Hindustan Zinc Boosts Production and Safety with Emerging-Tech
Hindustan Zinc Limited has reaffirmed its leadership in innovation through a series of pioneering technology deployments that are reshaping the future of the metals and manufacturing sector. The company recently deployed tele-remote and guidance-enabled loaders (vehicles used to transport ore) that allows operators on the surface to control loaders operating underground during shift changeovers. Enabled through the in-house optical fibre backbone, this innovation has significantly improved productivity at the Rampura Agucha mine (in Rajasthan), increasing shaft hoisting capacity from 6,500 TPD to 8,000 TPD (tonnes per day).
Another key milestone is the deployment of smoke-hours drilling technology, making Hindustan Zinc the first Indian metals company to implement this automation-driven solution. This breakthrough allows production drilling to continue during shift transitions wherein the operator manages the unit from the surface. On an average, this has yielded in an additional 22,000 tonnes of metal in concentrate annually over the last three years. This technology is operational at both Rampura Agucha (in Rajasthan), the world's largest underground zinc mine, and Sindesar Khurd (in Rajasthan), among the top five silver-producing mines globally.
In its pursuit of smart manufacturing, the company has also integrated an AI-driven, sensor-based predictive maintenance system, developed in collaboration with Infinite Uptime, an emerging-tech start-up. By deploying a network of over 1,000 intelligent sensors, Hindustan Zinc has successfully minimized machine failure risks and recorded a reduction of nearly 500 hours in unplanned operational downtime across its mining and smelting units. Hindustan Zinc has also deployed an AI-based automation tool aimed at enhancing zinc production efficiently. The tool leverages AI/ML (Artificial Intelligence / Machine Learning) driven recommendation models to optimize usage of consumables such as zinc dust, sodium sulphate, lime, cement while maintaining top-notch product quality through an intelligent model extensively trained on historical data.
Arun Misra, CEO Hindustan Zinc Limited, said, “Technology is core to our value chain. We strive to implement industry-first technologies that enhance our manufacturing excellence and assist in delivering superior product quality while using resources very judiciously. By integrating such technologies, we are also reducing our environmental footprint and providing a standardized work experience for all. In fact, we are increasingly becoming a technology company, as tech is now integral to our metal production. By rapidly adopting AI/ML, robotics, automation we are propelling the industry and nation forward.”
