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RedCon System for
Aluminium Smelters

RedCon, is a state-of-the-art system from Hamilton Research that helps the aluminium smelting plants optimise their process parameters to become more efficient and sustainable.

Our R&D team has developed technology solutions for precise process control of electrolytic cells in Aluminium Smelters, which are cost-effective and customised to suit individual plants. The core of the system is to maintain the optimise alumina concentration, cryolite composition and ledge profile using intelligent algorithms. The technology has helped our customers to achieve the best KPI figures far exceeding the global average in:

  • Current Efficiency
  • Specific Power Consumption
  • Anode Effect Duration / % Anode Effect Termination

For retrofit cases, throughout the implementation, we strive to minimise downtime & ensure seamless operations.

The Pot Control System is an indispensable component of an Aluminium Smelter.

Block diagram below depicts a generic pot control system, which is customized to suit the requirement of the plant in consultation with the operations team.

This diagram represents a generic system and will change depending on customer requirements and plant specifications.

  • RedCon Pot Control System Components

    • HARTWare Controller for controlling Reduction Cells
    • HARTivD for transmission of Line Current & Line Voltage in real-time
    • HARTNet for communication with HARTWare & HARTivD Controllers
    • HARTBit for user interaction & supervisory controls
    • HARTApp for integration with mobile devices
    • HARTDb for Database management
    • HARTWeb for Intranet Services
    • HARTAW for audio alarms and warning


RedCon’s Control Over The Process

  • Automatic Feed Control
  • Automatic Resistance Control
  • Automatic Noise Control
  • Automatic Anode Effect Prediction & Prevention
  • Automatic Anode Effect Killing
  • Automatic Fluoride Control
  • Metal Tapping Control
  • Anode Change Control
  • Anode Beam Raise
  • Priority Management

Optimises Operating

Increases Current

Increases Pot

Reduces Energy

Reduces Environmental

Improves Workers’
Quality of Life

Long Product Life Ensuring
Low Maintenance Cost

Ensures the Baking
Profile of the Anodes

Minimises Flue to
Flue Deviation

Fuel Efficiency

Manages Crossover

Maximises Utilisation of
Pitch Volatile Burning

Enhances Refractory

Optimises Changeover