Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

PRE- FEASIBILITY REPORT

For

THE PROPOSED ENHANCEMENT OF ZINC PRODUCTION CAPCITY

FOR Hydro Plants – I & II (From 4,20,000 TPA to 5,04,000 TPA) Under 7 (ii) clause of EIA notification, 2006 & Category ‘A’ of project activity Sr. No. 3 (a) Metallurgical Industries (Ferrous & Non - ferrous)

Submitted to

Ministry of Environment, Forest & Climate Change (MOEF&CC)

New Delhi

Submitted by

HINDUSTAN ZINC LIMITED (HZL)

Environment Consultant:

Vimta Labs Ltd. 142, IDA, Phase-II, Cherlapally Hyderabad–500 051 [email protected], www.vimta.com (QCI/NABL Accredited and ISO 17025 Certified Laboratory, Recognized by MoEF&CC, New Delhi)

November, 2019

Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

1.0 EXECUTIVE SUMMARY

Hindustan Zinc Limited (HZL) is one of the largest integrated producers of Zinc, Lead and leading producer of Silver in the world and a major producer of Sulphuric acid. The Chanderiya Lead-Zinc Smelter, located in the district of Chittorgarh, Rajasthan, is the one of the largest zinc-lead smelting complexes in the world. Its current metal production capacity is 620,000 tonnes per annum (525,000 tonnes per annum of zinc and 95,000 tonnes per annum of lead). The plant has captive power plants of 254 MW and additional power is generated through Waste Heat Recovery boilers of 34.9 MW. The original complex was built from 1989 and commissioned in 1991. It produces zinc, lead, silver and other precious metals.

1.1 Description of Existing Projects

Chanderiya Lead-Zinc Smelting (CLZS) complex comprises of one lead-zinc pyro metallurgical smelter (Pyro Plant: 1,05,000 TPA zinc and 35,000 TPA lead), one lead smelter (Ausmelt: 60,000 TPA) and two hydro metallurgical zinc smelters (combined Hydro-I & II 4,20,000 TPA). It employs roast leach electro-winning technology in its hydro metallurgical smelters, Imperial Smelting Process in lead- zinc smelter and top submerged lance technology coupled with cansolv technology for its lead smelter. The complex has captive thermal power plants as to supply the power requirements for its metallurgical operations. The power balance and demand of the existing and proposed project is given in Table -1. The main products are special high grade (SHG) zinc, continuous galvanizing grade (CGG) zinc, prime western (PW) zinc and pure lead. It also produces a number of valuable by-products including silver.

CLZS utilizes a combination of best proven technology and innovation to continuously improve environmental and operational performance. This approach has enabled HZL to be one of the largest and most efficient zinc and lead smelting complexes in the world.

Proposal It is proposed to increase the capacity from 4,20,000 TPA to 5,04,000 TPA (20%) in its Zinc Smelter I & II on combined basis by improving the current efficiency in cell house from 89% to 93%, increasing current input in cell house from 190 kA to 200 kA, Debottlenecking and increasing the number of cells from 124 to 132 in Hydro-I cell house. The proposed plant production capacities of existing units of CLZS complex are presented in Table 1. The manufacturing process consists of roast leach electro-winning technology.

TABLE -1 CAPACITY DETAILS

Name of As per EC Existing Additional Total Capacity After the Unit (Dec’2006) Status Proposed Proposed Enhancement Capacity Hydro 420000 TPA 420000 TPA 84000 TPA 504000 TPA Smelter & (20% Expansion) Fumer

2 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

Source: HZL-CLZS 1.2 Description of Proposed Project

CLZS proposed for enhancement of zinc production capacity from 4,20,000 TPA to 5,04,000 TPA (20%) in its Zinc Smelter I & II on combined basis by improving the current efficiency in cell house from 89% to 93%, increasing current input in cell house from 190 kA to 200 kA, Debottlenecking and increasing the number of cells from 124 to 132 in Hydro-I cell house. The manufacturing process consists of roast leach electro-winning Technology. This is only 20 % increase in the existing capacity without addition of any additional process. Table-2 presents the existing and proposed enhancement of zinc production capacity details and salient features respectively.

TABLE-2 SALIENT FEATURES OF THE PROPOSED ENHANCEMENT OF ZINC PRODUCTION CAPACITY (HYDRO PLANTS –I & II)

Unit As per EC Existing Additional Total Capacity (Dec’2006) Status Proposed After Proposed Capacity Expansion Hydro Smelter 420000 TPA 420000 TPA 84000 TPA 504000 TPA (20% Expansion) Land 335.89 ha 335.89 ha - No Change Requirement Water 30670 cum/day 30670 - No Change Requirement cum/day Source of Water Gosunda Dam (Captive)/STP Udaipur/Proposed STP of Chittorgarh/Bhilwara/Other Proposed STPs Power 220 MW 220 MW 20 MW 240 MW Requirement Power Source Captive Thermal Power Plant / WHRB (18.8 MW)/ Captive Solar Power Plant/ Rooftop Solar Panels/Floating Solar Panels/ AVVNL (4.59 MW DG Sets for Emergency Purpose) Raw Material Concentrate: 677177 TPA 677177 TPA 21282 TPA 698458 TPA

Calcine:- 206000 TPA 206000 TPA 131990 TPA 337990 TPA

Employment 5141 5141 - No Change Project Cost (Rs 2647 2647 138.5 2785.5 in Cr)

Environment 190.1 190.1 48.5 238.6 Protection cost (Rs in Cr) • No Change in existing Process Technology (roast leach electro-winning Technology). • No Change in land & Water requirement. • 20% Expansion in Hydro Plant by improving the current efficiency, 8 new cells installation & Debottlenecking project. Source: HZL-CLZS

3 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

2.0 IDENTIFICATION OF THE PROJECT/BACKGROUND INFORMATION

2.1 Identification of the Project & Project Proponent

The company's segments are mining and smelting of Zinc and Lead, and Wind energy. It also produces Sulphuric Acid, etc. as by-product. The company's operations include Zinc-Lead mines, Zinc Smelters, a Lead Smelter, a Zinc-Lead Smelter, Sulphuric Acid Plants, a Silver Refinery Plant and Captive Power Plants (CPP) in the state of Rajasthan. In addition, the Company also has Zinc, Lead, Silver processing and refining facilities in the State of Uttarakhand. The company also has wind power plants in the States of Rajasthan, Gujarat, Karnataka, Tamil Nadu and Maharashtra. It has a metal production capacity of over one million tons per annum with its key Lead-Zinc Mines in Zawar, Rajpura Dariba, Rampura Agucha, Sindesar Khurd and Kayad and smelting complexes in Debari, Chanderiya and Dariba, all in the state of Rajasthan.

HZL’s operations are broad based and its activities range from exploration, mining and ore processing to smelting and refining of lead and zinc. During over last four decades, HZL has endeavored for a steady improvement in its operations through forward planning, excellent teamwork, research and development, and technology versatility.

CLZS Hydro Plants - I & II are currently producing total 4,20,000 TPA of Zinc as a product from (2,10,000 TPA from Hydro –I and 2,10,000 TPA from Hydro –II Plants) and 254 MW power from its Captive Power Plants at Putholi village, Gangrar tehsil, Chittorgarh district, Rajasthan. The manufacturing process consists of roast leach electro-winning technology.

2.2 Brief Description and Nature of the Project

The proposed enhancement of zinc production capacity from 4,20,000 TPA to 5,04,000 TPA of both Hydro Plants -I & II on combined basis, thereby by increasing the number of cells from 256 to 264 and current input in cell house from 380 kA to 400 kA (Increasing the number of cells from 124 to 132 /132 to 132 and current input in cell house from 190 kA to 200 kA / 190 kA to 200 kA of Hydro Plants – I & II respectively).

As per Environmental Impact Assessment EIA Notification dated 14th September, 2006, The Proposed Enhancement of Zinc Production Capacity (from 4,20,000 TPA to 5,04,000 TPA) of both Hydro Plants – I & II under 7 (ii) clause of EIA notification, 2006 for Environmental Clearance (EC) to MoEF & CC as to grant EC for expanded capacity for both Hydro Plants – I & II.

HZL - Chanderiya lead smelters, zinc smelters, CPPs have been accorded Environment Clearance (EC) by Ministry of Environment, Forest and Climate Change (MoEF&CC), Consent to Establish (CTE) and Consent to Operate (CTO) from Rajasthan State Pollution Control Board (RSPCB). The list of statutory clearances for existing units in the Chanderiya Lead Zinc Smelter (CLZS) Complex is given in Table-4. The list of list of statutory clearances of Hydro Plants – I & II are enclosed as Annexure – I.

