building a smart anode plant - future aluminium forum

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Future Aluminium Forum 2020

Building a Smart Anode Plant The concept

Presented by: Yury Kokin Head of Digitalisation RUSAL

2 Future Aluminium Forum 2020

Contents

1.Concept

2.Production management module

3.Quality management module

4.Repairs and maintenance management module

5.Cost management module

6.Expected outcomes

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Concept

Smart Anode Plant


Four Modules Of a Smart Anode Plant

Production Management Module

Quality Management Module

Maintenance Management Module

Product Cost Management Module

Smart Anode Plant


Digital Tools Of a Smart Anode Plant

Digital twins

Artificial intelligence

Operation Centre

Smart wearables

Service-oriented architecture


Architecture Of a Smart Anode Plant

Digital twins

Calcination complex Energy generation complex

Auxiliary production

Green anode production Baked anode production

Artificial intelligence and predictive analytics systems



Repairs And

Maintenance Management Module


Operation Centre

Corporate management systems (ERP) Corporate Level

Smart Anode Level

Field Level


Five Steps Of Implementation

Step 1: Development and implementation of a company-wide system for the classification and coding of equipment and the production facility assets.

Step 2: Standardisation of requirements for the automation of production processes

Step 3: Creation of a company-wide storage of historical parameter data

Step 4: Creation of a company-wide automated operator and dispatch management system for the production processes

Step 5: Deployment of company-wide digital technologies at the production facility

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Smart Anode Plant


Anode Digital Twin

• Putting an anode ID on the surface

• Storing all information for each anode:

When was it made?

What raw materials was it made from?

What were the process parameters?

What were the QC findings?

Increasing availability of information for each anode Improving product quality through deep analytics Improving precision and tracking of production

Coke

Pitch Anode paste

Green anode

Baked anode Electrolysis

RFID tag on the anode rod

assembly

Anode rodding shop

Anode plant Aluminium smelter

RFID tag reading Coded anode Putting the code on the anode

RFID tag


Personnel assignments are issued to the terminals

and smart wearables

Automated Planning And Recording Of Output • Full scheduled process down to individual production steps

• Keeping track of all the factors (raw materials, energy consumption, staff, warehousing capacity)

• Real time tracking of each operation status

• Anode life cycle tracking to analyse the genealogy of production process

Ensuring consistency of production processes

Boosting the speed of production planning and tracking

Production cost optimisation


Process Digital Twin • Imitation of the production process using mathematical

models

• Forecasting KPIs based on statistical assumptions

• Optimising logistics and warehouses

Improving the precision and reducing the time of planning Improving the productivity of the plant Reducing costs by optimising the production KPIs


Operation Centre • A video wall with interactive dashboards

and a 3D model of the assets

• Instantaneous presentation of any information

• Instantaneous notification of every event

• Sharing of information through smart wearables

• Production CCTV and integration with SCADA

Reduced time and improved quality of management decisions Collection of data for subsequent analysis Improved plant management transparency

Situational awareness interface

Delivery of information to devices of any type

Scalability and extension of functionality

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Smart Anode Plant


Quality Management Systems

Improved quality of the produced anode blocks

Ensuring consistency of the production process

Minimising production cycle losses

Monitoring the quality of the anode production process

Timely detection of deviations in key parameters

Correlation analysis of deviation parameters

Forecasting the probability of defects


Machine Learning And Machine Vision

Improving the quality of calcined coke, anode paste and anode blocks Reducing the probability of industrial accidents Reducing the production costs

• Optimising the production modes

• Identifying emerging production defects

• Optimising the production recipe

• Identifying and classifying product defects


Non-destructive Anode Testing

Improved quality of anode blocks Improved defect detection precision Reduced defect detection time

• Electrical resistance testing

• Use of test data to analyse recipes

• Identification of correlations between recipes and test data

• Statistical quality control based on electric conductivity data

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Repairs And Maintenance Management Module

Smart Anode Plant


Predictive Diagnostics

• Stationary vibration monitoring

• Vibration and acoustic tests

• Visual and instrumentation control

• Thermal monitoring

• Electrotechnical laboratory

Reduced number of accidents and unscheduled equipment downtime

Reduced number of accompanying and cascade equipment failure

Increased service life of components, parts and machinery


Risk-oriented Equipment Maintenance

• Classification of equipment by accident risk and accident consequences

• Link with the predictive diagnostics system

• Classification of assets based on data about their state

• Fast re-scheduling of maintenance tasks

• Use of wearable electronics

• Risk based planning of demand for spare parts and consumables

Reducing the number of accidents and unscheduled downtime

Reducing asset operating and maintenance costs

Increasing asset productivity


Virtual Simulators For Staff

• Training scenarios based on 3D models and interactive elements

• Collective training capabilities

• Integration with mathematical models of equipment and imitation models of processes

• Virtual tours through the production premises without hard hats

Improving health and safety and reducing injuries Reducing personnel training time Reducing the costs of repairs and maintenance

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Smart Anode Plant


Managing The Costs Of Utilities And Environmental Protection

• Continuous monitoring and analysis of energy flows

• Transparency of the actual energy budget

• Energy planning and forecasting

• Tariffs managing

• Improving the energy efficiency of production processes.

• Monitoring generation and use of secondary energy resources

• Monitoring environmental parameters

Improving the energy resources use efficiency

Improving the precision of forecasting the demand for energy resources

Reducing emissions and production waste

Reducing costs

Energy management Purchasing energy Use of energy

Total costs

Electricity Heat Water Compressed air Fuel oil Etc.

Forecasting further consumption

Automatic load scheduling

Compliance with purchase contracts

Transparent energy and material balance

Automatic reporting Identifying

optimisation potential

Fast and pro-active

decision making Resource

preservation Preventing errors

Reporting system

Monitoring and balance

Planning

Current condition


Integration With ERP And Material Balance

• Accounting costs of the company from various angles

• Monitoring product costs incurred in production

• KPI based cost planning

• Automatic estimation of energy and material balances

Reducing the production costs Improving the precision and effectiveness of cost planning Increasing the transparency and monitoring of costs

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Expected outcomes

Smart Anode Plant


Expected Effects Of The Digital Factory

Reduced emissions as a result of a more consistent production process

Improved health and safety

Improved product quality at the Anode Plant and reduced number of defects through the use of artificial intelligence to optimise production modes and recipes

Potential improvements in the performance of the reduction area as a result of improved anode block quality

Improved equipment KPIs as a result of reduced number of accidents and unscheduled downtime

Reduced anode production costs as a result of reduced consumption of fuel and energy

Reduced errors due to the human factor A report by PwC** on digitalisation in the metal production industry: 31% of metal production companies in the world have a high level of digitalisation 62% will have a high level of digitalisation in 5 years **PricewaterhouseCoopers is the world's largest business consultancy and audit company

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building a smart anode plant - future aluminium forum

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