The Wolfson Centre for Bulk Solids Handling Technology

RUSAL implements ‘BigData’ project in Siberian smelters

(Posted on 27/06/19)

RUSAL, one of the leading global aluminium producers, is launching a potroom control system as part of its production efficiency improvement strategy. Such a development will use advanced scientific and methodological approaches based on forecast analytics known as ‘BigData’.

The development and implementation of the new system will increase the Company’s aluminium production efficiency twofold; by decreasing the abnormalities throughout the process and improving the reduction cell control quality. At the end of 2019, the project investment will amount to around RUB 20 mln.

Currently, the causes of inefficient reduction cell operations are troublesome post factum, whereas there is no control over an operation of efficient reduction cell in the optimum process window. These are limiting factors which handicap the best performance indicators of both a potline and the whole smelter. As such, therefore the Technical Directorate and IT Department have initiated this project to develop a potroom control system using advanced scientific and methodological approaches based on forecast analytics (BigData). The system is expected to detect the causes of any reduced reduction cell performance, recognise the optimum conditions depending on the status of equipment and most importantly, predict malfunctions.

Several smelters of RUSAL in Siberia are implementing the pilot project. The system, which is currently being designed if successful, is due to be rolled out to other productions of the Company at no extra cost.

‘The use of forecast analytics in potroom control is just one step towards our target that we have set within our R&D framework. If successful, similar approaches will be enrolled for analysis and to increase efficiency at other stages of the production chain. Such efficiencies will assist in minimising our energy consumption and improve our overall performance of the aluminium production.’ – said Viktor Mann, RUSAL’s technical director.

RUSAL is a leader of the global aluminium industry. In 2018, the Company accounted for about 5.8% of global production of aluminium and 6.2% of alumina production. The Company employs about 64,000 people RUSAL's offices are operating in 20 countries all over the world and across 5 continents.