IndiaChemicals and materials2019 – ongoingTata Chemicals
AI decision support for carbonation towers and boilers at Mithapur
Tata Chemicals' AI advice for soda ash towers raised yield by 0.5% and saved about Rs 5.2 crore a year
Problem
Carbonation tower efficiency at the Mithapur soda ash plant stood at 67.8%, against a target of 70%. A 1% yield gain was worth up to $400,000 in annual margin.
Approach
Tata Chemicals built digital twins and prescriptive analytics with TCS, using data from more than 32,000 plant sensors. The system recommends temperature, pressure or flow settings that operators apply on the existing control screen. Three towers went live in September 2019 and the other 11 in May 2020. An AI algorithm also sets real-time points for two boilers.
Results
Takeaway
Operators kept control of the settings and the system advised them. The company needed 12 to 18 months of historical data to build it.
Categories
- Size
- Large enterprise
- Industry
- Chemicals and materials
- Business function
- Production and quality
- Innovation type
- Process innovation
- AI technology
- Predictive analytics and MLOptimization
- Adoption
- Partner co-development
- Evidence
- Company's own claim
Sources
Source summaries
Tata describes the decision-support systems for 14 carbonation towers and two boilers at Mithapur. It gives go-live dates, an average yield gain of 0.5% and annual savings of about Rs. 5.2 crore.
Full details are in the original sources.
