Hindustan Zinc Adopts AI to Revolutionize Zinc Production Efficiency

Ganpat Singh Chouhan

Udaipur – Hindustan Zinc Limited (NSE: HINDZINC), India’s only and the world’s largest integrated zinc producer, has taken a major leap in industrial innovation by deploying an AI-powered automation tool aimed at optimizing its zinc production processes. This cutting-edge solution uses machine learning-based recommendation models to automate and refine the dosing of critical consumables such as zinc dust, sodium sulphate, lime, and cement, ensuring superior quality and higher operational efficiency.

AI Integration for Smart Manufacturing

Trained on extensive historical datasets, the AI tool enhances predictive and adaptive process optimization, reducing manual intervention and increasing consistency. Developed in partnership with Ripik.AI under Vedanta’s global accelerator Vedanta Spark, the system intelligently automates dosing operations, drastically improving resource efficiency across multiple smelting units.

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This initiative reflects Hindustan Zinc’s strategic embrace of digital transformation by combining AI, ML, IoT, AR/VR, drone technology, and computer vision to address critical areas such as metal recovery, asset reliability, productivity, and sustainability.

Advanced Deployment Across Smelting Units

The automation has been rolled out across Hindustan Zinc’s key facilities:

Chanderiya Smelting Complex (Chittorgarh)
Dariba Smelting Complex (Rajsamand)
Zinc Smelter Debari (Udaipur)

The system integrates seamlessly with the company’s Laboratory Information Management System (LIMS), Distributed Control Systems (DCS), and Programmable Logic Controllers (PLCs) to enable real-time monitoring and advanced process control.

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Executive Perspective on Digital Innovation

Arun Misra, CEO of Hindustan Zinc Limited, emphasized the strategic importance of intelligent automation:

“Leveraging technological innovation is central to our vision of becoming a truly intelligent enterprise. Automation of manual processes enhances real-time insights, reduces human dependency, and ensures optimized material consumption for exceptional operational performance.”

Startup Collaboration & Digital Leadership

Hindustan Zinc is currently collaborating with over 40 tech startups on more than 60 active projects, exploring emerging tech through Vedanta Spark. These ventures span process optimization, real-time diagnostics, AI-powered computer vision, and remote monitoring, reaffirming the company’s commitment to pioneering a tech-driven future in mining and metals.

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The company has also launched a digital collaboration centre, a first-of-its-kind in India’s mining sector, to unify and analyze data across all BUSINESS units for faster, insight-led decision-making.

Sustainability and Market Leadership

As part of its green initiative, Hindustan Zinc has launched EcoZen, Asia’s first low-carbon ‘green’ zinc brand, boasting a 75% lower carbon footprint compared to conventional zinc. The company is also recognized as:

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World’s most sustainable metals and mining company (S&P Global Sustainability Assessment 2024)
Top 5 global silver producers
3.32x Water Positive Certified

Conclusion

Hindustan Zinc’s integration of AI and emerging technologies marks a pivotal shift in the Indian mining and metals industry. By prioritizing digital automation, sustainability, and smart operations, the company sets a benchmark for intelligent manufacturing and reinforces its role as a global leader in sustainable resource production.

Author Profile

Ganpat Singh Chouhan: My name is Ganpat Singh Choughan. I am an experienced content writer with 7 years of expertise in the field. Currently, I contribute to Daily Kiran, creating engaging and informative content across a variety of categories including technology, health, travel, education, and automobiles. My goal is to deliver accurate, insightful, and captivating information through my words to help readers stay informed and empowered.