Tag Archives: Hindustan Zinc

GHH India’s contract mining arm wins plaudits for work with Hindustan Zinc

GHH India’s recently established contract mining arm, GHH Bumi Mining Service, has notched up its first significant award, being recognised by Vedanta Group/Hindustan Zinc Ltd (HZL) for the work it is doing at the Zawar Mala zinc-lead underground mine in Rajasthan, India.

In a recent online event, GHH Bumi Mining Service, established late last year, was named as the recipient of the Best Performing Business Partner by the companies.

The award winner was chosen out of all business partners and recognised a job well done, GHH said.

Over the last six months, GHH Bumi has been carrying out contract mining at Zawar Mala, and was presented the award, GHH says, based on excellent performance involving all contract mining activities, including those related to safety, production and asset optimisation.

Since January, GHH BUMI has been responsible for production and mine development with more than 350 employees at Zawar Mala. For this purpose, the company has access to more than 20 LHDs, dump trucks and drilling rigs from the GHH Group.

Dr Jan Petzold, CEO of GHH Group, said: “With this award, we as GHH Group see ourselves confirmed in our efforts as a reliable business partner for HZL – a cooperation that started almost four years ago with the supply of mining machinery and has resulted in being awarded as mining contractor and OEM.

“This is a special incentive to be able to conclude the second mine developer and operator contract with HZL, which is currently in preparation.”

The latest generation of GHH mining equipment, with its new dump truck MK-42, LF-14 and LF-10 LHDs as well as two FM 2.3 boom drill rigs from GHH group company, Mine Master, are on their way to India and are expected to be on site beginning of August, GHH said.

GHH says GHH Bumi is also currently working on preparing for the expansion of the Mochia Balaria Decline project, where a rapid development proposal is under way.

FLSmidth to deliver dry-stack tailings solution at Hindustan Zinc’s Rajpura Dariba mine

FLSmidth has been contracted to deliver an integrated dry-stack tailings solution and a paste fill plant to Hindustan Zinc’s lead-zinc mine in Rajpura Dariba, Rajasthan.

The solution will ensure environmental sustainability and significant process water recovery, as well as reduce the footprint of the tailings storage facility, the mining OEM said.

The new order, which was booked in the December quarter, includes design, engineering, procurement, supply of equipment and the commissioning for integrated dry tailings and stacking along with tailings paste fill plant. FLSmidth will also supply two Automatic Filter Presses (AFP-IV™, pictured), two E-Disc filters and one 26 m diameter High-Density Thickener as the main pieces of equipment. The project is expected to be completed by February 2022.

This new order follows a previous tailings-related order for Hindustan Zinc at its Zawar mine site in 2018.

Hindustan Zinc operates beneficiation plants at Rajpura Dariba and Sindesar Khurd, which both discharge tailings to the same tailings pond. The tailings dam was reaching capacity for conventional wet tailings deposition and so Hindustan Zinc needed a way to resolve this issue, FLSmidth said.

The solution the company required would involve creating a small dry-stack tailings area with minimal environmental and physical footprint and also a method to backfill the mine by using an adjusted dry filter cake mix.

By choosing FLSmidth’s hybrid technology – a combination of the E-Disc filter and the AFP-IV Automatic Pressure Filter – Hindustan Zinc will now be able to achieve this and recover around 85% of process water, according to FLSmidth. This recovered process water can be reused by the process plant located at the mine site with minimum operating and capital expenses.

The cake from the E-disc filter will contain below 16% moisture and can be used for mine backfilling, while the cake from the automatic filter press, with below 12% moisture, can be stacked on the surface in a safe and compact manner, FLSmidth says.

“The solution will also significantly reduce industrial water consumption, something that is of heightened importance in water-scarce areas, such as Rajasthan,” the company said. “The site will also have zero effluent discharge, further boosting its sustainable mining goals.”

Manfred Schaffer, Mining President, FLSmidth, said the order was another strong “proof point” for the quality and flexibility of the company’s technology for filtration and engineering solutions for tailing management.

“This project resolves the customer’s challenge through optimum utilisation of available space and ensures the paste backfill requirements are met with the lowest possible operating and capital costs,” he added. “Importantly, it also secures a high level of reusable water for the mine site, which helps their sustainability efforts and supports our own MissionZero ambition.”

FLSmidth FerroCer wear panels increase uptime at Hindustan Zinc operation

FLSmidth’s FerroCer® Impact wear panels have proven their worth in the mineral processing circuit at Hindustan Zinc’s Rampura Agucha operations in Rajasthan, India, having significantly outlasted the previous manganese liners the lead-zinc mine was using.

By the end of 2018, the mine couldn’t say exactly just how good FerroCer wear panels were as they were still in place over a year since installation.

