Rajpura Dariba Mine

The strategic focus at Rajpura Dariba Mine (RDM) is aligned to our target of scaling the ore production capacity to 1.75 Mtpa in FY 2024-25. In line with this strategy, we continue to deploy cutting-edge automation technologies, such as autonomous vehicles. We also endeavour continuously to boost the operational efficiency at the mine. We have prioritised stringent safety protocols to safeguard our workforce. To ensure optimal resource utilisation as part of our sustainability thrust, we have incorporated predictive maintenance system into our operations.
Rajpura dariba mine
Icon representing mining operations
KEY OPERATIONAL MILESTONES OF FY 2023-24

During FY 2023-24, we made significant strides in augmenting the productivity and efficiency at RDM. We delivered strong numbers across the key metrics of our performance at the back of our focussed initiatives.

1.34 Mt

Ore Production

5.17%

Grade

54.63 kt

Mined Metal Production

9.10 km

Mine Development

DRIVING INNOVATION TO DELIVER GROWTH

  • Upgraded RD mill capacity from 0.9 Mtpa to 1.1 Mtpa, to improve the mill reliability, recovery and treatment capacity
  • Successfully commissioned a 1.8 Mtpa capacity paste-fill plant; completed reticulation in E3, M5 and S4 blocks
  • Raised 592 metres long ventilation from surface to -87 mRL, and commissioned the same for East Lode
  • Raised 82 metres long intake ventilation from 100 mRL to 25 mRL, and commissioned it for NB block
  • Installation and commissioning of 800 KW fan in progress at 2060 North section
  • Commissioned 650 horsepower (HP) dewatering pumps at 11 mRL, to eliminate stage pumping and deliver the water directly to surface
  • Established Geotech Gallery at Rock Mechanic Cell
  • Provided battery-operated illumination in cage, and placed operation switch inside the cage to improve safety

AUTOMATING & DIGITALISING TO BOOST EFFICIENCIES

  • Achieved smoke hour drilling of 1,500 metres per month with automation
  • Commenced digitalisation of online water management system to integrate all the flow parameters and to detect any abnormal consumption or leakage
  • Installed delay timers in crusher chain feeders, thus drastically reducing the crusher jamming
  • Installed winder simulator to improve the skill of the operators
  • Installed rope damage detection sensor in the main shaft cage winder
  • Completed automation of 160 KW compressors at 2060 North for reduction in power consumption by 86,000 units/month, resulting in 83.72 tCO2e monthly GHG emission savings

ENHANCING SAFETY FOR WORKFORCE

  • Installed depth indicator with digital screen at 11 mRL main ore pass grizzly, to eliminate manual intervention
  • Installed rupture valve in loader, to enable locking of boom and bucket and preventing it from collapsing due to hose puncture during lifting operation
  • Installed new camera system, along with display having a navigation mark, for better visibility during turning in Charmec
  • Provided anti-collision devices with mechanical stoppers in heavy earth moving machinery (HEMM) - 2 & 3 electric overhead travelling (EOT) crane
  • Provided cage interlocking at 0 mRL, 100 mRL and 250 mRL in auxiliary shaft
  • Initiated work on replacement of plain cable bolt with bulbed cable bolt to reduce slippage between rock and cable bolt

CASE STUDY

Commissioning of Paste-Fill Plant to Improve Flow

Our hydro-fill plant had a lower flow rate of 70 m3/hour. It also required addition of water to fill mixture, at 60:40 solid-to-water ratio. The year-on-year production growth was leading to an increase in the requirement for backfill. To meet the enhanced production requirements and improve the flow, we commissioned 1.8 Mtpa paste-fill plant during the year.

Key features
  • Flow rate increased from 70 m3/hour to 130 m3/hour
  • Increase in solid percentage from 60% to 80%
  • Reduction in plug curing time from 7 days to 3 days
  • Water consumption reduced by 62%
  • Eliminated need for additional infrastructure for tailing dilution for hydro-fill
AWARDS & RECOGNITIONS
Award icon
  • Won 2 awards at National Quality Circle Forum of India (QCFI); 1 project selected for international level competition in Sri Lanka
  • Won 4 gold category awards at QCFI, Rajsamand Chapter Awards, endorsing our commitment to quality excellence
  • Rajpura Dariba Complex honoured with prestigious Bhamashah Samman-Shiksha Vibhushan during 27th Bhamashah Award Ceremony, organised by the Government of Rajasthan
  • Received 1st prize in Afforestation, 2nd prize in Waste Dump Management, and 3rd prize in Mineral Beneficiation in the 34th Mines Environment & Mineral Conservation Week 2024, under the aegis of Indian Bureau of Mines, Ministry of Mines, Ajmer Region
  • Received 4 awards along with 2nd runner-up in ‘Overall Mechanised Mines’, and 1 award along with 1st runner-up in ‘Overall Ore Beneficiaries’ Plant’ in 47th Mine Safety Week, held under the aegis of Directorate General of Mines Safety (North-Western Zone)

At Hindustan Zinc, our focus is on unlocking endless possibilities and fostering sustainable growth through digitalisation. Our pioneering spirit empowers us to embrace cutting-edge innovations, such as underground battery electric vehicles, realtime equipment monitoring and tele remote solo drilling. These initiatives not only make the mining operations smarter and safer but also contribute to the well-being of our employees, business partners and the entire ecosystem.

Balwant Singh Rathore
CEO, IBU Dariba

Bhamashah award

Mining truck operating underground with a load being tipped.

CASE STUDY

Enhancing Efficiency with UG Equipment Optimisation

To enhance the operational efficiency at RDM, we undertook various measures during FY 2023-24 to optimise the equipment used in underground (UG) mining. These initiatives included:

I. Replacement of the double piece jaw plate with a single piece jaw plate in the underground crusher, and

II. Conversion of actuator system to cylinder system in the underground drilling machines

The first initiative was aimed at improving the life of the jaw crusher plate, which was reduced by frequent loosening of the centre wedge after 180 kt of crushing. The other initiative was aimed at countering the frequent breakdown of the drilling machine due to gripper arm misalignment, caused by damaged actuation system. The new cylinder system is easier to maintain and replace, in the event of total damage or overhaul.

Key outcomes – Initiative I
  • Achieved 250 kt crushing with single crusher jaw plate
  • Jaw plate replacement shutdown time halved, from 12 to 6 hours
  • Increase in crusher availability
  • Enhanced safety due to direct locking of the single piece jaw plate with body in the centre
Key outcomes – Initiative II
  • Higher reliability of simple twin cylinder mechanism following replacement of the complex motor and gear system, which was prone to wear and tear
  • Reduced cost of installation, from ₹ 25 lakhs to ₹ 5 lakhs
  • Reduction in lead time for spares, from 4 weeks to 1 week
Aerial view of a mining facility with blue-roofed structures and various processing units.
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