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National, June 11th, 2026: RUSAL, one of the world’s largest aluminium producers, has commenced the development of a corporate platform to manage the full life cycle of digital twins across its alumina refineries, marking a significant step in the company’s digital transformation journey.
The new platform will build upon RUSAL’s existing digital twin programme, under which advanced real-time digital models are already being used to optimise production processes at facilities including UAZ, BAZ, AGK, Friguia and Ewarton. Between 2026 and 2028, the platform is expected to support more than 100 digital twins across the company’s alumina operations.
Digital twins have become a critical tool in improving process stability, operational efficiency and decision-making across our alumina operations. The development of a unified corporate platform will enable RUSAL to scale these capabilities more effectively, standardise best practices across sites and unlock additional value from advanced analytics and real-time process optimisation.
Designed to enhance operational efficiency, equipment reliability and production safety, the initiative expands on the success of RUSAL’s existing digital technologies, which generated an economic effect of approximately ?798 million in 2025.
Digital twins form the foundation of RUSAL’s Model Predictive Control (MPC) framework, a methodology that leverages real-time digital models to assess operating conditions and determine optimal production parameters. By continuously analysing process data, digital twins enable more precise control of operations and support faster, data-driven decision-making.
As part of the programme, specialists at the RUSAL Engineering and Technology Centre (RUSAL ETC) developed recommendation systems for three complex process facilities at the Urals Aluminium Smelter (UAZ) during 2024–2025. These systems identify the current state of production processes, calculate optimal operating conditions and provide actionable recommendations to operators through a dedicated web platform.
The new corporate platform is expected to accelerate the deployment and management of these capabilities across RUSAL’s alumina refineries, creating a unified ecosystem for digital twin development, monitoring and optimisation.
