Building a larger, multi-metal enterprise
The global transition towards clean energy, infrastructure development, and electrification has created strong, long-term demand for critical metals. Zinc for corrosion resistant infrastructure, renewable energy, and urbanisation. Lead for energy storage solutions and SLI (switching, lighting and ignition). Silver for renewable energy, electronics, and advanced manufacturing. These are areas with limited substitution potential.
Beyond these, a new tier of critical minerals has become indispensable, given their industrial importance and India’s import dependence. Through HZL 2.0, we are positioning ourselves to address these long-term structural demand drivers while supporting India’s self-reliance ambitions. The programme is expected to drive volume-led earnings growth, improve asset utilisation, and strengthen cash flow generation, while creating sustained long-term value for all stakeholders.
The 2x expansion: scale that changes the game
Anchored in scale, integration, and disciplined capital allocation, HZL 2.0 journey is designed to nearly double our refined metal capacity and further strengthen our position as the world’s largest and India’s only integrated zinc producer. Predominantly brownfield in nature, the expansion leverages our robust asset base, extensive mineral resources, and proven execution capabilities.
The expansion programme represents a synchronised, end-to-end capacity build-up across mining, beneficiation, and smelting to ensure a smooth ramp-up while avoiding operational bottlenecks.
Board-approved Phase 1 projects
250 ktpa integrated zinc smelter (along with matching mines and mills capacity)
Tailings reprocessing plant with 10 Mtpa feed capacity
Exploration programme
Expansion projects overview
Mining and Concentrator Expansion
Mining capacity expansion is underway across Rampura Agucha, Kayad, Sindesar Khurd, Rajpura Dariba, and Zawar clusters, supported by strong reserves and resource base of 468.6 Mnt, providing long mine life and operational visibility.
The concentrator capacity will be enhanced through brownfield redesign and debottlenecking to improve throughput and metal recoveries while maintaining capital efficiency.
Smelting Expansion
Smelting expansion, includes a 250 ktpa integrated zinc smelter at Debari, and a 400 ktpa integrated zinc smelter and 200 ktpa integrated lead smelter at existing locations. The project will be designed to leverage existing infrastructure, captive power availability, and integrated logistics, reinforcing our global cost leadership and operational reliability.
Tailings Reprocessing and Sustainability
The tailings reprocessing plant would enable recovery of residual metal from legacy tailings at Rampura Agucha, reduce environmental impact, and provide incremental concentrate supply.
The circular economy approach strengthens operating margins and leadership in ESG performance.
Scaling Exploration
A parallel 2x exploration program across key mining clusters is underway to extend mine life beyond the 2 Mtpa horizon. Targeted metal reserves expansion from 13 Mnt to 50 Mnt, primarily across Zawar and Rajpura Dariba clusters, is expected to support a mine life of over 25 years.
Becoming a Multi-Metal Enterprise
We are advancing the exploration and evaluation of new critical minerals to strengthen long-term resilience and drive portfolio diversification. These minerals are critical to global energy transition and future technologies, with rising demand as the world shifts towards clean energy and digital infrastructure. For India, they present a strategic opportunity to enhance self-reliance and emerge as a global hub for critical minerals.
Key blocks secured
