Capacity Building on Heat Balance in Electrolysis of Aluminium

The development of digital simulation games for aluminium electrolysis represents a strategic shift in industrial training, aimed at accelerating the acquisition of complex cognitive skills related to heat balance control. By externalizing tacit knowledge that traditionally requires years of apprenticeship to master, these simulations bridge the critical gap between slow-moving chemical processes and immediate operator decision-making. The primary objective is to transform plant operators from procedural followers into informed knowledge workers capable of navigating the challenges of harsh production environments and limited real-time data.

The methodology relies on an iterative co-design process that integrates high-fidelity dynamic process models with user-centered design. By involving both novice and expert operators throughout the development lifecycle—from initial paper prototypes to final digital iterations—the project ensures that the simulation accurately reflects workplace requirements while fostering operator ownership. This approach allows users to simulate, anticipate, and reflect on the long-term consequences of their operational adjustments in a risk-free, interactive environment.

Empirical evaluation confirms the efficacy of this pedagogical approach, with participants demonstrating a 61% mean increase in knowledge regarding heat balance control. These findings validate the simulation as a robust tool for both initial training and the reinforcement of skills among experienced staff. Supported by the Norwegian Research Council’s BIA program and implemented in collaboration with industry partners like Hydro, the initiative is now transitioning into formal apprenticeship and competence development programs. This integration marks a significant advancement in industrial education, providing a scalable solution for managing complex, high-stakes manufacturing processes through experiential learning and cognitive task analysis.