• New AI-enabled Switchyard & Rectifier Hotspot
Monitoring System at Debari, Rajasthan offers real-time anomaly detection, dual
access, and automated tier-wise alerts
Hindustan
Zinc Limited, India’s only and the world’s largest integrated zinc producer and
one of the top 5 silver producers globally has successfully implemented an
AI-enabled Switchyard Hotspot Monitoring System at its Debari smelter (the
world’s oldest zinc smelter) in Rajasthan to improve equipment reliability and
efficiency. The digital solution provides real-time detection of electrical up
and downs, automated WhatsApp and tiered email alerts and dual access through
on-premises and cloud platforms. By converting unplanned shutdowns into planned
maintenance, the system is expected to enhance uptime and increase production
efficiency.
Developed
in collaboration with the startup Ripik.AI (an applied AI company developing
computer vision agents, based out of Gurugram), the application incorporates
extensive feedback and enhancement requests received during its trial phase. By
enabling early issue detection and prompt intervention, this solution has
significantly reduced total production losses by nearly 20% through 100%
elimination of unplanned outages.
With
seamless accessibility through cloud deployment as well as in the Electrical
SCADA (Supervisory Control And Data
Acquisition) Room, the system ensures operational teams can respond instantly
to potential inefficiencies. This marks a key milestone in Hindustan Zinc’s
broader initiative to deploy AI-powered monitoring and automation solutions
across its operations, further maximising asset utilisation. Technology is
planned for scale-up across Hindustan Zinc’s Mines & Smelters switchyards,
Rectifiers & Flexible Busbars.
Commenting
on the development, Hindustan Zinc’s CEO – Arun Misra said: “The Switchyard
& Rectifier Hotspot Monitoring Application is another step forward in our
journey towards more optimized operations. At Hindustan Zinc, we believe digital
innovation is key to shaping the future of metals and mining. By embedding
innovative AI-driven monitoring and technology-led predictive systems, we are
not only increasing production efficiency but also solidifying the foundation
for scalable, tech-first operations across all our units in Rajasthan.”
Hindustan
Zinc continues to drive innovation in the metals & mining sector by
deploying advanced technologies that enhance safety, efficiency, and
sustainability. The company has established a first-of-its-kind digital
collaboration centre that analyses data from all business units and provides
real-time insights for robust decision-making process. Hindustan Zinc has also
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. By integrating this technology, Hindustan Zinc has enhanced
operational efficiency by 20-30% while significantly reducing the need for
manual intervention by nearly 50%. Additionally, the company has deployed
robotic automation in smelting operations, boosting precision, streamlining
metallurgical workflows, and ensuring consistent product quality. Through these
innovations, Hindustan Zinc is redefining the future of mining in India and setting
new global benchmarks for the industry.