4 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

TABLE-4 LIST OF STATUTORY CLEARANCES OF HYDRO PLANTS – I & II

Sr.No. Name of Issuing Letter No Date the Unit authority A Zinc Smelter I & CPP - 2,10,000 Zinc & 154MW 1 Environment MOEF&CC F.No.J-11011/158/2003-IA.II(I) 31.03.2004 Clearance & (EC) 06.12.2006 2 Consent to RSPCB F.12(Chittor-60) RPCB/Gr.III/14372 19.07.2004 Establish & (CTE) 08.01.2007 3 Consent to RSPCB F(CPM)/Chittorgarh(Gangrar)/2(1)/2016- 25.08.2016 Operate 2017/6058-6060 (CTO) B Zinc Smelter II (with Fumer) 2,10,000 Zinc & CPP 100 MW 1 Environment MOEF&CC F.No.J-11011/279/2006-IA.II(I) 06.12.2006 Clearance (EC) 2 Environment MOEF&CC F.No.J-11011/279/2006-IA.II(I) 5.10.2015 Clearance (EC)- Fumer 3 Consent to RSPCB F.12(CH-78) RPCB/Gr.III/2588 08.01.2007 Establish (CTE) 4 Consent to RSPCB F(CPM)/Chittorgarh (Gangrar)/ 01.08.2017 Establish 2(1)/2016-2017/3942-3944 (CTE)- Fumer 4 Consent to RSPCB F(CPM)/Chittorgarh (Gangrar)/ 03.08.2016 Operate 2(1)/2016-2017/5434-5436 (CTO) Fumer CTO and Hydro I & II CTO renewal is applied and under process

2.3 Need of the Project and its Importance to the Country and Region

Global Zinc & Lead consumption is expected to grow steadily by 4-5 % per annum in coming years which needs to be met by higher mine & smelter output. As India is one of the fastest growing economies in the World, adequate support from metal sector is essential to support & sustain infrastructure development & growth. Galvanized iron products play key role in infrastructure development and therefore the requirement of zinc metal is essential. Lead requirement in batteries is increasing with Automobile Industry expansion & power back up. Proposed enhancement project will augment the supply of zinc to the domestic market for industrial growth. In addition to this, there is ample opportunity for increase in indirect employment due to transport and other services. Skill development & training programs to make local youth employable will continue for development of community.

Zinc is a very versatile non-ferrous metal. Zinc’s different applications rank it as the 4th most common metal in use after iron, aluminum and copper. Global zinc consumption is forecast to grow at a compound average annual rate of 2.4 % p.a.

5 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

over the period 2019-2024. Global zinc consumption is projected to grow to 20 Mt in 2035 representing average annual increase of 0.28 Mt.

2.4 Demand-Supply Gap

Proposed Growth in industrial production period 2019-2024 is given in Table –5.

TABLE –5 DOMESTIC REFINED ZINC SUPPLY & DEMAND (KT Zn)

Year 2019 2020 2021 2022 2022 2024 Demand (kt) 699 844 833 828 824 827 Supply (kt) 643 838 811 849 837 837 Source: Wood Mackenzie Long Term Outlook

2.4.1 Import Vs Indigenous Production

The present production capacities of zinc in India are sufficient to meet the domestic requirements. However, the demand for zinc in India is expected to grow at a 7.1% which makes it viable for the expansion of the zinc production capacities. Further, the deficit in international market during the upcoming years provides opportunity for export.

2.4.2 Export Possibility

Indian exports majorly catered to South East Asian and African nations. In India, since Hindustan Zinc is the largest producer of primary zinc, export of zinc is highly feasible and will bring value addition.

2.4.3 Domestic/Export Market

Zinc having found primary application in galvanization, a range of galvanized products are produced to meet various Industrial and consumer demands. Galvanized sheets (corrugated and plain), galvanized pipes, galvanized structure, galvanized sheet, galvanized wires are used for various applications. Galvanizing Segment accounts for 68% share of the overall zinc demand in India while Non- Galvanizing accounts for 32% share. Among the major customer segments, Galvanized Sheets accounts for major share of the zinc consumption followed by structure and alloys. The following chart explains the demand for zinc in India and its segment wise break-up India has the potential for exporting zinc profitably as global zinc demand continues to be high & driven mainly by galvanizing sector in the emerging of Asia and Africa. The reported increase in Chinese manufacturing activities and US automotive sales along with emerging signs of stability in Europe’s manufacturing and services sector are expected to support zinc demand. The distribution is shown in the following PIE-chart of zinc demand (Figure - 1).

6 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

FIGURE – 1 PIE-CHART OF ZINC DEMAND

3.0 DETAILS OF PROJECT

3.1 Type of Project Including Interlinked and Interdependent Projects if any

HZL is proposed to increase the Zinc Production capacity from 4,20,000 TPA to 5,04,000 TPA (20%) of Zinc Smelter I & II on combined basis by improving the current efficiency in cell house from 89% to 93%, increasing current input in cell house from 190 kA to 200 kA, Debottlenecking and increasing the number of cells from 124 to 132 in Hydro-I cell house. The manufacturing process consists of Roast Leach Electro-Winning Technology.

The installation of 8 nos of new electrolytic cells will be within the existing building of the Hydro Plants I for which space provision has already been made at the time of original design. Hence, no new land acquisition is required.

3.2 Location Details

The Zinc Smelter and Captive Power Plant are located in Chanderia Lead Zinc Smelter Complex at village Putholi of Gangrar tehsil, Chittorgarh district, Rajasthan. The latitude and longitude of all sections of Zinc Smelter (Hydro-I & Hydro-II) is mentioned in the table 7.

Table 6

Coordinates for Zinc Smelter (Hydro-I, Hydro-II -With Fumer)

7 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

Hydro I 24°57’39”N 4°39’28”E A 24°57’37”N 4°39’29”E B 24°57’37”N 74°39’ 06”E C

24°57’28”N 74°39’11”E D Hydro II (with Fumer) 24°57’37”N 74°39’ 06”E A

24°57’28”N 74°39’11”E B 24°57’32”N 74°38’44”E C 24°57’22”N 74°38”43’’E D CPP 24°57’54”N 74°39’53”E A 24°57’58”N 74°48’12”E B 24°57’47”N 74°40’09”E C 24°57’44”N 74°39”55’’E D

The index map of the plant is given in Figure-2. The study area map and google imagery of 10 km radius from the project site are shown in Figure-3 & Figure- 4. The layout of CLZS complex is shown in Figure-5. The list of other industries is shown in Figure-6. The photographs of the existing CLZS complex and the area allocated for proposed project are shown in Figure-7.

8 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

FIGURE- 2 INDEX /LOCATION MAP

9 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

FIGURE-3 STUDY AREA MAP OF 10 KM RADIUS

10 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

FIGURE-4 GOOGLE MAP OF STUDY AREA OF 10 KM RADIUS

11 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

FIGURE-5 OVERALL LAYOUT OF CLZS COMPLEX

FIGURE-6 LIST OF OTHER INDUSTRIES (10 KM RADIUS)

12 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

FIGURE-7 PHOTOGRAPHS SHOWING THE EXISTING PLANT FACILITIES

3.3 Details of Alternate Sites Considered

The proposed enhancement of zinc production capacity will be within the existing plant premises located at Chanderiya Lead Zinc Smelter (CLZS) complex. As enhancement of production, will take place within the existing complex, hence no alternative site have been studied. The environmental setting of project site is given below in Table-5.

TABLE-5

13 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

ENVIRONMENTAL SETTING

Sr. No. Particulars Details 1 Location Putholi village, Gangrar tehsil, Chittorgarh district, Rajasthan 2 Co-ordinates Hydro I 24°57’39”N 4°39’28”E A 24°57’37”N 4°39’29”E B 24°57’37”N 74°39’ 06”E C 24°57’28”N 74°39’11”E D Hydro II (with Fumer) 24°57’37”N 74°39’ 06”E A 24°57’28”N 74°39’11”E B 24°57’32”N 74°38’44”E C 24°57’22”N 74°38”43’’E D CPP 24°57’54”N 74°39’53”E A 24°57’58”N 74°48’12”E B 24°57’47”N 74°40’09”E C 24°57’44”N 74°39”55’’E D

3 Area Details ➢ Total existing plant area of CLZS is 335.89 Ha. ➢ No additional land is required for the proposed expansion as the same will be done within the existing plant premises 14 Elevation (MSL) 400 - 592 m 5 Nearest village Putholi, adjacent to the plant (0.3 km, S) 6 Nearest town & Chittorgarh (8.1 km, S) district 7 Nearest highway Chittorgarh – Ajmer highway (NH-79) (5 km, NW) Udaipur-Chittorgarh – Shivpuri Highway (NH-76) (5 km, E) 8 Nearest railway line Chanderiya (2.5 km, SW) 9 Nearest airport Maharana Pratap Airport – Udaipur 84 km, SW 10 Nearest seaport Kandla port (499 km, WSW) 11 Interstate boundary Madhya Pradesh-Rajasthan (16.2 km ,E) 12 Reserve forests Shikargarh Salera RF (1.7 km, NNW) Bir Salarmala PF (2.0 km, NW) RF near Bhilyakhera village (3.3 km, E) RF near Surjona village (3.4 km, ESE) Modia Magra PF (3.6 km, NW) RF near Chanderiya village (3.8 km, SW) Nilia block RF (5.2 km, E) Kabra RF (5.5 km, NNW) RF Chittorgarh (5.6 km, SW) Samra block RF (7.1 km, E) Era RF (7.3 km, NW) Barkhera block RF (7.7 km, SE) Dundaria block (10.0 km, ENE) Gorasiya block RF (10.6 km, SE) Jaleshwar RF (11.3 km, E)

14 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

Sr. No. Particulars Details Baramagra RF (11.4 km, NNW) Bhurariya block RF (11.4 km, E) Dadiya RF (11.8 km, N) Thukrarabarada RF (13.1 km, WSW) Rajpuriya block RF (13.3 km, E) Dhywadiya block RF (14.0 km, SE) 13 Water bodies Seasonal River Berach near to eastern side plant boundary and flowing towards North direction. Seasonal Putholi nallah is adjacent to HZL plant boundary towards North and subsequently join seasonal Berach river. Seasonal Gambhir Nadi is 4.2 km, S from the plant boundary. 14 List of other RIICO area at Ajoliya ka khera (1.1 km, N) industries Birla Cement works and captive limestone mine (2.5 km, SSW) Marble stone cutting units (4.6 km, SSW) Existing unit of Chanderiya Lead-Zinc smelter of Pyro & Aumelt Lead Smelter . 15 Archaeologically Chittorgarh fort (6.5 km, SSW) important places 16 National Bassi wild life sanctuary (14 km, NE) parks/Wildlife sanctuaries 17 Seismicity Zone-II (IS 1893:Part-I) 2002 18 Water Source Gosunda Dam (Captive) 18 km in SW direction

3.4 Process Description

3.4.1 Zinc Smelter

3.4.1.1 Roasting Plant

The zinc concentrate, which is in zinc sulphide form along with other sulphides, is not leachable at normal temperature and acidity. It is therefore necessary to convert this sulphide material to acid leachable form. The purpose of Roasting is to convert the Zinc sulphide to Zinc oxide (Calcine) by burning with air in a fluo-solid Roaster thereby expelling the sulphur as SO2 gas and subsequently recovering as sulphuric acid in acid plant.

