Hindustan Zinc unveils AI hotspot monitoring at Debari smelter

Post by : Meena Rani

Hindustan Zinc Ltd has announced the launch of an AI-enabled Switchyard Hotspot Monitoring System at its Debari smelter in Rajasthan, the world’s oldest operational zinc smelter. The initiative marks a major step in the company’s ongoing digital transformation strategy, aimed at enhancing equipment reliability, minimizing downtime, and increasing production efficiency.

This digital-first monitoring solution provides real-time data on electrical fluctuations, generates automated alerts via WhatsApp and tiered emails, and can be accessed both through on-premises infrastructure and cloud platforms. By transforming unplanned shutdowns into planned maintenance schedules, Hindustan Zinc expects to significantly improve operational uptime and safeguard production cycles.

Collaboration with Ripik.AI

The development of this solution was carried out in collaboration with Ripik.AI, a Gurugram-based applied AI company specializing in computer vision technologies. The monitoring system underwent rigorous trials, incorporating user feedback to refine accuracy and performance.

The proactive solution detects irregularities in switchyard operations at an early stage, enabling rapid response to potential faults. According to company officials, the system has already contributed to an impressive 20% reduction in total production losses, primarily due to the complete elimination of unplanned outages.

By integrating with Hindustan Zinc’s Electrical SCADA (Supervisory Control and Data Acquisition) Room, the system ensures seamless response and decision-making.

Expansion of AI-driven automation

Hindustan Zinc has set a roadmap to extend this AI-enabled monitoring technology beyond switchyards. Future deployments will target rectifiers, mines, smelters, switchyards, and flexible busbars, further enhancing asset utilization across the company’s value chain.

CEO Arun Misra highlighted the broader vision, stating:

“The Switchyard & Rectifier Hotspot Monitoring Application is another step forward in our journey towards more optimised operations. At Hindustan Zinc, we believe digital innovation is key to shaping the future of metals and mining. By embedding AI-driven monitoring and predictive systems, we are not only increasing efficiency but also creating a foundation for scalable, tech-first operations across all our units in Rajasthan.”

Hindustan Zinc’s vision for digital transformation

This project forms part of Hindustan Zinc’s wider strategy to leverage artificial intelligence, robotics, blockchain, and the Industrial Internet of Things (IIoT) for next-generation mining operations. The company has already established a pioneering digital collaboration centre that aggregates and analyses data from all business units, offering real-time insights to enhance decision-making and operational resilience.

By consolidating operations under one digital framework, Hindustan Zinc aims to lead India’s mining industry in terms of efficiency, sustainability, and safety.

AI-powered safety and robotics

Beyond efficiency, Hindustan Zinc has invested heavily in AI-powered safety monitoring systems. A large-scale rollout of AI-driven camera surveillance across its operational sites has enhanced workplace safety, ensured regulatory compliance, and reduced risks for workers. The system has led to measurable outcomes:

• 20–30% improvement in operational efficiency.

• 50% reduction in manual intervention.

In addition, the integration of robotic automation within smelting operations has increased precision, reduced process variability, and improved product consistency. By automating metallurgical workflows, the company has streamlined production while maintaining the highest quality standards.

Driving global mining benchmarks

Through these innovations, Hindustan Zinc is positioning itself as a global leader in the adoption of digital mining solutions. Its focus on predictive maintenance, workplace automation, and AI-enabled monitoring reflects a broader industry trend toward reducing human dependency, minimizing environmental impact, and achieving higher sustainability benchmarks.

The Debari smelter initiative demonstrates how legacy infrastructure can be modernized with AI and IIoT technologies, ensuring that even the oldest zinc smelter in the world remains competitive and efficient in the global metals and mining landscape.

Hindustan Zinc’s AI-enabled Switchyard Hotspot Monitoring System is more than a technological upgrade—it is a strategic step towards digital-first mining operations. By reducing outages, optimizing efficiency, and prioritizing safety, the company is setting new benchmarks for India’s mining industry while contributing to global standards of innovation and sustainability.

As Hindustan Zinc continues to scale its AI-driven automation and monitoring technologies, it underscores a future where advanced digital tools are central to mining operations, ensuring resilience, efficiency, and responsible resource utilization.

Hindustan Zinc, Debari smelter, AI monitoring system, Switchyard Hotspot Monitoring