Chanderiya Lead Zinc Smelter - ISF - Pyro-metallurgical Project Management

1. [JLZIC Silver Jubilee Conference Lead, Zinc and Cadmium into the 90s
LEAD ZINC SMELTER AT CHANDERIYA
- CONCEPT TOWARDS REALIZATION
S.N. Wazir, D.S. Sethi, T.C. Rajagopalan,
M.K. Mallik & P.R. Chandna.
Metalurgical & Engineering Consultants (I) Ltd., Ranchi.
ABSTRACT implementation of the project for providing
Lead and Zinc are among the strategic non consultancy, detailed engineering,
ferrous metals which find extensive use in procurement, project management and site
important sectors of industries contributing to supervistcn.
the growth of the nation. Our present
dependence on import of Lead and Zinc is The project has been taken up for
likely to continue and may be 77 percent and implementation in two phases within a total
60 percent respectively, by the turn of the period of 48 months. While the Phase I of the
century. project has been completed with the
submission of Firm Cost Estimates, Phase II
To bridge the increasing gap between demand activities have been initiated so that the
and indigenous production, HZL propose to project is commissioned by early 1991.
set up an integrated project for the production
of 70,000 t Zinc and 35,000 t Lead per annum INTRODUCTION
based mainly on lead-zinc concentrates from Due to the scarcity of nonferrous metals in the
Rampura-Agucha mines. Recovery of country and our dependence on import of
bypro ducts such as Silver, Gold, Cadmium, these metals, the setting up of an integrated
Mercury, Bismuth and Sulphuric acid is also plant for extraction of lead and zinc becomes
planned. imperative. This wlll not only result in
conservation of valuable foreign exchange but
The proposed plant will be first of its type in also aims towards self sufflclency in these
India and fourth such plant in Asia. The plant metals.
is based on the pyrometallurgtcal route of
extraction of Lead and Zinc simultaneously The first commercial .productton of lead
through Imperial Smelting ·Process. The started in India in 1942. The production of
important advantages of this process are the zinc could start only two and half decades
possible treatment of complex concentrates, later with the commissioning of two plants at
lower energy consumption and less power Binanipuram and Debart. The present
requirement. Further refining of energy installed capacities for Lead and Zinc are of
consumption and less power requirement. the order of 30.000 t/year and 99,000 t/year
Further refining of lead and zinc has also been respectively. The country's present domestic
envisaged. Waste heat recovery from launder demand for lead and zinc is being satisfied
boiler and LCV gases and advanced through imports to the extent of 67 percent
automation and instrumentation will be the and 40 percent respectively for these metals.
special features of the plant. Our dependence on import of Lead and Zinc is
likely to continue and may amount to 77
MECON has been associated with this project percent and 60 percent, .respectively by the
from the preparation of Feasibility Report in turn of the century. To bridge the increasing
1982 and has now been entrusted with the gap between demand and indigenous
7.1

2. I ILZIC Silver Jubilee Conference Lead, Zinc and Cadmium into the 90s I
production, HZL propose to set up an For expedttious implementation, the project
integrated project for the production of 70,000 has been divided into 15 turnkey packages
t zinc and 35,000 t lead per annum. With the covering detailed engineering, procurement,
setting up of Chanderiya Lead Zinc Smelter fabrication, construction, installation and
installed capacities of these metals will commissioning by Indian contractors. The
increase to 65,000 t Zyear and 169,000 t/year interface worked between various turnkey
respectively . packages and other work for the project are
being carried out on Non-turnkey basis. The
The proposed plant will be tirst of its type in vartous activities for the total implementation
India and fourth such plant in Asia. The plant of the project are being monitored through the
is based on the pyrornetallurgtcal route of help of network. Budgeting and cost control
extraction of Lead and Zinc simultaneously techniques will also be utilized to control the
through Imperial Smelting Process. Though project cost and time and to take corrective
this process is comparatively new about 10- measures at the early stages of the project.
15% of World's primary Lead and Zinc is
produced through this process. Besides The Phase I of the project has already been
producing Lead and Zinc it is also proposed to completed and Phase II activities are expected
recover by-products, viz., Silver, Gold, to be started soon so that the project is
Cadmium, Mercury, Bismuth and Sulphuric commissioned by early 1991.
acid. The refining of zinc would be carried out
through process of electro-refining to produce SALIENT FEATURES OF THE PROJECT
high quality Lead and recovering Silver, Gold The Lead Zinc Smelter Complex being
and Bismuth. The proposed plant will have proposed near Chittorgarh will have nominal
the unique feature of generating electic power capacity of 70,000 t/year of Zinc metal and
of the order of9 MW, from Waste heat recovery 35,000 t/year of Lead metal. The plant will be
systems, viz., Launder boiler land LCV gases, based on Imperial Smelting Process. Besides
whereby partly satisfying. its own requirement Lead and Zinc, it is proposed to recover
of electricpower. important by-products like Cadmium, Silver.
