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Zn India Metal Bulletin, London May06
- 1. Zinc Metals Industry in India
10th Zinc & its Market Seminar
24th – 26th May, 2006
Sheraton Park Lane Hotel, London
Zinc Metal Industry in India
20 May 2006 1
©MECON LIMITED, Bangalore
- 2. Zinc Metal Industry in India
Presentation By:
D.K. Basu@, B.C. Kabra#, P.R.Chandna#, S.Roy$
@ -General Manager In charge, # Deputy. General Manager, $ - Asst. General Manager
Zinc Metal Industry in India
20 May 2006 2
©MECON LIMITED, Bangalore
- 3. CONTENTS
Indian Zinc Heritage
Sectoral Zinc Consumption in India & the World.
Growth of Indian Zinc industry
Indian Zinc Industry among Top 5 producers
Indian Zinc Mines & Reserves
Indian Zinc Smelting Capacities & Productions
Indian Zinc Demand & Supply.
Drivers for Zinc Growth in India
Future Indian Zinc Scenario
Indian Zinc Cash Costs
An Introduction to MECON Limited
Indian Lead – Zinc Industry & MECON’s Association
Conclusions
Zinc Metal Industry in India
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©MECON LIMITED, Bangalore
- 4. Indian Zinc Heritage
Zinc in India has a rich history and
heritage. Lead & Zinc metals have been
known in India during Vedic times.
The excavation work carried out by
British Museum, MS university and
HZL at Zawar Mines and existing slag
heaps at various ancient mining sites at
Rajasthan provide conclusive proof of
highly developed extractive
metallurgical technology for zinc metal
in India.
American Society of Metals (ASM)
recognised these sites at Zawar Mines as
one of the International Historical
Landmarks.
Picture Courtesy HZL
Ancient Zinc Retorts at Zawar Mines
Zinc Metal Industry in India
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©MECON LIMITED, Bangalore
- 5. USES OF ZINC
Zinc’s largest single use is in the corrosion protection.
Galvanizing is the main method of protection against corrosion
of steel, i.e., the steel is coated with a layer of zinc in order to
protect it from decay.
Brasses are alloys of copper and zinc, and they have good
mechanical properties and good corrosion resistance.
Die casting are precision casting that can be mass-produced.
Rolled zinc is used for architectural and building applications,
and for dry cell batteries.
Zinc oxide has its main use in tyres and rubber products.
Many other zinc chemicals are used in a wide range of
applications.
Health - humans and animals alike need zinc in their food for
good health and healing of wounds
Zinc Metal Industry in India
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©MECON LIMITED, Bangalore
- 7. World Zinc Uses
FIRST USE FOR ZINC END USE FOR ZINC
Zinc Metal Industry in India
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©MECON LIMITED, Bangalore
- 8. World’s Top 5 Zinc – Lead Mines
Mines Capacity k t/yr
Lead Zinc
Red Dog 125 570
Century 80 500
Antamina - 320
Rampura Agucha 25 375
Brunswick 70 260
TOTAL 300 2025
Source: ILZSG/ Private Communication
Zinc Metal Industry in India
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©MECON LIMITED, Bangalore
- 9. Growth of Indian Zinc Industry
1967:10,000 TPA BINANI Zinc Smelter, at Alwaye (RLE Process).