The zinc concentrate to be treated is stored in a surge bin, with a holding capacity for more than one shift.

The concentrate is discharged from the bin by means of a slow running rubber belt. The capacity of Roaster furnace is 1050 Tonnes of concentrate per day (Dry) with a hearth area of 123 m2.

The principal roasting reactions are as follows:

2ZnS + 3O2 = => 2 ZnO + 2SO2 + 223.6 Kcal

15 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

4FeS + 7O2 = => 2Fe2O3 + 4SO2+ Heat ZnO + Fe2O3 = => ZnOFe2O3 (Zinc ferrite)

In order to avoid any gas leakage, in particular through the charge openings, the furnace is maintained under a slight negative pressure. This draught is provided by the SO2 gas blower and controlled by a louver type damper. The roasting gas at the furnace exit has a temperature of about 950 to 10000C and a SO2 content of approximately 9% (Vol.). In a waste heat boiler, the gas is cooled to about 3500C.

The waste heat boiler is of the forced circulation type. It is designed to produce superheated steam at ~40 bar / 4000C. The boiler design provides for tube lined walls and the use of evaporator bundles. All the bundles are suspended at the boiler roof. To avoid any air ingress, the roof is tight welded. A part of the flue dust may adhere on the tube surface; all the bundles are equipped with an effective rapping device, controlled by a timer to make this adhering calcine to fall. The rapping periods may be set as required to optimize operation.

Only de-aerated and treated feed water will be used for the boiler. This water is prepared in the de-mineralized water treatment plant. It is fed into the boiler drum by means of a boiler feed pump. From the drum, the circulating pump delivers the water into the evaporator bundles and wall tubes and the cooling coils of the roaster.

The calcine, collected in the waste heat boiler, drops into a longitudinal hopper arranged underneath the boiler and is discharged by a continuous air-cooled chain conveyor and water-cooled rotary valve. The calcine, collected from the roaster and waste heat boiler, passes through a rotating drum cooler, to be cooled to a temperature below 1500C.

The cooler discharge then passes through a ball mill. The mill discharge and the fine dust coming from the cyclone and hot gas precipitator are combined and transported to an intermediate bin. From the intermediate bin the calcine is pneumatically transported to the leaching plant. A bag filter is provided to ensure de-dusting of the calcine handling system.

Before the first start-up, as well as for start-ups after long shutdowns, the fluid bed furnace and the waste heat boiler have to be preheated. For this purpose the roaster is equipped with a preheating unit for starting-up purposes, which consists of an oil tank with a pump, oil burners and oil lances. The necessary combustion air is taken from an air blower. Start-up gases are withdrawn by a start-up fan and vented via a start-up stack to the atmosphere provided after gas cleaning section..

3.4.1.2 Gas Cleaning

The purpose of gas cleaning is to clean the gases of dust particles, saturated with water vapour, cooling and making it optically clear by removing the mist particles, thereby making it suitable for feed to the acid plant.

The gas cleaning section consists of the following units:

a) Hot gas cleaning; b) Wet gas cooling/condensing;

16 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

c) Acid mist precipitator; and d) Mercury Removal System (Calomel Process) a) Hot Gas Cleaning

The dust loaded SO2 gases from the waste heat boiler are de-dusted in one single line three field hot ESP.

The hot gas electrostatic precipitator comprises of three separate electrostatic fields arranged in series. The dust particles are charged and separated on the collecting electrodes by the influence of the electrostatic fields. A gas distribution plate located at the electrostatic precipitator inlet ensures the even gas distribution over the sectional area of the electrostatic precipitator. The dust adhering to the collecting electrodes, discharge electrodes and gas distribution plate is removed at certain intervals by motorized rappers.

The removed dust drops into a longitudinal hopper arranged below the electrostatic precipitator casing and is discharged by a continuously operating dust conveyor and two rotary valves arranged in series. The collecting electrodes consist of cold-rolled strips of steel plate. They are arranged in passages. The discharge electrodes of large cross section are rigidly fixed into pipe frames, which are vertically suspended between the collecting electrodes. This rigid frame design is highly efficient.

Both electrode system – collecting electrodes and discharge electrodes – are equipped with highly efficient motorized rapping systems. Hot purge air will be injected to prevent any condensation of sulphuric acid mists on the surface of the supporting insulators of the discharge electrode systems. The casing of the electrostatic precipitator will be fabricated from steel sheet and welded gas tight. It has to be fitted with particularly carefully designed heat insulation to avoid condensation of sulphuric acid and corrosion. Each transformer rectifier is controlled by an automatic high voltage control system. b) Wet gas cooling/condensing

❖ Washing Tower

After pre-cleaning in the hot-gas cleaning system, the gas is routed to the wet gas section equipped with a washing tower, which cools the gas adiabatically to a temperature of about 600C by means of circulating liquid. The washing tower also serves to wash out the bulk of the solids entering from the hot gas ESP’s, as well as condensed volatile impurities. Excess liquid will be discharged to a stripper for SO2 removal.

❖ Cooling Tower

The cooling of the SO2 gas is done in a packed gas-cooling tower. In counter current flow, cooling liquid (weak acid) is sprayed into the tower and flows downward through packing. By direct contact between the warm gases and the cooling liquid, heat is transferred. Flue gas cools down, gaseous water condenses and the cooling liquid is heated. The condensate leaving the cooling tower is collected in its sump from where it is delivered to the nozzles by means of a gas

17 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

cooler flushing pump. The surplus of condensate is withdrawn by gravity from the sump to the washing tower weak acid circuit. c) Acid mist precipitator

From the washing and cooling section, the gases are forwarded into two wet gas ESP’s for mist elimination arranged in two stages. These ESP’s are of the proven tubular type and are constructed mainly of plastic with high mechanical strength and a high chemical resistance. All parts in contact with the gas are of plastic or homogeneously Lead-lined steel. The materials are selected according to the operating environment and stresses acting on the various components. The gases pass through the ESP tubes in a vertical direction, in the first stage flowing upwards and in the second stage flowing downwards. Spike design of discharge electrodes ensure that the mist particles are charged and separated on the tubes. The discharged condensate flows as a film along the tube surface to be collected in the bottom section of the ESP from where it is drained. The condensate stream is combined with the wash acid in the washing tower. d) Mercury Removal System (Calomel Process)

The mercury contained in zinc concentrate is transferred mainly into metallic mercury vapour during roasting. Some of the mercury may condense or re- combine with other components in the gas to form insoluble compounds. These particles or compounds may be separated in the conventional unit for gas cleaning and cooling before the gases enter the sulphuric acid plant. But some amount of mercury vapour passes the conventional gas cooling and cleaning system as metallic vapour that must be removed from the gas before feeding to sulphuric acid plant.

❖ Description of Mercury Removal System

The calomel process was originally developed for the purpose of removing mercury vapour from zinc concentrates roaster gases, after these gases have been treated in the conventional cleaning, washing and cooling plant.

The reactor for removal of mercury treats gases at a temperature of 380C. The reactor is a counter current absorption tower made of glass fiber reinforced plastic. The tower is packed with plastic rings made of polypropylene. The HgCl2 solution is sprayed over the packing by nozzles. The mercury vapour comes in contact with mercuric chloride solution and transforms to mercurous chloride. When mercury content in circulating water increases, some of the mercurous chloride is taken to a chlorination tank to convert mercurous chloride to mercuric chloride, which is used as make-up in circulating water. The mercurous chloride (calomel) is withdrawn periodically and stored for sale to interested buyers. The main reactions are as follows:

HgCl2 (l) + Hg0 (gas) ==> Hg2Cl2 (s) Hg2Cl2 (s) + Cl2 (gas) ==> 2 HgCl2 (l)

The towers are furnished with demisters in order to prevent drops leaving the tower with the purified gases. The clean gas then goes to Sulphuric acid plant for production of H2SO4.

