The Aksu Ferroalloy Plant of JSC TNK Kazchrome, part of ERG, has begun implementing artificial intelligence (AI) tools into its IT-based furnace management system. The pilot initiative is being rolled out on ore-thermal furnace No. 64.
The first phase of the project has been completed, including the collection, extraction, and analysis of three months of Big Data. Initial findings confirmed the strong potential of using this data to develop a recommendation-based AI model. In the future, the system is expected to help stabilise production processes, boost efficiency and energy savings, and reduce accidents and operating costs.
“Today, introducing AI into the mining and metallurgical sector is no longer a trend but a matter of competitiveness and industrial safety,” said project manager Ruslan Eskendirov of ERG’s Research and Engineering Centre. “Our approach is pragmatic: sensors → data → models → measurable KPIs.”
Earlier this year, ERG assembled a project team including specialists from its research and engineering centre, IT subsidiary BTS, Kazchrome, and the group’s metallurgy department. Working with an international technology partner that has already deployed similar AI tools at ferrochrome plants abroad, the team verified that the plant’s existing data is sufficient for building effective AI modules.
Overall, ten AI modules are planned for deployment, each designed to optimise different aspects of furnace operation. One example is a predictive tool for electrode breakage, which could significantly reduce downtime and financial losses.
The next phase will involve creating digital modules for controlling and monitoring furnace No. 64, integrating them into the existing automated process management system. The focus will be on predictive diagnostics, intelligent process optimisation, “soft sensors,” and operator guidance. If successful, the solution will be scaled across other furnaces.
