1. Report On Industrial Training From Submitted To:- Submitted By:- Ved Prakash, Dept. of METarun Kumar Dhanuka,IV Year, ME Krishna Kumar Purohit, Dept. of ME

2.  Introduction about the Industry  Certification  History and Milestones  Key Financial Aspects  Products Manufactured by the Industry  Applications of different products  Processes Involved  Corporate Social Responsibility  Health, Safety and Environment

3.  HINDUSTAN ZINC LTD. (HZL) is the only integrated Zinc manufacturer in India and owns captive Zinc mines that supply complete requirement of Zinc Concentrate for its smelters.

4.  Rajpura Dariba Mine has annual ore production capacity of 0.90 million tonnes and achieved a production level of 21.96 kt of contained zinc and 5.35 kt of contained lead in FY 2010. Bulk concentrate production at Rajpura Dariba has resulted in significant recovery improvements in Zinc, Lead and Silver.

5.  The management system of Rajpura Dariba comprises of: the Quality System ISO 9001:2008, the Environmental System ISO 14001:2004 and the Occupational Health, Safety Management System OHSAS 18001:2007, SA 8000:2008 and 5S Certifications.

6. HISTORY-  Hindustan Zinc Limited was incorporated from the erstwhile Metal Corporation of India on 10 January 1966 as a Public Sector Undertaking.

7. MILESTONES- 2011  Commissioned 1.50 million tonnes per annum concentrator at Silver-rich Sindesar Khurd Mine  Commissioned 160 MW (80X2) Captive Power Plant at Dariba Smelting Complex  Around 48 MW addition in wind power generation capacity

8.  Revenue of Rs. 9,912 Crores and PBDIT of Rs. 6,454 Crores.  Highest ever production of Zinc-Lead Mined metal, Refined Zinc metal and Silver.  Return on capital employed (ROCE) continues to be strong at 56.06%  Earnings per share of Rs. 11.60.

9. 1). ZINC Special high grade(SHG) High grade(HG) Prime western(PW) 2). LEAD 3). BY PRODUCTS Silver Cadmium

10. Uses of ZINC:-  Over 11 million tonnes of zinc is produced annually worldwide. Around 48% of the amount is used for galvanizing to protect steel from corrosion. Approximately 17% is used the production of zinc base alloys like die castings etc.

11. Other uses of ZINC:- 1. Galvanising 2. Zinc Oxide 3. Die Castings 4. Alloys 5. Rolled Zinc

12. Uses of LEAD:-  SLI (Starting-Lighting-Ignition) batteries, which currently accounts for around half of the total lead demand. These are mainly used in cars and light vehicles.  Industrial batteries, which currently consumes around a quarter of the total lead produced.

13. Uses of Silver:-  Silver is used in a number of varied applications like the most important uses of silver being the industrial and decorative uses, photography, and jewelry & silverware; together, these three categories represent more than 95 percent of annual silver consumption.

14.  Mining and Drilling  Primery Crushing  Secondary/ Tertiary Crushing  Grinding  Reagent Process  Flotation Process  Thickeners Process

15.  BMCL established this Mines in 1991 with an estimated depth of 170m as Open Cast mines.  Initially, production capacity was 0.9 million tones/annum with strip ratio of 1: 4.5.  Ore body has 15% metal content, out of which 13% is Zn and rest 2% is Pb.  Rock type of ore is GBSG i.e Garnate Biotite Siliminite Gneiss.

16.  After the mining stage is over ore is brought to the ore beneficiation plant where it is first processed in the primary crushing plant.  There are two primary crushers:-  Superior mk-1 54-74’’ gyratory crusher. (old)(375KW)  Superior mk-2 54-75’’ gyratory crusher. (new)(450KW)

17. Pic.:-Superior mk-2 54-75’’ gyratory crusher. (new)(450KW)

18.  After Primary Crushing the ore is send to the secondary and tertiary crusher.  Crushed ore of size (-150mm), coarse ore storage is fed into 5nos.Reciprocating feeder through crushed feed conveyor the material is brought to double disc vibrating screen.

19. Pic.:- Secondary/Tertiary Crushing Process

20.  Products from rod mill are dumped into the first stage sump.  From this sump it is feeded to the primary cyclone which has rubber lining in it.  Overflow from first stage goes to second stage classification cyclones having diameter of 15”.

22.  Different reagents are added to perform different operations or to add different properties to zinc and other products and by products.  Some of the reagents used are as follows:- CuSO4, NaCN, Nigrosine, Lime etc.

23.  Flotation is a selective process and can be used to achieve specific separation from complex ores such as lead-zinc, copper-zinc, etc.  In flotation concentration, the mineral is usually transferred to the froth, float fraction, leaving the gangue in pulp or tailing.

24. Pic.:- Flotation Process

25.  After froth flotation the products i.e., Lead concentrate & Zinc concentrates are pumped to respective thickeners.  Tailing is disposed off to tailing dam via neutralization tank.  All the existing four thickeners have been upgraded & retrofitted to hi-rate thickeners.

27.  We continue to impact over 500,000 lives through our relentless Corporate Social Responsibility (CSR) initiatives. We are committed to raise the quality of life and social well-being of communities where we operate. We believe in engaging with our stakeholders in two-way, open dialogue, which is the key to the development of sustainable communities.

28.  Health: Eliminate occupational illness.  Safety: Provide a safe workplace.  Environment: Minimum harm to the environment by conserving natural resources through efficient use.