GE to implement first digital smelter twin for AOG

The digital solutions will operate in the cloud, powered by Predix, GE’s operating system for the Industrial Internet

The industrial complex of Aluminium of Greece is one of Europe’s most modern vertically integrated production plants.
The industrial complex of Aluminium of Greece is one of Europe’s most modern vertically integrated production plants.

GE and Aluminium of Greece (AOG), a Mytilineos Group subsidiary, today signed a 10-year agreement in Dubai to implement a global first-of-their-kind digital smelter solutions for AOG to enhance its aluminium smelting process.

The agreement was signed by Dimitris Stefanidis, CEO of Aluminium of Greece and Joseph Anis, president and CEO of GE’s power services business in the Middle East and Africa.

The digital solutions are said to be a significant step in charting the next generation of smelting operations globally.

“As the largest vertically integrated bauxite, alumina, and aluminium production and trading unit in the European Union, we are constantly looking at innovative technologies to enhance our performance standards.

“The application of digital industrial solutions is a remarkable opportunity to achieve process optimisation across our operations and to push productivity levels,” said Stefanidis.

“With GE’s digital smelter solutions, we are setting a global first for the aluminium industry that will contribute to our operational efficiency and set new benchmarks in the sector.”

The project will be executed by the team based at the COE in Dubai, while the facility that the solutions will be implemented at is located in Agios Nikolaos, Viotia, Greece.

Anis said: “GE has been at the forefront of digitising the future of industry globally and in the region, providing digital industrial solutions for power generation and the LNG industry, among others.

“By bringing together the strengths of our multi-locational teams and GE Power’s Digital Smelter Centre of Excellence in Dubai, we will collaborate with AOG to create a new chapter in the history of smelting operations as well.”

The digital solutions will operate in the cloud, powered by Predix, GE’s operating system for the Industrial Internet.

Virtual sensors will facilitate the ongoing evaluation of parameters such as temperature and chemistry that are not ordinarily monitored continuously.

This, in turn, will help to anticipate the health and condition of the pot, providing timely monitoring reports on the operations of the plant.

“We will be able to recreate an actual smelter using artificial intelligence and physics-based models,” added Bhanu Shekhar, chief digital officer for GE Power in the Middle East and Africa.

“This is a living digital model that will continuously generate smelter data, and will be a game changer in helping to address the challenges of power usage and the consumption of raw materials in the smelting industry.”

“The application of the digital smelter solutions will contribute to the operational efficiency improvement of the Aluminium of Greece, by lowering raw materials’ consumption, decreasing energy consumption, and reducing pot leakages,” concluded Stefanidis. 

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