Hindustan Zinc Integrates Emerging Technologies to Enhance Mining Operations

Hindustan Zinc Limited, part of the Vedanta Group and India’s only integrated zinc producer, has announced the adoption of several technology solutions across its operations. The initiatives are aimed at improving production efficiency, workplace safety, and operational reliability.

Among the key developments is the implementation of tele-remote and guidance-enabled loaders at the Rampura Agucha mine in Rajasthan. This system allows surface operators to manage underground loaders during shift changeovers, supported by an in-house optical fibre network. As a result, the mine's shaft hoisting capacity has increased from 6,500 to 8,000 tonnes per day.

The company has also introduced smoke-hours drilling technology, which enables production drilling to continue during shift transitions. This system is in use at both Rampura Agucha and Sindesar Khurd mines and has contributed an annual average increase of 22,000 tonnes of metal in concentrate over the past three years.

To reduce unplanned downtime, Hindustan Zinc has collaborated with Infinite Uptime to deploy an AI-based predictive maintenance system. Over 1,000 intelligent sensors are in place across mining and smelting units, resulting in a reduction of nearly 500 hours in unexpected operational interruptions.

The company has further integrated an AI-based automation tool to optimize the use of consumables such as zinc dust, sodium sulphate, lime, and cement. This tool leverages historical data and machine learning models to support consistent product quality and efficient resource usage.

An AI-powered surveillance system has been introduced for monitoring workplace safety and compliance. According to the company, this has reduced the need for manual oversight by approximately 50 percent. Robotic automation is also being used in high-temperature smelting processes to improve consistency and precision.

Looking ahead, the company plans to implement drone-based stope scanning using LiDAR technology to improve underground mine mapping and extraction planning.

Hindustan Zinc is currently engaged with over 40 technology startups through Vedanta Spark, working on more than 60 projects focused on production, cost optimization, safety, and environmental management. The company also encourages internal innovation through platforms like Innovation Cafés and supports MSMEs in its supplier network.

Hindustan Zinc Limited supplies zinc to over 40 countries and holds approximately 77 percent of the primary zinc market in India. It ranks among the top five silver producers globally and was recently recognized in the S&P Global Corporate Sustainability Assessment 2024. The company also introduced EcoZen, a zinc brand produced using renewable energy.