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Highlights
- Tata Chemicals has the largest saltworks in Asia, the third-largest soda ash manufacturer, and the sixth-largest sodium bicarbonate manufacturer globally.
- Their manufacturing operations have many continuous steady-state processes and heavy equipment, whose cost failure is very high. As process variations and asset downtime significantly impact the average yield and margins, it is important that the assets run at optimal efficiency and that any process variations are avoided.
- TCS has been a growth and transformation partner for Tata Chemicals in driving IIoT-based transformation, covering the end-to-end cycle for Tata Chemicals’ plant personnel to adopt the new way of life.
Tata Chemicals reimagines its operations at the Mithapur plant with TCS’ AI-driven asset and process digital twins.
TCS enables AI-led production excellence to life at Tata Chemicals
One of the oldest plants in India charts its journey towards becoming future-ready.
Tata Chemicals, the world's third-largest producer of soda ash and the sixth-largest producer of sodium bicarbonate, reimagined its operations at the Mithapur plant with TCS AI-driven asset and process digital twins.
To address challenges on throughput, quality, energy, and environmental sustainability owing to process variation, asset maintenance, and plant downtime, the soda ash plant's carbonation towers were identified for the first digital twin implementation.
With TCS' AI-driven digital twin for carbonation towers, plant operators could now ensure that the carbonation towers operated efficiently. They could precisely determine which parameters must be adjusted and receive early warning alerts with priority levels.
Digital twin solutions were further deployed for other use cases across different plants.
In the cement plant, we enabled Tata Chemicals to manage the clinker output quality at desired levels and provided early warning alerts for induced draught (ID) fans.
In one instance, the early warning advisory allowed plant operators to avoid a critical failure of the pre-heater fan drive end bearing, thus saving two to three days of production loss.
As a strategic partner, TCS is proud to enable Tata Chemicals to drive predictability, adaptability, and data-led decision-making across its plant processes and position them to lead the way for the factory of the future.
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