PRESENTATION ON

HINDUSTAN ZINC LIMITED

By Raman Shrivastava Roll No-0802840058

Introduction
Hindustan Zinc Limited (HZL) is an integrated mining and resources producer of zinc, lead, silver and cadmium. It is a subsidiary of Vedanta Resources PLC. HZL is the world's second largest zinc producer. It's FY2011 revenues were Rs. 108.91 billion Vision Be the world's largest and most admired Zinc-Lead & Silver company. Mission Enhance stake holder's value through exploration, innovation, operational excellence and sustainability. Be a globally lowest cost producer. Maintain market leadership and customer delight.

History
Hindustan Zinc Limited was incorporated from the erstwhile Metal Corporation of India on 10 January 1966 as a Public Sector Undertaking. In April 2002, Sterlite Opportunities and Ventures Limited (SOVL) made an open offer for acquisition of shares of the company; consequent to the disinvestment of Government of India's (GOI) stake of 26% including management control to SOVL and acquired additional 20% of shares from public, pursuant to the SEBI Regulations 1997. With the above additional acquisition, SOVL's stake in the company has gone up to 64.92%. Thus GOI's stake in the company now stands at 29.54%.

Hindustan Zinc : Smelters

Chanderiya Complex
Pyrometallurgical Lead Zinc Smelter:

INDIA

Debari Smelter Hydrometallurgical Zinc Smelter: Zinc 88000 MT Sulphuric Acid 419,000 tpa Captive power29 MW

105,000 t Zinc 35,000 t Lead 120 t Silver Hydrometallurgical Zinc Smelter: 420,000 t Zinc AusmeltTM Lead Smelter: 50,000 t Lead 851,000 t Sulphuric Acid Captive Power Plant: 234 MW

Vizag Smelter Hydrometallurgical Zinc Smelter: Zinc 56,000 t

Capacity Build-Up (t) Product Zinc Lead C.P.P (Coal Based) 2002 169,000 35,000 2007 581,000 85,000 234 MW 2008 669,000 85,000 234 MW 2010 879,000 185,000 474 MW

Sulphuric Acid 91,000 tpa

2nd Largest Integrated Zinc Producer in the World

Safety
Accidents is most unwanted interruption because in involves life and the main effects of accidents are : Stopping of production Human suffering Loss of good skilled employees Material loss Demoralizing effect employees and society. Legal proceeding Harassment to management Compensation.

Safety precaution should be taken by Mechanical Engg. Trainees at HZL are as follows :

Always wear the protective helmet in plant Do not wear the loose and nylon clothes. Always wear rubber and strength shoes. Do not roam in the plant without any supervision of instructor. Do not touch any machine or switching parts. Always keep distance from fast moving machine. Do not visit silver refinery and acid plant without any written permission. Always wear ear mask in plant because heavy machines produces huge noise which is very harmful to ears. Always wear mouth mask in plant because certain poisonous gages like CO, SO2, CO2 smoke dust etc. are very harmful for human health.

Mines & Smelting Project of Hindustan Zinc Limited in India

Mines Rampura Agucha :230 kms north of Udaipur, Rajasthan, India Sindesar Khurd:80 kms north-east of Udaipur, Rajasthan, India Rajpura Dariba:76 kms north-east of Udaipur, Rajasthan, India Zawar: 40 kms south of Udaipur, Rajasthan, India Smelter Chanderiya :110 kms north of Udaipur, Rajasthan, India Debari:13 kms north of Udaipur, Rajasthan, India Vizag:Andhra Pradesh, India

Zinc Products & Its Usages:First Use

Corrosion Protection(Galvanizing, Zinc Thermal

End-Use
Building/Construction, Energy/Power, Steel

Spraying, Electro plating, )

Brass (Copper-Zinc alloys) Aluminums alloys, Magnesium alloys Rolled Zinc Batteries

Furniture, Agriculture, Automotive/Transport.

Building/Construction, Fittings Automotive and Electrical equipments. Building/ Construction. Automotive/Transport, Computers, Medical

Equipment, Construction products.

Zinc Compounds Food industry, Animal feed, Fertilizers, Pharmaceutical industry, Cosmetics industry. Zinc Oxide Paint pigments, Ceramic glazes Electrostatic Copying Paper.

Zinc Smelter Debari

Zinc Smelter Debari is a Hydrometallurgical zinc smelter situated at Debari, about 13 kms from Udaipur, in Rajasthan, India. The primary product of Debari is High Grade (HG) zinc and it also recovers cadmium as by-product Zinc Smelter Debari was commissioned in the year 1968 with an initial production capacity of 18,000 tonnes per annum of zinc. In the past several years the capacity of the smelter has been expanded five folds to its current production capacity of 88,000 tonnes per annum of zinc.

Hydro Metallurgical Process Description: -

Hydro metallurgical zinc extraction process is conventionally known as Roast-Leach-Electro win process which can broadly be divided into following processes. Roasting Leaching and Purification Cell House

Roasting:The roasting of a concentrate is a process which precedes smelting in hydro metallurgy and leaching in hydro metallurgy. An oxide is more easily reduced to the metal than a sulphide, and leaching becomes easier if the metals were present as sulphate, chloride or oxide. The objective of the roasting process is to convert zinc sulphide to acid soluble zinc oxide and sulphur dioxide gas, utilising the following reaction: 2 ZnS + 3O2 = 2ZnO + 2SO2 The solid zinc oxide (ZnO, Calcine) is separated from the gaseous sulphur dioxide (SO2) utilising various techniques. The collected zinc oxide is sent to the Leaching Plant and the sulphur dioxide goes to the Sulphuric Acid Plant via the gas cleaning plant.

