Simulation tools to complement cast house design and daily operation

Abstract

In this paper, cast house operation is considered as a true example of a Flexible Manufacturing System (FMS), where a target product mix is achieved by adapting both process parameters and production plans, respectively. The examples presented here were initiated by challenging cast house operation situations. The results derived from the simulation scenarios were used to propose mitigating measures and to corroborate suggested solutions. From the components of the simulation tool-set, further models are built. As is often required, these models can be configured and applied to, among others, cast house design, production planning and operations decision support. Moreover, they can be used for operator training. In-depth knowledge of cast house operations and dynamic process modeling has been turned to a practical engineering tool which is regularly used by Bechtel’s Mining & Metals “Center of Excellence” (COE) group to deliver recommendations and results to clients in global aluminum smelter projects.