Gold. Bismuth and Mercury Metals along with
MECON has been associated with this project Sulphuric acid. The overall process flow
since 1982 with the preparation of Feasibility diagram is shown in Figure I. The new
Report. MECON is now involved in carrying smelting capacity has been based on the
out the consultancy and engineering services utilisation of the concentrates obtained mainly
covering, acceptance of basic engineering, from Rampura-Agucha Mines, Rajasthan.
preparation of firm cost estimates, detailed Rich deposits of lead-zinc ore have been
engmeering.. procurement, supervision of discovered recently at Rampura Agucha
construction, erection and commissioning, estimated to be 60.35 million tonnes with
and project management for the project. The 13.5% zinc and 1.9% lead metal. The plant is
project implementation is planned to be proposed to be located at a site 10 Km north of
carried out in two phases within a total period Chittorgarh town near Chanderiya village.
of 489 months.
Process
Phase I The activities consisted of: Imperial Smelting Process. a pyre-
- Basic engineering and metallurgical process. has been adopted for
firming up of scope the combined production of lead and zinc at
Procurement activities Chanderiya. The Imperial Smelting Process
before commitment accounts for 10 to 15 percent of the world zinc
Preparation of firm cost and lead output. Imperial Smelting
estimates Technology is a well established process route
in operation since the year 1960. Presently 13
P e II will consist of: plants based on this process are in operation
Procurement in 11 different countries.
Erection/ Construction
Commissioning The Imperial Smelting Process has the
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3. ILZIC Silver Jubilee Con erence Lead, Zinc and Cadmium into the 90s
following advantages as compared to the cleaning system. During the cleaning lead.
combination of electrolytic zinc and zinc. mercury and cadmium dust are
conventional blast furnace lead smelting recovered before the gas is sent to sulphuric
route. acid plant.
Increased flexibility to treating The Sulphuric Acid plant has been designed
concentrates with higher impurities based on double conversion and double
absorption (DCDA) process route for the
Lower overall energy requirement per production of sulphuric from sinter gases
tonne of zinc and lead. . containing S02 and would ensure S02 content
at the outlet of the stack limited to 2.7 kg/t of
Lower electric power requirement. H2 S04' About 580 t/rlay of 98.5% H2S04 will
be produced from the sinter gases containing
Lower capital investment and 5.8% S02'
operating costs.
ISF Plant will comprise of the charge
Higher by-product recovery . preparation and furnace charging. furnace.
condenser and Cowper Stoves. gas washing
The proposed plant will include Raw Material and LCV distribution system and Brtquetttng
Handling Plant, Sinter and Gas Cleaning plant. .
Plant. Sulphuric Acid Plant, Imperial Smelting
Furnace and Power Generation. Zinc Refinery. Lead Zinc Sinter. Briquettes and Metallurgical
Lead Refinery. Precious Metal Recovery Plant Coke in hot condition are charged in Imperial
and Cadmium Plant. Smelting Furnace from the top and hot blast is
injected through tuyeres located at the bottom
For the production of Zinc and Lead through of the furnace. The pre-heating of coke and
Imperial Smelting Furnace .process blast air for the furnace will be accomplished
approximately 400.000 tonnes of various raw in coke preheaters and regenerative. type
materials and Metallurgical Coke will be Cowper Stoves respectively using LCV gases
handled through elaborate system of as;fuel. The metallic zinc formed as vapour will
unloading. storing & reclamation. One month pass through the furnace off take into the lead
storage facilities for zinc and lead splash condenser. These zinc vapours will be
concentrates have been envisaged. whereas condensed by shock cooling the gases with a
for metallurgical coke it will be for three spray of finely divided droplets of lead
months requirement. produced by the rotors rotating at high speed.
