LOGISTIC SIMULATION OF DISCRETE MATERIAL FLOW AND PROCESSES IN ALUMINUM SMELTERS

Aluminum production depends on a Multitude of different operations requiring discrete transport of materials factors more than the volume of metal produced. The efficient integration of additional transport and process demand due to capacity creep or brownfield expansion into the existing infrastructure is intricate. Hydro Aluminium has a long history of solving the logistic challenges using simulation tools. Limitations of the existing models concerning model set-up and control logic suggested the development of a more flexible, modular and powerful simulation tool. The targeting range of applications includes the evaluation of transport logistics of existing smelters, but also the optimization of new mega smelter designs, new. potroom operating concepts and support to investment decisions. The paper outlines the relevant discrete material flows, processes and procedures and some details of the model architecture. Examples highlight the range of applications and illustrate the outcome and gain of the systematic simulation approach.