18 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

3.4.1.3 Sulphuric Acid Plant

The SO2 gas from the gas cleaning section is converted to sulphuric acid by first converting the SO2 to SO3 in converter in presence of V2O5 as catalyst. The rd converter has four layers of V2O5 catalyst. After 3 mass, the gas is withdrawn and passed on to intermediate absorption tower where the SO3 gas is absorbed to produce sulphuric acid. The residual SO2 is further converted to SO3 gas in 4thmass in order to achieve maximum conversion efficiency. The withdrawal of rd SO3 gas after 3 mass and converting it to H2SO4 accelerates conversion of SO2 to SO3 in fourth mass. Conversion of SO2 to SO3 in two stages and absorbing SO3 in two stages is known as double conversion and double absorption (DCDA). In this process, the conversion of SO2 to SO3 gas is very high (more than 99.7%) 3 thus allowing very low SO2 emission (less than 650 mg/Nm ).

The sulphuric acid plant mainly consists of 3 plant sections:

a) The drying and absorption section; b) The converter section with the gas-to-gas heat exchangers; and c) The product acid tank farm.

a) Drying and Absorption Section

The drying and absorption section mainly consists of the drying tower, the intermediate absorber, the final absorber, the acid pumps, the acid pump tanks, the acid coolers and the acid piping.

The gas flow through the towers is counter-current to the acid flow, i.e. the gas flows from the bottom to the top of the tower. From the bottom of the tower(s) the acid flows to the pump tank and is pumped from there by the acid pumps (via the acid coolers) back to the spray system.

Acid transfer lines between the drying tower, the intermediate absorber and the final absorber and injection lines for dilution water at the intermediate absorber and final absorber allow control of the necessary acid concentration for each of the towers.

The sulphuric acid is produced as +98% H2SO4 and the product acid is taken from the final absorber pump tank. The acid is then cooled in the product acid cooler and pumped to the existing acid storage tanks.

b) Converter section with the gas-to-gas heat exchangers

In the converter, the SO2 bearing gas is converted to SO3 (sulphur trioxide) in the presence of Vanadium Pentoxide as catalyst, which is subsequently absorbed in acid towers to convert into sulphuric acid.

The converter system consists of a four-layer central tube converter. The intermediate absorption is following outlet of the 3rd layer. The converter itself is an insulated, vertical and cylindrical vessel divided in four sections called layers or trays with a central tube. The catalyst required for the conversion of SO2 to SO3 is arranged on these layers. The SO2 gas flows up stream through layer 1 and down stream through layer 2, 3, 4.

19 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

Three gas-to-gas heat exchangers II, III and IV are designed as mixed cross flow/counter flow shell and tube heat exchangers. These heat exchangers mainly consist of inlet and out let chambers, the tube sheets, the tubes and baffles. Heat exchanger III ensures the optimum gas temperature for the intermediate absorber as well as for the inlet of layer 4.

Another heat exchanger I, inside the converter, arranged in the bottom of the central tube between layer 1 and 2, is designed as counter flow for pre heating SO2 gas to the inlet temperature of layer 1.

❖ SO2 Gas Blower

The SO2 gas blower is arranged downstream of the drying tower and routes the gas from the zinc roaster section via the gas cleaning plant through the sulphuric acid plant. The blower will be provided with an electric motor.

❖ Pre-heater

A pre-heater is needed to preheat the converter system from cold condition to operating temperature, whereas during normal operation of the plant the heat released within the process allows auto-thermal operation of the plant. In addition, lower or varying SO2-concentrations can be compensated. The separate pre-heater preheats air or, in the start phases, SO2-gas to the required temperature. c) Product acid tank farm For the production of the sulphuric acid, SO2 containing gases from the zinc concentrate roasting are used. There are four main process criteria in the production of these kinds of gases by the contact/converter process. They are:

❖ Gas drying ❖ Water balance ❖ Absorption of SO3 ❖ Heat balance ❖ Conversion of SO2 to SO3 ❖ O2/SO2 ratio ❖ Gas Drying

Gas drying is an important process in this type of contact plant. Gas drying protects cooler parts of the plant, such as heat exchangers, against corrosion by acid condensation. It safeguards against the formation of acid mist, which can be very difficult to absorb at a latter stage of the process. It also protects the catalyst from acid condensation during plant shutdowns. Therefore, the life of the plant and also the tail gas purity largely depend on appropriate gas drying.

The substantial amount of heat, not just the heat of dilution of the sulphuric acid but also the heat of condensation of the water, is liberated in the gas drying stage. For that reason the circulated acid is generally cooled by indirect heat exchanger before being recycled to the dryer. ❖ Water Balance

20 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

The water balance of contact sulphuric acid plants in general may simply be defined by the specific amount of process water required for achieving the desired product acid strength from the amount of SO2 converted to SO3.

In the case of acid gas plants (like roaster plants) the process water requirements are usually balanced nearly completely by the water vapour content of the SO2 feed gases entering in the drying tower except for a small margin necessary for the automatic acid strength control.

Thus at a given SO2 gas concentration and SO2 conversion rate and at a fixed product acid strength, the only variable that can and has to be controlled or limited is water vapour content of the feed gasses entering the drying tower in order not to exceed the water balance of the whole system. This is done in the wet gas purification system by cooling the SO2 gasses down to the dew point temperature corresponding to the maximum allowable water vapour content. For determination of the required dew point temperature, it is important not only to consider the negative pressure, for which the gas purification system is designed, but also the external barometric pressure, which depends largely on the elevation of the plant above sea level.

❖ Absorption of SO3

Sulphur trioxide formed by catalytic oxidation of sulphur dioxide is absorbed in sulphuric acid of at least 98% concentration, in which it reacts with existing or added water to form more sulphuric acid. The process gas leaving the converter system is cooled, first in a gas-to-gas heat exchanger to a temperature of about 1600 C before entering the absorber. The gas entering the absorber is therefore not completely cold and it transfers heat to absorber acid as it passes through absorber, by the time it reaches the outlet it is virtually at the same temperature as the incoming absorber acid.

A substantial amount of heat is also generated in the absorber acid from the absorption of sulphur trioxide and the formation of sulphuric acid, and the acid temperature rises as a result by a margin, which depends on the acid circulation rate. The acid concentration is maintained constant by adding process water to the acid leaving the absorber and the acid cross flow from the dryer (to the intermediate absorber only) at a rate controlled by a concentration measuring device. The circulated acid is cooled by indirect cooling.

❖ Heat Balance

The SO2 gases leaving the wet gas cleaning system enter the acid plant at a 0 0 temperature of 35 -40 C (depending on the SO2 concentration). After removing the residual water content in the dryer, the process gases must be heated up to the required converter inlet temperature of 4400 C. This is achieved by indirect heat exchange with the available sensible gas heat released by SO2 oxidation in the converter. The main objective of designing such a cold gas plant is to attain auto thermal operating conditions, which becomes primarily a question of the required gas heat exchanger surface, depending on the feed gas SO2 concentration.

The reaction heat in a double catalysis plant based on roaster gases is released from;

21 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

- Catalytic oxidation SO2 + ½O2 ==> SO3 + 23.45 Kcal (1) - Sulphur trioxide absorption and sulphuric acid formation SO3 + H2O = => H2SO4 (2) - Dilution to the acid production strength of 98.5% H2SO4

Condensation heat for water content of the gases entering the drying tower system.

❖ Conversion of SO2 to SO3

The catalytic oxidation of sulphur dioxide with atmospheric oxygen in the presence of a solid catalyst to form sulphur trioxide can be described as the classical example of an exothermal, reversible reaction

SO2 (g) + ½ O2 (g) ==> SO3 (g) + 23.45 Kcal

The decisive factor for conversion is in each case also the O2 concentration of the feed gas. Although, from stoichiometric aspects, a SO2/O2 ratio of 1:0.5 would be sufficient, it results already from the consideration of the chemical equilibrium that oxygen in excess will have a favorable influence on SO3 formation.

In practice, the O2 content of the gas entering the converter corresponds to 1.0 up to 1.8 times the SO2 content, this being especially due to the influence of SO2/O2 ratio on the activity of the catalyst.

The heat of reaction liberated by SO2 oxidation (1) Leads to a temperature rise of the gas on its adiabatic passage through the catalyst layer so that the conversion is limited in accordance with the temperature equilibrium curve. With respect to obtaining a maximum SO2 conversion efficiency to perform the catalytic SO2 oxidation in several steps and to cool the gas to the most favorable temperature before it enters the next catalyst layer.

The theoretical basis of the double catalysis process is relatively simple and can be derived from the law of mass action. After a defined preliminary SO2 rd conversion, after 3 catalyst layer, the SO3 formed at this stage is removed from the chemical equilibrium by intermediate absorption so that the equilibrium is shifted in favour of SO3 formation.

On the basis of the corresponding temperature/conversion equilibrium it is possible to note already qualitatively that with the same number of contact layers as compared to the normal catalyst process, an essentially higher final SO2 conversion is achievable which is more than 99.7% in practice.

A decisive advantage of the double catalysis process is the possibility of feeding gases of higher SO2 concentration than with the normal catalysis process and this means smaller gas volumes and consequently smaller equipment dimensions at comparable production capacities.

❖ O2/SO2 Ratio

For the conversion of SO2 to SO3 the proportion of O2 volume in the feed gas to the converter called SO2/O2 ratio, is an important factor for the conversion rate.

22 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

❖ Product Acid Storage Tank

The total acid production received in the intermediate and the final absorber is pumped from the final absorber pump tank via the product acid cooler to the acid storage tanks.

