Where are we really in digitalization in primary aluminum production?

Last month in my Linkedin article, I talked about some of the challenges of digitalization of primary aluminium production, which is, a good example of many process industries and why progress is slower than we perhaps think. In late April, I had the privilege to present on the state of digitalization in the aluminium industry at the CRU World Aluminium Conference in London. Today, I would like to relay some of the findings on what already is out there.

At Outotec, we have developed a simple five-stage framework for applications in complex process industries that serves as a testament of our maturity in different stages of the value chain:

1. Measuring and managing data: Systems including both hardware and software for analyzing, sensing and monitoring processes, as well as equipment visualizing measurement results without analyzing them at least in the advanced manner.
2. Sensing and diagnosing: Software solutions and systems that draw data from assets and processes, which provide analytics and visualization of asset availability, performance and condition for asset maintenance and performance management.
3. Simulating and creating a “twin”: Stand-alone systems that support decision making and learning by exploring process and equipment behavior and testing different scenarios.
4. Optimization: Applications that stabilize, advise and optimize by connecting to process control and equipment, having an algorithm and actionable suggestions to adjust process control parameters manually or in closed loop in order to improve efficiency, performance and availability while reducing costs
5. Robotics and autonomous operation: Systems and equipment that can autonomously operate based on sensing and gathering information dynamically.

With the definitions clear as above, we interviewed our main customers, performed a wide search in literature from recent years to understand where we are in different parts of the value chain. And I’m happy to share our findings with you – please read my latest article written for Outotec’s Aluminum Insights Newsletter: https://www.outotec.com/company/newsletters/aluminum-insights/digitalization-of-primary-aluminium-production-solutions-and-challenges/