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GE Digital announced the availability of its newest process analytics solution, Digital Smelter. The software creates a Digital Twin of the aluminium smelting process to deliver additional insights and prescriptive guidance to help more safely maximize production, reduce raw material costs, and optimize energy consumption.
Digital Smelter delivers a full analysis of the components within a pot as well as each pot line, providing a Digital Twin to help increase the efficiency of the smelting process. The software also helps operators predict potential process and equipment anomalies and prescribe more effective decisions. These capabilities help to keep operations safer and production more optimal while reducing operator error.
Digital Smelter is able to better predict pot leaks to contribute towards reduction of unplanned stoppages and more optimized pot health. Providing alerts for anomalies, such as pot instability, and undesirable events, such as anode spikes, help to optimize energy consumption and keep the process more reliable. Digital Smelter can also improve the quality of aluminium and reduce raw material consumption by modelling an optimum amount of aluminum fluoride to use in each batch.
Digital Smelter also helps to enable all levels of management to more easily access dashboards showing the productivity, efficiency, and health of each potline or multiple lines across the organization. With the ability to benchmark performance across potlines, lower performing lines can be more quickly identified and operators can review heat maps, performance trends, and pot health indicators to make decisions to help restore the line’s performance and create more value for the business. The Digital Twin can then prescribe the most appropriate actions to help ensure the plant doesn’t shut down over costly equipment failures or Environment, Health & Safety (EHS) events, which could lead to fines and additional regulatory requirements.