3.4.1.4 Leaching Plant

The calcine produced in the roaster and the calcine procured from the other smelters is stored in the silos. This calcine is conveyed to two hoppers situated where the leaching plant tanks are located. From there it is distributed throughout the different stages of the process by variable speed screw feeders and conveyors, which are regulated by pH meters that control the process variables.

a) Neutral Leaching (NL)

The slurry that comes from the cells cleaning and the spent from the electrolysis area, are pumped into the head tank, where Iron content is adjusted in order to improve impurities removal. During the neutral leaching stage, the solution contained in the head tank is pumped to the first tank. The control room predetermines the flow rates. Calcine from the hopper is fed into this tank. The stream from the first tank passes through the tanks successively. The stream from the last tank flows by gravity to neutral thickners after adding flocculent. The neutral overflow, free of solids, is pumped into the purification plant. The underflow is pumped into the weak acid leaching tanks. b) Weak Acid Leaching (WAL)

The underflow from the neutral leaching and pre-neutralization thickener is fed into the first of a series of tanks, together with spent electrolyte, as required. In these tanks, remaining zinc oxide and some zinc ferrite are leached. After leaving the last tank flocculent is added to the stream before it enters the weak acid leaching thickeners. The underflow from the thickener is pumped to the Conversion section of leaching stage while the overflow is pumped to Pre- neutralization of zinc leaching section.

c) Pre- Neutralization (PN)

This section receives solution from weak acid leaching and from jarosite section. This solution is neutralized and impurities are precipitated and sent back to weak acid leaching section for further treatment. The unreacted zinc going along with the precipitate slurry is also leached and recovered in Jarosite section. The overflow solution is sent to neutral leaching section.

d) Jarosite Precipitation (JP)

This section receives slurry from weak acid leaching section which contains mainly the zinc ferrites. These are treated at high temperature of > 95 deg C and high acidity of 30 gpl. In this section, ferritic zinc is leached, wherein Zn is recovered and impurities are precipitated in the form of Jarosite with the help of Sodium Suplhate.

23 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

3.4.1.5 Purification Plant

The neutral overflow is pumped to the purification section where impurities are removed until levels drop to the point which facilitates the best possible results in the electrolysis section. Special considerations in the design of this plant are:

➢ The plant has to produce the best quality purified solution; ➢ Minimum zinc dust consumption; ➢ To obtain the best by-products quality; ➢ The plant has to be fully automated; and ➢ The control philosophy for the plant design is to be integrated in a distributed control system, managing at the same time leaching and purification plants.

Main instrumentation in the file is:

➢ Frequency speed drives; ➢ pH meters; ➢ Flow meters, regulation and control; ➢ Automatic reagents feeding as a function of the flow; ➢ Temperature measurement, regulation and control; ➢ Density meters, regulation and control (thickeners’ underflow); ➢ Torque measurement, regulation and control (thickeners); and ➢ Zn, Cu, Co, Cd, analyzers.

The purification section consists of the following stages:

❖ Pre-filtration; ❖ Cu removal; ❖ Hot purification; and ❖ Polishing/Gypsum removal.

The neutral solution that is fed into the purification section shall comply with the following requirements:

Solid matter <0.2 g/l

Zn 140 – 150 g/l

As <0.200 mg/l

Sb <0.200 mg/l

Ge <0.100 mg/l Fe <10 mg/l Mn 2 – 5 g/l Mg <10 g/l Cl <300 mg/l F <10 mg/l

a) Pre Filtration

24 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

In the pre-filtration section, neutral over flow solution (containing app. 150 gpl of Zn as Zinc sulphate) produced in the leaching plant at >65oC temperature is sent to remove any suspended solids or mica etc.

b) Copper Removal

The neutral leaching overflow is processed in a series of reactors along with zinc dust in order to remove the copper and cadmium in the solution. The amount of zinc dust added is adjusted according to the results obtained from the control analysis every hour. The mixture flows by gravity in reactors, from there it flows by gravity into the pumping tank. The mixture is pumped to the automatic filter presses, where the solid matter containing the removed impurities, is retained. The filtrate from filter press is collected in a tank and pumped to the hot purification stage for further treatment.

The copper removal cake is treated with spent electrolyte (at controlled pH) in separate reactors to allow for the selective leaching of excess Zinc dust. The solution flows by gravity into the second tank and then it is pumped to filter presses, where the solid matter containing the copper is retained as cake. The filtrate is collected in a tank which it is pumped to Conversion section of Leaching Plant.

c) Hot Purification/Cobalt Removal

The Cu removal filtrate is pumped through heat exchangers to the first of a series of tanks. The temperature at the entrance of this tank is a constant 820C, and is regulated by controlling the supply of steam to the heat exchangers. In the first tank both a solution containing Potasium Antomony Tartrate (PAT) (premixed in the preparation tanks) and Copper sulphate and zinc dust are added. After leaving the last tank of the series, the mixture is pumped to the automatic filter presses, where the solid matter containing the removed impurities, is retained. This filtrate is further purified in polishing section by pumping to series of tanks, where zinc dust is added for removing of any residual impurities, if any. After leaving the last tank of the series, the mixture is pumped to the filter presses, where the solid matter containing the removed impurities, is retained.

The working cycle of the filter presses is between four to twelve hours. Once the cycle has been completed the filter press is isolated from the circuit and the cake is discharged onto re-pulping tank, and then to the first tank of the Enrichment Plant for further recovery of excess Zn dust.. The filter cloths are also washed online to remove the solid particles adhering to them.

The pH of the solution, previously filtered through the hot purification stages, is adjusted by the controlled addition of spent, before the solution enters in the tank from where it is pumped up to the cooling towers.

3.4.1.6 Electro-Winning

The purified and cooled zinc sulphate solution is electrolyzed in cell house (electrolytic cells) using aluminum cathodes and Lead anodes. The zinc metal gets deposited on the cathodes and the spent electrolyte containing sulphuric acid

25 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

with depleted level of zinc is returned to leaching section. The zinc deposited on cathodes will be pulled out and stripped off with automatic stripping machines as per input current.

For the proposed plant, large size cells have been selected for reducing floor area requirement. The current density, temperature etc. have been selected to optimize the area required, deposit quality and power consumption while rendering high operational efficiency.

This plant consists of the following sections: a) Cooling and Basic Salt Separation (Gypsum Removal) b) Cell house; c) Automatic handling and stripping of cathodes; and a) Cooling and Basic Salt Separation (Gypsum Removal)

The purified solution from the hot purification section must be cooled down from 75oC to approx. 35oC prior to being fed to the electrolyte cycle. During this cooling operation, basic zinc salts as well as gypsum crystals together with some impurities are partly precipitated in line with the temperature-dependent solubility limits in aqueous zinc sulphate solutions.

Cooling is achieved in atmospheric cooling towers, where the solution is contacted with air in counter current flow. The cooled solution is collected in a launder system and flows to a settler where the solids, mainly basic zinc salts and gypsum crystals, will settle. The settler overflow is fed to the purified electrolyte storage tank. The cooler cake obtained while periodical cleaning of cooling tower is discarded. b) Cell House

The purified solution, after having been treated for basic salt, is stored in the purified electrolyte solution tank. The tank house will be designed according to the latest commercial technology using 3.5 m2 cathodes as well as an automatic cathode transport system and full automatic stripping of the zinc deposits. Spent electrolyte discharged from the tank house via the main collecting launder is collected in spent electrolyte storage tanks. From there a certain amount of spent electrolyte is pumped directly to the neutral leaching plant.

The major portion of the spent electrolyte is pumped to atmospheric cooling towers, where the spent electrolyte is cooled down to approximately 35oC-40C. The cooling towers are of the same design as those for the neutral solution. The mixing of neutral leach solution and spent electrolyte takes place in the circulation tanks.

The electrolytic recovery of zinc is brought about by passing continuously electric current through the aqueous zinc sulphate electrolyte acidified with H2SO4 and the insoluble electrodes, causing the decomposition of the zinc sulphate and the

26 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

water. The metallic zinc settles on the cathode and the oxygen on the anode, thereby recovering sulphuric acid from the hydrogen of the water.

This process takes place in lined and insulated cells equipped with 115 anodes and 114 cathodes each. The tank house contains 132 cells. The electrodes of each cell are coupled in parallel by bus bar.

The electrolyte is supplied to the individual cells via distributing launder and pipes. Reagents, such as strontium carbonate, Arabic gum, are added to improve deposit quality, increase current efficiency and suppress acid mist formation.

The direct current is fed from the rectifiers to the individual cells via bus bars mounted on isolators, which rest on special supports. The basic reaction in electrolysis is as follows;

-- -- ZnSO4 + electricity ==> Zn++ + SO4

Zn++ +2e- = => Zn

c) Automatic handling and stripping of cathodes

During the electrolysis process as already mentioned the zinc is deposited on aluminum cathodes, which in a cycle as per input current have to be taken out from the cells in order to remove the zinc deposit. The cathodes are automatically stripped in stripping machines. The transport of the cathodes to the stripping machines is performed by a cathode and anode transport system provided with a special grab device, which is able to lift unstripped cathodes from the cell. The cathodes are washed in a washing device prior to being distributed to the stripping unit of the stripping machine. The feeding of the inlet chain conveyors of each stripping machine with the cathodes is automatically regulated by the control system.