1968:18,000 TPA HZL Zinc Smelter, at Debari (RLE Process)
1977:27,000 TPA HZL Zinc Smelter, at Debari (RLE Process)
1978:30,000 TPA HZL Zinc Smelter, at Vizag (RLE Process)
1983:4,000 TPA HZL Zinc Smelter, at Debari (Conversion Process)
1991:70,000 TPA HZL Zinc Smelter, at Chanderiya (ISF Process)
1995:20,000 TPA BINANI Zinc Smelter, at Alwaye (Expansion)
2001:10,000 TPA HZL Zinc Smelter, at Debari (Expansion)
2001:10,000 TPA HZL Zinc Smelter, at Vizag (Expansion)
2005:170,000 TPA HZL Zinc Smelter, at Chanderiya (New RLE
Process)
2005:8,000 TPA BINANI Zinc Smelter, at Alwaye (Expansion)
Zinc Metal Industry in India
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©MECON LIMITED, Bangalore
- 10. Location of Major Zinc Mines
Zinc Metal Industry in India
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©MECON LIMITED, Bangalore
- 11. Indian Zinc Mines Reserves
In Million tonnes as on 31st March 2004
MINES Resources Reserves
Measures & Inferred Proved &
indicated Probable
Qty. Zn% Pb Qty. Zn% Pb% Qty. Zn Pb
% % %
Rampura 11.1 12.7 1.7 13.8 12.2 1.7 50.1 12.8 1.9
Agucha
Rajpura 12.2 7.5 2.5 19.6 5.7 2.1 10.6 5.9 1.7
Dariba
Zawar 22.5 4.8 1.9 13.8 3.7 3.1 5.8 4.4 1.8
Kayar 0.8 13.3 2.2 4.5 11.0 1.5
Total 46.6 7.5 2.0 51.7 7.4 2.2 66.5 11.0 1.9
Source: HZL Annual Report
Zinc Metal Industry in India
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©MECON LIMITED, Bangalore
- 12. Indian Zinc Smelter Capacities
Zinc Smelters Capacity t/yr
Debari Zinc Smelter 80,000 ( RLE Process)
Vizag Zinc Smelter 56,000 (RLE Process)
CLZS, Chanderiya 105,000 (ISF Process)
CLZS, Chanderiya 170,000 (RLE Process)
Binani Zinc Smelter 38,000 (RLE Process)
CLZS, Chanderiya 170,000 (RLE Process)
(Under Implementation)
Zinc Metal Industry in India
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©MECON LIMITED, Bangalore
- 13. Indian Refined Zinc Productions
Year HZL BZL Total
2000-01 148,092 29,923 178,055
2001-02 176,395 28,814 205,209
2002-03 207,066 28,459 235,525
2003-04 220,664 29,218 249,882
2004-05 212,445 26,346 238,791
18,200E 302,200E
2005-06 284,000
Note: E – Estimates
Source: MMR/ Annual Reports- HZL/BZL
Zinc Metal Industry in India
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©MECON LIMITED, Bangalore
- 14. World Refined Zinc Productions
(in Thousand Tonnes)
2002 2003 2004 2005
Europe 2,914 2,741 2,721 2,649
Africa 147 194 259 273
America 1,903 1,930 1,993 1,889
Asia 4,189 4,450 4,912 5,051
Oceania 567 553 474 457
Total 9,720 9,868 10,359 10,319
Source: ILZSG
Zinc Metal Industry in India
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©MECON LIMITED, Bangalore
- 15. Indian Zinc – Demand & Supply
Year Demand Supply Gaps %
Satisfaction
2004-05 400,000 239,000 161,000 60
2009-10 650,000 540,000 110,000 83
2014-15 960,000 557,000 403,000 58
2019-20 1410,000 557,000 853,000 40
Zinc Metal Industry in India
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©MECON LIMITED, Bangalore
- 16. Drivers for Indian Zinc Growth
India’s real GDP growth @ 8.4%; 7.5% & 8.1%
for the past three years.
Industrial production has grown @ 7.1%, 8.1%
and 9.4% in the same years.
Increased activities in the manufacturing sectors.
Continuing liberalisation.
Infrastructure growth – recent setting up of
Infrastructure Bank will further boost the demand.
Zinc Metal Industry in India
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©MECON LIMITED, Bangalore
- 17. Expected Future Growths
India: 10-12%
China: 15-17%
USA: 9%
World: 3-4%
Source: ILZSG
Zinc Metal Industry in India
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©MECON LIMITED, Bangalore
- 18. ZINC PRICES
Mainly two factors – shortage of zinc concentrate & investment opportunity
have led to the growth in the present zinc prices worldwide. Further increase
would be detrimental to zinc demand growths in the small & medium sector.
Zinc Metal Industry in India
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©MECON LIMITED, Bangalore
- 19. Cash Costs for Zinc
Indian cash costs are one among the lowest worldwide.
60
50
40
Trend Line
US Cents/lb.
30
20
10
0
2000-01 2001-02 2002-03 2003-04 2004-05
Years
Source:: HZL Annual Reports
Zinc Metal Industry in India
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©MECON LIMITED, Bangalore
- 20. Future Indian Zinc Scenario
In the past six years zinc metal productions in the country has
increased by ~70%.
Per capita consumption of zinc is only ~ 0.4 kg; quite low as compared
to developed countries & world averages - indicating great potential
for further growths.
On commissioning of the new zinc smelter of 170,000 TPA by March
2008; percent demand satisfaction will rise to 80 -83%.
