investor visit hzl mar09
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ENDURING
VALUE
THROUGH
VALUES
Akhilesh Joshi
Chief Operating Officer
HINDUSTAN ZINC LIMITED
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Largest Integrated Zinc - Lead Producer 2010
Competitor data from Brook Hunt
1064
kt Zn
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Solid Growth with Low Risk
2006 2007 2008 20102005 2012
ChanderiyaHydro I
170 ktpa
RampuraAgucha Mineexpansion
2.3 mtpa to3.75 mtpa
ChanderiyaCPP
2 x 77 MW
ChanderiyaAusmelt LeadSmelter
50 ktpa
ChanderiyaHydro II
170 ktpa
Rampura AguchaMine expansion
3.75 mtpa to 5mtpa
Chanderiya &Zawar CPPexpansion
2 x 80 MW
Gujarat & Karnataka WindPower Plant 124 MW
Chanderiya &Debari ZincDebottlenecking
88 ktpa
Dariba Smelter
Zinc 210 ktpaLead 100 ktpaSilver350 tpa
Dariba CPPexpansion
2 x 80 MW
RampuraAgucha Mineexpansion
5 mtpa to 6mtpa
SK Mine expansion
0.3 mtpa to 1.5mtpa
New Mine at Kayar0.3 mtpa
Delivered Under Implementation
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Key Highlights
HZL stands out with 29% EBITDA in Q3 09, even asmajor integrated producers like Xstrata, Teck, Bolidenetc. with negative EBITDA margins struggle to survive.
HZL continues to maintain zero inventory levels.
HZL continues to invest in its expansion projects(phase III project capexRs. 3,600 crores) asplanned.
Strong balance sheet with cash balance of over Rs.
9,300 crores and Nil gearing.
Last man standing philosophy
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World Class Mining Assets
Rajpura Dariba Mine
Lead-Zinc R&R:
Reserves 7.2 MtResources: 41.9 MtZinc Grade: 4.4%Lead Grade: 2.3%Ore Production Capac ity:1.2 mtpaCPP: 80 MW
Zawar Mining Complex
Rampura Agucha Mine
Lead-Zinc Ore R&R:Reserves: 63.6 MtResources: 43.8 MtZinc Grade: 13.9%Lead Grade: 2.0%Ore Production Capac ity:5.0 mtpa. Will increase to 6.0mtpa
Lead-Zinc Ore R&R:Reserves: 7.1 MtResources: 17.6 MtZinc Grade: 6.6%Lead Grade: 1.7%Ore Production Capac ity:0.60 mtpa. Will increase to0.9 mtpa
Sindesar Khurd Mine
Lead-Zinc Ore R&R:
Reserves: 1.96 MtResources: 35.2MtZinc Grade: 5.8%Lead Grade: 3.8%Silver Grade: 215 ppmOre Production Capac ity:0.3 mtpa. Will increase to 1.5mtpa
Note: Map not to scale
Kayar Mine
Resources: 9.01 Mt,Avg: 10.6%, Zn,1.7% Pb0.3 mtpa Capacity
Kayar Mine
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World Class Smelting Assets
Pyrometallurgical Lead Zinc Smelter:105,000 tpa Zinc35,000 tpa Lead150 tpa SilverHydrometallurgical Zinc Smelter:420,000 tpa ZincAusmeltTM Lead Smelter:50,000 tpa Lead851,000 tpa Sulphuric AcidCaptive Power Plant: 234 MW
Vizag Zinc Smelter
Hydrometallurgical Zinc Smelter:88,000 tpa Zinc419,000 tpa Sulphuric Ac idCaptive Power Plant: 29 MW
Hydrometallurgical Zinc Smelter:56,000 tpa Zinc91,000 tpa Sulphuric Ac id
Dariba Complex Phase III
Hydrometallurgical Zinc Smelter:210,000 tpa ZincLead Smelter100,000 tpa LeadSilver Refinery350 tpa SilverCaptive Power Plant: 160MW
Note: Map not to scale
Dariba Smelting Complex is under implementation
Chanderiya Smelting Complex Debari Zinc Smelter
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Highlights
Note: COP w/o royalty
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1%
3%
3%
PROMISING FUTURE
Global consumption is growing @ 34% CAGR, world needs ~0.5 Mt more zinc every year
Indian consumption at ~ 0.47 Mt in FY 08 is robust & expec ted to grow at double digits and
also likely to double in 5-6 years at the back of strong demand drivers.