The stripped zinc sheets are stacked below the stripping machine, weighed and transported by forklift to the storage platform inside the melting and casting plant. The cathode transport system is also used for the anode cleaning operation.

3.4.1.7 Melting and Casting Plant

The zinc sheets coming from the stripping machines are first stored on the storage platform in order to ensure that they are completely dry prior to feeding them into the melting furnaces.

a) Melting of Zinc Cathodes

The zinc sheets are fed into the induction furnaces via charging conveyers by means of forklifts. The zinc sheets are melted down under a layer of ammonium chloride which serves the purpose to destroy the oxide film that may be formed during the melting operation, thus ensuring that the amount of zinc going into the dross is kept relatively low.

27 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

The molten zinc is pumped from the furnace’s sump by graphite made vertical pumps through steel launders lined with heat resistant materials to the slab/jumbo casting machines

b) Casting of Zinc Slabs

The zinc ingot production will be cast into standard 25 kg slabs / 1,000 kg zinc blocks. The molten zinc is pumped from the induction furnace through the launders to the casting machine. The casting machine is provided with automatic zinc pouring and skimming devices that ensure the proper filling of each casting mould with the required amount of molten zinc. The zinc slabs/blocks are cooled down inside the casting machine by water sprays. Afterwards, the slabs are automatically stacked in the stacking device and weighed on a scale. The bundles of zinc slabs with a weight of 1000 kg are collected on bundle conveyors from where they are strapped and transported to the storage section by forklift. Some of the Zinc metal along with Aluminium, Magnesium and Cupper is used for production of Zinc alloy.

c) Dross Treatment Section

The dross from the zinc cathode melting furnaces, which contains approximately up to 90% of zinc, is firstly stored and cooled down in the transport containers. The dross mills are discontinuously charged with dross produced at the main induction furnaces. During the grinding operation a suction fan continuously withdraws the fine dross particles mainly consisting of zinc oxides and ammonium chloride. The mixture of air and dust passes through a cyclone and afterwards the bag filter. The clean air is discharged to atmosphere; whist the fine dust is collected and conveyed to the raw-material storage. The metallic zinc is sent for melting/ charging in the induction furnace.

3.4.1.8 Zinc Dust Plant

The zinc dust plant consists mainly of three sections:

❖ Atomizing furnace; ❖ Expansion chamber with a de-dusting bag house; and ❖ Dust screening and storage.

Zinc slabs are charged into the gas/electric heated atomizing furnace. This furnace has at its lowest point a special plug which permits to drain about 1 to 2 tph of liquid zinc. A special designed compressed air jet nozzle atomizes these 5 to 8 liquid zinc streams by blowing them into the expansion chamber/cyclone.

In the expansion chamber/cyclone, which is under slightly negative pressure the solid zinc dust will precipitate and collect in a bin, which discharges onto vibration conveyors that extract the zinc dust, from the expansion chamber.

The main quantity of zinc dust, which is precipitated in the expansion chamber, is transported to the zinc dust screening station. At this screen, oversize zinc dust

28 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

is separated which is recycled to the induction furnace. The clean air passes through bag filter before it leaves into the atmosphere through stack. The process flow schematic of Hydro Plants – I & II are shown in Figure – 10.

FIGURE- 10 HYDRO PLANT PROCESS FLOW SCHEMATIC Existing and proposed mass and material balance of Hydro Plants – I & II are presented in Table-6 (A) & (B) and the schematic flow of materials is shown in Figure –11.

The pollution load after expansion of the project is shown in Table- 7 (A) & (B). Further Figure-12 and Figure-13 highlights the changes in the process technology for increased efficiency in Hydro Plants –I & II.

29 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

TABLE – 6 (A) MASS AND MATERIAL BALANCE OF HYDRO PLANTS – I & II – EXISTING

Existing Material Balance Qty Grade Metal %

A Zn Concentrate 677177 50% 338588 B Calcine Production 590752 56% 330821 C Calcine Receipt from other 206000 56% 115566 Unit

Total Input 446387 Total Output 420050 E Jarosite 300000 6% 18897 F PF Cake 12520 35% 4382 G ETP Losses 9600 2% 192 H Anode Mud 2200 35% 770 I Cooler Cake 5000 35% 1750 J Cobalt Cake 1000 35% 350 Total Loss 26341

TABLE – 6 (B) MASS AND MATERIAL BALANCE OF HYDRO PLANTS – I & II –PROPOSED (AFTER MODIFICATION) Proposal Material Balance Qty Grade % Metal With Fumer A Zn Concentrate 698458 50% 349229 B Calcine Production 595364 56% 333404 C Calcine Receipt from other 337990 56% 189612 Unit

Total Input 523016 Total Output 503978 E Jarosite 200000 4% 7000 F PF Cake 12520 33% 4069 G ETP Losses 9600 2% 192 H Anode Mud 2200 35% 770 I Cooler Cake 5000 35% 1750 J Cobalt Cake 1000 35% 350

30 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

Pyrometallurgical Slag 143666 2% 3477 Goethite Cake 11471 6% 688 Lead-silver cake 12874 6% 743 Total Loss 19039 Source: HZL-CLZS TABLE – 7 (A) POLLUTION LOAD AFTER EXPANSION OF HYDRO PLANTS – I & II

Name of the Stack Emission Unit Stack Connected to PM Norms (mg/Nm3) Hydro Plant Acid plant-Mist 50 (H- I) Bag house attached to melting furnace no. 1 (a) 50 Bag house attached to melting furnace no. 2 (a) 50 Bag house attached to dross milling 50 Bag house attached to Zinc Dust 50 Hydro Plant Acid plant-Mist 50 (H- II) Bag house (a) & (b) attached to melting furnace No. 50 1 Bag house attached to dross milling 50 Bag house attached to Zinc dust plant 50

TABLE – 7 (B) POLLUTION LOAD AFTER EXPANSION OF HYDRO PLANTS – I & II

SO2 Emission from Acid Plant

Acid Plant SO2 Norms Emission Factor (kg/Tonne of acid Production) Acid plant-(Hydro-I) 2 Acid plant-(Hydro-II) 2 Note: No Additional Emission Impact after proposed Expansion

Source: HZL -CLZS

31 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

FIGURE- 11 MATERIAL AND PROCESS FLOW DIAGRAM OF HYDRO PLANTS

32 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

FIGURE-12 EXISTING PROCESS FLOW DIAGRAM OF HYDRO PLANTS – I & II

33 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

FIGURE-13 PROPOSED PROCESS FLOW DIAGRAM OF HYDRO PLANTS – I & II

34 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

3.5.1 Raw Material Requirement

The major raw material required is zinc concentrate, which will be sourced from the captive Mines of HZL viz, Rampura Agucha Mine, Kayad Mine, Rajpura Dariba Mine, Zawar Mine and Sindesar Khurd Mine, while required calcine will be sourced from HZL and other Zinc Smelter (Captive / imported) located in Rajasthan. Raw material are given in Table-11 (A) & (B).

TABLE-11 (A) RAW MATERIAL REQUIREMENT HYDRO I & II

Unit Total Capacity Additional As per EC Existing After Proposed (Dec’2006) Status Proposed Capacity Expansion Zinc concentrate (TPA) 677177 677177 21282 698458

Calcine (ZnO) 206000 206000 131990 337990 Zinc Dross/ Ash/ Zinc 15000 15000 - 15000 bearing waste 4800 4800 Aluminium Metal - - 60 60 Magnesium Metal - 600 600 Copper Metal - - *25000 MT Dross approval is available in Recycler category,15000 MT for Unit-II, 10000 MT for Pyro

Source: HZL – CLZS

TABLE-11 (B) RAW MATERIALREQUIREMENT (FUEL) HYDRO I & II

Hydro Plant-I Total LPG (kg) 171 Oil (Ltr) 20,623 HSD (KL) 476 Propane (MT) 1000 Hydro Plant-II Total LPG (kg) 50 Oil (Ltr) 20,816 HSD (KL) 480 Propane (MT) 210

35 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

3.5.2 Products and By Products

Details of Products & By-products are given in below table

Unit Total As per EC Additional Capacity Existing Proposed After Status (Dec’2006) Capacity Proposed Expansion SHG Zinc 420000 420000 TPA 84000 TPA 504000 TPA Cathode/Ingot/ Zn TPA Alloy/(Special High (20% Grade) Expansion)

By products

Sulphuric Acid 578000 578000 TPA 37548 TPA 615548 TPA TPA

Cadmium metal / 1360 TPA 1360 TPA - No Change Sponge (equivalent metal)

Calomel - - 40 TPA 40 TPA

Copper as Copper 1020 TPA 1020 TPA - No Change cement/ sulphate/ matte/ concentrate /Compound (equivalent metal)

Waste Heat power (in 18.8 MW 18.8 MW - 18.8 MW MW)

Low grade lead 30000 30000 - No Change Concentrate (MTPA) equivalent metal) (10000 MT Lead)

Sodium Sulphate (TPA) - - 2500 2500

Sodium Chloride (TPA) - - 500 500

3.6 Water Requirement

No additional water required for this expansion project of Hydro Plants - I & II and CPPs. The water requirement of existing Hydro Plants I & II and CPP is 30670

