Hindustan Zinc Boosts Production and Safety with Emerging-Tech

12 May 2025 CW Team

Ahead of National Technology Day, Hindustan Zinc Limited, India’s only and the world's largest integrated zinc producer, 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 (tonne 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.

Speaking on the occasion, 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.”

Hindustan Zinc has embedded technological excellence and innovation such as robotics, artificial intelligence, blockchain, and the Industrial Internet of Things (IIoT), across its operations. Recently the company announced the implementation of an advanced AI – powered camera surveillance system, across its operations. This innovative solution ensures workplace safety, operational efficiency and compliance monitoring resulting in almost 50% reduction in manual intervention. Additionally, the company has deployed robotic automation in high temperature smelting operations, boosting precision, streamlining metallurgical workflows, and ensuring consistent product quality. Looking forward, Hindustan Zinc is set to introduce LiDAR-enabled drone-based stope scanning to elevate the accuracy of underground mine mapping and optimise extraction planning.

Hindustan Zinc actively engages with startups focused on core areas such as production volume augmentation, cost optimisation, value creation, ESG (environment, social & governance) excellence, and enhancing safety practices. Currently, Hindustan Zinc is engaged with more than 40 tech startups on over 60 different projects through Vedanta Spark. Vedanta Spark is Vedanta’s unique global corporate accelerator and ventures program that collaborates with innovative startups to drive large-scale transformative impact by addressing critical business challenges through emerging technology. Under Vedanta Spark, Hindustan Zinc has unlocked high-potential opportunities by leveraging technologies such as Artificial Intelligence/Machine Learning, computer vision, drone technology, the Internet of Things (IoT), and Augmented Reality/Virtual Reality (AR/VR).

Hindustan Zinc is actively utilising new-age technologies and fosters a startup mindset internally through Innovation Cafés, enabling Hindustan Zinc to achieve best-in-class asset reliability and operational excellence. Over the years, the company has supported numerous MSMEs associated with Hindustan Zinc’s business partner and supplier network across various domains such as supply chain, mine development, and production.

Hindustan Zinc Limited, a Vedanta Group company, is the world’s largest integrated zinc producer and is amongst the top 5 silver producers globally. The company supplies to more than 40 countries and holds a market share of about 77% of the primary zinc market in India. Hindustan Zinc has been recognised as the world’s most sustainable company in the metals and mining category for the second consecutive year by the S&P Global Corporate Sustainability Assessment 2024. The company also launched EcoZen, Asia's first low carbon 'green' zinc brand produced using renewable energy. As an energy transition metals company, Hindustan Zinc is pivotal in providing critical metals essential for a sustainable future.

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