Profitability Improvements with DTE's Potroom Solution

Explore the profitability improvements achievable by implementing DTE’s portable elemental analyzers and AI-based cloud platform, IRIS, in a primary aluminum smelter potroom. DTE’s solution utilizes Liquid-Phase Laser-Induced Breakdown Spectroscopy (LP-LIBS) for real-time chemical analysis of molten aluminum, replacing traditional, slower, prone to error manual sampling methods.

Overview

A profitability study was conducted to assess the impact of implementing portable elemental analyzers, paired with an AI-based cloud platform from DTE (IRIS), at a primary aluminum smelter potroom. These analyzers, using liquid-phase laser-induced breakdown spectroscopy (LP-LIBS), provide real-time chemical composition analysis of molten metal.

DTE’s solution, Ireas, integrates these analyzers with a cloud platform, replacing manual aluminum sampling methods with automated, real-time analysis. Ireas, now IRIS, transforms this real-time data into valuable insights, leading to improved profitability, reduced manual errors, enhanced operator safety, faster response times, and increased process automation.
The study revealed that Ireas significantly boosts profitability in electrolysis potrooms, primarily through reduced operational costs. Each smelter's benefits with Ireas are unique and require individual evaluation using DTE’s profitability analysis tool.

The Challenge

Current practices in aluminum sampling typically require an operator to manually collect a sample, cast it into a mold, wait for it to solidify, and then transport it to a laboratory for chemical composition analysis, usually performed using spark optical emission spectroscopy (spark-OES). This method is time-consuming and prone to errors such as sample mix-ups, mold contamination, and incorrect sample preparation.
These issues can lead to inaccurate results and inefficiencies in the smelting process. By enabling real-time analysis of liquid aluminum samples, the risk of errors is significantly reduced, and results are obtained immediately. This capability is crucial for maintaining accuracy and efficiency in the challenging smelter environment.

The Results

The deployment of DTE’s solution in a primary aluminum smelter potroom presents several significant benefits. These include faster chemical analysis results, increased operator safety, reduced energy consumption, and fewer pot tapouts. These improvements collectively lead to increased profitability. However, the exact profitability gains will vary for each smelter, as each has unique processes, technologies, and business conditions. Overall, DTE’s solution uncovers opportunities to optimize aluminum production, streamline operations, and maximize both benefits and value.