Low per capita consumption in India coupled with a growth in infrastructure, construction,
consumer durables, automobiles etc.
Zinc does not have a risk of substitution
Robust Zinc Demand
Per capita zinc consumption in 2007 (kg/capita)
Note: Indian per capita zinc consumption in 2008 was 0.43 kg/capita
Ref: Brook Hunt 2008 Q4
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Asia (Excl China)
Latin America
Western Europe
Africa Oceania
North America
Asia accounts for close to 50% of Global Zinc demand
SAARC Nations are freight Friendly
Asian Zinc market is in deficit
Global Production : 11,753
Global Consumption : 11,371
Surplus : 382
Note:All figures in thousand tonnes
Ref: Brook Hunt 2008 Q4
Global Market : 2009
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Overall R & R increased by 115 million tonnes , pre-depletion of 26.3 million tonnes.
HZL R&R - Three pronged approach
In mine exploration Near mine exploration Greenfield exploration (area applied in Indiazinc rich belt)
Focus on Developing Resources
143.7
232.3
209.4177.6
164.8146.3
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Total R&R as on 31 March 2008 is 232.3 million tonnes containing 27.5 million
tonnes of zinc-lead metal
Rampura Agucha mine achieves landmark of crossing 100 million tonnes
(actual: 107.3 million tonnes) containing
Increase in R&R by 28.7 million tonnes containing 4.0 million tonnes of
metal, prior to depletion
Increase in mine life to 24 years
Robust Reserves & Resources
Exploration Success in FY 2008
Sindesar Khurd Mine R&R increased from 13 million tonnes in 2005 to over 35 million tonnes in 2008
Ore body of SK mine is open in depth
Total R&R as on 31 March 2008 is 37.17 million tonnes containing 3.5 million
tonnes of zinc-lead metal & 257 Moz of contained silver metal.
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Silver A New Dimension
Highest primary silver producer in India (currently): 3.7 million ounce
per annum
Ramping the capacity to 16.1 million ounce per annum by 2012 in
phases
Major contribution from SKM and RAM expansions
High silver grade of Sindesar Khurd ore ~ 215 ppm
New silver refinery with a capacity of 350 tonnes per
annum (~11.3 million ounce per annum) to be
commissioned by 2010
Recovery of silver from zinc circuit (all hydro smelters)
Capture 2.5% of Global silver market post expansion
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Best Zinc People in the World
n Organization Structure enhancing performance
- Empowered SBU work culture
- Leadership development for succession planning
- Talent identification, positioning and rewards
- Performance oriented online appraisal.
n Competence Building
- Over 1,000 employees have undergone specially
designed general management & technical
training programme.
- To attract best talent at induction level
Qualification of fresh joineesFirst Class Graduate
- Ac c e le ra ted d eve lopm ent o f exec u t ives th roug h
sp ec ia lized p rog rammes at rep uted inst itut ion s -IIM / IIT / ISM / BITS
- Exposure to other world-c lass operations
n Cutting edge combination of experienced and
young engineers in expertise & energy levels
n Tremendous focus on quality of life
FRESHERS HIRING (2002-2008)
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Robust safety policy, prac tices organization - supported by safety stewards.
Increased focus on the behaviour based safety program of all employees.
Daily Safety performance review in unit meetings with total engagement of employees.
External HSE audits are being done by agencies of international repute PwC, E&Y, B.S.C
Proactive actions like analysis of near miss incidences, periodical independent reviews,
regular training etc.
Equal focus on contract workmens safety
Compulsory use of Persona l Protective Equipment (PPE) including by contract workmen.