36 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

KLD (Existing approval for water is 62,000 m3/day). The additional water requirement is well within the limit of water approval for Hydro Plants -I & II and CPP). In addition to captive Gosunda Dam, STP Udaipur/Proposed STP of Chittorgarh/Bhilwara and Other STPs water will be utilized to minimize the fresh water consumption in the plants. The water requirement for existing plant is mentioned in Table - 12. The water balance diagrams of Hydro Plants – I & II of the existing and proposed are shown in from Figure - 14 to Figure – 17. TABLE - 12 WATER REQUIREMENT AND WATER BALANCE OF HYDRO PLANTS – I & II

Environmental Additional Total Capacity Name of the Existing Clearance Proposed After Proposed Unit Status (EC) Approved Capacity Enhancement Hydro Plant-I 19,670 (Including 19,670 KLD - No Change KLD CPP) Hydro-II 11,000 (Including 11,000 KLD - No Change KLD CPP) Hydro I & II 30,670 Combined 30,670 KLD - No Change KLD including CPP Source: HZL-CLZS

37 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

Water Balance of CLZS RAW WATER from ActualGosunda Dam

62000

Domestic [250+20+82+108]=460

5600 2300 19670 11000 HYDRO-1 & CPP HYDRO-2 & CPP Loses PYRO Ausmelt (154MW) (100MW) & Fumer Loses=96 STP=364 2352 450 ETP-2 1500 3296 (4200 m3/day)2352 26 Used for lime slurry 5246 preparation ETP-1 2326 (8400 m3/day) RO- 2 1200+100 (3840 m3/day)2326 RO permeate 1884 Used for Slag Gr+ lime Used in process 3946 RO permeate 442 Used in Process RO-1 Reject 3157 (3312 m3/day) 1231 789 3rd stage RO Reject (1250 m3/day) RO permeate Reject 750 500

Solar Evaportaion Pond & SLF * All values in m3/day

Figure 13 Existing & Proposed Combined Water Balance of CLZS

FIGURE - 14 Existing & Proposed Water Balance Hydro I & CPP 154 MW

38 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

FIGURE - 15 Existing & Proposed Water Balance Hydro II & CPP 1OO MW

3.7 Power Requirement and Supply/ Source

The additional power requirement of the proposed enhancement of zinc production capacity will be about 20 MW on combined basis of both Hydro Plants – I & II. The power requirement will be met from existing Captive Thermal Power Plant / WHRB (18.8 MW)/ Captive Solar Power Plant/ Rooftop Solar Panels/Floating Solar Panels/ AVVNL.

DG Set Details for Emergency Power

Existing five DG Sets (capacity 750 kVA, 650 kVA, 0.64 MW, 0.55 MW and 2 MW) being used for emergency power backup purpose.

3.8 Quantity of wastes to be Generated (Liquid & Solid) & Scheme for their Management/Disposal

3.8.1 Wastewater Generation & Management

The total wastewater generated for the Hydro Plants - I & II for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA – 5,04,000 TPA under 7 (ii) clause of EIA notification, 2006 will be 5648 m3/day (3296 H-I & 2352 H-II) waste water is /will be generated which is treated in the existing ETP’s of capacity

39 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

of 8400 m3/day and 4200 m3/day respectively. This is further processed in RO & the RO permeate is further recycled while RO Rejects is being send to the Evaporation System of adequate capacity to maintain Zero Discharge at site

Besides, domestic wastewater at about 147.6 m3/day (65.6 H-I + 82 H-II) are generated and treated in existing STP of 1000 m3/day capacity. No additional manpower required for this proposed enhancement project. Hence, no increase in domestic wastewater generation.

3.8.2 Solid Waste / Hazardous Waste Generation and Management

1. Secured Land Fill (SLF) for disposal of process waste, spent catalyst, ETP sludge, etc. – Double composite liners – Leachate collection system – Operation and maintenance by expert agency 2. Jarofix Yard for disposal of Jarofix – Jarosite cake is stabilized by adding lime and cement in set proportions before its (Jarofix) disposal – Operation and maintenance by expert agency 3. Piezometric wells for ground water monitoring 4. Organic Waste Converter for the treatment of biodegradable waste generated from canteen, guest house, township and horticultural activities

3.8.3 Utilisation of Hazardous and Non-Hazardous Waste

The various types of hazardous waste are generated in RLE process where most of the waste are sold to the registered recyclers. Whereas the Non-ferrous sludge from ETP is currently disposed to secured landfill. To reduce the waste footprint, the non-ferrous sludge can be used in the co- processing for cement making.

Jarosite was in hazardous waste category in HWM, 2008 schedule 3-part A. But there were studies conducted by National Environment Engineering Institute (NEERI), Nagpur. Based on various studies and recommendations Jarosite was removed from the hazardous waste category in 2016 as per the HWR, 2016.

Based on study conducted by National Cement Council and Building Material (NCCBM) Jarosite can be used as a replacement of gypsum in cement manufacturing. Jarosite can also be used in the paste fill in the mine backfilling as a replacement of cement. In paste fill Jarosite gives provides enough strength as it works as a binder.

In similar way, Jarosite has a huge potential to be use in ready mix concrete as a replacement of cement as per study conducted by IIT Roorkee.

Jarosite when stabilised with lime and cement and converted into Jarofix. It attains enough strength can be used in the embankments as per recommended by IISC Bangalore and also in retain fill and embankments in the road construction basis on the trial conducted and recommendations given by Central Road Research Institute (CRRI) and (NEERI).

40 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

Solid waste generated quantities, method of treatment and disposal details of the existing CLZS complex as well as from proposed enhancement are given in Table-14.

TABLE-14 SOLID WASTE GENERATION & MANAGEMENT DETAILS OF HYDRO PLANTS -I & II

Total (After Granted Additional Method of Sr. Type of Waste Enhancement) Quantity Quantity Treatment and No. Quantity (Units) Quantity (Units) (Units) Disposal (Units)

Reuse/Recycle/Sale to registered 1 Cooler cake (MTPA) 5,000 1000 6000 recycler/Co- processing/ Disposal in SLF

Reuse/Recycle/Sale to 2 Anode mud (MTPA) 2,200 0 2200 registered recycler /Disposed in SLF

Reuse/ Sale to 3 Used/Spent oil (KLPA) 80 16 96 registered recycler

Reuse/Sale to 4 Waste oil (KLPA) 270 0 270 registered recycler

Reuse/Recycle/Sale to 5 Cobalt cake (MTPA) 1,000 0 1000 registered recycler /Disposed in SLF

Purification cake / Reuse/Recycle/Sale to 6 Enrichment cake 12,520 0 12520 registered recycler (MTPA) /Disposed in SLF

Reuse/Recycle/Sale to Mercury and Mercury 7 22 MTPA -22 MTPA 0 registered recycler compounds /Disposed in SLF

Sale to registered 8 Spent catalyst in KL 60 0 60 recycler/disposed in SLF

Reuse/Recycle/Sale to Non-ferrous Sludge 9,600 9 4,000 13,600 registered recycler from ETP and scrubbers MTPA /Disposed in SLF/Co processing in Cement

41 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

industries

Discarded Reuse/Recycle/Sale to containers/barrels/liners 1,400 10 0 1,400 No's/Y registered recycler used for Haz. No's/Y /Disposed in SLF Waste/chemicals

Reuse/Recycle/Sale to Flue gas cleaning 11 2.0 MTPA 0 2.0 registered recycler residue /Disposed in SLF

Spent ion exchange Sale to registered 12 resin containing toxic 1.0 MTPA 0 1.0 recycler/disposed in metal secure land fill

Sale to registered 13 Water purification Resin 2.0 MTA 0 2.0 recycler/disposed in secure land fill

Sale to registered Filter and Filter recycler/disposed to 14 material which contain 100 MTA 0 100 secure land organic compound fill/approved Incinerator

Sale to registered recycler/disposed to Oil Soaked Jute/cotton 15 - 10.0 10.0 secure land waste/Used PPE’s fill/approved incinerator

Utilization in Cement Manufacturing/ -1,00,000 Road/Rail 16 Jarosite cake* 3,00,000 (after 2,00,000 embankment/Concrete Fumer) construction/ disposal in Lined Jarofix yard

Recovery of Glauber MEE Salt - 5000 5000 17 Salt/ Disposal in SLF

Source: HZL-CLZS

*Jarosite has been excluded from the schedule 1 of the Hazardous Waste Management Rules 2016 as the high volume low effect waste.

42 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

4.0 SITE ANALYSIS

4.1 Connectivity

The Chittorgarh/Ajmer highway (NH-79) and Udaipur-Chittorgarh – Shivpuri highway (NH-76) passes at a distance of 2.5 km, NW from plant boundary. The nearest railway station is at Chanderiya at a distance of 2.5 km in the NW direction, which is under western railway situated on Chittorgarh - Ajmer railway line.

The Maharana Pratap Airport – Udaipur is located at a distance of 84 km from the project site. The kandla port is the nearest port is located at a distance of 499 km in WSW direction.

4.2 Existing Land Use Pattern

The proposed enhancement of zinc production capacity will be executed within the Hydro Plant - I & II areas. No additional land will be required for the said enhancement.

4.3 Topography

The CLZS complex is surrounded by hills with heights ranging from 400 to 592 m above MSL.

4.4 Land Use Pattern

No additional land is required for this expansion project. Total area existing CLZS complex total area: 335.89 ha. The total area under the possession of HZL at existing CLZS complex. The land use is in industrial category. The installation of 8 no of new electrolytic cell will be within the existing building of the Hydro Plants -I & II. Hence, no additional land is required.

