RUSAL, one of the world’s leading aluminium producers, has rolled out two new AI-powered systems designed to make its factories more efficient and reliable. The company has introduced machine hearing in alumina production and machine vision in aluminium melting. Both systems are part of RUSAL’s plan to modernise and automate its operations.
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The machine hearing system analyses mill vibrations during bauxite ore processing. Recording these vibrations, AI can easily identify whether the mill is overloaded or underused. Accordingly, it can adjust the measurement of ore that is being fed to the machine. Thus, it helps to maintain an optimised load balance, which saves electricity and prevents unnecessary wear and tear of the equipment. It helps RUSAL produce higher-quality alumina, which in turn supports more efficient aluminium production
For the production of alloy, RUSAL has deployed a machine vision system which helps to monitor the melting process of aluminium. The process has around 20 steps, and the AI helps operators follow each one correctly. Using a camera and a neural network, it checks the composition of the alloy and spots areas of dross that need to be cleaned away.
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Mikhail Grinishin, who heads production automation at RUSAL’s Engineering and Technology Centre, said that the new system “helps operators stay focused on key moments during alloy preparation and makes the cleaning process more efficient.”
RUSAL has been adding digital and AI tools across many parts of its business. These include systems for controlling electrolysis, monitoring raw materials, managing logistics, and improving plant safety. Many of these technologies have been designed by RUSAL’s own engineers.
The combination of hearing and vision systems powered by AI empowers RUSAL to cut energy use, limit human error, and raise overall production quality. The company says these upgrades will help it stay competitive while setting new standards for smart and sustainable aluminium manufacturing around the world.
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