Digitalisering i industrien - Industri 4.0 initiativer i Hydro. Hans Erik Vatne, CTO, Hydro , Haugesund, Energirike

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1 Digitalisering i industrien - Industri 4.0 initiativer i Hydro Hans Erik Vatne, CTO, Hydro , Haugesund, Energirike

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 Industry 4.0 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 Stock pile management Project aims to use drone (photogrammetry) and laser scanner (LIDAR) 5

6 Collision avoidance and fatigue of truck drivers Smart sensors Algorithm development Remote monitoring and control Reporting Fatigue Assess. Network Control room Supervisor Network Network Intervention Fast supervisor intervention CAS On board Technology (CAS, AF & Dispatch system) Dispatcher (6)

7 Karmøy teknologipilot er ikke bare verdensledende på energiforbruk, men også en digital spydspiss for Hydro Årsproduksjon tonn Energiforbruk <12.3 kwh/kg aluminium vs globalt snitt 14 Spin-off teknologielementer til eksisterende aluminiumsverk Men også digital testarena: - automatisering - sensorer - kommunikasjon - maskinlæring 7

8 Automatisering Example: Advanced pot tending machine with improved functionality like cover handling PTM (Pot tending machine) Automatic cover handling Global positioning system RFID reader (sensor data) 8

9 Mobile maintenance operator increases efficiency and effectiveness Trådløs oppkobling i sanntid Personalized view of work orders Checklist functionality increases quality and traceability of preventive maintenance Easy access to technical documentation linked to technical object 9

10 Karmøy testing a digital «safe zone» solution Sensors and real-time connectivity 10

11 Utilising big data throughout the production process Automatic anode tracking system RFID Green Anode Baked Anode Loading Unloading Collar filling Casting Butt Stripping Mating Thimble Stripping Straightening Shot Blasting Grinding Graphiting 11

12 Machine learning - Automatic intraday trading, Havøygavlen wind farm 16 wind 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 12

13 Machine learning/ai-engine/advanced analytics - Nice example of Havøygavlen by Hydro Energi - Will these techniques replace the need for domain competence? 13

14 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

15 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 CASTHOUSE PROCESSES EXTRUSION PLANT Electrolysis Casting Homogenisation Extrusion Ageing 7 15

16 Potential use of the digital twin optimisation model Extruder ordering billets Adaptive press parameter control Order 4 PRO 3 TM CASTHOUSE PROCESSES Electrolysis Casting Homogenisation 5 Extrusion EXTRUSION PLANT Ageing 7

17 Med teknologipiloten og andre digitale initiativer, ser vi store forbedringsmuligheter i prosessene våre 17

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