Roaster Plant

Leaching: Leaching is a widely used extractive metallurgy technique, which converts metals into soluble salts in aqueous media.The calcine is first leached in a neutral or slightly acidic solution (of sulfuric acid) in order to leach the zinc out of the zinc oxide. The remaining calcine is then leached in strong sulfuric acid to leach the rest of the zinc out of the zinc oxide and zinc ferrite. The result of this process is a solid and a liquid; the liquid contains the zinc and is often called leach product; the solid is called leach residue and contains precious metals (usually lead and silver) which are sold as a by-product. There is also iron in the leach product from the strong acid leach, which is removed in an intermediate step, in the form of goethite, jarosite, and haematite. There is still cadmium, copper, arsenic, antimony, cobalt, germanium, nickel, and thallium in the leach product. Therefore it needs to be purified.

There are a variety of leaching processes, usually classified by the types of reagents used in the operation. The reagents required depend on the ores or pretreated material to be processed. A typical feed for leaching is either oxide or sulfide. Leaching process in hydro metallurgical extraction of zinc metal consists of following major steps: Neutral Leaching Weak Acid Leaching Hot Acid Leaching Strong Acid Leaching Pre neutralization Lead-Silver residue Filtration Jarosite Precipitation & Filtration Jarofix Production Magnesium Removal Purification of Solution Copper-Cadmium Recovery

Purification: In the neutral leaching process along with zinc oxide, all other metal oxides also get leached in metal sulphates. These metal sulphates are more than the tolerable limits, which are copper, cadmium, cobalt, nickel. All these impurities are removed by zinc dust cementation process in the purification section.

The basic reaction is that of electrolytic reduction of those metals, whose positions in the electromotive series for sulphate are below that of zinc:
CuSO4+Zno CdSO4+Zno CoSO4+Zno ZnSO4+Cuo ZnSO4+Cdo ZnSO4+Coo

Flow Process

Zinc Electrolysis Plant

Electrometallurgy: - Electrometallurgy includes all metallurgical processes which utilize electricity and electrical effects. The various electrometallurgical processes are electro winning, electro refining and electro deposition. Electro winning process: - The process by which metals is extracted from electrolyte, whether it is aqueous or fused salt is termed as 'electro winning'. The electrolyte is an aqueous medium for the recovery of metals like Zn, Sb, Cu, Cr, Ga, Mn, etc., while it is a molten salt in case of reactive metals like Na, K, Al, Mg etc. The main factors influencing the electro winning of metal are: Current density Temperature Composition of electrolyte Addition agents Influence of impurity ions in the metal deposition Hydrogen over voltage.

Zinc Electrolysis plant consists of the following sections: Gypsum removal section Electrolyte storage and circulation system with cooling towers Cell House Cathode stripping Anode washing and cell cleaning Reagent preparation and addition

Salient features of the cell house at ZSD

No of cells Cell Volume No of anodes in each cell No of cathodes in each cell Effective cathode area: Nominal current density: Stripping machines Stripping cycle: Rectifier for DC AC to DC conversion eff. Power consumption/ MT cathode Cathode production Strontium Carbonate addition Gum Arabic Anode cleaning cycle Cell cleaning Cycle No of neutral coolers No of spent coolers 124 35 m3 115 114 3.5 400-480A/m 2 Nos 48 h 2*95 KAmp (190 Kamp Max.) 98.5 % 2995 DC kWh (3041 AC kWh) 521 MT/Day 2-4 Kg/MT Cathode 94-110 gm/MT Cathode 30 Days 60 Days 3 12

Zinc Melting & Casting Plant:No of Furnaces Type of furnaces Make No of Inductors in each furnace Rating of each inductor Melting rate each furnace No of charging Columns in each furnace Molten metal holding capacity Temperature range Slab casting capacity Jumbo casting capacity Total production capacity 2 Water cooled induction furnace AJAX-TOCCO 4 600 Kwh 22 MT/hr 2 100MT 500-525oC 273MT/Day 273MT/Day 546MT/Day

Conclusion
It was a great experience to be there in HZL, Debari for my practical training. Like every good thing, it had to come to an end and so it did. Though i am feeling sad at this point of time while leaving from here but i do have the great memories of time spent here. During these days, i certainly learnt a lot about every aspect of this field, right from the working environment and people management to the technical details of various equipment and process. Really i knew here that only theoretical knowledge is not sufficient. I should have pragmatic approach while dealing in industries. Good communication and sincerity are the most important things in industries. By these two factors you can impress your seniors and colleagues. The things are numerous, while words are only few. To conclude, I would rather say that even after my full try, i could pick up only a mouthful of knowledge out of sea. The time was really very less while there was a lot to learn. Well, thats how life goes on. I hope I would have another chance to visit and learn more from it.

Thank You