Processes at UC RUSAL Aluminium Smelters Mikhail Grinishin, Viktor - PowerPoint PPT Presentation

Applying Digitalization to Processes at UC RUSAL Aluminium Smelters Mikhail Grinishin, Viktor Buzunov Presented by: Viktor Buzunov, Director Aluminium Technology & Technical Implementation, ETC Rusal

Contents About UC RUSAL • Development of digitalization at UC RUSAL • SAAT – Reduction process control system • ElVIS – Cell visualization and operating control • Information Technology System (ITS) - analysis, • planning, strategic management Virtual cell – dynamic digital model • New and promising digitalization projects • 2

About UC RUSAL UC RUSAL's production facilities are located in 13 countries. The Company employs 62,000 people Aluminium output (2018): • 10 smelters – 3.75 Mtpa • 5.8% of world output Alumina output: • 8 refineries - 7.77 Mtpa • 6.2% of world output Own R&D base: RUSAL Engineering & Technology Centre Ltd., RUSAL VAMI, • SibVAMI Own technologies of aluminium smelting: RA-300, RA-400, RA-500 (under development), RA- • 550 (under development), inert anodes (under development) Own technologies of alumina refining: • Alumina production from bauxites, nephelines, alunites, kaolins (under development), red mud processing (under development) 3

Development of digitalization at UC RUSAL Since 1988 own automation product range of various levels has been developed. From analogue cell control to digitalization and robot automation of the entire production. 2020 Transport logistics 2008 Anode current 2015 1988 2019 2016 1991 1996 1999 2004 2010 distribution New Modification of SAAT-4 measuring system SAAT-2.5 SAAT-3 ALUMAT Alumatic SAAT-1 SAAT-2 sensors “Aluminiy - 3” 2019 2016 2018 2012 2013 2003 - 2012 1993 2001 Virtual El. Virtual El. Web ElVIS Web ITS Web ElVIS ITS Updating ElVIS, ITS, Virtual El. 3.0 Virtual El. 2.0 ElVIS 2.0 2020 Digital CFD- ecological Predictive models monitoring analytics 4

Development of digitalization at UC RUSAL SAAT – lower level • ORACLE Potroom Automated workstation Portable workstations server of technology manager Portable meters automation system (L1) Data integration with a pot tending assembly ElVIS – upper level for • Computer speech visualization and operating generation ElVIS control (L2) ITS – MES level system for • analysis, planning and Ethernet process network strategic management (L3) Data concentrator Virtual С ell – mathematical • model of a pot (L2, L3) Cells Cells Cells Rectifier 5

SAAT reduction process control system SAAT – a standard of a process control system of UC RUSAL’s reduction area 100+ measurable parameters in the automatic mode • Integration with PTAs, portable devices and meters • A system for individual measurement of anode • currents High-precision anode frame position sensors • High-frequency voltage measurement sensors • Over 4,300 cells of the Company under SAAT control 6

SAAT reduction process control system individual anodes current measurements: Individual anode’s noise • Automatic evaluation of anodes current • distribution coefficient (ACDC) ACDC adapted alumina feeding • High-precision anode superstructure position sensors: Automatic metal inventory assessment and new tapping algorithm: Low - , Medium - , High- frequency noise estimation of metal inventory • dynamic of the metal height • tapping duration control • ~ 18 min before AE High-frequency voltage measurement sensors: PAH noise detection • 7

ElVIS – cell visualization and operating control Differentiation by access rights – • ANALYSIS OF OPERATING from viewing and analysis to control PARAMETERS POTROOM CELLS STATUS DAY/WEEK/MONTH with logging of all actions MONITORING Control of cell algorithms setting • and operating modes Flexible settings of visualization • and reports The platform is extendable and • integrated with other process control systems (PTMs, GTCs, centralized alumina distribution system) Over 5,000 users 8

ITS – analysis, planning, strategic management Uniform MES of Reduction Area for data aggregation, analysis and control Includes all intellectual control systems:  Bath composition stabilization  Control of specified voltage  Tapping planning and control  Planning and control of automated alumina point feeders  Planning and control of stud pulling (setting) / anode replacement 9

