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

Presented by: Viktor Buzunov, Director Aluminium Technology & Technical Implementation, ETC Rusal

Applying Digitalization to Processes at UC RUSAL Aluminium Smelters

Mikhail Grinishin, Viktor Buzunov

• 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

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Contents

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)

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About UC RUSAL

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.

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1988 Modification

• f

“Aluminiy-3” 1999 SAAT-1 2004 SAAT-2 2010 SAAT-2.5 2016 SAAT-3 2019 SAAT-4 1993 ElVIS 2003 ITS 2012 Web ITS 2013 Web ElVIS 2019 Virtual El. 3.0 2018 Web ElVIS 2.0 2015 New sensors 2016 Virtual El. 2.0 2001 Virtual El. 2008 Anode current distribution measuring system 1991 1996 ALUMAT Alumatic

• 2012

Updating ElVIS, ITS, Virtual El. Digital ecological monitoring CFD- models 2020 Transport logistics 2020 Predictive analytics

Development of digitalization at UC RUSAL

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• SAAT

– lower level automation system (L1)

• ElVIS–

upper level for visualization and operating control (L2)

• ITS – MES level system for

analysis, planning and strategic management (L3)

• Virtual Сell – mathematical

model of a pot (L2, L3)

• f technology manager

Portable meters

Computer speech generation

Data integration with a pot tending assembly

SAAT reduction process control system

SAAT – a standard

• f 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

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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

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~ 18 min before AE Low - , Medium - , High- frequency noise High-precision anode superstructure position sensors: Automatic metal inventory assessment and new tapping algorithm:

• estimation of metal inventory
• dynamic of the metal height
• tapping duration control

High-frequency voltage measurement sensors:

• PAH noise detection

ElVIS – cell visualization and operating control

• Differentiation by access rights –

from viewing and analysis to control with logging of all actions

• 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

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ANALYSIS OF OPERATING PARAMETERS DAY/WEEK/MONTH POTROOM CELLS STATUS MONITORING

ITS – analysis, planning, strategic management

• 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

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Uniform MES of Reduction Area for data aggregation, analysis and control Includes all intellectual control systems:

ITS – analysis, planning, strategic management

• Designer of data analyzer:
• Table forms
• Control charts
• Histograms

METAL GRADE DYNAMICS PER YEAR 10

CONTROL OF DEVIATIONS

TEMPERATURE DISTRIBUTION

Over 2,500 users – from shift foremen, process engineers to plant administrative personnel

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
• f process parameters and products
• Automatic calculation of charge materials
• SAP integration

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ITS – analysis, planning, strategic management

• Maintaining a melting

practices sheet

• Control of equipment
• peration (casting machines,

filters, saw, etc.)

• inventory tracking
• Finished products tracking
• Drawing-up of

accompanying documents:

• Certificates
• Labels
• Bills of lading

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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

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Virtual cell – dynamic digital model

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New digitalization and robot automation projects (ecological monitoring)

The system can:

• Detect, localize,

classify the intensity of smoke and flame

• ccurrences
• Compare with the data
• n the current cell status
• Make conclusions on the

degree of cover failure

• Notify the process

personnel with light and sound alarms

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Digital ecological monitoring based on computer vision and artificial intellect

New digitalization and robot automation projects (ecological monitoring)

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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

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New digitalization and robot automation projects (transport logistics)

Stage 1

Robot automation of machinery

• Telemetry and navigation control of

machinery

Stage 2

• Smart logistics of machinery control

Stage 3

• Remote control

Stage 4

• Pilotless transport

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Video camera

Positioning

Sonars

Lidar

New digitalization and robot automation projects (BigData)

изация производства

Stage 1

• Control of technological processes in

Reduction Area and Alumina Production based on virtual sensors

Stage 2

• Control based on a digital twin

“Virtual cell 3.0” based on artificial intelligence

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SELECTION OF CORRECTIVE ACTIONS

Comprehensive monitoring data analysis Set of “analytical portraits” Algorithms for identification of production cycle abnormalities Methods for risk analysis of aluminium performance degradation Formation of risk management solutions

SOFTWARE MODULE

Warnings PCS data

MEASUREMEN T

TARG ET INPUT PARAMETE RS

OUTPUT PARAMETERS PRODUCTION PROCESS

Predictive analytics and computer-assisted training

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

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Promising digitalization and robot automation projects

Virtual reality simulators

A prototype of a 3D virtual simulator

• f an operating caster at JSC “RUSAL

Krasnoyarsk”

• Realistic safe training

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Promising digitalization and robot automation projects

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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

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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

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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.

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Thank you very much!