However, ten years from now; self sufficiency will again fall back to
the present levels of 60%.
Therefore, before 2010 setting up of an additional Zinc Smelting
capacities would be an imperative. Export potential to our
neighbouring country - China would further shorten this time frame.
At the preset levels of productions the existing mines reserves would
only be sufficient for the next 15-18 years, unless augmented by new
explorations.
Zinc Metal Industry in India
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©MECON LIMITED, Bangalore
- 21. An Introduction
- MECON LIMITED
MECON Limited is the India’s frontline engineering,
consultancy and contracting organisation, offering full
range of services for setting up of Projects from Concept
to Commissioning including EPC/ Turn-key execution. It
is a multi-disciplinary company with 950 experienced
engineers, scientists and technologist, having a network of
offices spread over the country. Areas of activities are:
Iron & steel
Non-Ferrous metals
Power
Oil & Gas
Infrastructure
Zinc Metal Industry in India
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©MECON LIMITED, Bangalore
- 22. Indian Lead Zinc Smelters
&
MECON’s ASSOCIATION
Zinc Metal Industry in India
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©MECON LIMITED, Bangalore
- 23. Chanderiya Lead Zinc Smelter
Chronology of Events for Execution of CLZS Plant:
1977: Discovery of Rampura Agucha Mines.
1980: Takeover of Mines by HZL
1982: Preparation of mining Feasibility Report – SNC, Canada.
1982: Preparation of Smelting Pre-Feasibility Report – Stolberg, Germany.
1982: Preparation of Smelting bankable Feasibility Report – MECON.
1987: Execution of setting up of plant in Two phases:
Phase-I: Preparation of Firm Cost Estimates ± 5% - MECON.
Phase-II: Detailed Engineering, Site Construction & PMC – MECON.
1991: Lead Refinery Commissioned in March.
ISF plant Commissioned in October.
Zinc Metal Industry in India
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©MECON LIMITED, Bangalore
- 24. Chanderiya Lead Zinc Smelter
Salient Features:
Plant Capacities:
Zinc: 70,000 TPA
Lead: 35,000 TPA
Sulphuric Acid: 160,000 TPA
Cadmium: 235 TPA
Silver: 50 TPA
The plant was commissioned within the time schedule, in spite of
deterrents during the execution period like; oil crisis during Iran-
Iraq war & change in the lead technology from Electro-refining to
Pyro-refining and the project was commissioned within budgets
Capex of Rs 5170 Million..
Zinc Metal Industry in India
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©MECON LIMITED, Bangalore
- 25. Chanderiya Lead Zinc Smelter
METHODOLOGY OF IMPLEMENTATION:
The project was implemented in two phases on Turn-key
Concept for the main process units.
Phase- I:
Basic Engineering & Firming up of scope
Procurement activities before commitment
Preparation of Firm Cost Estimates within an accuracy
of ± 5%.
Phase-II:
Procurement
Erection/ construction
Commissioning
Zinc Metal Industry in India
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©MECON LIMITED, Bangalore
- 26. Chanderiya Lead Zinc Smelter
METHODOLOGY OF IMPLEMENTATION:
Various Turnkey Packages:
1. Raw Material storage & handling plant 9. Sulphuric acid plant
2. Sintering & Gas Cleaning Plant 10. Effluent Treatment plant
3. Imperial Smelting Furnace Plant 11. Power Distribution & Lighting
4. Zinc Pyro- Refining 12. Auxiliary Power & DG Sets
5.Lead Electro-Refining & Minor Metals plant 13. Water Supply System
6. Copper Recovery (SX-EW) plant 14. Utility System
7. Precious Metals plant 15. Telecommunication
8. Cadmium Plant
Zinc Metal Industry in India
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©MECON LIMITED, Bangalore
- 27. Debari Zinc Plant Expansion
Services Rendered:
1991: FR for Revamping of RA Plant –I.
1992: Technology Selection & Feasibility
Study – RLE vis-à-vis Pressure Leach
Processes.
1997: FR for Expansion of Debari Zinc
Smelter plant by 10,000 TPA.
2001: Expansion & Performance of Debari
Zinc Smelter by 10,000 TPA – M/s AdZ
Technology.
Presently plant is producing more than
75,000 TPA.
Zinc Metal Industry in India
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©MECON LIMITED, Bangalore
- 28. Vizag Zinc Plant Expansion
Services Rendered:
1997: FR for Expansion of Vizag Zinc
Smelter plant by 10,000 TPA.
