Arun Misra
CEO & Whole Time Director, Hindustan Zinc Limited
What is your thought on the evolution of India’s mining sector?
India’s mining sector has seen a steady growth in the past 5 years, growing at a 7.5% in FY24. This has come on the back of steady evolution of India’s mining industry, which can be attributed to technological innovation, supportive government policies and a commitment to sustainable practices. The adoption of automation and digitalization has driven the industry to a sustainability-focused, technology-powered force. Innovative practices such as in-pit crushing and conveyor systems have also revolutionized traditional mining practices, making the industry more energy efficient and aligned with global sustainability standards.
Further, at Hindustan Zinc, we have taken a step towards making the mining industry more diverse and gender neutral and currently boast of more than 600 women employees in core operations, about 22% of our workforce.
All these steps have led to a gradual and substantial evolution of the mining industry in India, which has led to India becoming one of the top five mineral producers in the world. Today, the mining sector is a key contributor to the economy, accounting for over 2% of the national Gross Value Added (GVA) and serving as a multiplier for industrial growth.
What are some of the innovations used by Hindustan Zinc as a leader in the metal manufacturing?
At Hindustan Zinc, we spearhead innovation by incorporating advanced technologies like Artificial Intelligence (AI), Machine Learning (ML), Internet of Things (IoT), drone technology, and Virtual Reality (VR), across our operations. Employing air-conditioned helmets and smart wearables enables us to mitigate heat stress, and AI-enabled cameras for safety incident monitoring ensures safe and smart mining operations. Our cutting-edge extraction techniques enhance sustainable use of resources.
We focus on areas like process optimization, enhanced metal recovery, and sustainability. We are producing critical metals by mitigating our carbon footprint through the augmentation of quantum of renewable energy in our power mix, improving operational efficiencies and utilizing alternate fuels. We are producing Asia’s first low carbon ‘green’ zinc, EcoZen which alludes to the best of eco-sensitivity and peace-of-mind of a top-quality zinc product. This low carbon eco-friendly zinc has one of the lowest global warming potential values (GWP) on the market about 75% lower than the global average.
We have further deployed computer vision-image processing technology, virtual reality-based simulator for training, augmented reality-based tools and drone technology for exploration inside the mines. Furthering our commitment to innovation, we actively collaborate with tech start-ups specializing in robotics, AI, blockchain, and IIoT. These collaborations enable predictive maintenance, real-time monitoring, and data-driven decision-making, thereby improving productivity, reducing downtime, and enhancing operational efficiency.
What kind of equipment and technologies are being adopted by Hindustan Zinc in its mining activities?
Hindustan Zinc is at the forefront of integrating advanced technologies to enhance efficiency, safety, and sustainability in its mining operations. Initiatives include the deployment of battery-powered electric vehicles (BEVs) to replace traditional diesel vehicles, implementation of Mobile Miner technology, and the use of drones, IIoT sensors, AI/ML, and cloud technology to achieve our 'Mines of the Future' vision.
We employ the Long Hole Open Stoping mining method across all our mines, utilizing tailings to backfill stope voids as paste or hydraulic fills. Typically, stoping is mined in a bottom-up sequence, with backfill forming the working platform for the next level of extraction. However, at our Rampura Agucha mine, the world's largest underground zinc mining operation, we apply a top-down extraction sequence, showcasing our innovative approach.
Technological innovation also supports our exploration efforts for sustainable reserve utilization. Technologies such as Focused Loop Borehole Electromagnetic Survey (FLBHEM), DRX drill hole targeting systems, Tunnel Seismic Profiling (TSP), and Motorized Directional Drilling (MDD) have been employed with favorable results.
Through the adoption of these innovative technologies and practices, Hindustan Zinc continues to set benchmarks in the mining industry, reflecting its commitment to operational excellence and environmental stewardship.
How is Hindustan Zinc pushing sustainable practices in mining?
India's mining sector is increasingly embracing sustainable practices to minimize environmental impact and promote resource efficiency. Key initiatives gaining momentum include:
Renewable energy integration: Mining companies are investing in renewable energy sources such as solar and wind power to reduce greenhouse gas emissions. At Hindustan Zinc, we have also replaced our diesel-based mining vehicles with battery operated underground mining vehicles. Further, implementing energy-efficient practices, such as installing LED lighting and utilizing energy-saving equipment helps lower the industry's carbon footprint while improving long-term operational cost-effectiveness.
