Hindustan Zinc, Ripik.AI Launch AI Hotspot Monitoring System

• Hindustan Zinc has deployed a Switchyard and Rectifier Hotspot Monitoring System at Debari smelter
• The system has reduced unplanned outages, cutting production losses by nearly 20%
• The company’s digital programme includes AI-powered surveillance, robotic automation, blockchain, and IIoT technologies

In collaboration with Gurugram-based startup Ripik.AI, Hindustan Zinc has introduced an AI-powered Switchyard and Rectifier Hotspot Monitoring System at its Debari smelter in Rajasthan. This system allows real-time identification of electrical disturbances, automated alerts sent via WhatsApp and varying levels of emails, and it operates on both on-premises and cloud platforms.

The company stated that this technology has converted unplanned shutdowns to planned maintenance for improved uptime and operational efficiency. Hindustan Zinc has partnered with Ripik.AI to implement AI hotspot monitoring for enhanced smelter safety and operational efficiency.

The system aided in the nearly 20 percent reduction in total production losses by avoiding unplanned outages that improve the overall efficiency. Operational teams can react to potential issues immediately through deployment from the cloud or from the Electrical SCADA room.

This initiative leverages industrial AI and mining technology to provide AI in smelters, industrial safety solutions, and improved zinc production.

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Hindustan Zinc is working on adopting this technology in its mines and smelters, covering areas from switchyards, rectifiers and flexible busbars. It is part of the company's digital program, which also includes a Digital Connection Centre that identifies, informs and connects data across business units for real-time insights.

"The Switchyard and Rectifier Hotspot Monitoring Application is another step forward in our journey towards more optimised operations. By embedding AI-driven monitoring and predictive systems, we are increasing production efficiency and creating the foundation for scalable, technology-led operations across all our units in Rajasthan", stated Arun Misra, CEO, Hindustan Zinc.

Hindustan Zinc is also implementing AI-powered cameras to monitor safety and compliance, robotic automation in smelting operations, and has adopted and deployed advances such as blockchain and the Industrial Internet of Things. Collectively, these initiatives improved operational productivity by 20-30 per cent while reducing manual intervention by 40-50 percent.