Digitalization in the smelting industry and how it can help to improve safety, efficiency and sustainability

The smelting industry is undergoing transformation and facing challenges in various aspects. The priorities include enhancing safety and operational performance, meeting the expectations of the future workforce on the tools they use, and creating value from the sensor and production data that is now collected and stored more efficiently than ever before. Another opportunity is to utilize the collected data for transparency and traceability of the metals throughout their production chain, in response to the end-user demands for environmentally and socially responsible raw materials. This is especially relevant for the battery metals value chain and for copper products that have e.g. the green label.

How automation and digital technologies improve safety

One of the benefits of digitalization is the possibility to augment personnel and replace the need for performing manual tasks to increase safety. Automation and digital technologies can reduce the exposure of human operators to hazardous conditions, such as high temperature or toxic gas, and decrease the risk for injuries from operating manual tools. For example, sensors can monitor the status and performance of the equipment and process and alert the operators of any potential risks or deviations. Sensors can also detect and prevent leaks, upcoming process disturbances or emissions that could harm the environment or the health of the workers.

Operational efficiency – when your best operator runs every shift

Another benefit of digitalization is the enhancement of operational efficiency and productivity. Automation and digital technologies enable achieving consistent and optimal performance, regardless of the shift or the operator. For example, our suit of Process Advisors can provide real-time guidance and recommendations to the operators, based on the data from the sensors and the process, as well as the metallurgical digital twin running in the background. The digital twins are virtual replicas of the processes that simulate and optimize various scenarios and advise or control the process parameters.

Adoption of digital technology is key to cashing in on the benefits

Automation and digital technologies can transform the way the smelting industry operates through connecting global expertise into remote locations, but this also requires new skills and mindset from the workforce. Therefore, it is important to design and implement digital solutions that fit the users’ needs and are user-friendly and intuitive. This means meeting the needs and expectations of the future workforce already familiar with digital tools in their daily life. Some of our best experiences to make this a reality have been through collaborative co-creation projects where the end users participate in the formulation of the solution and have the opportunity to give feedback along the development journey. 

Extracting value from data

Every second massive amounts of data is generated and collected from the equipment and processes. For that data to create real value, it needs to be analyzed and utilized effectively. For example, predictive maintenance can use the data and machine learning to anticipate and prevent failures, breakdowns or downtime of the equipment. Combining data during the whole process, production and maintenance can be scheduled and optimized efficiently.

Data and sustainability

A vital challenge for digitalization in the smelting industry is the sustainability of the operations and the end products. Automation and digital technologies can help the smelting industry reduce its environmental impact and increase social responsibility, but they also need to be aligned with the goals and standards of the stakeholders and the regulators. For example, data and simulation can be used to track and calculate the material and energy consumption and the carbon footprint of the processes and end products, utilizing environmental performance as a metric online, and to identify and implement opportunities for improvement and innovation.

In conclusion, digitalization is a for the smelting industry, as it can help address some of the most pressing challenges and opportunities in the sector. Digitalization can improve safety, efficiency, productivity and sustainability of smelting operations, by using automation, sensors, advisors, digital twins, data and simulation. However, digitalization is also about people. It requires adaptation and talent from the workforce. We have a great offering for digitalization in the smelting industry that can help you to achieve your goals and create value with your data. We have proven experience and expertise in the field so don’t hesitate to contact us.

Mikael Jåfs, Director of Digital Technology, has been with Metso and its predecessors since 2005. He has been working closely with our Smelting technology and customers, especially on the implementation of digital technologies.