1. "Water, water, everywhere, nor any drop to drink" - Rhyme of the Ancient Mariner, by Coleridge.

2. Chanderiya Lead Zinc Smelter, Chittorgarh
Hindustan Zinc Ltd

3. World Class Smelting and Power Assets
Chanderiya Smelting Complex
Pyrometallurgical Lead Zinc Smelter: ,000 tpa Zinc
35,000 tpa Lead tpa Silver Hydrometallurgical Zinc Smelter: 420,000 tpa Zinc AusmeltT M Lead Smelter: ,000 tpa Lead Captive Power Plant: 234 MW
Rajasthan
World class assets – Chanderiya Smelting Complex
Phase III expansion – Dariba Complex
Chittorgarh
Note: Map not to scale 3

4. CSC is IMS certified
Certifications
ISO 9001:2000
ISO 14001:2004
OHSAS :2007

5. HZL Vision & Mission VISION
Be the world's largest and most admired Zinc-Lead & Silver Company.
MISSION
Enhance stakeholders value through exploration, innovation, operational
excellence and sustainability.
Be a globally lowest cost producer.
Maintain market leadership and customer delight .

6. Milestones
Delivered
Debari & Vizag Zinc De-bottlenecking32 ktpa
Chanderiya
Zinc Debottle-necking
35 ktpa
Chanderiya
Hydro I Smelter
170 ktpa
Chanderiya
Ausmelt lead Smelter
50 ktpa
Chanderiya
Hydro I I Smelter
170 ktpa
Chanderiya & Debari Zinc De-bottlenecking 88 ktpa
Dariba Smelter
Zinc – 210 ktpa Lead – 100 ktpa
2003
2004
2005
2006
2007
2008
2010
Chanderiya CPP
2 x 77 MW
Chanderiya & Zawar CPP expansion
2 x 80 MW
Note: The year mentioned is Calendar Year

7. Chanderiya Smelting Complex
PYRO-METALLURGICAL PLANT
HYDRO-METALLURGICAL PLANTS
AUSMELT LEAD PLANT
CAPTIVE POWER PLANT 7

8. Water Management at CLZS

11. Accolades& Recognition
S.No.
Name of Award / Rating / Certification
Name of Awarding / Rating / Certifying Organisation
Year
Theme of the Award* 1
CII GBC National award for Excellence in water
Confederation of Indian Industries.(CII-GBC), Hyderabad
2008
Water conservation excellence 2
Water efficient Unit Award
Confederation of Indian Industries.(CII)
2010
Water conservation 3
Green Manufacturing excellence award
Frost & sullivan
2012
Eco-sustainability

12. Source of Water We have got a captive source of water i.e. Gosunda dam
Process water
28900 (m3/day)
City supply
2500 (m3/day)
Zinc Colony
600 (m3/day)

13. WATER BALANCE GOSUNDA DAM 4900 4100 4900 15000 3100 To CLZS 32000
To City 2500
RO Prod. 3200
100
STP Prod.
1600
Evap
Evap
Evap
Evap
1700
Evap
Evap
100
14300
3200
4200
4400
5800
6500
15100
600
4900
Hydro-I]
Hydro-II
CPP
Potable Water
Pyro & Aushmelt
Plant, TS
200
300
1400
2300
1700
SWP
STP [Plant+TS]
800
ETP-I
ETP-II
300
Lime Prep. +Moist.
1900 [Sinter, F.Washing, Moisture etc.]
2300
2100
200
RO-I
RO -II
Gardening
100
Net Reject=900
For CPP
600
700
RO-III
[Dust suppr.+Evapor.]
1700 [Prod.]
ALL FIGURES ARE AVERAGE & IN M3/D
1600 [Prod.]
200 [Prod.]

