Hindustan Zinc Centre of Excellence: Innovation, Automation, TechnologyL

Digitally Scaling Wider Horizons

Smoke Hours Drilling Using Automation Features

Additional production in drilling by utilising automation features and tele-remote operations of production drills during shift changeover duration. We have achieved +10% additional drilling at both Sindesar Khurd and Rampura Agucha Mines.

Use of Artificial Intelligence (AI)/Machine Learning (ML) -based Analytical Modules

Use of image processing technologies enable identification of any unsafe act or conditions on the shop floor. We developed a video analytics-based model to inspect the physical surface quality of finished goods (FG), i.e., zinc ingots, and detect any physical defects for timely corrective action.

Drone-based Stack Health Inspection

Helps to monitor frequently the health of an inaccessible structure - safely and remotely. Based on visual, thermal and ultrasonic inspection (non-destructive testing), we can assess the condition, such as thickness of steel structure, and can accordingly ensure timely maintenance.

LiDAR-based Scanning of Ore-pass

Drone-based light detection and ranging (LiDAR) mapping system enables data capture of critical underground (UG) mine excavations for new insights to optimise mine development and operations.

Heavy Earth Moving Machinery (HEMM) Idle Time Reduction by Monitoring through Internet of Things (IoT) Sensors

Installation of IoT-based smart sensors to identify and minimise idle time of low-profile dump trucks (LPDTs) has helped to reduce diesel consumption and overall cost per hour (CPH).

Deployment of Advanced Process Control (APC) at Mills

APC eliminates operator-induced variations and ensures consistent and stable plant operations, which has resulted in consistent concentrate grade and recovery improvement by 1% with optimised throughput.

Collision Avoidance System and Personnel Tracking

The collision avoidance system helps to improve an operator’s situational awareness in UG mining, and thereby prevents the machine-to-machine and man-to-machine interaction. Personnel tracking system enables a two-way communication channel for sending alert messages from control room to individual tag and vice-versa.

Predictive Maintenance (PdM), Condition Based Maintenance (CBM) & Real-time Reliability Health Index (RHI) of Critical Assets

Improves the availability, reliability and efficiency of critical assets, by using AI-based solutions that runs auto-fault diagnostics to detect any anomalies for taking timely corrective actions.

Use of IoT Technologies to Deploy Smart Sensors on Remote Equipment

Real-time monitoring and control of remote assets, like steam trap health, vibration of critical drives, water ponds level and UG fleet utilisation, etc.

AR/VR-based Winder Training Simulator System

Helps to provide training and awareness for operators through use of the virtual reality (VR) and augmented reality (AR)-based training and simulation system. It improves workplace safety and accelerates the training speed as well as proficiency.

Hindustan Zinc’s London Metal Exchange (LME) certified finished goods i.e. zinc and lead ingots are now also certified for the BIS Standard Marking. This certification of purity of metal ensures conformity with the best quality standards.

Case Study

Augmenting Drilling Productivity through Automation

Deployment of automated and tele-remote controlled drilling operations during shift-change (termed as smoke hours), particularly in a challenging environment or where the operator needs to view objects not visible from the cabin, lends flexibility for increased production, visibility, and control from outside the drill cabin. The tele-remote control offers more range and features than other remotes thereby enhancing productivity by enabling the operator to work from a comfortable space, such as a control room in a remote location.

Advantages

Significant increase in productivity during smoke hours
Improvement in safety
Increased consistency of daily operations

Outcome

10% additional drilling achieved during FY 2022-23
Complete drilling of stopes with geotechnical challenges using tele-remote operations, thereby eliminating risk

Enhancing Value through Innovations, Collaborations and Benchmarking

Silver (Ag) Promoter for Improving Ag Recovery at Zawar

Silver promoter/modified collector helps in enriching silver grade and recovery (~4%). Additional Ag metal in concentrate (MIC) at Zawar in FY 2022-23: 6 tonnes per annum (TPA).

Special High Grade (SHG) Zinc Production at Zinc Smelter Debari (ZSD)

Developed and implemented process changes which helps in reducing lead (Pb) impurity in the cathode, producing SHG zinc FG. This change will improve payable premiums.

Replacement of Flotation Reagent with Efficient Non-Hazardous Reagent

Replaced hazardous reagent with eco-friendly reagent, while also achieving cost saving.

Current Efficiency Improvement in Electrowinning at ZSD Plant

ZSD electrolyte composition achieved as desired, resulting in increase in current efficiency by ~5%.

Utilisation of Na2SO4 Crystal Produced In‑house at ZSD Plant

As part of waste to wealth drive, consumption of in-house produced Na₂SO₄ crystals in Jarosite Precipitation process at ZSD, led to reduction in the cost of production.

Enhancing Equipment Efficiency

With the objective of setting a new benchmark for asset performance, we have identified and developed Model Workplaces – ‘Utthan - Model Mines’ at Rampura Agucha Mines, ‘Aadarsh - Model Mills’ at Zawar Mines and ‘Utkrisht - Model Digital Mine’ at Sindesar Khurd Mines. The programme has improved safety, productivity, utilisation, recovery, and reliability performance, through intervention of various best practices and focussed approach on pilot areas and equipment.

The equipment under Model Workplace has shown 5% more availability and 44% more utilisation in mines, along with 5% improvement in overall equipment effectiveness (OEE) at mills, in addition to increased zinc, lead and silver recovery.

Collaborations for Integrating Best Practices

‘Samvad – Integrating Best Practices’ is a platform developed to identify excellence in pockets and spread it across the value chain through collaboration. Apart from Community of Practices, collaboration sessions under various themes like hydrocarbon management, condition monitoring, shutdown management were conducted throughout the year. Visits to other industries were also organised to inculcate best practices from across the spectrum.

NABL Accreditation of our QC Labs

Quality consciousness is imbued in the Hindustan Zinc’s organisational fabric. Our technological upgradations and innovations are aimed to ensure sustained quality across our systems and processes. The competence of our quality control (QC) laboratories is validated by National Accreditation Board for Testing and Calibration Laboratories (NABL) accreditation, awarded as per ISO/IEC 17025:2017 standards for our raw material zinc concentrate, lead concentrate, coal, biomass and met coke, as well as FG testing. As a standard, we have also deployed laboratory information management system (LIMS) in all our labs to record and report on various quality metrics, integrated into our enterprise resource planning (ERP) and historian system for data analysis.

Digitalising the Procurement Process

At Hindustan Zinc, adoption of the latest technologies, digitalisation and automation is an all‑encompassing activity, extending across the entire value chain, right from the process of procurement. Besides adoption of digitalised procurement processes in mining operations, we have in place a cloud-based case management module for risk mitigation.

Automation of inbound and outbound logistics, along with e-invoicing and paperless working are among some key digitalisation initiatives undertaken in the procurement process. We are working towards launch of a cloud-based supplier sustainability platform in CY 2023 to enhance our responsible sourcing programme in the areas of human rights. The initiative is also aimed at establishing supply chain decarbonisation of all value chain partners by helping us to connect digitally with our business partners.