CASE STUDY

Zawar group of mines consist of 4 mines, i.e., Mochia, Balaria, Baroi, Zawarmala. Zawar
group of mines are located about 40 kilometres south of Udaipur, in the state of Rajasthan in
India. Zawar is very well connected with roads. Power requirement is adequately sourced
from its 80 MW coal based captive thermal power plant.
Mining:
Lead -Zinc ore is divided into stope blocks which are drilled and blasted using long hole open
stoping mining method. Ore is either crushed to underground or at surface to feed mill. A
backfill and a paste fill plants were recently completed to use tailings from ore beneficiation
plants. The mine also has a dry stack tailing plant, the first of its kind in India.
Processing:
The ore is further crushed and milled before undergoing a flotation process, to produce the
concentrate. Zinc and lead concentrates produced are transferred to our smelters.
Surging ahead on its growth journey, Zawar Mines (ZM) crossed the major milestone of 4 Mt
ore production mark in FY 2021-22. This group of four heritage mines, with mining history
spanning over 2,000 years, celebrated many iconic achievements during the year. The four
underground mines - Mochia, Balaria, Zawarmala and Baroi, also scaled new levels of
mechanisation and digitisation. The mines, located 40 kilometres southeast of Udaipur in the
state of Rajasthan, successfully harnessed various technological advancements to report
exemplary performance during the year.
The Zawar Mines touched new frontiers of growth and expansion during FY 2021-22,
discovering new lenses and achieving overall milling recovery of 90.80%.

Key Facts
Location: Zawar, Rajasthan, India Mining Type: Underground Mining Method: Long hole
open stoping Products: Lead and zinc concentrate
Certifications: ISO 9001:2008, ISO 14001:2004, OHSAS 18001:2007, SA 8000:2008 & 5S
ZAWARMALA MINES PLANT :
From Cement storage silo(100 m3) , the material is feed to Bin and feed to Rotary feeder and
then it passes to screw conveyor no. 52 and 53 and finally passes through Mixer.
Fly ash silo also follows the same path.
Tailing is feeding into live bottom feeder (126 Tph) and it passes through belt conveyor and
finally poured into Mixer.
Water is supplied at 275 m3/h into Mixer.
Then the paste passes through Paste Hopper and supplied through PD pump into pipes.
At CRF, cement passes through screw conveyor no 51 and then with water it mixes into the
shaft and it passes to Hopper by level sensor and finally supplied through Centrifugal pumps
into pipes.

Capacity of PD pump - 92 m3 and of Centrifugal pump - 13.5 m3.

Out of 79% solids [69% tailings + 10% cement].
CRF density is below 1.5.
Admixture added is 0.05%.

Below give table of stope Description of S11 :

Stope Description S11 (80 to 187 mRL)

Stope Dimension (L*W*H) in metres 60*24*100

Stope Minable Volume 83000 cum

TotaL Volume Mined Out 71400 cum

Volume Required to be filled 65000 cum

Daily Filling Rate 47 cum/hr

Total time required to fill 6 months (Dec 20 to May 21)

Water decantation process By perforated and bleed pipes in barricade
Pressure on barricades after plug formation Constant for sometime, 30KPA

Pressure after curing Zero KPA

Instrumentation in underground backfill system EPC, PTs, Cameras, Leaky feeder system

Details of backfill recipe 70% tailings, 5-10% cement, 21-25% Water

Figure : Paste Plant Process Flow Diagram

430 mRL
BM-240/240 m
O- 45/45
Pipe Drill- 600/600 Pip*
Paste
Ere-600/600 355 mRL Discharge
6H- 100/240 m
D- 3: Stope (PI)
Pipe Drill- 84/84
Pipe ere-64/B4 250 mRL 6H- 0/120 m
Paste
0- 55/95
Pipe Drill- 50/80 Discharge
Pipe Ere-20/60 210 mR
D- 22/30
Pipe Doll- 20/70
Pipe Ere-70/70

187 mRL

>35/35 Pipe Dnll-

80/80 Pipe Ere-
110/110

160 mRL

D-O/O
Pipe Drill- 0/10
Pipe Ere-0/10

Figure : Reticulation Design

 Figure : Vertical Section of Shotcrete Barricade

Ol
LT5

DEC-20 JAN-21 FEB-21 MAR-21 APR-21 MAY-21

Figure : Pressure on Barricade in KPA

Figure : UCS Test Report

Figure : Front View of Shotcrete Barricade Framework

 Figure : LVS Zawarmala Mine

Fill Plant Basic Details

Capacity 47 CUM/hr 2000 MT
Live bottom feeder, Belt conveyor, Mixer, PD pump,
Tailing stock pile capacity
Silos, HP wash pump, Fresh water tank, Compressor
Major Equipments House, front end loader for feeding tailing in to hopper,
dumpers for tailing transportation from DTP to paste fill
plant.
Interlocks, PTs, Rupture spools, Blasting TEE, Level
sensors, Cameras, EPCs, Leaky feeder system.
Instruments
 ►

Dry tailing dam Dry tailing

Belt Conveyor(126tph) hopper

To Mixer

Figure : Tailing process

Screw conveyor 52 Screw conveyor 53

To Mixer
Cement silo Fly ash silo

Rotary bin and feeder Rotary bin and feeder