Alumina & Aluminum Smelting
Electrolytic aluminum production requires coordinated operation of alumina feeding, potlines, high-current DC rectifiers, and fume treatment. VITECH engineers, integrates, and programs control systems for individual pots, material distribution equipment, electrical systems, and gas-cleaning facilities. Process data, alarms, and operating history are consolidated to support potline condition supervision and energy management.
1. Potline Control & Process Supervision
Electrolysis Pot Monitoring
Integrating signals from each pot to supervise feeding status, anode position, bath temperature, fume extraction equipment, and operating permissives through a centralized operator interface.
Voltage, Current & Process Trending
Acquiring pot voltage, current, and associated process variables with limit alarms and trend displays for analysis of electrolytic operating conditions.
2. Alumina Feeding & Material Handling
Point Feeder Control
Programming crust-breaking and alumina dosing cycles for point feeders according to pot status, with actuator feedback and material-blockage supervision.
Alumina Distribution to Potlines
Controlling silos, air slides, conveyors, or pneumatic transport systems while coordinating distribution valves and level measurement for alumina delivery to potline areas.
3. High-Current Electrical & Rectifier Integration
Rectifier Control Integration
Connecting rectifiers, rectifier transformers, and cooling auxiliaries with potline supervision for setpoint, status, alarm, and trip-signal exchange.
DC Bus & Electrical Protection Monitoring
Acquiring total DC current, bus voltage, busbar temperature, and protection-relay status while classifying electrical events for coordinated rectifier and potline operation.
4. Anode & Cathode Process Monitoring
Anode Effect Detection & Change Support
Detecting anode-effect conditions from pot-voltage behavior, issuing graded alarms, and providing permissive sequences to support anode-changing operations.
Cathode & Pot Condition Monitoring
Combining potshell temperature, current distribution, and operating indicators to trend cathode condition and identify abnormal thermal or electrical deviations.
5. Fume Treatment & Environmental Control
Gas Cleaning System Control
Automating dry scrubbers, adsorbent alumina feeding, filtration, and material recovery with sequences based on differential pressure, flow, and equipment status.
Fans, Dampers & Emissions Monitoring
Coordinating extraction fans and dampers to maintain potline fume capture while integrating flow, pressure, and emissions-monitoring data.
6. Plant Data & Operational Support
Historian, Alarms & Trend Analysis
Configuring a pot-level historian with synchronized events and alarms so engineers can review conditions before, during, and after process abnormalities.
Production & Energy Monitoring
Consolidating production, DC energy use, alumina feeding, and equipment-status data into dashboards for shift reporting and operational review.
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