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Hindustan Zinc Limited (Hzl) 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,
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