc-Lead Smelter (A.P) 3. Tundoo Lead Smelter (Dhanbad), Bihar 4. Chanderiya Lead-Zinc Smelter

5. CHANDERIYA LEAD ZINC SMELTER

Date of commencent Date of completion

17.11.88 16.05.91

Situated in Chittorgarh District of Rajasthan, the Chanderiya Lead-Zinc smelter is around 8 kms north of Chittorgarh town on the state highway. This gigantic super smelter is integrated with Ramura Agucha Mines at a cost of Rs. 617 crore. The Chanderiya Smelter treating Lead-zinc concentrates is based on the Imperial Smelting Process route adopting blast furnace technology for simultaneous production of lead and zinc metal. The Indian installation is the 14th furnace being in U.K., Australia, Zambia, Japan, Germany, France, Italy, Yugoslavia, Romania, Poland and China.

5.1 PRODUCTION:12

New facilities have been built at Chanderiya which will take total zinc output to some 400,000 tpa. This is being accompanied by a new 50,000 tpa lead smelter, giving lead capacity of 85,000 tpa, which is due for commissioning by March 2006. The output at Rampura Agucha lead-zinc mine has been expanded to 3.3 mtpa, and eventually 3.75 mtpa, to feed the new smelting capacity. A 154 mw coal fired power plan has been competed which will provide power for both the new and existing facilities. The expansion projects were commissioned ahead of schedule in May 2005 and the total cost was 15% below the estimated budget of $425m

5.2 PRODUCTION CAPACITIES

PRODUCTS REFINED ZINC REFINED LEAD SULPHURIC ACID SILVER COPPER CATHODE/SULPHATE CADMIUM

CAPACITY ( TPA) 70000 35000 176000 74 2100 375

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5.3 AIMS OF AN INDUSTRY

a) b) c) d) e) f) g)

To produce goods To have continuous production To produce goods at low cost To produce goods of higher quality Have long life of equipment Social heritage Economic growth

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6. SINTER PLANTHZLs CLZS zinc and lead production begins with zinc and lead concentrates wherein zinc and lead are present as sulphides is imported from its own captive mines in India. Concentrates is received in trucks and stored inn a Raw Material House. From the Raw Material House, it is transported to Bins in Sinter Plant by a well controlled belt conveyor system, where along with certain other necessary ingredients like fluxes, secondary materials and water it is mixed in a prefixed proportion and fed to sintering machine. Sintering serves the dual purpose of converting the sulphides into oxides and agglomerates the product into porous, high strength lumps called sinter. In the sintering process the sulphides of lead and zinc react with oxygen of air to form SO2 gas: 2 ZnS + 3 O2 2ZnO + 2 SO2 2 PbS + 3 O2 2 PbO + 2 SO2 The sinter plant has following main sections: 1. 2. 3. 4. 5. 6. Raw Material Handling Plant (RMH) Charge Proportioning and Conditioning System Sinter Machine Sinter and Return Fines Handling (Crusher Plant) Gas Cleaning (Acid Plant) Slurry Handling

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6.1 RAW MATERIAL STOCK YARD AND UNLOADING STATION:Concentrate and fluxes are delivered by truck and unloaded into the unloading hoppers. The raw material is transported to a tripper belt conveyer which distributes the raw material to individual boxes of the raw material stockyard. Storage capacity of the stockyard is as follows: Zinc concentrate-Rampura agucha mines-6250 tonnes.

Zinc concentrate-Ambamata mines-1600 tonnes. Zinc concentrate-Rajpura dariba mines-1600 tonnes. Bulk concentrate-Ambamata-3500 tonnes. Lead concentrate-Rampura agucha mines-2500 tonnes. Lead concentrate-Rajpura dariba mines-2500tonnes. Lead concentrate-Zewar mines-2500 tonnes. Lime stones flux-450tonnes. Iron flux-700 tonnes.On an average the composition of the raw material from mines from mines is as follows; The composition of Zinc concentrate is Zn 50-55%, S 30-32%, Pb 2-5% The composition of Lead concentrate is Pb 40-55%, S 16-18%, Zn 1.-2%.

