SAMI and Bentley’s digital twin tech is set to transform operations at Chalco's Zhongrun Aluminium smelter

To cope with the shifting operational paradigms of the aluminium industry, Chalco's Zhongrun Aluminium smelter embraced digital twin technology, a first-of-its-kind initiative. SAMI partnered with Bentley to address challenges in design, construction, and data integration.

Shenyang Aluminium & Magnesium Engineering & Research Institute (SAMI) collaborated with Bentley Systems, utilising their integrated applications to develop a plant-wide digital twin for Zhongrun Aluminium smelter. This innovative approach significantly reduced modelling time and operational costs.

SAMI and Bentley Collaboration - Challenges Faced

The project faced tight timelines for design and construction, involving 52 sub-projects and 15 specialisations. SAMI addressed challenges in creating a comprehensive digital factory model, enhancing construction efficiency, and managing extensive data integration.

Bentley's professional modules, customised software, and 3D design played crucial roles. The use of Bentley power PID software facilitated efficient asset coding, while software-controlled construction progress precisely. The integration of VR technology and digital twins allowed for optimised design, inspections, and training, revolutionising factory management.

Future of digital twins in the aluminium industry

The application of digital twins aims to evolve towards fully remote-controlled operations. The vision includes utilising display consoles and terminals for data access and, in the future, leveraging AR technologies for precise production forecasting. While key areas already demonstrate remote control capabilities, widespread adoption depends on the advancement of artificial intelligence.

If you are interested in learning more about digitalisation in the aluminium industry, please have a look at AL Circle’s special report, Digitalisation Transformation in the Aluminium Industry.