+91 33 400 11 461 / 462 info@hart.co.in


APC – Advanced Pot Controller for Aluminum Smelters


  • Electronic Pot Controllers
  • Communication Controllers
  • Supervisory & Line Computers
  • Control Software

HART offers a complete process control technology solution package that is economical and reliable. It is appropriate for both large and small-scale producers who need cost-effective technology to run their business along viable lines. The technology upgrades, superior in both design and configuration of digital controls, can be easily integrated to the functional plants and process. In retrofitting, HART provides the best solution which are truly international in quality. In addition, it minimizes downtime -as it takes less than half a shift to install and commission the control package. HART helps its customers stay ahead in profitability and productivity by installing the state-of-the-art Controller Technology in pot lines.

APCs Controls over the process :

  • Alumina Concentration Control
  • Automatic Resistance Control
  • Automatic Noise control
  • Anode Change/Stud Pulling Compensation
  • Automatic Anode effect Predication and Prevention
  • Automatic Anode Effect Detection
  • Automatic Anode Effect Killing
  • Automatic Aluminum Fluoride Addition and Control

Direct Indirect
Rise in current efficiency Lower environmental pollution
Decrease in consumption of raw materials Boosts morale of workers
Increase in Pot life Ensures better health of workers
Low maintenance cost Real time messaging
Lower specific energy consumption Saves times on supervision
Reduced voltage Superior acceptability in market
  International quality at lower cost

Advanced Pot Controller

HART's Pot Control System is a Fully Distributed Process Control System designed around Intel’s Atom Processor. There remains a dedicated controller for each reduction cell and is capable of independently handle the pot in case of any kind of network trouble. The heart of the system is a Host Computer (HC) which can range from a single PC to a number of PCs on a network. The Controller named as Advanced Pot Controller (APC), is designed for the purpose of automatically controlling reduction cell in Aluminum Smelter Plants. Each APC consists of embedded controller with 256 MB of RAM expandable to 2GB, 512 MB Flash expandable to 64GB, Analog to Digital conversion, digital input/output capability, communication sub-system, SATA and USB interface, front panel with display devices push button switches and membrane keypad. APC software provides anode movement control and Aluminum feed control based on a predetermined strategy for each reduction cell. It also maintains history information like cell operating parameters, various events and exceptions for each cell. When connected to the HC the system provides for data acquisition and report generation facilities. APC Software is highly parameterized, enabling the end user to fine tune/adjust control algorithm from the HC on individual pot or group of pots.

HRS - Heat Regulation System for Anode Baking Furnaces

HRS is a user friendly process control solution for the anode baking plant. Based on the state-of-the-art microprocessor based technology and structured with the distributed control system architecture, HRS supports automatic burner control and draught control for individual flue line of the furnace. Particularly designed for shop floor installations with reliable communication techniques, it aims to regulate the heat generated by high temperature, carbon and organic fume-filled environment inside the baking plant.

The system comprises of:

  • Supervisory computer
  • Industrial workstation
  • Fire control panel
  • Draft control Panel
  • Air control panel
  • Air pressure interface
  • Under pressure interface

The objective of control strategy, achieved by Temperature Control and Draught Control are :
  • Ensures anodes are baked as per the baking schedule.
  • Maximises fuel efficiency by complete fuel combustion.
  • Ensures minimum deviation in flue temperature from the target.
  • Optimizes energy utilization by burning of pitch volatiles.
  • Enhances refractory life.
  • Prevents temperature excursions

Salient Features of HART's HRS
  • Accurate control of flue line temperature
  • Increase in fuel efficiency
  • Removal of fire hazards
  • Better pollution control
  • Detection of leakage of air
  • Greater life span of refractory
  • Optimum control of pitch volatile combustion
  • Minimum time in fire change operation
  • Identification of burner disorders
  • Minimum human error in furnace operation
  • Diagnostic and alarm messaging facility
  • Maintenance of comprehensive history data

SCADA - Supervisory Control and Data Acquisition

HART has developed and successfully installed and commissioned SCADA - Supervisory Control and Data Acquisition for monitoring and controlling the health of traction power of the Indian Railways. Numbers of microprocessor based Remote Terminal Units (RTU) are placed over widely dispersed terrain. Such system are generally used in mission critical applications and run 24 hours a day, 365 days a year, uninterrupted and often unmanned.

The system adheres to strict specification of Indian Railways and approved by RDSO, the Technical Wing of Indian Railways

The sections commissioned are: Jhaja-Mughalsarai section with 32 RTU
Vallatol Nagar –Ernakulam section with 9 RTU
Vishakapatnam-Palasa with 21 RTU
Sealdah division with 45 RTU &
Kharagpur division with 46 RTU

The Software is designed to support following features:
Hot standby through redundant hardware.
Distributed software architecture (single failure not causing catastrophe).
Detection of faulty instruments / transducers or malfunctioning hardware.
Failsafe system output, On-line diagnostic & Ease of upgrades.

Generally a power plant is tightly linked with the process/plant with which it is associated. The goals of the power plant varies depending on the type of plant and the needs of the process.

SCADA systems for such power plant are designed to control the Power Generation, Transmission, and Distribution, following a specific scheme with the following objectives:

  • Load Management
  • Supevisory Control
  • Data Acquisition
  • Process Control
  • Local Control

Primary functions of SCADA system are:

These are set of standard fucntions and valid for any plant with proper configuartion and tuning.

Operating Environment, Data-base, Configuration, Network Facility, Operator Interface, etc.

Representation of complete power scheme with Mimic diagram, following proper symbol and nomenclature, and validation of input parameters and commands.

Facility to record analog variables, defined in terms of Sample Rate, Recording Duration, Event Recording, etc.

These are specific to the Plant or Process, and requires customized design as well as implementation.

SMS - Superheat Measurement System

Conventional methods of achieving energy efficiency in modern smelter plants, like resistance control, optimized feed strategy, etc. has almost reached a saturation point and it is unlikely that further significant improvements in current efficiency figure can be obtained by these methods. Therefore, alternative methods of enhancing the cell performance are being actively pursued by scientists and engineers in the industry. One of the most promising paths towards this goal has been to achieve stable cell operation by maintaining thermal balance of the cell. The method requires accurate measurement of Superheat.

New approach to achieve stable cell operation:

  • Combined stabilization of mass and energy.

Method involves direct measurement of:
  • Superheat - the difference between the bath temperature and the liquidus Based on the measurement, an approximate control algorithm is applied to each cell so that optimum stability is obtained resulting in an increase in current efficiency and reduced energy consumption.

Standalone system with:
  • Reusable Thermocouple
  • Online data recording
  • Cooling curve display
  • Data transfer to the Supervisory Computer
  • Suggested control action to be taken

  • Housed in a trolley, movable from pot to pot
  • Reusable thermocouple, sample cup and a motor for stirring fitted on an mechanical arm.
  • Operator moves the trolley to a convenient position close to the pot and breaks the crust through which the thermocouple with the sample cum is manually inserted.

  • Capable of storing data for 500 Measurements
  • Easy transfer of data to Supervisory Computer
  • Necessary control action command
  • Easy user interface
  • Reusable thermocouple

  • More stable pot operation and improved performance
  • Less variations in process parameters
  • Increase in current efficiency
  • Reduction in energy consumption
  • Optimum use of chemical additions to maintain composition control