2001: Expansion & Performance of Vizag
Zinc Smelter by 10,000 TPA – M/s
AdZ Technology.
Presently plant is Producing more
than 50,000 TPA of Zinc.
Zinc Metal Industry in India
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©MECON LIMITED, Bangalore
- 29. Vizag Lead Plant Expansion
Services Rendered:
1987: FR for Modernisation of Lead
Refineries at Tundoo & Vizag Lead
Smelter plants.
1989: Detailed Engineering & Project
Management of Lead Refinery
Modernisation – MIM Technology.
1999: 22,000 TPA Lead Smelter Plant – Due
Diligence & Health Study.
Zinc Metal Industry in India
20 May 2006 29
©MECON LIMITED, Bangalore
- 30. Chanderiya Lead Plant Expansion
Zinc Metal Industry in India
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©MECON LIMITED, Bangalore
- 31. Chanderiya Lead Plant Expansion
First Slag Tape
Construction of Ausmelt Furnace
Zinc Metal Industry in India
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©MECON LIMITED, Bangalore
- 32. Salient Features
– CLZS Lead Plant Expansion
Capacity: 50,000 TPA Lead Bullion
Know-how & Technology: M/s Ausmelt, Australia
Implementation Philosophy:Project Non- Turnkey (10 Nos. Major
Cost Packages)
Project Cost: $ 35 Million.
Schedule: 24 Months
Civil/ Structural Quantities: Excavation: 11,200 Cub.m.
RCC: 6,000 Cub.m.
Steel Structures: 1,650 tonnes.
The plant has been completed within the time schedule and the quality of
the work has been appreciated by the Process licensor – M/s Ausmelt,
Australia..
Zinc Metal Industry in India
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©MECON LIMITED, Bangalore
- 33. Indian Lead Smelter capacities
Lead Smelters: Capacities TPA:
CLZS, Chanderiya 35,000 (ISF - Process)
CLZS, Chanderiya 50,000 (Ausmelt Process)
TOTAL 85,000
Zinc Metal Industry in India
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©MECON LIMITED, Bangalore
- 34. Other Assignments in Zinc Industry
TEFR, Basic Engineering, & Procurement services, for
Ganesh Himal – Lead Zinc Project, - M/s Nepal Metal
Company Ltd.
Formulation Report for setting up of Zinc Smelter plant of
60,000 TPA, Kapasan – M/s Hindustan Zinc ltd..
Setting up of 100,000 TPA Zinc Ingots Custom based Zinc
Smelter Plant - M/s Sterlite Industries Ltd.
Site Selection report for setting up of 170,000 TPA Zinc
Smelter Plant – M/s Hindustan Zinc Ltd.
Zinc Metal Industry in India
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©MECON LIMITED, Bangalore
- 35. Conclusions
To accept the present challenges by the Indian Zinc Industry, adaptation
of some of the following measures are imperative in the near future to aim
self sufficiency of the zinc metals in India:
Explorations at a greater pace to discover the new economically feasible Zinc
mineral resources.
Setting up of new Zinc Smelters with economy of scale capacities &
environmental sustainability between the years 2010 - 2015.
Technological up gradation to improve metal recoveries & productivities and
to reduce cash costs at the existing Mines and Smelting operations, like
setting up of mechanized tank houses etc.
Recovery of Metal values from the process wastes like leach residues/ EAF
dusts/ tailings etc., by adopting the low investment capital cost &
environmentally sound technology.
Indian consultancy need to play a more proactive role in the absorption of the
new technologies, development of basic know-how & engineering in areas
other than proprietary equipment/technologies and to execute the projects
within the budgeted costs & time schedules.
Zinc Metal Industry in India
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©MECON LIMITED, Bangalore
- 36. Acknowledgement
The permission from MECON Limited to
write and present this paper is gratefully
acknowledged. Authors also thankfully
acknowledges the various sources of
information/ data.
Zinc Metal Industry in India
20 May 2006 36
©MECON LIMITED, Bangalore
- 37. THANK YOU
MECON LIMITED
# 89, Southend Road,
Basavanagudi,
Bangalore – 560 004, Karnataka – INDIA
Tel:+91-80-26571661 to 1668
Fax: +91-80-26576352
E-mail: nf@meconblr.com or meconblr@vsnl.com
Web site: www.mecon.co.in
Zinc Metal Industry in India
20 May 2006 37
©MECON LIMITED, Bangalore