However, by March 2019, it was confirmed the FerroCer liners had completed about 480 days (16 months approximately) in operation and had withstood some 2.45 Mt of lead-zinc ore conveyed through the U-13 tripper chute, located after the primary crusher at the mine.

This is a significant improvement on the previous 40 mm-thick manganese steel liners, which had a life span of only 23-25 days, according to FLSmidth.

The constant wear on these liners meant the material handling system needed to be frequently shutdown so the worn-out liners could be replaced with new manganese steel liners, which weighed about 50 kg each.

“Because of the elevated location of several chutes, replacement of the liners required safety preparations (such as scaffolding and other access and handling arrangements), with five to six workers required to get inside the chutes to handle the liners,” FLSmidth said.

FLSmidth visited officials at the Rampura Agucha mines in June 2017 and recommended FerroCer wear panels to address the high wear issues in the material handling chutes.

“Each panel comprises a set of abrasion-resistant ceramic inserts enclosed in a matrix of malleable steel, which ensures only the top surface of the insert is exposed to material impact,” FLSmidth said. “The sides of the inserts are tapered within the matrix, keeping them in place and preventing material particles and fluids from damaging the panels.”

Some in-situ results from the 220-day mark showed the wear on the panels measured only 8-10 mm and had withstood around 1.5 Mt of lead-zinc ore conveyed through the U-13 tripper chute.

“This means FerroCer outlasted the previous panels by over 10 times, meaning a much longer replacement cycle,” FLSmidth said.

Clearly delighted with this outcome, Hindustan Zinc is now looking to use FerroCer impact wear panels across its high-impact wear locations, according to FLSmidth.

Praveen Bhardwaj, Assistant General Manager (Mechanical), HZL – RA Mines, Rajasthan, said: “FerroCer has reduced maintenance time due to the much longer replacement cycle, eliminated possible damage to the mother plate and spillage of material due to the highly abrasive nature of ore, and significantly reduced safety hazards. HZL intends to install FerroCer impact wear panels in all the high impact wear locations.”

The results at the Hindustan Zinc site follow on from results from two mines in Australia. One mine operated for more than a year without replacing its wear liners and the other site is on the same track, approaching its first year without the need for liner replacement.

Meanwhile, in a Peruvian copper mine, 24 smaller and lighter FerroCer panels, each made of steel plates with ceramic inserts, replaced six generic liners. After a total of 12.6 Mt passed, with a feed of 7,500 t/h, wear was no more than 3%, FLSmidth said.

“At that rate, FerroCer lasts at least 10 times longer than the most expensive and recognised wear liner on the market.”

RCT brings teleremote options to Hindustan Zinc’s Rampura Agucha mine

Autonomous solutions specialist RCT has entered into its first automation project in India, commissioning its technology on machinery at Hindustan Zinc’s Rampura Agucha zinc-lead mine in Rajasthan province.

The agreement with Hindustan Zinc Limited and its mining services provider Barminco will see ControlMaster® Guidance Automation installed on two Cat R2900 underground LHDs at the mine. These loaders will now undertake teleremote mining in open stopes developed by Barminco.

Barminco, in February, was awarded a three-and-a-half-year underground mining services contract at Rampura Agucha. The mine, meanwhile, is currently undergoing an expansion to boost production to 5 Mt/y of ore.

RCT will install two underground ControlMaster Automation Centres, as well as four ControlMaster Area Access Cabinets into mine stopes, as part of this package. These will collectively enable machine operators to safely manage the machines away from the mine face, according to RCT.

The Automation Centres will also be equipped with Multiple Machine Selection and Multiple Machine Control options, enabling a single operator to manage both machines at one time, according to RCT.

The project represents the first time RCT has deployed its proprietary digital communications network RCT Connect into a mine site anywhere in the world, the company said, adding that RCT will carry out training programs to empower local operators and maintenance personnel then machine servicing works on an ongoing basis.

Hindustan Zinc after improved safety, productivity with Epiroc’s Mobilaris solution

Hindustan Zinc, India’s only zinc-lead-silver producer, has selected Epiroc to equip its flagship Rampura Agucha mine with Mobilaris Mining Intelligence™ (MMI).

A decision support solution for mine safety and efficiency, MMI enables superior situational awareness and is designed to visualise and support mining operations in all its complexities, in real-time, Epiroc says.

Hindustan Zinc has introduced various technologies and innovations and has obtained success in enhancing safety, efficiency and exploration, according to Epiroc.

Back in 2017, the miner looked to automate many of its operations, acquiring Epiroc drill rigs, LHDs, haul trucks (including the MT65) and exploration equipment to be used in five of its mines in northwestern India. The automation and other high-technology features of the equipment were enabled through the common Rig Control System, with most machines are equipped with the telematics solution CERTIQ.

