Gen3 System

Advanced Centralised Potline Operation, Control and Management System

  The world’s first purpose-built centralised control system

 Gen3 comprises of smelter-specific software and database technology with management tools to create a comprehensive smelter control and management system.

The Gen3 package includes:

  1. Specialist software and database technology which centrialises processes and analyses all available smelter data for fast and effective, user-friendly management and operational reporting.
  2. The system contain diagnostic tools, which are coupled with advanced control strategies and scientific decision guidelines to help all levels of smelters roles: from management, supervisory and operation personal. 
  3. A set of benchmark standard operation procedures (SOP's) is imbeded in the system for training and guiding smelter personal to operational excellece. The tools implemented in this system promote continuos improvement calture, both for managers and smelter operators.

Using the Gen3 system will transforms aluminium smelter potline operations through a generational leap in management and control strategies. This system is ideal for new smelter development or easily customised for existing smelters, and it is available as a complete product solution or through a staged modular instalments.

Gen3 Value

Through Gen3’s advanced control and management systems smelter operations are able to :  

  • Identify variance for early detection of abnormalities - special analytical tools use real-time signals collected by the smelter to detect early signs of abnormality. The system will alert the smelter staff and suggest ways to either confirm the situation or amend it. 
  • Improve efficiency and energy consumption across potline performance - the system improve currect efficiency and reduce power consumption by removing the causes of abnormailities in early stages and keeping the potline at optimal operation.
  • Reduces carbon consumption, emissions and man hours per tonne - the improved efficiency and the smooth operation of the smelter due to early removal of abnormalities means incidences of anode effect can be reduced, optimal operation will lead to reduced carbn consumption. The system enable shifting the focus from "fire-fighting" mode to preventative mode where issues are dealt and resolve at early stages.
  • Enables systematic voltage reduction- reduced abnormalities with smooth operation open the opportunity to reduce voltage without loss of current efficiency.
  • Increase overall smelter profitability - smoother operation with optimal performance leads to improved profitability as cost of production decreases. 


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Gen3 System Control philosophy and Modules

Gen3 has been designed to maximise and simplify system-human integration for continuous process improvement. This system integrates the work of operators, engineers and managers and it learns and adapts to changes and new findings, through continual tracking of diagnosis, response performance and removal of the causes.The simplicity and transparency of this system allows users to carry out their work with clear objectives while incorporating learning and improvements to their work. The system contain few modules that set it apart from current smelter control systems:

  1. Data Acquisition and Calculation - the system collects information from various sources in the smelter from data coming from the pot controller through off-line data like lab results.
  2. Feeding Control (including normal control strategies and abnormality control strategies
  3. Noise Control
  4. Heat Balance Control (including normal heat balance control strategies and abnormality heat balance control strategies)
  5. Abnormality Detection
  6. Root Cause Diagnosis
  7. Response Plans

The system presents the analysis results  in a user-friendly way that offer the users quick understanding of the current conditions and prompt for action when intervention is needed.