The EU MONSOON project
AI for the factory of the future
The EU MONSOON project
Success story
Bringing AI to the process industries: Rio Tinto-Aluminium Dunkerque & GLNPlast
Challenge
Aluminium Dunkerque, a Rio Tinto company, manufactures anodes, which are one of the main components used in aluminum electrolysis. The performance of the electrolysis process depends on the den sity of the anode. Aluminium Dunkerque turned to Probayes for a process optimization solution to increase anode densities.
The project
Working closely with the customer’s experts, we tackled the project from two angles. First, we took around 40 continuously-monitored process parameters to build a classifier to identify times when the anode densities were low. Second, we integrated an explainability module into the classifier that generates, in real time, a list of the top five parameters that caused the lower anode densities.
We also built a recommendation engine powered by a regressor. Here is how it works: If it is determined that the anodes coming off the production line are low-density, the engine generates three recommendations to increase density. Finally, we developed a user interface re-training module so that the solution can adapt to the constantly-evolving process.
Results
The final version of the solution went live at Aluminium Dunkerque in the summer of 2019. It is expected to significantly reduce the number of low-density anodes produced, for estimated annual savings in the hundreds of thousands of euros.
The research that led to the development of the solution was presented at TMS annual meeting and a book chapter was published.
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Last name First name
Position – Company
Success stories
The EU MONSOON project
Bringing AI to the process industries: Rio Tinto-Aluminium Dunkerque & GLNPlast
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