14. Treatment technologies
Zero Discharge is maintained
Effluent generation ~ 6000 m3/day
8400 m3/day and 4200 m3/day Effluent Treatment Plants.
2 Reverse Osmosis Plant of ~ 7000 m3/day capacity to treat ETP treated water
III stage Reverse Osmosis Plant of 1000 m3/day capacity to treat the reject generated from 2 Reverse Osmosis Plants.
Generating ~ 5000 m3/day of reusable water, thereby reducing fresh water consumption.
100% recycling of water
Sewage treatment plant (1000 m3/day) at Plant & colony and treated water used for plantation purpose

15. Effluent treatment Plant- For process effluent

16. ETP: Flow Sheet Primary Reaction Effluent Tank Collection Thickener-I
Lime
Soda Ash
DM Regeneration
Softening Unit Regeneration
Cathode Wash
Anode Wash
Filtrate
Primary
Reaction
Tank
Thickener-I
Thickener-II
Effluent
Collection
Tank
Secondary
Reaction
Tank
U/F
U/F
Filter Press
Filtrate
Dilute acid
ETP cake
SLF
Lime
Final
Reaction
Tank
Fluoride
Reaction
Tank
Magnesium Bleed
Gas Cleaning
Filter Press
Recycle
RO Feed
ETP cake
SLF

17. Reverse Osmosis- For ETP treated water

18. Sodium Meta bi Sulphite Internal Use & Evaporation Pond
RO: Flow Sheet
Back wash
Coagulant
Polyelectrolyte
NaOCl
Flash Mixer
Clarifier
Multi
Grade
Filter
Ultra
Filtration
ETP Treated Water
Filter Press
Sodium Meta bi Sulphite
Antiscalant
Permeate
RO - I
Micro
Cartridge
Filter
HCl
RO Product
Tank
reject
Permeate
RO -II
reject
Internal Use & Evaporation Pond 18

19. WATER CONSUMPTION AND CONSERVATION Specific water Consumption
Year
M3/MT
13.15
10.33
8.98
8.27
8.11

20. WORLD BENCHMARKING

21. For Sustainable Business-Water
For CSC Water Policy formulated and widely circulated.
Target are taken every year along with BP for specific water consumption
Every morning discussion on last day water consumption
An executive designated to work as a Water police to control water consumption, arresting & highlighting leakages and wastage of water.
Water conservation projects are identified by
6-sigma
Brain storming
Suggestions

22. For optimum utilization of Water
Utilization of ETP treated water instead of fresh water
Conditioning tank[Leaching] instead of fresh water
RMH (to maintain moisture)
For preparation of lime and Soda.
For ISF slag & Ausmelt slag granulation
In Packed Gas cooling tower.
Utilization of CPP/Pond water instead of fresh water
Sinter plant & GCP
For Pumps Gland cooling in Acid &ETP
Utilization of CPP/Pond water instead of treated water
For Wet Gas precipitator in pyro plant.
For fluorine tower make up.
In Tail Gas treatment plant for pump priming
In sinter venturi system
Recycling
ACF(Activated carbon filter) backwash water recycling in system in DM plant.
PSF(Pressurised sand filter) backwash water recycling in system in DM plant.
Leaching condensate water recycling in DM plant.
Recycling of Seal cooling water from CH area to CT-4
Ultra filtration backwash, Ro flushing & PSF backwash are recycled in RO plant itself

23. Water Conservation Initiatives
Water Conservation drives in Plant & colony like water conservation week
For creating awareness in all for water conservation
Brain storming
Suggestions are appreciated by prize distribution
Integrated Effluent treatment plant along with RO to maximize recycle of waste water
Spray of chemicals over Gosunda Dam to reduce the water loss through evaporation
Installation of Drip/Sprinkler system in plantation to save 60% water
STP treated water is used for irrigation purpose
Increase in Cycle of Concentration to reduce cooling tower blow down by Chemical addition
Changes in Blade angle of CT fans to reduce airflow and evaporation losses.
3D Trasar Project For Water Reduction by online monitoring of Cooling Water parameters
Filter Press in CPP bottom ash system to recover water

24. Future plans for Water conservation
Focus on effluent reduction through in-situ recycling.
Improve house keeping, Spills and Leaks through automation, operational control and supervision
Construction of adequate sheds for raw material and HW storage area so as to avoid contaminating rain water with pollutants
Isolation of process drains from storm water – wherever possible
Installation of Multiple Effect Evaporator
Installation of 3rd stage RO for treating RO reject
Additional rainwater holding ponds – capacity to hold and treat rainwater

25. Thank You