RUSAL, one of the world’s leading aluminium producers, has rolled out two new AI-powered systems designed to make its factories more efficient and reliable. The company has introduced machine hearing in alumina production and machine vision in aluminium melting. Both systems are part of RUSAL’s plan to modernise and automate its operations.
The machine hearing system analyses mill vibrations during bauxite ore processing. Recording these vibrations, AI can easily identify whether the mill is overloaded or underused. Accordingly, it can adjust the measurement of ore that is being fed to the machine. Thus, it helps to maintain an optimised load balance, which saves electricity and prevents unnecessary wear and tear of the equipment. It helps RUSAL produce higher-quality alumina, which in turn supports more efficient aluminium production
For the production of alloy, RUSAL has deployed a machine vision system which helps to monitor the melting process of aluminium. The process has around 20 steps, and the AI helps operators follow each one correctly. Using a camera and a neural network, it checks the composition of the alloy and spots areas of dross that need to be cleaned away.