High-Precision Personnel and Vehicle Positioning Project for a Smelting Plant

Zijin Nonferrous Metals Co., Ltd., a subsidiary of Zijin Mining Group, is a leading nonferrous metal smelting enterprise and a regional model for circular economy development. Established in 2004, the company specializes in smelting, mining, and processing zinc, other nonferrous/ferrous metals, and energy minerals.

Challenges

The sprawling Zijin plant employs over 1,800 personnel and operates under complex conditions:

Hazardous environments: High-temperature, high-pressure zones; corrosive areas with strong acids, heavy metals, sulfur dioxide, and acid mist.

Continuous operations: Large-scale equipment runs 24/7, alongside heavy vehicle traffic (zinc ingot transporters, sulfuric acid tankers, waste material trucks, and raw material logistics vehicles).

Safety risks: Unmanaged personnel/vehicle movements in restricted zones, inefficient emergency response, and limited oversight of high-risk areas.

The company sought a comprehensive RTLS (Real-Time Location System) to digitally monitor personnel, vehicles, and critical zones, ensuring operational safety and efficiency.

Solution

After evaluating multiple options, Zijin partnered with Henggao Technology to deploy a UWB solutions-based management system. Key components include:

Full-coverage RTLS infrastructure: Positioning base stations installed across the plant for zero-blind-spot real-time location tracking.

Wearable tags: Personnel badges and vehicle-mounted tags enabling Real-Time Personnel Location Trackingand vehicle monitoring.

2D/3D mapping: Digital maps highlighting restricted zones, hazardous areas, and asset locations.

System functionalities

Real-time visibility: Track personnel/vehicle movements and historical trajectories.

Visitor management: Access permissions and automated gate controls.

Safety inspections: Route planning, duration monitoring, and task compliance tracking.

Restricted zone controls: Geofenced alerts for unauthorized entry or prolonged stays.

Video integration: CCTV feeds linked to map coordinates for targeted surveillance.

Outcomes

Since implementation:

Vehicle speeding incidents dropped to near zero.

Hazardous zone risks are now systematically managed.

Safety protocols are enforceable with real-time data.

Visitor experiences and operational orderliness improved significantly.

Next Steps

Zijin plans to further optimize the RTLS for:

Proactive identification and mitigation of safety vulnerabilities.

Data-driven workforce and vehicle allocation.

Enhanced competitiveness through IoT-driven operational excellence.

Conclusion

By adopting UWB solutions and Real-Time Personnel Location Tracking, Zijin transformed its safety and efficiency frameworks. The RTLS not only resolved critical pain points but also established a scalable model for smart industrial management, aligning with global standards for hazardous environment operations.