Russia Teaches Alumina Mills to Listen
Russian aluminum giant RUSAL has introduced a 'machine hearing' system that uses sound analysis to optimize ore processing, boosting efficiency and extending the life of critical equipment.
Russia’s aluminum industry is taking another step in its digital transformation. RUSAL, a global leader in aluminum production, has for the first time deployed a 'machine hearing' system at its alumina facility. The pilot project was launched at the RUSAL Krasnoturinsk plant, enabling smarter ore extraction and processing, according to dprom.online.
Unlike the widely adopted 'machine vision' systems in industry, this new technology relies on vibroacoustic sensors. These devices are mounted on mill supports and 'listen' to the grinding of bauxite ore. The captured sound signal is converted into digital format and analyzed by a specialized algorithm trained to filter out background noise. By processing frequency and amplitude in real time, the system determines the mill’s load and automatically signals when to add new raw material.
The technology directly addresses one of the key challenges in ore processing. Underloading the mill leads to idle operation, wasted electricity, and accelerated wear of protective linings. Overloading, on the other hand, reduces grinding quality, lowers alumina yield, and causes unplanned maintenance shutdowns. By maintaining optimal operating conditions around the clock, 'machine hearing' conserves resources and extends equipment lifespan.
There are now plans to adapt the system for the Achinsk alumina plant, the only facility in the world that processes a mix of nepheline and limestone ores. This will require the AI to 'learn' a new vibroacoustic profile, showcasing its scalability to meet the diverse needs of Russian industry.
