RUSAL's AI initiatives set new benchmarks in the aluminium industry

The Russian aluminium giant RUSAL is at the forefront of digital innovation, harnessing technologies such as artificial intelligence (AI) to streamline operations from raw material extraction to product delivery.

The newly announced Department of Industrial Artificial Intelligence underscores RUSAL's dedication to crafting state-of-the-art solutions for its manufacturing processes. With 18 ongoing projects, including those already integrated into industrial workflows, RUSAL is primed to revolutionise efficiency, quality, and innovation throughout its aluminium operations, setting new benchmarks within the industry.

Among RUSAL's recent breakthroughs is the adoption of AI-powered video cameras in the sintering furnace at Pikalevo Alumina Refinery, which are replacing traditional cameras. This upgrade enables engineers to manage the furnace plant precisely, resulting in a substantial upswing in the production of high-quality sinter.

Furthermore, RUSAL's commitment to innovation and environmental stewardship has garnered acclaim. Notably, the "Emission Detection Seal Control Video Systems" project clinched the title of Project of the Year at the National AI Awards. This system operates round the clock, scrutinising equipment seals and promptly alerting operators to irregularities.

Using machine vision and big data analysis, it detects over 95 per cent of irregularities in the electrolysis process, overcoming various interferences.