Autonomous operation of industrial plants refers to the ability of a plant or facility to operate and manage its processes with minimal human intervention. It involves the integration of advanced technologies such as artificial intelligence (AI), Machine Learning, Robotics, and the Internet of Things (IoT) to enable self-monitoring, self-diagnosis, decision-making, and control.

The goal of autonomous operation in industrial plants is to improve productivity, reduce operational costs, enhance safety, and optimize resource utilization. By leveraging advanced technologies and intelligent systems, these plants can achieve higher levels of efficiency, reliability, and responsiveness in their operations.

In an autonomous industrial plant, various systems and components work together to optimize performance, productivity, and efficiency while ensuring safety and compliance. With one integrated solution, Metris ANDRITZ-Digital solutions combine various key aspects to achieve autonomous operation in industrial plants.

The path to full autonomy through industrial digital transformation

With the help of Machine Learning and Artificial Intelligence methods, Autonomous industrial plants utilize machine learning algorithms and AI systems that analyze the collected data, identify patterns, and make predictions.

These technologies can recognize anomalies, predict failures, and optimize processes based on historical and real-time data. Metris All-in-one platform is based on AI technologies and covers all the needs for data storage and analyzing functions.

Industrial plants employ sensors, actuators, and IoT devices to collect data from different equipment and processes. These sensors monitor parameters like temperature, pressure, flow rates, and quality metrics. The data is collected in real-time and used for analysis and decision-making.

ANDRITZ Automation has developed several Metris Smart Products for various process islands in pulp & paper plants, which act as a basic data information and control layer at the shop floor level. Furthermore, ANDRITZ Automation is a turn-key and full-line supplier for Classic Automation including Electrification and Instrumentation (AEI).

To operate industrial plants autonomously, it is necessary to identify potential equipment failures and maintenance requirements in advance. By analyzing the data patterns, Metris Risk-based Management systems can predict when an asset is likely to fail and trigger maintenance actions before a breakdown occurs.

This solution considers data coming from motors, valves, cyber-security supervision, past maintenance activities, and many more information sources.

As an outcome of the AI-based calculation Metris Risk-based management indicates all the assets with their risk level for an unplanned shutdown. Maintenance crews are then running their activities based on the highest asset risk level given to prevent any unplanned events in the industrial plant.

How to optimize industrial plants' performance

Autonomous plants must dynamically adjust process parameters and control systems based on changing conditions. AI algorithms optimize the operation by considering several factors such as used raw materials, energy efficiency, production targets, environmental constraints, and quality standards.

Consequently, ANDRITZ Automation has developed over the last decade several integrated Metris ACEs (Advance control expert functionalities) that ensure the above-described targets are met, and the plant runs optimally.

Autonomous plants also employ advanced algorithms and optimization techniques to make decisions in real-time. These decisions can include adjusting production schedules, allocating resources, optimizing energy consumption, and balancing the whole plant to meet the given production targets efficiently.

With Metris OPP (Optimization of Plant Performance) contracts, ANDRITZ Automation offers the possibility to tune and optimize industrial plants' performance on a long-term basis together with customers to achieve commonly agreed results.

It is essential for autonomous operation that robust safety measures and security protocols are incorporated. Systems needed to be designed to detect and respond to potential hazards, ensuring the safety of personnel and assets.

With Metris Cybersecurity solutions powered by Otorio, ANDRITZ helps its customers minimize digital and cyber risks. The integrated cybersecurity solutions are an additional vector for the calculation of the overall risk level of the industrial plants.

Digitalization addressing real individual needs​ 

ANDRITZ understands the importance of both digital and leadership capabilities. We have created digital solutions to help our customers address their current issues. Going digital is a different reality for each market, mill, and individual. ANDRITZ developed tools, processes, and methodologies aiming to support the enhancement of mill processes, assets, and people's needs.

We have strong partnerships with our customers and are dedicated to helping mills around the world create tailored digital transformation strategy is suited to their unique operational and business needs.

Have you identified your plant's level of autonomy?

The ANDRITZ portfolio covers automation and digitalization solutions for the entire plant life cycle and its assets. Our experts work with our customers to create solutions and implement technologies that help lower energy use, upgrade product quality, speed up production, and reduce operating costs.

This end-to-end approach enables customers to optimize and modernize their plants, setting them on a path toward autonomy.

Stay tuned to our next content to learn more about the technologies, methodologies, and business models ANDRITZ can offer to help kickstart or advance your digital transformation and path toward fully Autonomous Operations.