Konkrete eksempler på bruk av Industri4.0 i Hydro. Hans Erik Vatne, CTO, Hydro , Oslo, Styreinstituttet

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1 Konkrete eksempler på bruk av Industri4.0 i Hydro Hans Erik Vatne, CTO, Hydro , Oslo, Styreinstituttet

2 A resource-rich and customer-oriented aluminium company With robust positions across the value chain Bauxite & Alumina Energy Primary Metal Rolled Products Extruded Solutions Global provider of alumina, aluminium and aluminium products and solutions Leading businesses along the value chain; raw materials, energy, primary metal, rolled products, extruded solutions and recycling 35,000 employees at more than 150 locations in more than 40 countries on all continents Market cap ~NOK 110 billion/usd 14 billion Annual revenues ~NOK 137 billion (2016)* Included in Dow Jones Sustainability Indices, Global Compact 100, FTSE4Good *) The sum of Hydro s and Sapa s individual turnover In 2016 (4)

3 Digitalisering - er det en revolusjon eller en hype? eller bare en ny inntektsstrøm for konsulenter og leverandører? 3

4 What is Industry4.0 for Hydro? For Hydro the business case is not to sell digital platforms and solutions but to utilize the digital opportunities to improve productivity, cost, safety and environmental footprint Explorational initiatives in 5 main categories: Automation/robotization Real-time connectivity Smart sensors Advanced analytics/machine learning Digital twins 4

5 Automation drones for inspection Alunorte stocks: Bauxite, hydrate and coal are stored in different ways: covered sheds or open patios Hydrate remote stock Bauxite remote stock Bauxite shed Bauxite pile Total capacity of storage: Hydrate = t Bauxite = t Coal = t Aprpoximately 15% is stored in covered sheds Coal pile Coal shed Hydrate sheds 5

6 Stock pile management Project aims to use drone (photogrammetry) and laser scanner (LIDAR) 6

7 Automatisering kommer og fjerner uønskede arbeidssituasjoner (ergonomi, eksponering og skaderisiko) Calibration of thermocouples Level measurements Superheat measurements 7

8 Avansert kran med økt automatisering og funksjonalitet Pot Tending Machine (PTM) for håndtering av celledeksler ved anodeskift PTM (Pot tending machine) for håndtering og drift av elektrolyseceller Automatisert håndtering av celledeksler, her i drift ved Qatalum Automatisert anodeskift vil delvis baseres på globalt posisjoneringssystem og utføres med delvis eller full automatisering RFID reader (innhenter informasjon fra sensorer på bestemte objekter ved hjelp av radiobølger) 8

9 Process Automation Pilot Årdal Finance Software robots for controlling Implementing Robotic Process Automation (RPA) of financial reporting in Årdal Finance Month End Closing Årdal SAP Input DLS AAK AAF AAM ASI Årdal KPI Årdal High number of very fragmented processes to be automated APICS Estimated Assumptions Current year C&M DLS BP C&M DLS C&M AAK BP C&M AAK C&M AAF BP C&M AAF C&M Rodding BP C&M Rodding C&M ASI BP C&M ASI EBIT Årdal More than 130 Spreadsheets involved in period closing process Power Prices Norwegian Melters Price Reporting Coke and Pitch Kraftbilag Deviation Report AAK Deviation Report AAF C&M Elektrolyse BP C&M Elektrolyse Deviation Report ASI NOC BOC HFM Input from , meetings, xls sheets from Corporate Casthouse Assumptions Anode and Butts Prices C&M AAM BP C&M AAM BOC BP CAPEX Management Report Goal of the project is to free up time to be used for more value adding tasks Anode and Butts Prices estimates Estimate from Project leaders Input from Corporate Create Fixed Cost Sheet Validate Fixed Cost Sheet Validate Fixed Cost Sheet Deviation Report AAM Validate Fixed Cost Sheet Validate Fixed Cost Sheet Deviation ReportÅrdal Current Year Help Tool Updated by multiple inputs Update Help Tool PRP Update Help Tool PRP Update Help Tool PRP Update Help Tool PRP Update Help Tool PRP Phase 9

10 Dashboards with relevant information to relevant employees real-time Real-time connectivity 10

11 Mobile Solutions SAP preventive maintenance Real-time connectivity Maintenance worker shall have access to all relevant information and do all necessary requests at the workplace to enable high efficiency and effectiveness Online through WiFi Notification handling Work order handling Measurement readings Access to engineering documentation

12 Collision avoidance and fatigue of truck drivers Smart sensors (12)

13 Anti-fatigue system Anti-fatigue (Calibration) (13)

14 Anti-fatigue system Reporting Algorithm development Remote monitoring and control Fatigue Assess. Network Control room Supervisor Network Network Intervention Fast supervisor intervention CAS On board Technology (CAS, AF & Dispatch system) Dispatcher (14)

15 Machine learning - Automatic Intraday trading Havøygavlen wind farm 16 mills with an installed capacity of 40 MW and yearly production of 90 GWh Challenging to predict future wind production, resulting in high costs in the balancing markets 15

16 Machine learning/ai-engine/advanced analytics - Nice example of Havøygavlen by Hydro Energi - Will these techniques replace the need for domain competence? 16

17 Digital twins The concept of digital twins: A complete digital/numerical simulation model of a physical process, like a machine, electrolysis cell or a complete plant, based on a combination of: 1. Physically-based models 2. Advanced sensors/measurement systems (to continuously calibrate the model) 3. Advanced analytics algorithms (statistics, machine learning, artificial intelligence) Control system Data handling & storage AI-engine (advanced analytics) Physicallybased model

18 Complete extrusion value-chain simulation model Digital twin: Complete Through Process Simulation, including neural optimisation tool DC-casting Homogenisation Extrusion Artificial ageing Alstruc solidification Alstruc homogenisation HyperXtrude Alsoft NaMo 18

19 Temperature Ram speed Adaptive control in production of aluminium extrusions Use of the digital twin in an extrusion press Material Data Sheet PRO 3 TM i ii iii QR code 1 Position Time Pre-heating Extrusion 19

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