OPTIMISING SMELTER CONSUMABLES THROUGH DIGITAL TECHNOLOGY

PROBLEM STATEMENT

Our smelters utilise various consumables such as zinc dust, sodium sulphate, polymeric aluminium trihydrate (PAT), lime, and soda ash, etc., which are vital for maintaining chemical reactions, controlling processes, and ensuring the smooth operation of our smelting activities. It is crucial to optimise the utilisation of such consumables, which constitute a significant portion of our overall smelting spend base.

OUR APPROACH

• Successfully implemented an artificial intelligence (AI) and machine learning (ML) based system to optimise the use of such high-value non-fuel consumables
• Integrated Laboratory Information Management System (LIMS) with Distributed Control Systems (DCS) and Programmable Logic Controllers (PLCs) for better process control
• Integrated the solution with smelting operations at Chanderiya, Dariba, and Debari

KEY OUTCOMES

• Eliminated manual intervention with fully automated dosing and AI-driven precision which leverages real-time data and IT-OT integration to ensure optimal consumable usage
• Strengthens our commitment to digital transformation, efficiency, and sustainability by automating consumable additions, reducing waste, and driving major cost savings by optimising a significant spend base of spares & consumables