Following the latest MMI order, Sunil Duggal, CEO, Hindustan Zinc, said: “We are continuously making efforts to develop better, connected and intelligent mines. The partnership with Epiroc will support our direction to develop safer and more productive operations at Rampura Agucha mine”.

Ulla Korsman-Kopra, Global Business Manager, Automation and Information Management at Epiroc, said the company would support Hindustan Zinc’s operational (mining) improvement processes with the MMI solution. “The globally-acclaimed features will take Hindustan Zinc’s operations to the next level of performance gains,” she said.

The MMI portfolio features situational awareness, short interval control, including machine data integrations, and traffic awareness promises to get maximum productivity and efficiency out of a customer’s mine, according to Epiroc.

“Thanks to the openness and transparency of the MMI solution, integrations with mixed fleet machines, sensors and more will create the foundation for vital real-time analytics,” Korsman-Kopra said.

The system is expected to be operational during once the networking is up and running at the Rampura Agucha mine.

Rampura Agucha is the second largest zinc mine in the world, according to Hindustan, with production of 3.9 Mt in the company’s 2018 financial year. It has a zinc-lead reserve grade averaging 15.7% Zn+Pb, with total reserves of 46 Mt as of March 31, 2018.

The ongoing underground mine project is being developed with a vision of producing 5 Mt/y of ore and includes a main production shaft of 955 m depth, 7.5 m diameter and hauling capacity of 3.75 Mt/y; two ventilation shafts, two declines from surface and paste fill plants, according to Hindustan.

Barminco wins extension at Hindustan Zinc-owned Rampura Agucha zinc-lead mine

Ausdrill’s recently added subsidiary, Barminco, has been awarded an underground mining services contract at the Rampura Agucha zinc-lead mine in India from Hindustan Zinc worth approximately A$100 million ($71 million), the ASX-listed company says.

Hard-rock underground miner Barminco has operated at Rampura Agucha for Hindustan, a subsidiary of Vedanta Limited, since late 2016. The new underground mining services contract is for a three-and-a-half-year term, subject to review and mutual agreement of rates after the first year.

The scope of work includes the extension of development works that were being provided under a recently completed contract, plus the addition of production work in the Barminco-developed area of the mine. Under the contract, Hindustan will provide capital equipment and consumables. Barminco will commence work immediately, Ausdrill said.

Barminco CEO, Paul Muller, said: “We are very pleased to have been awarded a contract that extends our operations at the Rampura Agucha mine with an expanded scope to include production works. We look forward to deepening the relationship we have built with Hindustan Zinc over the past few years by delivering on this extended scope of works both safely and efficiently.”

Rampura Agucha is the second largest zinc mine in the world, according to Hindustan, with production of 3.9 Mt in the company’s 2018 financial year. It has a zinc-lead reserve grade averaging 15.7% Zn+Pb, with total reserves of 46 Mt as of March 31, 2018.

The ongoing underground mine project is being developed with a vision of producing 5 Mt/y of ore and includes a main production shaft of 955 m depth, 7.5 m diameter and hauling capacity of 3.75 Mt/y; two ventilation shafts, two declines from surface and paste fill plants, according to Hindustan.

Loadscan measures up for Hindustan Zinc’s Rajpua-Dariba and Zawar mines

Hindustan Zinc is using Loadscan’s load volume scanners (LVS) to monitor material at two of its mines in India, the equipment manufacturer says.

At its Rajpua-Dariba mine, Hindustan Zinc’s oldest mine, it has a custom-mounted Loadscan (LVS-3CMX model) underground to measure ore, where it is crushed before taken to the surface by lift. Within this mine, there’s also a block-mounted portable unit (LVS-3BMP) positioned at the portal to measure trucks as they come to the surface. Another two custom-mounted scanners (LVS-3CMX) were purchased for the Zawar mine.

Pavan Kaushik, Vice President and Head of Corporate Communication at Hindustan Zinc, said the Loadscan units have been helpful to improve operational performance by “managing haul-back to reveal our true shift tally”.

“We can now accurately calculate net volumes delivered for processing,” Kaushik said. “Time is also saved by minimising paperwork; there’s no manual data entry, driver records or after-shift record sorting.”

Increased trucking “factors” has led to production gains, including lower cost per tonne of material hauled, optimising truck loading and improved productivity,” he added.

Loadscan says: “The Loadscan LVS is the original non-contact, automated ‘drive-through’ truck load measurement instrument. It’s an affordable, effective alternative to heavy-duty truck scales for the monitoring, tracking, and management of load data.