The lead with absorbed zinc. will be pumped
The lead and zinc concentrates along with from the condenser to the launders where lead
lime stone. return sinter fines and other zinc is cooled to separate out lead and zinc.
recycle materials will be agglomerated in an The cooling will be by boiler tube banks
updraft sinter machine. It has been envisaged immersed in the launder. The steam generated
to use oxygen in the sintertng operation for from this boiler as well as the steam generated
operational improvement. better sulphur from LCV gases will be utilised for generating
burning rate. and reduction in volume of 9 MW of electric power thus partly satisfying
gases with sulphur burning rate. and the requirement of electric power for the plant.
reduction in volume of gases with consistency A duel fired boiler; two turbo. generators.
in S02 concentrations. The smtertng process heating & super heating elements. feed pumps
has also been envisaged to be closely along with other necessary facilities have been
monitored through a microprocessor based envisaged for both these systems. The
control system through a central control schematic diagram of launder boiler power
room. generation is shown in Fig. 2.
Sinter gases approximately 94.000 Nm3/h The briquettmg plant will condition the
from the sinter machine will be cleaned in gas various recycled fines and drosses from
cleaning plant, comprising of dry and wet gas various plant units into briquettes. The
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4. I ILZIC Silver Jubilee Conference Lead, Zinc and Cadmium into.the 90s I
briquettes thus produced will be sent to Cadmium plant has been envisaged to recover
smelting furnace. cadmium from fumes recovered in hot gas
precipitator of sintertng plant, through Ion
The Imperial Smelting Furnace will have Exchange Process. The Ion-exchange resin will
considerable slag fall and therefore a exchange cadmium from the acidic liquor. The
continuous tapping system has been caustic cadmium will be finally produced by
envisaged to ensure not only easy slag regenerating the Ion-exchange column,
handling but also loss of byproducts metals cementation of liquor thus produced and
into slag will be reduced. The block diagram of melting and casting of the cadmium sponge.
ISF plant is shown in Figure 3. These cadmium plates are sent to Zinc
Refinery plant for further refining to cadmium
Furnace Zinc from the ISF will be refined in a metal in the baby column.
refluxmg plant which will consist of lead
columns, cadmium columns and baby For this project, microprocessor based
column. Half the output will be produced as Distributed Digital Control System (DDC
GOB Zinc with 98.5% Zinc which is used by System) have been envisaged for three major
galvanizers directly and other half wtll be units viz., Sinter Plant, Imperial Smelting
distilled further to produce 99.99% purity Furnace and Power Plant.
SHG Zinc needed for special alloy applications
for which imports of zinc are made. The DDC System has major advantages over
the conventional system a) better man/
One of the important features of the zinc machine communication, b) higher system
refluxmg process is the use of silicon carbide reliability due to high mean time between
trays for distillation of SHG Zinc and cadmium failure of the system, c) modular construction,
from impure zinc. These super-imposed trays d) better system expandablltty., e) maximum
with staggered openings at the bottom configuration flexibility, 0 self-diagnostic
comprise a column. OWing into excellent feature making the system maintenance easy
properties of very high resistance to thermal and faster, g) controllers have self tunning
shock backed by very good thermal feature reducing system stabilization time, h)
conductivity these trays make an ideal data storage facilities make nost trip analysis
distillation unit working at high temperature. possible, t) redudant configuration is possible
due to use of microprocessors in various sub-
Refining of impure lead bullion from Imperial systems, j) ease of communication with
Smelting Furnace has been envisaged to be Similar systems and future production
electro-refined based on Bett s Process. planning computer. The typical configuration
Special features of a modern lead refinery diagram is shown in Figure 5.
include large cells of polymer concrete
construction, continuous anode casting The plant has been envisaged to work on
machine, cathode sheet casting and imported coke for first five years and there
preparation machine, anode & cathode after on indigenous coke. The plant capacities
preparation conveyor, spent anode washing for the proposed plant are based on utilization
and slime removal cranes, etc. The various of Indian coke. There will be an increase in
advantages of electrolytic lead refinery over outputs if imported coke with low ash content
pyrometallurgtcal route are automation of the is used as shown in the Table 01.
of the plant, better environmental control,
higher quality refined lead, increased IMPLEMENTATION CONCEPT
recoveries of lead and byproducts, simplicity The project has been conceived to be
of starting up & shutting down the process. implemented in two phases. The Phase I
Flowsheet for lead refinery is given in Figure 4. consisting of pre-investment activities to firm
up the scope of work and prepare firm cost
It has been envisaged to process dore metal estimate for submission to the Government.
produced from lead refinery electrolytically to The Phase II activities of total implementation
gold and silver bullion. of the project will start after the approval. The
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5. I ILZIC Silver Jubilee Conference Lead, Zinc and Cadmium into the 90s I
Table - 1 equipment supplies so as to be ready to
PROPOSED PLANT CAPACITIES release order immediately on receipt of
investment decision. Based on this approach.
