Alcoa Reduces Variable Costs with Pavilion Technologies; Pavilion's Advanced Process Control Solution Reduces Process Variability by 75 Percent.
Alcoa turned to Pavilion Technologies to achieve new levels of production efficiency to address the rising cost of raw materials. As part of Pavilion's ValueFirst(TM) initiative, Pavilion worked with the Alcoa team to evaluate how the kiln control application would contribute to Alcoa's key business objectives. Based on the analysis, Pavilion guaranteed a return on investment in 12 months. The project has exceeded this goal.
"Today's marketplace requires that we continuously identify ways to reduce variable costs," said Dennis Eisele, technical superintendent, Chemicals for Alcoa. "We selected Pavilion based on their understanding of process control, which enabled them to identify solutions to our toughest problems. The combination of a strong technical solution, experienced engineers, and guaranteed results made selecting Pavilion an easy decision."
The project at Alcoa's Point Comfort operations was implemented in January of 2005. In just six months, the installation has delivered the following benefits:
--Decreased the amount of unreacted calcium fluoride by a factor of almost three; and
--Reduced the process variability in critical downstream process by 75 percent.
The sixth kiln was commissioned last month.
"With our solution, Alcoa has achieved even higher levels of production performance," said Pavilion CEO Ralph Carter. "We are honored to work with Alcoa and other leading manufacturers to deliver bottom-line results year-over-year."
Alcoa Point Comfort operations is one of the largest producers of aluminum fluoride in the world. It is also one of the world's largest producers of alumina. Alcoa produces commodity hydrates and calcines -- the materials necessary for producing alumina-based chemicals. These products are used in the global alumina, commodity chemicals and aluminum ingot markets. Alcoa's Point Comfort operations which has an alumina refining capacity of 2.3 million metric tons per year, is one of several Alcoa facilities that services the global demand for alumina.
Pavilion's mineral and mining solution is powered by the multi-variable, model predictive capability of Pavilion's optimization and control software. Pavilion's software enables manufacturers to control and optimize key production variables, resulting in increased production, increased yield, and decreased energy consumption.
About Pavilion Technologies (www.pavtech.com)
Pavilion Technologies is the leading developer of advanced process control and environmental compliance solutions. Pavilion's ValueFirst(TM) customer relationship methodology aligns the company's people, products and processes to deliver rapid and recurring value for their customers. More than 350 leading companies worldwide, including ATOFINA, BP, Eastman Chemicals, Fonterra, Nestle and Weyerhaeuser depend on Pavilion's solutions to increase yield, enhance product quality, reduce variable costs and achieve environmental compliance each day. Pavilion Technologies is a privately held company based in Austin, Texas, with offices serving every region of the world.
Alcoa is the world's leading producer of primary aluminum, fabricated aluminum and alumina, and is active in all major aspects of the industry. Alcoa serves the aerospace, automotive, packaging, building and construction, commercial transportation and industrial markets, bringing design, engineering, production and other capabilities of Alcoa's businesses as a single solution to customers. In addition to aluminum products and components, Alcoa also markets consumer brands including Reynolds Wrap(R) aluminum foil, Alcoa(R) wheels, and Baco(R) household wraps. Among its other businesses are vinyl siding, closures, precision castings, and electrical distribution systems for cars and trucks. The company has 127,000 employees in 39 countries. For more information go to www.alcoa.com