Smelters Performance Overview

Hindustan Zinc continued to notch new milestones and surge towards new vistas of growth in its smelters business during FY 2022-23. Its 1 million tonnes refined metal production landmark underscored the success of its initiatives in the smelters business to promote efficiencies and sustainable growth.

Promoting Wealth from Waste

As part of our efforts to manage waste effectively and productively, we enhanced our copper sulphate (CuSO₄) production through appropriate modifications in the charging system and operational parameters. This has enabled us to ensure better-quality production of CuSO₄ solution in comparison with that produced earlier. The initiative has led to more cost-effective production, improved ore recovery and enhanced safety due to reduced consumption of hazardous chemicals like liquor ammonia and liquid carbon dioxide.

Reduction Achieved in Inventory

During FY 2022-23, we successfully reduced the work-in progress (WIP) stock in Pyro through various measures. By maximising the use of blue powder slurry, Imperial Smelting Furnace (ISF) dross and various lead refinery dross along with concentrate, and by controlling process parameters of sinter accordingly, we were able to bring down the WIP stock. ISF dross consumption was increased through modification in our in-house briquetting plant by revamping the existing equipment. Deployment of dedicated and skilled operators, and use of ‘Total Productive Maintenance’, has resulted in fewer breakdowns and increased the production of briquettes. By controlling the process parameters, we were able to maintain optimum lead level in kettle inventory, thus further reducing the in-process inventory.

Achieved metal gain of 11 kt and EBITDA gain of ₹264 crore in FY 2022-23.

Waste to Wealth: Recovery from Residue

The Hindustan Zinc minor metal complex achieved its highest ever EBITDA in FY 2022-23 recording a 56% increase over last year. This outcome was attained due to the various concerted actions taken by the team. We decreased the batch cycle time of the rotary furnaces, increased throughput of the plant, and optimised the chemical consumption norms. Consequently, the highest ever Cu dross and purification waste cake treatments were done at the plant, with significant improvement in recoveries.

CPP Performance Overview

At Hindustan Zinc, we have prioritised carbon neutrality and reduction in greenhouse gas (GHG) emissions as the key goals of our power business. We have made further investments in green initiatives at our thermal plants during FY 2022-23, while continuing our efforts to enhance operational excellence. With a keen focus on advancing on our sustainability journey, we have successfully achieved multiple milestones as we powered ahead towards ‘greener and cleaner’ operations.

Our Vision
To supply reliable, efficient, and sustainable power for Hindustan Zinc with zero harm and at lowest cost

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Milestone Achievements in our Power Capacities

Progressing on our Green Journey

• 200 MW Dariba renewable energy round the clock (RERTC) power delivery agreement (PDA) signed and project under execution
• 250 MW Chanderiya RERTC PDA signed
• Biomass consumed as replacement for coal, resulted in reduction of 89,896 tCO₂ emission

With focussed efforts and initiatives in expanding our green footprint, we have successfully avoided 8.66 lakh tonnes of CO₂ emissions during FY 2022-23, as against 6.13 lakh tonnes in FY 2021-22.

Towards Net-Zero

We have achieved new milestones on our journey towards achieving our goal of net-zero by 2050 or sooner. Our key initiatives in this direction during FY 2022-23 included:

• Turbine revamping with better energy efficiency
• Electrostatic precipitator upgraded in two units for increasing indigenous coal consumption (carbon emission reduction in Scope 3)

Future Roadmap

• Revamping of 4.3 MW backpressure turbine in Dariba
• Commissioning of 8.6 MW WHRB at Fumer project
• Execution of De-NOx system at Chanderiya
• Enhancement of Kayad mines solar plant

Touching New Vistas in our Conventional Power Metrics

During FY 2022-23, we scaled new vistas of performance excellence despite the challenges posed by high coal costs.

Thermal Power Generation at our 6 Power Plants in FY 2022-23

During the year, Hindustan Zinc CPP generated 2,996 mn units of power.

Strengthening our Safety Proposition

• Elimination of man-machine interaction during coal sampling and unloading at Zawar
• In-house pilot project – successful implementation of coal pipe hammering machines system to strengthen CPP safety
• Pilot project on bottom ash auto alignment scrapper system completed to reduce man-machine interaction

Enhancing Operational Efficiencies

• Successfully completed performance guarantee test for turbine revamping project
• Pilot project on ESP upgradation project stabilized
• Auger sampling commissioning completed at Chanderiya and Dariba
• Upgradation of programmable logic controller (PLC) at Chanderiya and Zawar

Augmenting Cost Efficiencies

• Cost savings achieved through ‘cash conservation and cost reduction programme’ including the benefits accrued via strategic power purchase
• 10% inventory reduction achieved
• Coal blend optimised by utilising low-cost coal, like domestic and off-spec coal, to reduce the cost of generation amid high volatility in coal prices in the international market
• Highest ever biomass consumption achieved across the Group