The Situation

The alumina refinery was struggling to achieve nameplate production rate and efficiencies.  They had been through a series of cost-cutting exercises which had eroded their technical and project delivery capacities.  Unlike some of their competitors, the refinery technical team was not part of a larger technical support network.

Scope

Under a Technical Service Agreement (TSA), which provided for a highly integrated co-operative approach to improvement of refinery performance, the scope was generally unconstrained. The goal was to uncover any opportunities to improve production and bauxite, energy and caustic consumption.

The work included site visits, refinery benchmarking, SysCAD process modelling, business improvement initiatives, project implementation and help desk support. 

Our Solution

Advisian developed a suite of capital and non-capital initiatives.  Initial site visits with remote support were augmented by addition of a site based role.  

Process improvement was driven mostly through non-capital initiatives.  Within a year, the key process performance metrics of production, bauxite energy and caustic consumption improved by USD $18M relative to the performance over the previous two years.