“Industry 4.0 in the Aluminium Industry means the entire ecosystem aims for zero emission production – fully automated – zero waste,” Éloïse Harvey, B. Eng. & Mgmt, President of Mecfor

Éloïse Harvey has been working for the heavy industry (with a strong focus on the aluminium sector) since 1999 holding various positions related to sales, marketing and business development for MECFOR and also CEGERTEC WORLEY PARSONS (with the Mining and Metals division). Today she is President of Mecfor - an equipment manufacturer delivering custom and specialised equipment and vehicles to the heavy industry and aluminium sector worldwide. 

In this interview, Ms. Harvey has shared with us an in-depth insight into the Industry 4.0 and its importance in the aluminium industry. She has also shared how Mecfor has revolutionized the equipment technology for aluminium smelters and what are its latest projects that promote Industry 4.0 framework in the aluminium sector. To know more, continue reading the interview.

AlCircle: What does Industry 4.0 mean to the aluminium industry? How can the implementation of its framework help the industry improve efficiency and productivity?

Ms Harvey: In our opinion, 4.0 in the Aluminium Industry means that the entire ecosystem aims for zero emission production – fully automated – zero waste.

Mecfor, as an equipment designer and manufacturer, needs to think about the equipment that will support this new way of doing and surrounding activities including rethinking the construction of new smelter that will reduce costs.

AlCircle: What is a Smart Factory? How does Mecfor help a plant in becoming a smart factory?

Ms Harvey: Well, innovation to us is a frame of mind. It starts with a spark, an idea. You can find it in small details or at a greater scale like Mecfor newest and most innovative piece of equipment: the AGV TEAM, an electrical auto guided vehicle dedicated for aluminium smelters operations, mainly in the electrolysis sector for hauling metal ladles and shortly, anode trays. Not only the AGV TEAM fits into the trendy ‘Industry 4.0’, but it aims to reduce ecological footprint of aluminium producers, an energy-intensive industry. Once proven, the AGV TEAM technology platform will open doors to many heavy-duty operations found in a smelter such as coil handling.

AlCircle: How has Mecfor revolutionized the equipment technology for aluminium smelters?

Ms Harvey: The industry and mentalities are transiting from more conventional to high-tech practices. We like to think that by adding technological features to our existing equipment we somehow contribute in making a step forward towards more automation, more data to improve prevention both operation and OSH wise. What we observe is that despite the buzz it creates, not all aluminium producers embrace it at the same pace and with the same endeavour. To that, as a solution provider, we need to adapt.

AlCircle: How does robotics and automation help in enhancing productivity, efficiency and safety in an aluminium plant?

Ms Harvey: At Mecfor, we believe that robotics and automation will alleviate stultifying jobs with highly repetitive tasks. It will allow, in a context of great shortage of skilled labour, to create positions/jobs that has added value to the industry. Operators will be assigned to other crucial tasks. Robotics and automation might be the solution to several challenges in the industry.

AlCircle: Mecfor unveiled the first Automated Guided Vehicle (AGV) designed for the worldwide primary aluminium industry in 2018. How does it help aluminium smelters improve its operations? 

Ms Harvey: The switch to an AGV hauler fleet embraces a technological journey requiring in-depth thinking of metal flow and how other processes are to be conducted. It represents entering into a new era of equipment dedicated for the aluminium industry, meaning that client will may have to re-think some processes and way of work. Mecfor AGV TEAM Hauler will work 24/7 using a smart opportunity battery charging. The equipment integrates tried, trusted and reliable guiding and safety technologies and Mecfor expertise of the impact of high magnetic field influences on components. We are confident that once fully deployed, the AGV TEAM will contribute to reduce safety hazards, will interact in a fluid way with other equipment and people, and will constantly communicate with the plant management system to optimize routing. Not only will the AGV TEAM help operate rigorously with constancy, but believed that the ROI will be beneficial to our customers despite the fact that Mecfor does not have all figures in hand to confirm this assumption.

AlCircle: Brief us on some of the latest projects by Mecfor that promote Industry 4.0 framework in the aluminium sector.

Ms Harvey: To name a few, we have put in operation a Molten Metal Transfer by Pressurization equipment for which all sequences are automated. We also are working on what we call ‘MecforLink’, being basically telemetry monitoring to help Reliability Engineers to be proactive. In addition, in our vision of greater automation, we are looking into integrating the ‘smart tooling’ in our Mecfor Casthouse Solution for which the operating system of the vehicle will recognize the tool that is being hooked to the mast deploying, for example, a fully automated sequence of furnace tending operations.

Mecfor’s ability for technological transfer from one industry to another is one characteristic of our company growth. As a matter of fact, from the design of the amphirol in operation in a mud lake in Quebec, we have worked the concept at a smaller scale for a complete different industry – watch for CAROL catalyst removal robot – that is one example, but very often, Mecfor will do the same for its equipment dedicated for the Aluminium industry.

AlCircle: How important it is for the Quebec aluminium sector to implement the industry 4.0 elements in their value chain?

Ms Harvey: It is important enough that, in 2018, the Quebec government has decided to support the actors of the industry under the initiative called “Aluminerie du Futur” project. This is to bring together at the same table all major stakeholders and have them think/dream how new technologies will impact the industry practices. At the end of its three-year commitment, the government will have invested $3 million to a committee co-sponsored by AluQuebec and the AAC. Mecfor is sitting on that committee and actively providing inputs. The aluminum industry is one of our flagships; we want to keep our head start ensuring the viability and maintaining added-value jobs, here in Quebec.

AlCircle: What according to you is the future roadmap for the aluminium industry in relation to Industry 4.0?

Ms Harvey: We are at the verge of many changes in the industry, almost a historical turn, with for example, the first shovelful of earth announced for the construction of Elysis in Saguenay. All these windows of opportunities brought by the technology are very stimulating. This effervescence energizes the industry. As always, roadmap will be driven by the market needs. To our opinion the manpower shortage and the environmental footprints will be the two major axis. We will see more automation in the casthouse and more equipment electrically powered.