In the non-ferrous production process of electrolytic
aluminum, refined copper and other non-ferrous
materials, the operation of raw material inventory
and electrolysis workshop is fragmented, resulting
in an annual average of 12% of the idle capacity and
8% of the energy waste. With the deep linkage of intelligent
storage system and electrolysis production line, an
industrial revolution that opens the data artery of
“storage-production-logistics” is reshaping the efficiency
ceiling of the industry.
First, the traditional mode of storage
and electrolysis production of the five
major breakpoints
1. Mismatch between inventory and production capacity
Alumina and other raw materials have a long storage period of
up to 15 days, resulting in a loss of more than 2 million yuan
for a single production transfer after the start and stop of
electrolysis tanks.
2. Raw material quality fluctuation out of control
Manual sampling cannot match the change of anode copper
grade in real time, resulting in imbalance of electrolyte
composition and 3%-5% decrease of current efficiency.
3. Ineffective management of hazardous waste products
Electrolysis residues and waste cathode plates are mixed and
piled up, and the risk of non-compliance of hazardous chemicals
storage is frequent, and the cost of environmental protection
penalty accounts for 2%-4% of the annual profit.
4. Difficult to trace the black hole of energy consumption
Warehousing and logistics are separated from electrolysis
production data, and it is impossible to locate the ineffective
loss link in the 14,000kWh electricity consumption per ton
of aluminum ingot.
5. Insufficient supply chain flexibility
Sudden orders require 72 hours to coordinate the allocation
of raw materials, and the customer loss rate due to delayed
delivery is as high as 18%.
Two, intelligent linkage of the four
major technology engines
1. Digital twin cross-system modeling
Construct virtual mirror covering raw material warehouse,
electrolysis workshop and finished product warehouse,
mapping the state of all elements of 100,000-ton aluminum
base in real time.
2. Dynamic inventory optimization algorithm
AI predicts the alumina consumption curve based on the
working conditions of the electrolyzer, compressing the
response speed of raw material replenishment from 48
hours to 4 hours and increasing the inventory turnover
rate by 60%.
3. AGV - overhead crane cooperative network
Unmanned forklift and intelligent traveling crane linkage
scheduling, unmanned anode plate from out of storage to
into the tank, electrolysis workshop material preparation
efficiency increased by 3 times.
4. Blockchain quality traceability
Raw material batches, electrolysis process parameters, and
finished product inspection reports are uploaded on the
whole chain, and customers can trace the carbon footprint
and energy consumption data of a single aluminum ingot.
Collaborative Reconstruction of Three
Core Scenarios
Scenario 1: Intelligent linkage of starting and stopping electrolysis tanks
Technical program:
Warehouse system receives real-time electrolyzer current
strength data, automatically calculates alumina demand,
and AGV accurately delivers to the designated slot.
Effectiveness:
After the application of a large aluminum plant, the
electrolyzer idle time is reduced by 70%, and the annual
power saving is 120 million kWh.
Scenario 2: Dynamic adaptation of raw material quality
Innovation point:
The X-ray inspection data is directly connected to the
electrolysis control system when the raw materials are
in storage, automatically adjusting the tank voltage and
pole spacing to stabilize the current efficiency of copper
electrolysis at more than 96%.
Scenario 3: Closed-loop management of hazardous
waste products
Protection mechanism:
After the output of electrolysis residue, intelligent storage
automatically matches special containers, and the AGV
transportation path is linked to the ventilation system,
so the risk of harmful gas leakage drops by 90%.
Scene 4: Global multi-base synergy
Data Center:
Intercontinental warehousing and electrolysis capacity
data are connected, unexpected orders automatically
trigger shipment from the nearest port warehouse, and
customer delivery cycle is shortened by 65%.
Four-dimensional value creation of
whole-chain synergy
1. Production efficiency breakthrough
The utilization rate of electrolysis tanks has been increased to
92%, the comprehensive energy consumption of tons of
aluminum has been reduced by 8%, and the annual production
capacity has been increased by 150,000 tons (based on a
500,000-ton plant).
2. Capital liquidity release
Raw material inventory occupancy was reduced by 30%, and
work-in-process turnover days were compressed from 22
days to 9 days, releasing liquidity of more than 500 million RMB.
3. Compliance risk control
The whole process of hazardous waste disposal has been
digitized and traced, the efficiency of environmental protection
audit has been improved by 80%, and the cost of non-compliance
risk has been reduced by 75%.
4. Accelerated Low Carbon Transformation
Chain-wide carbon footprint monitoring reduces carbon emissions
by 12% for a single ton of copper products and saves over 10
million yuan in carbon tariff costs.
V. Future Picture: Evolution from
Collaboration to Self-Organization
Intelligent linkage system is fusing with emerging
technologies to catalyze new forms:
AI big model supply chain optimization:
Predicting copper price fluctuations in the next 6 months,
automatically generating electrolysis capacity and futures
hedging linkage operation program;
Self-organized production network:
Multiple base warehouses and electrolysis workshops form a
“virtual factory”, and orders are automatically assigned to
the production unit with the lowest overall cost;
Real-time carbon flow tracking:
The carbon emission data of each batch of raw materials is
embedded in the electrolysis process parameter library,
and the production path is dynamically optimized to
achieve the lowest carbon emission combination.
Conclusion: Redefining the Competitive
Dimension of the Non-ferrous Industry
Intelligent warehousing and electrolysis production in-depth linkage
not only solves the traditional stubborn problem of “warehousing
pressure, production, etc.”, but also transforms the industry chain
into a value symbiosis through data communication. According
to industry forecasts, in 2028, the global market size of intelligent
linkage system in the field of non-ferrous metals will exceed 120
billion yuan, the first to realize the whole chain of synergistic
enterprises will build a multi-dimensional moat in the cost
control, green transformation, customer response.
The essence of this change is to upgrade warehousing from a
cost center to an intelligent regulator of the production system
- when every ton of raw material flow carries production
demand and market signals, the operation mode of the
non-ferrous industry will usher in a fundamental
reconstruction.