No cases of occupational health diseases
Nearly 50% reduction in LTIFR every year
Focus on Safety
*Lost Time Injury Frequency Rate
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Mid Day Meal - More than 200,000 primary school going children are being benefited
through 6 Hi- Tech Kitchens established by HZL
400 (increasing to 1,000) Anganwadi Centers adopted by HZL, benefiting around 16,000
children
1,000 computers installed in rural Government schools creating learning opportunities
covering more than 40,000 children's Covering 173 villages and among them transforming 59 poverty strickenvillages into model
one based on socio-economic indicators
32 model villageshave been completed and audited by ORG, New Delhi (>75% success)
Post Graduate Girls College in Ringus serving around 900 students coming from rural area
Corporate Social Responsibility - Snapshot
Impacting over 500,000 lives, covering173 villages
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n Process Excellence Award By International Quality & Productivity Centre, London in
2008n FICCIAnnual Awards 2007-08 in the category ofRural & C ommunity Development
n Ramkrishna Bajaj National Quality Certificate of Merit ( RBNQ 2008)
n Golden Peacock Award for Excellence inCorporate Governance-2007by the Instituteof Direc tors
n Asian Corporate Soc ial Responsibility Award 2007-08
n Dun & Bradstreet- American Express Corporate Award 2007 for Top Indian Company inthe Non-Ferrous Metals Sec tor.
n Pegasus Gold Corporate Social Responsibility Award 2008
n TERICorporate Soc ial Responsibility Award 2007 by Honble Finance Minister of India.
n Asian Power Plant of the Year 2007 and also Best Emission Reduction Project in Asia toChanderiya Captive Power Plant by Asian Power, Singapore
n FICCI-SEDFCorporate Soc ial Responsibility Commendation Certificate 2006 by HonblePresident of India.
n FIMICorporate Soc ial Responsibility Award 2007
n FIMIExcellence Award for the year 2007-08 to Rampura Agucha Mine.
n Golden Peacock National Training Award 2006.
n Golden Peacock Corporate Soc ial Responsibility Award 2007
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Rampura Agucha Mine
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Rampura Agucha Mine
A world class zinc asset
Largest zinc mine in the world
One of the lowest cost zinc mine
Modern efficient mining operations
Exploration Emphasis on exploration has been intensified in thelight of aggressive growth plan
Crossed the landmark of 100 million tonnes of R&R
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Mine Parameters
Mine pit dimension : 1650 m x 680 m Bench height : 10 m in Ore ; 10 m in Waste Berm width and bench angle : 6.5 m
: Individual bench angle 70at F/W & 80 at H/W Ultimate pit wall slopes
H/W : 42F/W : 36
Pit access : Ramp one each in H/W & F/W,: width 25 m , gradient 1 in 12.
Ultimate depth of pit : 440 meters from surface plan Waste Management : 4 X 10 m lift, with overall slope angle of 27
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Rampura Agucha Mine - An Overview
Commissioned : 1991
Location : 225 km north of Udaipur,
Rajasthan, India
Reserves : 63.6 million tonnes
(13.0% Zn, 2.0% Pb)
Resources : 43.8 million tonnes
(15.3% Zn, 2.0% Pb)
Ore Production : 5.00 mtpa and is being
enhanced to 6.00 mtpa
Certification : ISO 9001:2000, ISO
14001:2004, OHSAS
18001:1999, 5 S certified
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Largest Zinc Mine
2008
Note: All figures are in Kt Zn
Competitor data from Brook Hunt
Rampura Agucha - Largest Zinc Mine in the world
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OMS & Ore Production
n Continuous improvement in efficiency leading to higher ore production.
* OMS Output per man per shift
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Rising trend of Lead Recovery %
Rising trend of Zinc Recovery %
Note: The year mentioned is in Fiscal
Metal Recovery
Zinc recovery :
Consistency in operation & ore feed
Regrinding of scavenger & cleaner concentrate
Capturing more liberated particles.
Capturing fine particles of concentrate
Circuit modification of scavenger
Continuous Mineralogical auditing
Lead recovery:
Fine primary grinding from 79 microns to 72 microns
Circuit modification
Introduction of automation in cleaner circuit
Introduction of double launder system
Continuous Mineralogical auditing to
identify mode of losses and controlling.
