EVRAZ will save $ 12 million on new projects based on advanced analytics

EVRAZ plc has started pilot operation of smart advisor systems at six production sites. They were developed as part of the comprehensive Advanced Analytics program, implemented in conjunction with The Boston Consulting Group. The program is expected to generate $ 12 million in savings annually. Advanced analytics is a digitalization trend driven by solutions that include machine learning and other elements of artificial intelligence. Statistical models are used to analyze data collected from live equipment to develop recommendations for fine-tuning the production cycle to improve efficiency, optimize costs, improve quality, and reduce downtime.

EVRAZ has implemented intelligent advisor systems in three business areas Ural, Siberia and Coal:

Dynamic control of ore dressing at EVRAZ KGOK helps stabilize the quality of iron ore concentrate and helps to maximize plant productivity. The digital system collects data on the properties of ores from various quarries and determines the optimal proportions and parameters for their processing.

Optimization of loading parameters at the EVRAZ NTMK coke plant is necessary to efficiently use coal from the Group's mining assets (NTMK increased the share of its own coal mined from 48 percent in mid-2018 to 90 percent in mid-2020). Based on three years of data, the system maximizes the proportion of in-house coal produced while maintaining high coke quality.

Optimize out-of-furnace processing and casting in the EVRAZ ZSMK electric arc furnace to minimize non-metallic impurities in rail products. The digital advisor will guide the operator to intervene in two key stages of adding value when the metal is in the ladle furnace and in the vacuum degasser.

Dynamic recycling at the Abagur concentrator will help increase recycled concentrate production by reducing waste from recycling. The system will encourage the mill operators to intervene in an optimal way.

Advanced analytics for the operations center at Raspadskiy open pit mine enable real-time decision making to minimize production waste, reduce downtime and increase capacity utilization. Management of dynamic ore processing at Raspadskaya GOK is now at the first stage of implementation, allowing timely information on deviations in the production process and prompt response. At the second stage, the system will propose corrections.