Description
La Farga Rod process consumes high amount of energy, a combination between fuels and electricity (78:22). In the continuous process of manufacturing wire (electrolytic copper), a tiny mismatch on the process parameters leads to a decline in product quality. The main objective of the project aims to increase the energy efficiency of the wire electrolytic copper process and thereby reduce CO2 emissions to the atmosphere. In that way it is planned to develop a new software system capable to ensure in advance the quality of the final product in order to avoid as much losses, and the waste of energy associated: (i) to the reprocess of the refused products, and (ii) to be out of the optimal tune of production process.
Summary of project results
The objective of the project aims to increase the energy efficiency of the wire electrolytic copper process from La Farga Rod. In that way it has been developed two different kinds of data driven models. The first ones are able to determine the plant’s operation point and assists the plant’s operators in early detection of loss of process’ yield. The main parameters have been studied to obtain a two dimension map showing the optimal operation zone and the current operating point. The second ones, discriminate between final products with or without defect. The developed algorithms are based on the quantification and detection of fast transitions in the parameters of the refrigeration process by means of Artificial Intelligence techniques. The results achieved are a new process able to predict the quality before it is obtained by analysing the process indicators in real time and increase performance and energy efficiency by reducing wastage and optimal adjustment process.
Summary of bilateral results