Use of digital technology and automation: The adoption of technologies like drones, computer visions, IoT sensors, AI/ML-based predictive models, cloud-based technology, and implementation of autonomous systems across both open-pit and underground mines is significantly upgrading the way India’s mining industry works, making it safer and efficient.
In addition, using energy-efficient technology, digital and automation systems, and production of EcoZen, Asia’s first low carbon 'green' zinc, with a carbon footprint of less than 1 tonne of carbon equivalent per tonne of zinc produced, are all measures which are propelling Hindustan Zinc towards its target of Net Zero emissions by 2050.
It was this commitment towards innovation, operational excellence and implementing sustainable practices across the value chain, that won us the recognition of world’s most sustainable metals and mining company for the second consecutive year by the S&P Global Corporate Sustainability Assessment 2024. And we continue to innovate and progress further in this direction.
What are the smart technologies adopted by the company for efficiency and productivity in mining? What are the best practices employed?
In India, technology penetration in mine planning and operations continues to be lower than that in many leading economies. However, the country’s mining industry is heading towards a technology-driven optimization.
Hindustan Zinc has always been at the forefront of adopting innovative solutions and smart technologies for responsible mining. We recently introduced India’s first Battery Electric Vehicles (BEVs) in underground mining. This technology will help us drastically reduce carbon emissions, enabling the mine operations to become more environmentally friendly.
We are also implementing the Mobile Miner Technology in our mines. A rock-cutting process, the Mobile Miner makes planning and scheduling much easier due to its predictability, making mining more cost-efficient in their operations. Further, we are looking at introducing mineral sizer technology, which is the latest innovation in the crushing industry providing a compact and efficient way of comminution. We are also using Tele remote LHD, solo equipment, and jumbo equipment that removes the operator from the hazardous area and relocates them to a secure and protected location where they can control the machine via remote with the help of multiple cameras and sensors.
Electrical substation automation has also aided in faster troubleshooting and reduced non-working hours due to events such as power outages by optimising energy consumption and improving efficiency. Enhanced digitization and remote support of work activities allows us to take more integrated view of assets, business units, and the organization.
What are the major challenges faced by mining companies and what are some of the possible solutions?
Traditionally, the mining industry has faced environmental, health and safety and work-force related concerns. But as the industry has evolved in the past few years, a shift towards more sustainable mining practices has led to a tremendous growth in the sector. The current geopolitical risks may also lead to trade restrictions and supply-chain bottlenecks in some areas. As the world progresses towards low-carbon economies, the mining industry will further need to move towards low-carbon footprint mining practices.
To address this, organizations need to invest in R&D and technologies that reduce environmental impact, improve safety measures, and maintain transparency in their operations. Adapting to evolving regulatory frameworks, strengthening supply chains, increasing domestic demands through industry awareness initiatives, and invest in skill-development, along with community focussed initiatives can lead to an eco-system of sustainable growth in the mining sector. Government policies can go a long way in sustaining growth during the energy and technological transition that the mining industry is undergoing now.
What is your vision on sustainable future in mining?
At present, the mining industry is undergoing a transition, and it is estimated that global mining sector would require an estimated investment of USD 1.7 trillion to facilitate this transition. So, the question of sustainability is closely linked to the industry’s long-term growth.
At Hindustan Zinc, we believe that the future of mining must be responsible, resource-efficient, and technology-driven. As India’s leading zinc producer, sustainability is not just an obligation for us—it is a core part of our business strategy. Our vision is to set global benchmarks in sustainable mining by leveraging innovation, renewable energy, and circular economy principles.
We have already taken significant steps toward achieving net-zero emissions by 2050, in line with our commitment to the Science-Based Targets initiative (SBTi). Our investment in green energy, such as expanding solar and wind power capacities, is reducing our carbon footprint. Additionally, we are pioneers in water stewardship, operating with a near-zero discharge model to ensure water conservation in mining regions.
Technology plays a crucial role in our sustainability roadmap. We are deploying artificial intelligence, automation, and digital twins to enhance efficiency, reduce waste, and ensure safer mining practices. Our underground mining operations are some of the most advanced in the world, with best-in-class safety and environmental management systems. As a result, we have managed to achieve a 14% reduction in GHG (greenhouse gas) emission intensity compared to the base year 2020, while increasing production each year.