Product Capacity (t/yr) Increased project is scheduled to be completed in four
output years as per implementation schedule
due to use of indicated in Figure 7.
imported
coke (t/yr) The know-how and basic engineering for the
project will be supplied by M/s Davy McKee.
Zinc 70.000 82.000
Lead U.K. They are also providing technical
35.000 39.800
Cadmium 375 417 assistance for (a) preparation of firm cost
Silver 74 82 estimates. (b) detailed engineering. (c)
Gold (Kg) 60 68 Inspection of critical equipment. (d)
Bismuth 10 11 construction and commissioning of the plant.
Mercury 30 33
Suiphuric Acid 1.83.000 1.83.000 The know-how for the various plant
technologies were obtained from the following
Phase I activities have already been completed know-how suppliers:
and the Firm Cost Estimates were prepared
and submitted as per schedule. The various 1. Raw Material Handling Lurgt/Davy
activities as envisaged for the both phases 2. Sintertng Gas Cleaning Lurgf/Norzlnk
would be as follows. & Mercury Removal
3. Imperial Smelting ISPL
Phase - I Furnace
The major tasks of the Phase-I of the Project 4. Sulphurtc Acid Davy
consisted of: a) Receipt of Know-how and 5. Lead Refinery COMINCO/Davy
Basic Engineering Packages. b) Preparation of 6. Precious Metals Davy
basic engineering package. c) Preparation of 7. Cadmium ISPL
8. Zinc Refinery MECHIM
tender documents for turnkey packages based
9. PowerGeneration Davy/SHG
on know-how and basic engineering. d)
Shorthsttng Turnkey Contractors through
MECON is providing consultancy. detail
open tender, e) preparation of detail drawings
engineering. procurement. project
and estimation for non-turnkey/interface
management. and site supervision. For timely
areas. service building and infrastructure. 1)
implementation of the project it has been
Technical and commercial evaluation of offers,
broadly split into two areas : Turnkey and
final negotiation with tenderers and
Non-turnkey and would be executed by Indian
recommendations. g) Part of enabling works.
Companies. The major units of the project
and. h) Preparation of firm cost estimates.
were divided into 15 turnkey packages as
given below:
Phase -II
The activities during this phase will include: a)
1. Raw Material Storage and Handling
Placement of order, b) Detail engineering
Plant
services by contractorsconsultants. c)
2. Sintering and Gas Cleaning Plant
construction and erection. and d)
3. Imperial Smelting Furnace Plant
commissioning and stabilisation.
4. Sulphurtc Acid Plant
5. Lead Refinery and Minor Metals Plant
The implementation concepts for the project
6. Precious Metal Recovery
are depicted in Figure 6.
7. Zinc Refmery
8. Cadmium Plant
Project schedule envisaged investment
9. Copper Recovery Plant
decision by 3rd. quarter of 1988 to enable
10. Effiuent Treatrrient Plant
placing of firm orders to turnkey contractors.
11. Power Distribution and Lighting
It was also planned to complete techno-
12. Auxiliary Power Generation and D.G.
commercial negotiations for major contracts/
Set
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6. I ILZIC Silver Jubilee Conference Lead, Zinc and Cadmium into the 90s I
13. Water Supply System procedure thus followedduring the Phase I of
14. Utility System the project enabled submission of firm cost
15. Telecommunication estimates as per schedule. The Phase II
activities have already been initiated so that
The project is being implemented on the the project is commissioned by early 1991.
concept of turnkey contract package covering
detailed engineering. procurement. Project Planning And Monitoring
fabrication. construction. installation and The project planning monttortng for the
commissioning by contractors. The interface proposed project willbe executed by a group of
between various packages and other work fo,: . engineers of Project Planning. Monitoring and
the project is being carried out on non- Control Cell. The group will organise an
turnkey basis.Based on the above concept efficient reporting system from the site office
Indian companies of repute were technically as well as form varlous other agencies involved
and commercially evaluated and were in the execution of the project. The project
shortlisted for submitting their bids for planning and monitoring system is depicted in
various packages. Figure 8. By this system. stringent controls
will be exercised and corrective measures will
The design concept for various plant/units be taken at the early stages of the project at
were discussed during various design appropriate time to prevent cost and time
conferences held at Udaipur and Stockton. overrun.
