1. Improving the Quality at Alunorte using PI System J.A. Dias Lima ALUNORTE- Alumina do Norte do Brasil SA San Francisco - April 03 2000 Improving the Quality at Alunorte Using PI System

2. Our Mission “Supply alumina of superior quality, guaranteeing low operational costs with the best productivity, safety and protection to the environment”. Our Mission

3. General Information A company with global investment of U$ 875 millions. Start-up in 95, reaching nominal capacity in 97. 460 employees. 383 contracted workers. General Information

4. Process Flowsheet BAYER PROCESS FLOWSHEET DECANTERS FLASH TANKS BAUXITE BALL MILLS DIGESTERS SPENT LIQUOR CAUSTIC TEST-TANK HEATERS EXCHANGE VACUUM COOLING STEAM BOILER HOUSE MUD FILTRATION MUD WASHING HEATERS EXCHANGE RED MUD DISPOSAL PREGNANT LIQUOR FILTRATION PRECIPITATORS HYDRATE FILTRATION HYDRATE CLASSIFICATION CALCINERS CALCINED ALUMINA EVAPORATION PORT Process Flowsheet

5. Alunorte - Alumina do Norte do Brasil S.A.: Original design Production data (000 ton)

6. CHEMICAL PHYSICAL Alumina Quality Evolution

7. PI Sistem DCS ABB Master Control Stations Enterprise System Laboratory PI-Book PI-DataLink Operation Station DCS ABB Master DCS ABB Master Users Real time calculated values Values and Set-points Variáveis para Histórico Targets and Calculate d Values Trends, Graphics, Values and Reports Alunorte’s Network

8. u DIGITAL Personal Workstation (500 mhz), running Windows NT 4.0 Server u 256 Mb RAM Memory u 3 x 4gb HD u Raid 5 Controller u HP-9000, running HP-UX, 10 as interface between PI and DCS PI Hardware

9. u Alumina Storage Monitoring u Alumina Quality Monitoring u Continuous Ship Unloader Occurrence u Itens Control u Plant Occurrences Some Systems Developed Using VBA

10. u PI-Book is the only data link among plant floor and managers, including Director; u Intensive PI-Datalink use to find out the answers to Process and Maintenance problems u PI-Book consolidation as the unique tool to access all Windows based System u Intensive use of calculated tags in order to automate data generation What Means PI Culture ?

11. u Allows continuos alumina quality monitoring, in real time, in order to detect process deviations and pro-active actuation by process people u Was used as support system to ISO 9.0002 Certification u Totally developed by Alunorte’s people u Has been used by operational and process people as a routinely tool to track quality deviations u Was developed using a Drilling-down technique, in order to permit the scanning since the quality variables up to process variables in a sorted way and increasing the changes to find out the main reason to quality deviation in shorter time Alumina Quality Monitoring System

12. Alumina Quality Monitoring System Main Screen

13. If a red number appears, then you have a quality problem, and you must click in to start the process scanning

14. The process scanning in progress

15. The final level of the process scanning (fundamental variables graphics)

16. u Allows continuos alumina storage monitoring, in real time, in order to detect quality deviations, due to storage process, in advance and allow pro- active actuation by operational people u Was used as support system to ISO 9.0002 Certification u Totally developed by Alunorte’s people u Has been used mainly by operational people as a routinely tool to track alumina storage conditions Alumina Storage Monitoring System

17. Alumina Storage Monitoring System Main Screen

18. Checking out the alumina quality at silos entrance

19. Checking out the total alumina received by silos in the day

20. Checking out the delivered alumina quality

21. Checking out the alumina quality trend

22. Getting an warning due alumina quality problems at silos entrance