The aluminium industry is going through a massive transformation as it adopts the principle of Industry 4.0 technologies, also known as the Fourth Revolution. Companies have already implemented this ongoing change, improving the aluminium industry’s efficiency, productivity and sustainability. The Industrial 4.0 technologies in the aluminium industry include interconnectivity, automation and robotics, machine learning, real-time data, the Industrial Internet of Things, smart manufacturing, and augmented reality, many of which are still in their early implementation phases. We will give you a sneak peek at how adapting the new technologies of Industry 4.0 redefines the future of the aluminium industry.
Key elements driving digital transformation of the aluminium industry
Many industries are buzzing with discussions on “artificial Intelligence, IoT and IIoT, automation and robotics and digital production process and control.” Some of the key technologies that are driving the digital transformation of the aluminium industry include:
Digital production process and control
An aluminium plant’s digital production process and control system revolves around a computer system. The entire process of monitoring, analysing and optimising can be done effectively in real-time with the help of digitalisation by using the computer system. This includes hardware and software systems that pick up all of the data during the process and assets to ensure smooth operations, maintenance, and better error diagnosis and optimise performance.
Automation and Robotics
Automation and robotics technologies have reached a level where day-to-day tasks can now be performed in a high-risk, high-temperature zone, and with zero human intervention. Such critical operations are now found in an aluminium smelter, including pouring hot metal in the cast house furnace and processing measurements in pots and furnaces. Another use of Robotics technology is the construction of ingot bundles. Automated Guided Vehicles (AGV) is another technology that are now a part of pot rooms and cast houses.
AGV is a portable robot which moves along marked lines or wires on the floor or uses radio waves, vision cameras, magnets, or lasers for navigation. It can tow objects behind them in trailers to which it is attached anonymously. It helps move raw materials or finished products from one place to another.
Internet of Things & Industrial Internet of Things
The Internet of Things (IoT) is a type of computing concept that revolves around connecting everyday physical objects using the internet and letting them identify themselves to other devices. The industrial Internet of Things is being used in the aluminium industry as smart sensors and actuators. Both of these devices are responsible for enhancing the manufacturing and industrial processes of aluminium. They are also used in aluminium plants to track, gather, share, and analyse data from the equipment to improve production and industrial operations.
Machine Learning and Artificial Intelligence
Machine learning and artificial intelligence are interrelated. While the former is responsible for enabling machines to access data and learn how to work or perform functions independently, the latter is one of the fast-growing trends in the technological world, responsible for computer programs acting intelligently like a human brain. AI is in its infancy and poised to transform the aluminium industry by keeping tabs on energy use and more. Machine learning is rather widely applied to aluminium smelting. In order to control energy consumption, noise patterns can be captured in the reduction tank. Additionally, it can be used to predict the amount of alumina present in the battery and the anode effect.
Key Players Who Has Adopted Industry 4.0 Technologies
The aluminium industry is one of the most energy-intensive industries in the world. To improve the efficiency, productivity and sustainability of aluminium production, several companies ended up adopting the technologies of the Fourth Revolution. Some of the key global players who have embraced Industry 4.0 technologies in the aluminium industry include:
REEL International
Industrial groups like REEL International, which specialises in complex lifting and handling pieces of equipment and integrated systems solutions, have adopted the Industry 4.0 Technologies such as IoT, robotics and automation, and have created “REEL Vision”. This technology offers holistic digitalisation solutions and enhances safety, productivity, availability and efficiency for all equipment and systems of the aluminium plants.
Rio Tinto
Rio Tinto is a mining company and a global leader in the aluminium industry. It is based in Spain and focuses on finding, mining and processing the Earth’s mineral resources. It created its sustainability project, START, which is used in automating tasks and making informed decisions about aluminium production for its customers. Through this project, Rio Tinto aims to set a new standard in transparency and traceability for the aluminium industry.
Stirweld
Stirweld is a deep-tech organisation launched in 2017. Its mission is to democratise Friction Stir Welding worldwide. For the aluminium sector, they have products such as CNC and FSW spindles equipped with the latest robotics technology for collecting welding data (force control, temperature control etc.).
BALCO
BALCO, also known as Bharat Aluminium Company Limited, is India’s iconic aluminium producer. It has been maintaining an excellent record in the production of aluminium. BALCO has utilised Artificial Intelligence and developed a Pulse Data program that improves boiler reliability with smart predictions. It also uses machine learning and pattern recognition in the aluminium industry.
Wrapping up
Industry 4.0 emerged with the arrival of digital processes, automation and robotics technologies, IoT, machine learning and artificial intelligence. It has improved the aluminium industry’s efficiency, productivity, and sustainability. Many key players who have also embraced this technology include REEL International, Rio Tinto, Stirweld, and BALCO. These companies use these technologies to improve their aluminium production’s safety, productivity, availability, and efficiency.
To know more about the role of Indistry 4.0 in revolutionising the aluminium production processes, keep your eyes glued to the launch of our upcoming report on “Digital Transformation in the Aluminium Industry”.