Russian Industries Boost Efficiency with Artificial Intelligence

Russia’s metallurgical sector is embracing AI to overhaul industrial processes, aiming for gains where even fractions of a percent in accuracy can translate into millions of rubles in profits.

Russia’s metallurgy industry, a flagship of its industrial sector, is turning to advanced artificial intelligence technologies to drive major efficiency gains. This is not about isolated automation but a systemic shift in process management, where precision at the micro-level can mean massive profits, according to Expert magazine citing Anton Salin, Sales Director at Softline Solutions.

One of the biggest challenges for factories is the manual calibration of thousands of regulators that ensure production stability. When these systems run suboptimally, product quality suffers and losses mount.

AI technologies offer a breakthrough solution through self-calibrating systems. These platforms analyze Big Data from sensors in real time using machine learning algorithms, automatically adjusting regulator coefficients to ideal settings and preventing failures before they occur.

A case in point: one domestic plant installed such a system in its flotation unit, where maintaining a stable froth layer is critical. Previously, faulty regulator performance caused frequent fluctuations, undermining mineral recovery. With AI integration, the process stabilized, leading directly to higher concentrate quality and increased production output.

The economic effect underscores the value of investing in AI. Preliminary expert estimates suggest that self-calibration systems can boost plant productivity by 8–12 percent and cut equipment maintenance costs by 15–20 percent. Additional benefits include reduced energy consumption and a significant decrease in defective output.