Posted by Udaipur: Hindustan Zinc, India’s only and the world’s largest integrated zinc producer has deployed emerging tech solutions such as tele-remote and guidance-enabled loaders (vehicles used to transport ore), smoke-hours drilling and integrated an AI-driven, sensor-based predictive maintenance system. For the company, this makes industry-first tech solutions implementation across the entire value chain.
The deployment of tele-remote and guidance-enabled loaders ( also known as teleremote loaders or autonomous loaders) allows operators on the surface to control loaders operating underground during shift changeovers. Enabled through the in-house optical fibre backbone, this implementation has significantly improved productivity at the company’s Rampura Agucha mining site located in Rajasthan, increasing shaft hoisting capacity from 6,500 TPD to 8,000 TPD (tonnes per day).
The smoke-hours drilling technology implementation has enabled the company to drive automation in drilling processes. It 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 in Rajasthan’s two mining sites, Rampura Agucha – the world’s largest underground zinc mine, and Sindesar Khurd, which among the top five silver-producing mines globally.
Further, the company has also integrated an AI-driven, sensor-based predictive maintenance system, developed in collaboration with Infinite Uptime, an emerging tech startup to enable smart manufacturing.
Hindustan Zinc has deployed a network of over 1,000 intelligent sensors and successfully minimised machine failure risks and recorded a nearly 500 hours reduction in unplanned operational downtime across its mining and smelting units.
The company 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 optimise 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.
Besides, it has embedded robotics, artificial intelligence, blockchain, and the Industrial Internet of Things (IIoT), across its operations.
Moreover, the company has announced the implementation of an advanced AI – powered camera surveillance system, across its operations. This 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.
Going ahead, Hindustan Zinc has plans to introduce LiDAR-enabled drone-based stope scanning to elevate the accuracy of underground mine mapping and optimize extraction planning.
“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,” said Arun Misra, CEO Hindustan Zinc Limited.
“By integrating such technologies, we are also reducing our environmental footprint and providing a standardised 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,” added Misra.