Business Excellence Drivers – Digitalisation and Automation
Smarter operations, scalable outcomes
Hindustan Zinc is a global benchmark in the mining industry for operational productivity, safety, and sustainability.
We achieve this through investments in pioneering digital technologies, from autonomous systems to advanced analytics, that empower better decision-making and a safer, more efficient operation. This ensures delivering sustainable and responsible growth with industry-leading profitability while keeping us at the forefront of industry innovation and technological trends to unlock new value consistently.
DIGITAL EXCELLENCE AT HINDUSTAN ZINC
Organisational and talent strength
10
In-house digital team strength
Investments
₹ 18.77 crore
Invested in digital and automation efforts in FY2025
Major technologies deployed
IoT-enabled smart sensors and AI-driven analytics for predictive maintenance, condition-based monitoring and reliability health index
Sensor-based micro-seismic activity monitoring systems
Drone-based inspection for structural integrity enabling safe, remote, non-destructive monitoring of stacks using visual, thermal, and ultrasonic sensors
Drone-based stope scanning in underground mines for dilution control
Tele-remote drilling to minimise the risks of manual drilling and maximise the overall productivity
Tele-remote operation of loaders maximising ore hoisting, ensuring consistent mill feed while enhancing productivity and safety
Computer vision-based monitoring of unsafe acts in restricted areas of underground mines
HOW WE SCALED TECHNOLOGY EXCELLENCE IN FY2025
Automation
Technologies invested in
Closed Loop System for Consumables Addition
Implemented a fully automated system for non-fuel consumables (Zinc Dust, Sodium Sulphate, PAT, Lime, Soda Ash) by integrating laboratory information management system (LIMS) data with process control systems (OSI-PI & DCS/PLCs). Linear statistical models guide optimal dosing without manual intervention.
The system leverages Information Technology-Operational Technology (IT-OT) integration for real-time feedback and automated control, ensuring accurate dosing based on lab and analyser data, maintaining tight process control.
Benefits achieved
C.10%
reduction in specific consumable consumption
Improved
process efficiency, lower variability in usage
Eliminated
manual interventions
Artificial Intelligence/Machine Learning (AI/ML) based Analytical Modules
Technologies invested in
Roaster Sulphide-Sulphur Prediction Model
Developed an ML-based prediction model by integrating real-time operational data. This provides accurate predictions of sulphide/sulphur ratio and helps optimise roaster operations.
Benefits achieved
Increase
in the roaster’s throughput
Reduction
in emissions, ensuring sustainable smelting operations
Internet of Things (IoT) Applications
Technologies invested in
Predictive Maintenance (PdM) of critical assets
Utilising IoT-based smart sensors that generate data to be consumed by AI-based solutions for analytical anomaly detection, helping early detection of maintenance requirements to improve the availability and reliability of the critical assets and reduce their unplanned downtime through auto-fault diagnostics for taking timely corrective actions.
Benefits achieved
400+ Hours
of downtime saved
Improved
asset reliability
IoT sensors in Heavy Earth Moving Machinery (HEMM)
Built advanced data analytics using Industrial IoT sensor-based telemetry data for identifying and minimising idle time of Low-Profile Dump Trucks (LPDTs) and Load, Haul & Dump (LHD) machines.
Benefits achieved
5%
Reduction in HEMM idling
Cost Savings
by cutting diesel use and lowering idle-hour expenses
Collaboration Centre
Process optimisation via advanced data analytics
We have scaled data analytics efforts by centralising the collection and integration of operational data through IT-OT integration and sensorisation of critical assets.
All this data is hosted on central servers at our Collaboration Centre, which, combined with other business partners’ server data, is leveraged for data engineering tasks (cleaning, transformation, and feature engineering) to develop advanced solutions.
Additionally, we are developing user-friendly, interactive, and comprehensive dashboards that provide actionable insights, auto-scheduled reports, and subscriptions hosted via a Virtual Network (VNet) gateway linked with our Hindustan Zinc’s workspace. These dashboards will assist end-users and empower management with a robust decision-support system to enhance process efficiency and decision-making across various operational areas.
Benefits achieved
Condition-based Monitoring (CBM)
Reliability Health Monitoring of critical assets
Statistical Process Control (SPC)
Process Capability Analysis (PCA)
Predictive Maintenance (PdM)
AI/ML-based prediction models
Refer to the Health & Safety key digital interventions driving safety excellence, and the Operational Performance for digital advancements in mining and smelting operations