“Compared to conventional weighing systems, Loadscan boasts greater accuracy in payload measurements, and, unlike permanent weighbridge installations (that require extensive site works), the LVS is quick and easy to set up so trucks can be scanned without delay.”

As the target vehicle drives under the scanner, the LVS scans the load and creates a 3D model or ‘surface profile’. By comparing this profile with vehicle details stored on file for the same vehicle when empty, the LVS is able to calculate the load volume to a proven accuracy of +/- 1% or to the point of resolution which is 0.1 m³.

All the mining trucks in Hindustan’s fleet are fitted with RFID tags, allowing the LVS units (which feature tag readers) to automatically identify each truck as it passes under the scanner and match it to its load.

By working from volume rather than weight, Hindustan Zinc obtains a more accurate measure of its materials, according to Loadscan. “The LVS literally ‘sees’ the load, whereas volume measurement converted from the weight generated from a weighing system is commonly affected by environment factors such as moisture and varying material densities.”

The custom mount head on the LVS-3CMX was the preferred option for the various sites due to its ability to be mounted virtually anywhere, either directly, or by custom mount, according to Loadscan. “This makes it great for attaching on mining portals, tunnels or for attaching to the side of buildings.”

The Loadscan LVS custom mount truck measurement units can be hard wired to a site office or run via a dedicated Loadscan kiosk.

The Loadscan LVS-3BMP is the portable option for large or long-term portable truck measurement projects where there may be a need to move the load scanning location, Loadscan says. The unit is mounted on a pre-cast concrete mounting block, making it easy to move around site by forklift or by lifting from its mounting points.

Sandvik to show off OptiMine capabilities at Hindustan Zinc’s SK zinc-lead-silver mine

Sandvik is set to deliver one of the most comprehensive digital offerings globally at Hindustan Zinc’s Sindesar Khurd (SK) zinc-lead-silver mine in Rajasthan, India.

The company will use its OEM-independent OptiMine® digital solutions to ensure all required infrastructure and platforms are established to achieve world-class mining safety, efficiency and productivity, it said.

The system includes a comprehensive set of features for short interval control of the underground operations, including: OptiMine Monitoring, Location Tracking and Mine Visualization, Scheduler, Task Management and OptiMine Analytics, the latter with IBM Watson IoT. The system will be commissioned in 2019.

For this programme, Sandvik is partnering with Newtrax Technologies, which will deliver personnel tracking with cap lamps, tracking and telemetry data for the entire mobile underground fleet, including non-Sandvik equipment, numbering more than 150 drills, loaders, trucks and other equipment. The Newtrax offering will be seamlessly integrated with the Sandvik OptiMine digital platform creating an integrated mine management solution at the SK mine.

Patrick Murphy, President Product Area Rock Drills and Technologies at Sandvik Mining and Rock Technology, said: “Sandvik OptiMine modules can be combined as needed to build up the required functionality and to optimise mining operations. With open interfaces, the solution can also be integrated to other mine IT systems. This interoperability is crucial in enabling our customers to leverage the full value of digitalisation.

“Vedanta Hindustan Zinc has a vision of what the mine of the future will look like, and we’re excited to collaborate with them to make it happen at SK mine. The capability of this system will be virtually unmatched globally in underground hard-rock mining in terms of both scope and scale.”

Sunil Duggal, CEO at Hindustan Zinc, said: “We at Hindustan Zinc are leveraging digital solutions to improve our availability, utilisation and productivity at the SK Mine. With OptiMine, we will be able to plan, schedule and monitor overall operations in real time. This will add major value and increase our productivity, eliminating bottlenecks and allowing us to measure and monitor our key performance indicators in real time, proactively addressing problems before they occur.”

Hindustan Zinc is one of the world’s largest integrated producers of zinc and among leading global lead and silver producers. Its core business comprises of mining and smelting of zinc and lead along with captive power generation. It has a metal production capacity of more than 1 Mt/y with lead-zinc mines in Rampura Agucha and Sindesar Khurd; and key modern smelting complexes in Chanderiya and Dariba, all in Rajasthan, India.

SK Mine is a highly mechanised underground mine with an ore production capacity of 5.5 Mt/y. The mine’s products are zinc and lead concentrate and the mining method used is blasthole open stoping.

OptiMine is a digital platform for analysing and optimising mining production and processes. It integrates all relevant data into one source, delivering both real-time and predictive insights to improve operations. OptiMine is open, scalable, and adaptable to automated and manual applications.

OptiMine Analytics, with IBM Watson IoT, is the next generation of OptiMine that transforms data into process improvement via predictive insights and actionable dashboards embedded into operation management systems. The solution is part of the digital partnership between Sandvik Mining and Rock Technology and IBM and is backed by Sandvik and IBM digital experts around the globe.