In the 29th edition of the e-Magazine, themed “Digital Transformation in the Aluminium Industry: Drivers & Changemakers of 2024,” Vikas Arora, Managing Director and CEO of Hamilton Research & Technology Private Limited, shares his insights on driving innovation in aluminium plant operations through retrofit solutions. He highlights how the company’s deep industry expertise and strong in-house design capabilities are helping aluminium facilities become more self-reliant, profitable, and sustainable in a rapidly evolving industrial landscape. With over two decades of leadership in technology and engineering, Vikas combines technical acumen with strategic business insight, rooted in his MBA in Operations from Indian Management Technology CDL, Ghaziabad and a Bachelor's degree in Mathematics.

Here is an excerpt of his interview with us.

AL Circle: How does Hamilton integrate AI and machine learning to optimise energy efficiency and reduce carbon emissions?

Vikas Arora: Our systems leverage AI and machine learning to revolutionise energy efficiency and emission control. For instance, in REDCON, AI-driven algorithms predict and prevent anode effects, reducing energy wastage and carbon footprint. FIRECON utilises AI to optimise combustion processes and minimise flue temperature deviations, ensuring optimal energy use.

Another key feature is predictive maintenance, powered by machine learning. Our systems identify potential anomalies by analysing historical and real-time data, allowing proactive intervention and reducing downtime. These capabilities not only enhance energy efficiency but also contribute to significant reductions in the carbon footprint of smelter operations.

AL Circle: What upcoming trends will shape the aluminium industry, and how is Hamilton preparing to address them? 

Vikas Arora: Several key trends will influence the aluminium industry in the coming years:  

• AI-driven optimisation: AI will play a crucial role in predictive maintenance and process efficiency. We tailor our solutions to specific operational goals, whether it’s enhancing process control, integrating predictive algorithms, or adding advanced reporting capabilities. Scalability is another key aspect. As plants evolve, our systems can be upgraded to accommodate new technologies
• Digital twins: Virtual models allow plants to test and optimise processes without physical trials. 
• Sustainability solutions: Technologies like inert anodes are transformative, eliminating CO2 emissions from the smelting process. Hamilton Research is exploring how we can support the adoption of inert anode technology. 
• Automation expansion: From potlines to logistics, advanced automation will improve plant productivity and safety. 

By staying ahead of these trends, we aim to help the aluminium industry achieve its sustainability and efficiency goals.

 AL Circle: How does Industry 4.0 align with your solutions to improve productivity and reduce manual intervention? 

Vikas Arora: Industry 4.0 is integral to our technology roadmap. IoT-enabled devices in our systems provide real-time data from the field, enabling operators to monitor and control processes remotely. Automation features, such as feeding control and resistance management, minimise manual intervention while ensuring precision. For example, our wireless wedge monitoring system enhances safety and efficiency during potline shutdowns. Integrated with cloud-based monitoring, it ensures seamless data access and quick decision-making. These interconnected systems exemplify how we use Industry 4.0 principles to create smarter, more efficient smelter operations.

To read the full interview, click here