Companhia Brasileira de Alumínio: Improving Aluminum Reduction Plant and Smelter Operations

Companhia Brasileira de Alumínio (CBA) is the world's biggest integrated aluminum plant.

CBA encompasses the entire aluminum production cycle from alumina production, primary aluminum production to rolling. CBA is recognized as a benchmark for the Soderberg process operation. With 1,512 operating pot cells it produces more than 475,000 tons/year of aluminum for both internal and external markets.

Accenture collaborated closely with CBA to develop, produce and install the Score System solution for its entire aluminum reduction plant. Accenture also deployed wireless supervision and a redundant control system for a remote smelter operation.

Companhia Brasileira de Alumínio business challenges consisted of:

• CBA to become one of the top ranking smelter operations in the world.  
   
• Full control and visibility of the aluminum reduction phase. 
   
• Necessity for a turnkey project with a redundant control topology and advanced wireless operation.  
   
• Improve competitiveness.  
   
• Expand market share.  
   
• Costs reduction.  
   
• Improve overall efficiency.

Accenture was responsible for the development, production and installation of the Score System solution for the entire aluminum reduction plant, covering nine reduction lines and 1,512 pot cells. Accenture also deployed wireless supervision and a redundant control system for a remote smelter operation.

Additionally, a pot cell control algorithm was implemented. Accenture was also in charge of personnel training and empowerment.

Accenture delivered the following to CBA:

• Increase in current efficiency.  
   
• Increase in energy efficiency.  
   
• Increase pot cell stability.  
   
• Monitor and control of all pot cells.  
   
• Increase in operational flexibility (wireless system).
   
• Record and analyze key data.  
   
• Made it possible to have insightful decisions.  
   
• Continual optimization and improvement of smelter operations.  
   
• Reduction in greenhouse gases emission, lowering the environmental impact of the plant.  
   
• Reduction in maintenance costs and labor.