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6.2 CHARGE PROPORTIONATE AND CONDITIONING SYSTEMThe material is then carried to the charge proportionate and conditioning system by a series of conveyer system (tray conveyer). The raw materials, when it is oversized, is passed through a disintegrator. There are 15 storage bins of capacity 50 cu. Metre as: 6 for Zn cone.; 3 for Pb cone.; 1 for bulk cone.; 1 for iron flux; 2 for lime stones and 2 for return fines which are of 25 cu. Metre capacity. All bins are equipped with vibrators and shock cannons to prevent blockage. Moisture addition is done in a controlled way at mixing and conditioning drums, so as to get a moisture content of 6% in the feed to the sinter machine. All the various sources of inputs are controlled through weigh feeders located at the bottom of the proportioning bins.

6.3 SINTER MACHINE:The updraft sinter machine has an area of 120 sq. mts. And 109 pallets each measuring 3m x 1m in size. There are 444 grate bars in a pallet. The ore concentrate is reduces to size of 6mm by the hammer mill. After reducing the size, the ore concentrate is sent to the bins. In the bins the ore concentrate and the return fines are added in the ratio 3:1. Above the sinter machine, the main and the ignition layer bins are located. The ignition layer thickness is generally adjusted to give 30 mm height and the total layer max. height is 400 mm. The ignition layer is fired by 2 burners operating on light diesel oil (LDO), to get about 1000.C hood temp. After proper burning of the ignition layer the main layer is made and air is blown from down through the pump and then the main layer is burnt. 1. 2. Ignition Layer (10% to 15%) Main Layer (85% to 90%)

Here the main reaction are ZnS + O2 => ZnO + SO2 PbS + O2 => PbO + SO2 The SO2 is sent to the gas cleaning plant. 17

The big lump of PbO and ZnO is not suitable for the ISF plant. So it is necessary to reduce the size of the lump. For this purpose sinter breaker is located after the sinter machine, this breaker reduce the size of the lump upto 200mm. But this size too is not suitable so they are then sent to the spike roll crusher. These crusher reduce the size of lump to 65 to 130mm. These are then sent to the classifier which separate the lump size from 65-130mm from the rest. Then the suitable part is sent to the ISF Plant if it is in working condition otherwise it is sent to the storage yard by tray conveyer system. The lump of size below 65mm at temp 600-800.C is sent to the corrugated roll crusher, This crusher reduce the size to 35mm, then it is sent to the smooth roll crusher to reduce its size to 6-8 mm which is used as fines in sinter plant. These fines have high temp. so they are sent to the cooling drum. After passing through 7 The drum the temp of the fines is reduced to 90.C and then they are sent to the return fines bin. Anywhere where dust is formed, dust sucker are located. These dust sucker suck the dust and sent it to the bag filter. Bag filter collect the dust. The ignition gases are drawn by the ignition waste gas fan through wind box and conveyed to recirculating gas plant. Dust and spillage are removed in a solid separator from the sinter hood. The rich SO2 gas is drawn and sent to the wet gas cleaning plant through HGP (hot gas precipitator) with the help of booster blower. Beside the ignition fan, 4 fresh air fans and 1 recirculating fan is also there to supply fresh air and to recirculate air to 17 wind boxes of the sinter machine. There are 5 cyclones for dust removal of the ventilation air and recirculating gases in order to avoid any dust build up in the ducts and also to avoid wear of fans. The composition of the sinter product is: Zn 40-44% Pb 18-20% FeO 10-10.5% S less than 1% CaO 4.5-5% SiO2 3.5-4% Ratio of CaO:SiO2 1.2

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The composition of sinter fines is: Zn 42.50% Pb19.50% FeO 10.3% S 2.14% CaO 4.6% SiO2 3.7%

The specifications of the plant are as follows:Effective updrafts are of the sinter machine Width of the pallet Capacity (Dry basis) Sinter material Specific Sulphur burning rate Sinter Production Sulphur content of mixture SO2 content of the gases Moisture Content Bulk density of the crude charge : : : : : : : : : 120M2 3.0m 4600 tons per day 1.6tons per square meter per day 1080 tons per day 5%