Despite operational challenges in the form of extended maintenance shutdown at one of our roasters, the Hindustan Zinc Smelter business successfully delivered historically high refined metal production of 967 kt. While successfully navigating our way through various challenges, we have reset the system with a strong foundation to deliver stellar production performance in FY 2022-23. With continued focus on cost reduction and output quality, our teams are geared to stay ahead in the global metal production curve.
FY 2021-22 witnessed delivery of some key milestone projects for our smelter business. We undertook Debari Smelter revamping to replace damaged concrete cells with poly concrete cells, which are more efficient and have better shelf life, and lower need for repairing and maintenance. This was achieved without any adverse impact on our stripping operations at the cell house.
With steady supply of concentrate from our mining operations, we are successfully targeting production of 1 million tonnes of high-quality metal along with value added products.
We scaled up our achievement from the previous fiscal year into FY 2021-22 and yet again celebrated new milestones for both our Chanderiya Lead-Zinc (CLZS) Hydro Smelter and DSC Zinc:
A 3,000 KLD capacity RO ZLD plant has been successfully commissioned at our Debari unit, marking a key step to fulfil our ESG commitment. We are also exploring in-house consumption of the produced sodium salt to replace sodium sulphate.
Chanderiya Lead-Zinc Smelter is certified for ISO 50001-Energy management.
In Zinc hydrometallurgy process, Jarosite is produced during the leaching process. It is further treated with lime and cement to produce Jarofix. Cement industries can use Jarosite as replacement for gypsum in their final clinker grinding process. For this purpose, the moisture content in the jarosite should be less than 30-35%. The Jarosite produced during our operations has a 50% moisture content that can traditionally be reduced through an expensive process of Filter press, which requires significant capex outflow and time for erection and commissioning.
Our in-house team found a cost-effective method of using quick dry lime in the jarosite to bring it to the desired moisture levels. Later, the same method was successfully trialed at a cement plant. Going forward, the same practice will be continued on a sustainable basis as a permanent solution to gainful utilisation of waste.
Benefits
Improving productivity and efficiency levels of the Zinc Smelter Debari (ZSD) Cell House without suspending operations or compromising safety was no mean task. The challenge lay in replacement of the cells without EOT cranes, in a running plant. A key area of priority was to ensure the safety of the people, the plant building and other plant structures. What aggravated the challenge was the completion of the tasks of handling, lifting, and shifting of approximately 8,000 MT material within four months.
The team explored and worked out options to develop a method to mechanise the removal and replacement of cells. After two months of detailed deliberation, vendor selection and finalisation, it opted for the Mechanised Gantry System as a safe and suitable option for the replacement.
The Revamp Project
Hindustan Zinc’s power business is geared towards achievement of carbon neutrality and reduction in Greenhouse Gas (GHG) emissions, while being focussed on boosting the operational excellence of our thermal plants. With efficiency enhancement central to our strategic proposition, we continued to invest in expanding our green energy footprint during FY 2021-22. Our CPP journey during the year was marked by several milestone achievements, giving us so many reasons to celebrate our sustainability-led performance and growth.
To supply reliable, efficient, and sustainable power for Hindustan Zinc with zero harm and at lowest cost.
We expanded our renewable capacity during the year with the addition of 5.4 MW to our Waste Heat energy capacity.
Our efforts to reduce our carbon footprint is validated by our successful avoidance of 6.13 lac tonnes of CO2 emissions during FY 2021-22 as against 5.52 lac tonnes in FY 2020-21.
As a responsible corporate, we are committed to achieving our goal of Net-Zero by 2050. In line with this commitment, we are targeting a series of new projects to be commissioned in FY 2022-23.
These targeted initiatives have the potential to further enable us to avoid 2.41 lac tonnes of CO2 in the next fiscal.
THERMAL POWER BUSINESS – FY 2021-22 A YEAR OF ACHIEVEMENTS
Our power business showed remarkable progress during the year due its operational excellence, despite the challenges posed by the pandemic.
During the year, Hindustan Zinc CPP generated 3,891 million units of power.
Chanderiya Lead-Zinc Smelter CPP received 5-star rating and Sword of Honour from the British Safety Council for Safety and Well-being during the year.
Our smelters delivered historic-high metal production, overcoming operational set- backs in the form of extended maintenance shutdowns. With operational challenges behind us, we have reset the system for a robust delivery. Going forward, we are also committed to making step changes in our ESG journey and driving operational efficiencies and productivity with enhanced use of technology.”
C ChandruChief Executive Officer – Smelter IBU