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Global aluminiumAluminium producers face a dual imperative to deliver incremental metal at lower cost while demonstrably shrinking the carbonCarbon footprint. The Advanced Process ControlAdvanced process control Plus (APC+™) is a PLC-based and AI-assisted pot controller developed to meet this challenge by delivering effective break-and-feed sequences, dynamic AlF₃ dosing, fineFines-resolution voltage corrections and suppression of anode effectsAnode Effect (AE). The system includes a closed-loop architecture, and its secure SCADA/HMI is designed to deliver real-time analytics, mobile visibility, and remote optimisation support. SmelterSmelter trials on various technologies, legacy and modern, have shown that APC+™ consistently raises current efficiency (>1%), trims power (>0.2 MWh/t), and cuts the anode effectAnode Effect (AE) rate by more than 50%—significantly reducing CO2CO2-equivalent (CO2CO2-eq) emissionsEmissions. Based on trial results, the ALUCAM smelterSmelter has authorised a full retrofit of its potline with APC+™. This paper shows that APC+™ offers smeltersSmelter a rapid, low-risk pathway to sustain competitive metal production and progress toward “green aluminiumGreen aluminium” objectives.

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APC+™ – An Advanced and Versatile Solution for Pot Process Control

  • 会议论文

  • 发表日期：

    2026年

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  • Drago Juric,
  • Joe Kazadi,
  • Daran Emmett,
  • Andreas Schwarz

摘要

Global aluminiumAluminium producers face a dual imperative to deliver incremental metal at lower cost while demonstrably shrinking the carbonCarbon footprint. The Advanced Process ControlAdvanced process control Plus (APC+™) is a PLC-based and AI-assisted pot controller developed to meet this challenge by delivering effective break-and-feed sequences, dynamic AlF₃ dosing, fineFines-resolution voltage corrections and suppression of anode effectsAnode Effect (AE). The system includes a closed-loop architecture, and its secure SCADA/HMI is designed to deliver real-time analytics, mobile visibility, and remote optimisation support. SmelterSmelter trials on various technologies, legacy and modern, have shown that APC+™ consistently raises current efficiency (>1%), trims power (>0.2 MWh/t), and cuts the anode effectAnode Effect (AE) rate by more than 50%—significantly reducing CO2CO2-equivalent (CO2CO2-eq) emissionsEmissions. Based on trial results, the ALUCAM smelterSmelter has authorised a full retrofit of its potline with APC+™. This paper shows that APC+™ offers smeltersSmelter a rapid, low-risk pathway to sustain competitive metal production and progress toward “green aluminiumGreen aluminium” objectives.