EuroChem - Usolskiy Potash Plant (EuroChem-UKK)

EuroChem - Usolsky Potash Plant LLC (EuroChem-UKK) is part of the EuroChem international holding, uniting large producers of mineral fertilizers, mining and gas production enterprises in Russia and Europe, logistics infrastructure, sales and distribution network.

History

2025: Usolsky potash plant became a pilot platform for EuroChem's integrated approach to digitalization

EuroChem is actively introducing modern solutions at enterprises as part of the digitalization of the technological process. These solutions are based on advanced technologies of artificial intelligence, modeling, video analytics and the industrial Internet of Things.

Usolsky potash plant is the first enterprise where EuroChem has worked out an integrated approach to digitalization. The company sees digitalization as a long-term trend and tool to improve safety, efficiency and optimization of production processes.

The integrated digitalization of EuroChem's chemical production is a systematic management approach that covers all stages of the production process - from a separate unit to the workshop and the entire enterprise as a whole. This integrated method allows not only to optimize individual operations, but also to ensure the coordinated operation of the entire production chain in terms of efficiency and safety.

The Usolsk potash plant has become a pilot platform for EuroChem's integrated approach to digitalization of the production process. As of March 2025, more than 20 digital solutions with a total potential of 1.2 billion rubles are being implemented at the site, including:

• digital industrial platform,
• recommendation systems,
• engraftment monitoring system,
• video analytics,
• digital efficiency tool ("InsEf"),
• BI dashboards and
• industrial safety monitoring system.

Integrated digitalization is based on an automated process control system (APCS), which allows operators to control the process. The digitalization process begins by collecting information about each stage of production using production sensors. Further, the data is aggregated in the digital industrial platform (DSP). This opens up the possibilities for creating digital products.

The introduction of systems based on artificial intelligence helps to significantly increase the efficiency and security of processes. Allows you to identify hidden patterns and relationships between alterations, which ultimately leads to increased profits.

At the Usolsk potash plant, recommended drying and granulation systems have been introduced for the flotation processing plant. These systems, developed on the basis of machine learning and big data processing technologies, have increased the production of granulated potassium chloride by 9.9 thousand tons per year and reduced fuel gas consumption by 85 thousand m³ per year. The direct economic effect for 2024 amounted to 59.4 million rubles, which demonstrates the high efficiency of investments in digitalization.

Roman Bushmakin, Director of Digitalization and Automation of the Usolsky Potash Plant: "The introduction of recommendation systems based on artificial intelligence was a significant step to optimize the technological process of enrichment, as well as drying and granulation. The systems help operators make decisions and reduce losses of the finished potassium chloride product. All data is transmitted to the monitor in a convenient form, and the operator can only adjust the mode in accordance with the recommendations. This not only speeds up the process, but also allows employees to focus on quality control rather than manual calculations. The technology helps minimize routine operations and improves the efficiency of the entire team. "

The connection between digital tools at different levels allows not only to track these relationships, but also to take measures to optimize them. For example, at the drying station, the recommendation system calculates and predicts the optimum temperature of the exhaust gases as well as the dried material. The data is then transmitted to the Digital Industrial Platform (DSP). In the CCP on the dashboard, the operator is given recommendations online, with the help of which he can optimize the operating mode of drying furnaces. This approach ensures the stability of the process parameters and significantly reduces the specific consumption of fuel gas.

Further along the chain, at the granulation unit, the AI solution analyzes the operation parameters of the roller presses and predicts the optimal speed of rotation of the screw to achieve the maximum yield of granulated potassium chloride. Receiving operational data from the dashboard of the Digital Industrial Platform, the operator can quickly adjust the granulation mode, increasing the volume of production of finished products and improving its quality.

"The recommendation systems passed a series of pilot tests and were put into commercial operation. During operation, the system is self-learning online. Currently, the production digitalization team, together with the enterprise team, is developing an improved control system with automation elements, which will improve the efficiency of the enterprise. In addition, we are developing solutions for other alterations of the enrichment plant, "said Konstantin Ledovskikh, project manager for Digital Technologies and Platforms.

2024: Appointment to the post of general director Dmitry Tokarev

In November 2024, Dmitry Tokarev was appointed General Director of Eurochem - Usolsky Potash Plant LLC. This is evidenced by the data of the Kontur. Focus service, which TAdviser got acquainted with. Read more here