Controlling the variability of pots KPVs: The variability matrix

Abstract

Over the course of 30 years the Process Control softwares have narrowed the variations of individual reduction cells. The volume of data available for day-to-day management of the potlines have increased considerably while the number of technical personnel per pot and per potline have been considerably reduced. Combining the tools and principles of Continuous Improvement with in-depth knowledge of Reduction Process Control systems allows for a new generation of Potline Process Optimization techniques. These techniques, powered by new generation data integration software, can breathe a new life in the Energy and Environment Performance of all smelters. They can show their owners a new trend for improvement and demonstrate strong care to the local communities without mobilizing expensive capital resources and additional people. How much can we expect? What does it require in terms of Human and System capabilities? Where do we start and how far can we improve? We will bring an innovative answer by describing a new tool: the Variability Matrix.