4.5 Existing Infrastructure

The auxiliary services are all already existing in the smelting complex and are as follows:

• Water treatment plant; • Laboratory; • Stores; • Finished goods yard; • Fuel oil storage; • Instrument air/plant air supply unit; • Electrical system; and • Fire alarm system.

All the infrastructural facilities such as roads, construction water and power, construction offices/stores etc. are available at plant area.

43 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

4.6 Soil Classification

Two third area of the district is covered by hilly terrain. The soils of the district fall under the following broad categories: • Black soils; • Yellowish brown soils; • Greyish brown alluvial soils; and • Hilly soils.

Black soils are found in Pratapgarh, Arnod, Dungla, Kapasan, Begun and parts of Rashmi tehsils. Yellowish brown soils are predominant in Chittorgarh, Nimbahera, Bhopalsagar, Bhainsorgah and Bhadesar panchyatsamities. The hilly soils occur in Bhainsorgarh, Begun, Chittorgarh, Dungla, Chotti Sadri, and Nimbahera Panchayatsamities. There are broad stretches of light sandy loam soils along banks of river.

4.7 Climatic Data from Secondary Sources

The climatic conditions of the region as available are as follows: Maximum of daily temperature : 38.7 0C Minimum of daily temperature : 7.9 0C Relative humidity : 25 % to 83% Total rainfall : 676 mm Prevalent wind direction : SW (annual) The nearest IMD station is at Udaipur.

5.0 PLANNING BRIEF

5.1 Planning Concept (types of industries, facilities, transportation etc.) Town and Country Planning/Development Authority Classification

As per Environmental Impact Assessment EIA Notification dated 14th September, 2006, the proposed enhancement of Zinc production capacity Under 7 (ii) clause of EIA notification, 2006 & Category ‘A’ of project activity Sr. No. 3 (a) Metallurgical Industries (Ferrous & Non - ferrous) and requires Amendment in Environmental Clearance (EC) on combined basis of both Hydro Plants – I & II is to be obtained from MoEF & CC before the commencement of project activity.

HZL is currently producing 2,10,000 TPA and 2,10,000 TPA of Zinc as a product from Hydro Plants - I & II respectively of CLZS at Putholi village, Gangrar tehsil, Chittorgarh district, Rajasthan. Now, it is proposed to increase the capacity of zinc production from 4,20,000 TPA to 5,04,000 TPA of both Hydro Plants -I & II on combined basis, thereby by increasing the number of cells from 256 to 264 and current input in cell house from 380 kA to 400 kA (Increasing the number of cells from 124 to 132 /132 to 132 and current input in cell house from 190 kA to 200 kA / 190 kA to 200 kA of Hydro Plants – I & II respectively). The manufacturing process consists of roast leach electro-winning Technology.

Zinc production from the existing production capacity of both Hydro Plants – I & II on combined basis after Proposed Enhancement of Zinc Production Capacity

44 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

from 4,10,000 TPA to 5,04,000 TPA which is only 20% increase in the existing capacity without addition of any major process change. The installation of 8 no of new electrolytic cell will be within the existing building of the Hydro Plants -I & II. Hence, no additional land is required.

5.2 Population Projection / Manpower Requirement

There will be no change in employment after proposed enhancement of zinc production capacity and it will be run by the existing manpower.

5.3 Land use Planning (breakup along with greenbelt etc.)

Total area existing for both Hydro Plants – I & II in ha: 20 ha + 26.5 ha = 46.50 ha out of CLZS complex total area: 335.89 ha. No additional land will be required for proposed enhancement project. CLZS greenbelt consisting of 121.77 Ha. Which is more than 33% of the total plant area. Land use breakup and greenbelt is presented in Table-15 (A) & (B) and layout is shown in Annexure-II.

TABLE-15 (A) LAND USE BREAK UP Sr.No Particular /Unit Existing Area in Ha. 1 Pyro & Ausmelt 29

2 Waste Disposal Site & 118.62 Other Utility area including storage facilities etc. 3 Hydro I 20 4 Hydro II & Fumer 26.5 5 CPP 20 6 Green Area (Only CLZS) 121.77 (>33 %) Total CLZS Unit 335.89 Ha.

Source: CLZS, HZL

The total area is under the possession of HZL at existing CLZS complex of 335.89 ha. Hence, no additional land acquisition is involved.

TABLE-15 (B) LAND USE AND GREEN BELT

Particular Present Total Green Belt Area in % Total Land 335.89 335.89 >33 % (ha) Land under 121.77 121.77

45 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

plantation for CLZS (ha) Plant Species Neem, Neeli Gulmohar, Dhak, Sheesham, Gular, Amaltas, Imli, Peepal, Siris, Kachnar, Jhaoo, Kaner, Arjun, Kasod, Chural, Babool, Kikar, Bahera, Ratanjot, etc

5.4 Assessment of Infrastructure Demand (Physical & Social)

The necessary infrastructure like internal roads, parking provision and administration building is already developed and existing in the plant.

5.5 Amenities/Facilities

The existing infrastructure and utilities like internal roads, water supply, adequate parking provisions, power backup, fire fighting measures, landscaping, storm water drains, rain water harvesting and solid waste management are provided.

6.0 PROPOSED INFRASTRUCTURE

6.1 Industrial Area (Processing Area)

The total area under HZL’s possession is 335.89 ha. The proposed enhancement will be in the existing premises; therefore no additional land will be required for said project.

6.2 Residential Area (Non–Processing Area)

The land is already under industrial use and does not have any settlement. 6.3 Greenbelt

CLZS greenbelt consisting of 121.77 ha will be further strengthened which is more than 33 % of the total area under possession of CLZS. The existing greenbelt will be maintained and further strengthened in to order to increase survival rate. The existing greenbelt map is given in Annexure - I1I.

6.4 Connectivity (Traffic and Transportation Road/ Rail/Metro/Water ways etc.)

The Chittorgarh/Ajmer highway (NH-79) and Udaipur-Chittorgarh – Shivpuri highway (NH-76) passes at a distance of 2.5 km, NW from plant boundary. The nearest railway station is at Chanderiya at a distance of 2.5 km in the E direction, which is under western railway situated on Chittorgarh - Ajmer railway line.

The Maharana Pratap Airport – Udaipur is located at a distance of 84 km from the project site. The kandla port is the nearest port is located at a distance of 499 km in WSW direction.

6.5 Drinking Water Management

46 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

Drinking water requirement will be met from the existing water allocation from Gosunda dam. No additional water requirement is envisaged.

6.6 Sewerage System

There will not be any additional sewage generation for the proposed enhancement of zinc production capacity. Sewage is being treated in existing STP of 1000 KLD and reused for greenbelt.

6.7 Industrial Waste Management/ Solid Waste Management

There will be additional waste generation from proposed enhancement of zinc production capacity project.

7.0 REHABILITATION AND RESETTLEMENT (R&R PLAN)

7.1 Policy to be adopted (Central/ State) in respect of the project affected persons including home outsees, land outsees and landless labours (a brief outline to be given)

For the proposed enhancement of zinc production capacity in Hydro Plants -I & II will be set up within the existing respective plant premises, thus no additional land is required. Hence, R & R plan is not envisaged for the proposed enhancement in production capacity of zinc.

8.0 PROJECT SCHEDULE AND COST ESTIMATES

8.1 Likely date of start of construction and likely date of completion (Time schedule of the project to be given)

The proposed capacity enhancement will be completed within 10 months from the start of the construction activity at project site. The project construction start date will be decided after obtaining all the statutory clearances like Consent to Establishment (CTE) & Consent to Operate (CTO) from RSPCB and tie up of the finance for the project.

8.2 Estimated Project Cost along with analysis in terms of economic viability of Project

The estimated cost of the proposed enhancement of zinc production capacity in Hydro I & II will be Rs. 138.5 Crores including EMP cost Rs 48.5 Crores.

9.0 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)

9.1 Financial and Social Benefits with Special Emphasis on the Benefits to the Local People including the Tribal Population if any Rajasthan state will get revenues in terms of taxes. Business opportunities for local community will be available like transport of material to market, maintenance & house-keeping contract work, supplying goods, food to people etc. In addition, Corporate Environment Responsibility (CER) activities are being / will be carried out by the company. The allocation of environmental budget is given in

47 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

below Table – 16. The existing environmental pollution control measures are shown in Figure -18.

TABLE – 16 ENVIRONMENTAL BUDGET

S.No. Environment Expenditure Rs (Cr) 1. VFD in 8 Cell Addition area 0.1 2. Strengthening of ZLD for Hydro I & II at CLZS 40.0 3. CRRI (Study of Road Performance) 0.4 4. Jarofix Utilization in Road construction 8.0 Total EMP Cost 48.5

Source : HZL-CLZS

48 Pre-feasbility Report for Proposed Enhancement of Zinc Production Capacity from 4,20,000 TPA to 5,04,000 TPA on combined basis of both Hydro Plants - I & II at Chanderiya Lead Zinc Smelter (CZLS) Complex, Putholi Village, Gangrar Tehsil, Chittorgarh District, Rajasthan

Analyzer installed at ETP CAAQMS Inside

ETP Thickener RO Plant

FIGURE-18 EXISTING ENVIRONMENTAL POLLUTION CONTROL MEASURES

49