U.K. with the representatives of the different
know-pow suppliers. The preliminary basic The planning. monitoring and control
engineering was obtained from foreign know- techniques are closely related to the physical
how suppliers starting from July. 1987. progress of work and financial expenditure for
the work completed. To achieve the above
The technology being new and introduced for objective. network analysis will be used to
the first time in the country. it was decided keep a close watch on the physical progress of
that instead of getting the complete know-how the work at various stages in relation to the
and basic engineering. scrutinizing the same allotted time and cost.
and then dissipating it to the tenderer for their
perusal. the preliminary information obtained The task of the planning and control of the
after scrutinizing was passed on to the project will be:
tenderers immediately so that the same is
assimilated by them at early stage itself. The to establish a master plan for the
effect of this decision was that the tenderers project
were able to understand the technology and to design and establish an information
started their preliminary work quite in system for efftctent control of the
advance. The tenderers came out with number project.
of queries on technology and design and these to coordinate the activities of the
were sorted out from time to time. Prebid various agencies involved in the
conferences were held with the parties for implementation of the project.
different turnkey packages wherein all to hold follow-up master planning
outstanding points. both technical and meetings.
commercial were clarified. This helped to a to establish periodic reporting system
great extent in freezing/firming up the scope for the project progress.
of work within a reasonable short time-span.
Project planning. monitoring and control
Based on the technical and commercial bids group will play a dynamic role by keeping in
obtained and discussion held with the continuous contact with Hindustan Zinc Ltd..
tenderers. techno-commercial evaluation were overseas know-how suppliers. turn-key
carried out. This formed the basis of project contractors and other agencies. The first task
costs for the furnished by foreign consultants. will be to prepare a master PERf network.
These two capital costs were integrated to which would enable monitoring the progress
prepare the project cost estimates. The of the project with respect to time and cost.
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7. I ILZIC Silver Jubilee Conference Lead, Zinc and Cadmium into the 90s
Each of the turn-key contractors will be asked financial matters will cover two areas:
to provide an area PERf network for their
activities and a master network will be Project Budget and Funds Planning
prepared incorporating important activities Project Cost Control
from each PERf network as well as other
activities which will not be included under the The cell will also have experienced cost
turn-key suppliers' scope. Preparation of engineers/techno-economists to monitor the
specifications, tendering, tender evaluation, expenditure and maintain cost control. The
order placement, equipment supply, detailed task of the budget and cost control activity will
drawings, construction, erection and be as follows:
commissioning will all be covered in their
logical sequence and inter-dependence in the To establish general procedures on the
master network. matters of budget and cost control for
the project
With the initial plan flnalised and approved, To consolidate the budget for each
control will be achieved by reviewing the package into an integrated project
physical progress periodically and comparing budget
with the target. The periodicity of the review of To estimate and monitor overhead
the progress will be fixed in advance. The expenditure of the project
monitoring will be based on efficient reporting To monitor the expenditure from each
system to be organised so that up-to-date area
information is available from construction site To establish annual budget and funds
as well as from various agencies. The group requirement for the project
will prepare monthly reports describing To consolidate the contact variations
progress of the project and advise corrective and establish over-runs/under-runs
action to be taken as follows: for the project
To co-ordinate release of payment for
• Highlighting short-falls, bottlenecks or different contractors.
constraints.
* Examining the effect of these short- CONCLUSIONS
falls and problems on project On successful completion of the project most
completion as per estimates of time of the demand for Lead and Zinc in the
and also inter-related and inter- country will be met through indigenous
dependent programmes. production. It is expected that with the
• Providing feed-back data indicating commissioning of the plant, the demand
corrective actions to put lagging areas satisfaction level for Lead and Zinc will
back on course. increase to 64 percent and 85 percent
• Reviewing the corrective actions in respectively and also make the country less
response to feed-back instructions. dependent on import of these metals.
The various reports prepared will highlight the Phase I of the project has already been
following: completed as per schedule with the
.submtsston of the Firm Cost Estimates. Phase
List of activities due in next period for II activities have already been initiated and the
planning and progress reporting methodology adopted would enable
List of critical activities commissioning of the pro]ect by early 1991.
List of activities are-wise/agency-wise
List of activities in progress
List of activities, which have been ACKNOWLEDGEMENT
delayed, etc. MECON thankfully acknowledge M/s.
Hindustan Zinc Limited for the information
Budget and Cost Control provided on proposed Chandertya Lead Zinc
The Project Monitoring and Control covering Smelter for preparation of this paper.
7.7

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