BDO Unicon Business Solutions has introduced a system of intelligent management of fertilizer production at Uralchem

2020: Implementation of the system of intelligent control of the drying and pelletizing process in the KChK branch

On September 22, 2020, BDO Unicon Business Solutions announced the completion of the implementation of the intelligent control system for the drying and granulation process "Advisor to the Operator of the Granulator-Dryer Drum (BGS)" at the production plants of the KchHK branch of JSC OKHK URALCHEM. The system made it possible to increase the stability of operation and reduce the influence of the human factor during the process control, due to which the output increased by 2-6% while maintaining the quality - the size of the pellets of the manufactured products. During joint tests with the plant specialists, additional factors affecting the quality of the technological process were identified, and ways were outlined for further development and improvement of both the process itself and the developed solution.

As part of the project, the team of experts from BDO Unicon Business Solutions and URALCHEM went from developing and testing the prototype to deploying the solution at all production facilities of the workshop and conducting tests on all types of products that confirmed the achievement of the target effects from implementation at the full production cycle. The created solution is a full-fledged digital twin of a real drum and an intelligent model-adviser based on a self-learning neural network. The system collects and analyzes the history of changes in technological parameters of the plant operation, predicts the result based on an optimization mathematical model and offers the operator recommendations for correcting control parameters. The more accurately it follows these instructions, the more stable the operation of the equipment. Process parameter readings are loaded from the automated process control system and laboratory analysis database. As data accumulates, the mathematical model learns and improves continuously.

{{quote 'Digital technologies are increasingly penetrating real production and increasing its efficiency. For consulting customers, the key task is to find and identify potential areas for improvement and choose the most effective technologies for developing solutions aimed at achieving business effects for the client. The results of the project at URALCHEM prove that our project team and the customer succeeded, - said Bogdan Kotsovsky, General Director of BDO Unicon Business Solutions. }}

This is one of these projects that allows you to increase productivity without much investment, mainly thanks to an intelligent solution. The use of online advisers provides an opportunity to monitor processes in the current mode, eliminate errors and minimize risks. For us, this is strategic important, because BGS is not only at KCHHK. In the future, we will be able to implement this solution in other production areas, - said Azat Gafarov, General Director of URALCHEM Innovation LLC.