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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
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
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
20 May 2006                                              3
                        ©MECON LIMITED, Bangalore
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
   20 May 2006                                                             4
                           ©MECON LIMITED, Bangalore
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
20 May 2006                                                         5
                         ©MECON LIMITED, Bangalore
Sectoral Zinc Consumption in India




              Zinc Metal Industry in India
20 May 2006                                  6
                ©MECON LIMITED, Bangalore
World Zinc Uses
FIRST USE FOR ZINC                 END USE FOR ZINC




                Zinc Metal Industry in India
20 May 2006                                           7
                  ©MECON LIMITED, Bangalore
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
20 May 2006                                                            8
                                       ©MECON LIMITED, Bangalore
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
20 May 2006                                                          9
                        ©MECON LIMITED, Bangalore
Location of Major Zinc Mines




              Zinc Metal Industry in India
20 May 2006                                  10
                ©MECON LIMITED, Bangalore
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
20 May 2006                                                                                        11
                                       ©MECON LIMITED, Bangalore
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
20 May 2006                                                    12
                           ©MECON LIMITED, Bangalore
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
20 May 2006                                                                   13
                                       ©MECON LIMITED, Bangalore
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
20 May 2006                                                             14
                        ©MECON LIMITED, Bangalore
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
20 May 2006                                                     15
                         ©MECON LIMITED, Bangalore
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
20 May 2006                                         16
                   ©MECON LIMITED, Bangalore
Expected Future Growths
          India:      10-12%
          China:      15-17%
          USA:          9%
          World:       3-4%
Source: ILZSG




                   Zinc Metal Industry in India
20 May 2006                                       17
                     ©MECON LIMITED, Bangalore
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
20 May 2006                                                                        18
                            ©MECON LIMITED, Bangalore
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
20 May 2006                                                                                   19
                                                  ©MECON LIMITED, Bangalore
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
20 May 2006                                                               20
                          ©MECON LIMITED, Bangalore
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
20 May 2006                                                  21
                      ©MECON LIMITED, Bangalore
Indian Lead Zinc Smelters
                      &
              MECON’s ASSOCIATION



                  Zinc Metal Industry in India
20 May 2006                                      22
                    ©MECON LIMITED, Bangalore
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
20 May 2006                                                                    23
                           ©MECON LIMITED, Bangalore
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
20 May 2006                                                           24
                         ©MECON LIMITED, Bangalore
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
20 May 2006                                             25
                    ©MECON LIMITED, Bangalore
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
   20 May 2006                                                                26
                              ©MECON LIMITED, Bangalore
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
20 May 2006                                            27
                    ©MECON LIMITED, Bangalore
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
20 May 2006                                       28
                   ©MECON LIMITED, Bangalore
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
Chanderiya Lead Plant Expansion




              Zinc Metal Industry in India
20 May 2006                                  30
                ©MECON LIMITED, Bangalore
Chanderiya Lead Plant Expansion




                                                  First Slag Tape
   Construction of Ausmelt Furnace
                         Zinc Metal Industry in India
20 May 2006                                                         31
                            ©MECON LIMITED, Bangalore
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
  20 May 2006                                                        32
                            ©MECON LIMITED, Bangalore
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
20 May 2006                                             33
                    ©MECON LIMITED, Bangalore
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
20 May 2006                                                34
                     ©MECON LIMITED, Bangalore
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
20 May 2006                                                                    35
                            ©MECON LIMITED, Bangalore
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
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

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  • 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 20 May 2006 3 ©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 20 May 2006 4 ©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 20 May 2006 5 ©MECON LIMITED, Bangalore
  • 6. Sectoral Zinc Consumption in India Zinc Metal Industry in India 20 May 2006 6 ©MECON LIMITED, Bangalore
  • 7. World Zinc Uses FIRST USE FOR ZINC END USE FOR ZINC Zinc Metal Industry in India 20 May 2006 7 ©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 20 May 2006 8 ©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 20 May 2006 9 ©MECON LIMITED, Bangalore
  • 10. Location of Major Zinc Mines Zinc Metal Industry in India 20 May 2006 10 ©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 20 May 2006 11 ©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 20 May 2006 12 ©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 20 May 2006 13 ©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 20 May 2006 14 ©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 20 May 2006 15 ©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 20 May 2006 16 ©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 20 May 2006 17 ©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 20 May 2006 18 ©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 20 May 2006 19 ©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 20 May 2006 20 ©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 20 May 2006 21 ©MECON LIMITED, Bangalore
  • 22. Indian Lead Zinc Smelters & MECON’s ASSOCIATION Zinc Metal Industry in India 20 May 2006 22 ©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 20 May 2006 23 ©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 20 May 2006 24 ©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 20 May 2006 25 ©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 20 May 2006 26 ©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 20 May 2006 27 ©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 20 May 2006 28 ©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 20 May 2006 30 ©MECON LIMITED, Bangalore
  • 31. Chanderiya Lead Plant Expansion First Slag Tape Construction of Ausmelt Furnace Zinc Metal Industry in India 20 May 2006 31 ©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 20 May 2006 32 ©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 20 May 2006 33 ©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 20 May 2006 34 ©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 20 May 2006 35 ©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