ITS – analysis, planning, strategic management • Designer of data analyzer: CONTROL OF DEVIATIONS  Table forms  Control charts  Histograms TEMPERATURE DISTRIBUTION METAL GRADE DYNAMICS PER YEAR Over 2,500 users – from shift foremen, process engineers to plant administrative personnel 10

ITS – analysis, planning, strategic management Uniform MES of Casting Area • Covers all stages:  Planning  Mixing  Laboratory analyses  Casting  Sawing  Technical control and acceptance of products  Shipping • Continuous control of compliance of process parameters and products • Automatic calculation of charge materials • SAP integration 11

ITS – analysis, planning, strategic management • Maintaining a melting practices sheet • Control of equipment operation (casting machines, filters, saw, etc.) • inventory tracking • Finished products tracking • Drawing-up of accompanying documents: Certificates   Labels  Bills of lading 12

Virtual cell – dynamic digital model Make-up: Assessment of MHD stability • Heat model • Mass and electrical balance models • Functions: Optimization of a process using • modelling tools Training of process personnel • 13

Virtual cell – dynamic digital model 14

New digitalization and robot automation projects (ecological monitoring) Digital ecological monitoring based on computer vision and artificial intellect The system can: Detect, localize,  classify the intensity of smoke and flame occurrences Compare with the data  on the current cell status Make conclusions on the  degree of cover failure Notify the process  personnel with light and sound alarms 15

New digitalization and robot automation projects (ecological monitoring) 16

New digitalization and robot automation projects (CFD modelling) CFD (computational fluid dynamic modelling) Addressable issues by the example of alumina production: Erosion and cavitations • Boiling and condensation • Heat transfer and heat losses • Agitation and chemical reactions • Multiphase flows • Slurry separation • Particle classification by size • Combustion • 17

New digitalization and robot automation projects (transport logistics) Robot automation of machinery • Telemetry and navigation control of Lidar machinery Sonars Stage Positioning 1 • Smart logistics of machinery control Stage 2 Video camera • Remote control Stage 3 • Pilotless transport Stage 4 18

New digitalization and robot automation projects (BigData) SELECTION OF CORRECTIVE Predictive analytics and computer-assisted training ACTIONS PARAMETERS PARAMETE INPUT PRODUCTION OUTPUT • Control of technological processes in RS PROCESS Reduction Area and Alumina Stage 1 Production based on virtual sensors TARG ET Warnings PCS data MEASUREMEN • Control based on a digital twin T изация производства “Virtual cell 3.0” based on artificial Stage 2 intelligence Comprehensive monitoring data analysis SOFTWARE Set of “analytical portraits” MODULE Algorithms for identification of production cycle abnormalities Methods for risk analysis of aluminium performance degradation Formation of risk management solutions 19

New digitalization and robot automation projects (Smart Anode Plant) Digital twin (model) of an anode plant: • Pressing and sintering processes  Baking furnaces and other equipment  Computer-assisted training for control of • recipes and anode baking Monitoring of anode life cycle • 3D interactive environment for virtual • simulators, simulation modelling, interactive interaction with equipment 20

Promising digitalization and robot automation projects Virtual reality simulators A prototype of a 3D virtual simulator of an operating caster at JSC “RUSAL Krasnoyarsk” Realistic safe training • 21

Promising digitalization and robot automation projects 22

Promising digitalization and robot automation projects Ingot surface quality control system based on computer vision and training A plant for automatic measurement of ingot’s geometrical parameters is intended for control of ingot’s geometrical parameters and construction of a 3D model of the ingot body surface 23

Promising digitalization and robot automation projects Establishment of Production Control Centers Remote expert assistance • Comprehensive analytics • Identification and sharing of best practices • Control of sale order fulfillment • Optimization of process utilizations • Prompt comparison of enterprises • 24

Conclusion Since its foundation, RUSAL has been continuously developing its own digital technologies to manage existing smelters and design new ones. New state-of-the-art digitalization projects will dramatically change process control and management practices to make them more up-to-date, cost-effective and environmentally friendly. 25

Thank you very much!