RUSAL Deploys AI-Powered Machine Hearing and Vision Technologies to Enhance Aluminium Production Efficiency

New Delhi, October 29, 2025: RUSAL, one of the world’s largest aluminium producers, has announced the implementation of two new Artificial Intelligence (AI) technologies — machine hearing and machine vision — across its production processes to boost operational efficiency, reduce energy consumption, and improve product quality.

The Russia-headquartered company, which operates globally, has introduced machine hearing technology in alumina production and machine vision technology in aluminium melt preparation. These advancements are part of RUSAL’s broader push toward automation and digital transformation in manufacturing.

The machine hearing system uses mathematical algorithms to analyze acoustic vibrations generated during mill operations. By detecting specific sound patterns linked to mill loading, the AI can optimize bauxite ore input, prevent equipment overuse, and reduce power consumption. The algorithm is trained to distinguish between relevant operational sounds and background noise, ensuring accurate mill performance monitoring.

Maintaining optimal mill loading is critical for both energy efficiency and product quality. Underloading leads to wasted electricity and premature wear of grinding equipment, while overloading results in coarse grinding that affects alumina yield and increases the frequency of repairs.

In alloy production, RUSAL is also using machine vision technology to improve aluminium melt preparation — a process that involves up to 20 sequential steps. The AI system, powered by a neural network, continuously monitors the melt preparation process to help operators maintain correct alloy composition and minimize the risk of defects in the final product.

Mikhail Grinishin, Director of Production Automation at the RUSAL Engineering and Technology Centre, said: “The system, which operates using machine vision, reduces the impact of human error as it helps the operator not to miss key moments during alloy preparation, and to better identify the areas of dross on the hot melt surface to improve the efficiency of its cleaning.”

RUSAL has been steadily expanding the use of digital and AI-driven technologies across its operations, many developed internally. These solutions are currently applied in areas such as electrolysis control, smelter sealing, raw material quality analysis, logistics management, and production optimization.

Through the integration of advanced AI tools like machine hearing and vision, RUSAL aims to further strengthen its position as a leader in sustainable and intelligent aluminium production, setting new benchmarks for operational excellence and energy efficiency in the global metals industry.