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Conservation of Energy & Water
Reduction in specific energy consumptionkwh/tonne of ore treatment
Reduction in specific water consumptionm3/tonne of ore treatment
Energy Reduction:
AC variable speed drives (25 nos.) Optimization of pumps speed.
Maintaining system power factor0.99
Optimization of grinding media size & charge
Energy savers in lighting circuits
Employee participation & six sigma methodolog
WaterReduction
Recoup from tailing dam
Zero discharge of water through recycling
Water reservoir of 50,000 m3 for storage to
reduce the evaporation.
Garland drains all around mine pit & waste
dumps.
Domestic sewage water after treatment in STP
isutilized for plantation.
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Dust Prevention
Wet drilling operations
Water sprinkling on HaulRoad
Dust Extraction systemsat crushers
Chemical treatmentof haul roads
Aforestationsaround the mine periphery
Systematic stacking of waste and vegetation overinac tive benches
Adopted recycling and reuse of Water forZero discharge.
Tailing dam with continuousmonitoring
Rock filled with lining
Designed by experts from Central Water Commission and Indian Institute
of Science, Bangalore.
LDPElined for seepage control
Focus on Environment - Mines
One of the best managed mine in the World
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Sindesar Khurd Mine
Rajpura Dariba Mine
Sindesar Khurd
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mRL
BH-1BH-4 BH-2 BH-3
Ramp
N
Sindesar Khurd Longitudnal Vertical SectionDepthS
InclineVent. raise
Longitudinal Vertical Section SK Mine
Mt Zn % Pb % Ag ppm
Proved & Probable Reserves 1.96 5.32 2.08 117
M&I Resources 21.01 6.37 4.05 235
Inferred Resources 14.20 4.99 3.80 199
Total R&R 37.17 5.8% 3.8% 215
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Sindesar Khurd Mine
Drilling Total R&R(meters) million tonnes
FY 2005 710 13.50FY 2006 5,634 13.50FY 2007 18,174 13.62FY 2008 26,066 30.85FY 2009 14,300 37.17(till date) 64,884 37.17
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Chanderiya Smelting Complex
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Imperial Smelting Technology
Commissioned in 1991
105 KTPA Zinc,
35 KTPA Lead
Ausmelt Lead Smelter
Commissioned in 2006
Cansolv Technology Recovery +97%
50 KTPA Lead
Pyro Lead Zinc SmelterRLE Technology, Outotec
Commissioned in 2005 / 2007
2 x 210 KTPA Zinc,
Best & Proven Technology
Recovery +96%
Hydro I 100% EOU
Hydro Zinc SmelterBharat Heavy Electricals Ltd (BHEL)
Commissioned in 2005 / 2008
77 + 77 + 80 MW (234 MW)
Proven Technology
Operation outsourced to KoreaPower Services
Captive Power Plant
Worlds Largest Zinc Smelting Complex
Single Largest Zinc Smelting Complex in the World
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Operational Excellence
Reduced Sp. energy consumption to 17.11 GJ /t of metal
Reduced Sp. water consumption to 11.76 m3/t of metal
Increased byproduct recoveries ex: cd, cu, Ag, etc
Lead- Silver residue recovery in Hydro plant has been implemented
Six Sigma culture for problem solving, ex: silver refinery cycle time reduced to 20hrs
SpEnergyConsumptio
n(m3/tofmetal)
SpWaterConsumption
(GJ/tofmetal)
Sp Water Consumption m3/t of metalSp Energy Consumption GJ/t of metal
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Overall Zinc Recovery%
Cathode PowerConsumption KWH / MT Zinc
Key Value Drivers CLZS Hydro Smelters
World class zinc plants with latest andbest technologies
Benchmarking the efficiencies withthe global best smelters
Special teams focusing on such highimpact projects for improvements
Recording of leanings and theirimplementation
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Environmental Focus Smelters
Lowest SO2 emission
Latest technology (J arofix) - eliminates hazardous waste
generation
Zero discharge leading to reduced specific water consumption
Worlds largest and latest generation roasters
Extremely efficient waste heat energy recovery system coupled
with power generation
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THANK YOU
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