Have you ever experienced baking the perfect cake, but when you wanted to repeat it, you were not able to re-create it exactly right the second time around? When making NPK fertilisers, Yara operators experience this issue daily. Each production plant typically produces a high number of individual product grades with different optimal process parameters. In addition, the optimal ways to run the plant are also influenced by external conditions such as ambient temperature, the incidence of clogging in the plant or the types of raw material used.
Yara Digital Production, in collaboration with the Finnish production site at Uusikaupunki, set out to solve this problem. Together they defined and built the Golden Batch tool. The tool continuously monitors the production process and saves good production runs as ‘golden batches’ to a database, so that operators can easily retrieve them and use them as a reference in the future. Using the Golden Batch tool has enabled operators to achieve higher production rates with more intensive, focused and regular utilisation of the best reference batches when running production. Stable production can also be reached faster with a visually clear overview of target values after start up or a grade change.
This presentation explains how the Golden Batch tool was built and developed. It also covers the roll out of this tool across Yara production sites and the value that has been derived from using the tool.