Dr. Barry Sadler

Dr. Barry Sadler

Managing Director, Net Carbon Consulting Pty Ltd

Dr Barry Sadler has been involved in the Aluminium Industry for 40 years in a range of positions but always with a focus on anode carbon technology. He has BAppSc and PhD degrees in Metallurgy, graduating in 1982 and commenced his career at the Comalco (Now Rio Tinto Alcan) Research Centre (CRC) in Melbourne, Australia. Barry established the Carbon Technology Group at CRC before moving to Comalco’s New Zealand Aluminium Smelter (NZAS) as Carbon Plant Manager in 1989. After more than 7 years at NZAS, and following a stint as the General Manager of Organisational Effectiveness for Hamersley Iron, Barry was appointed as the Corporate Technical General Manager at Comalco Aluminium’s corporate headquarters in Brisbane, Australia. In this role he provided support to improve carbon and metal products operations at Comalco’s smelters. Barry resigned from Rio Tinto/Comalco in 2002 to successfully set up the independent consultancy - “Net Carbon Consulting Pty Ltd”. Net Carbon Consulting strives to reduce the cost and improve the sustainability of client’s operations by improving the effectiveness of coke and anode production/utilisation and better process management. This is achieved by providing advice and support on improving plant and process technology, while always maintaining a strong focus on the practical application of statistical thinking and methods to process management. Work undertaken has included plant audits and reviews, large scale coke and anode trials, running specialised training sessions, troubleshooting plant operating problems, process/plant upgrade design work, advising suppliers, implementing process management systems, and providing training/coaching on the application statistical thinking and methods to plant projects. The international client base of NCC has included Smelting companies and raw material suppliers from over 20 countries. Barry has authored or co-authored over 40 technical papers, has been an active member of the TMS for over 30 years including Editor of “Light Metals 2013”, is a regular lecturer on anode technology on the TMS anode course and has s been an invited speaker at a range of conferences and meetings.

Panelist: SESSION: Technology and Application
Vision without Execution is Hallucination: How can we move from targets to execution? From commitment and planning to action and results?

All Sessions by Dr. Barry Sadler

5:20 am - 6:00 am

  • To deploy new technology we need to mainly consider: Capital, Operating cost, and Operational skills among others. Where do we stand on each? What are the implications in the real world?
  • Will the performance be as good as it is being marketed? What is the transition from invention to commercial use? What are the timelines we are looking for?
  • What do operations people need in order to get the best out of new technology? How to take technology to the next level in terms of efficiency, lean manufacturing, increase productivity and improve performance on initial results? Are processes and protocols in place for the next wave of R&D?
  • How can academia and R&D take us to the next level of performance? What specializations are needed? Is academia in the loop as an active partner? Are they shaping the minds of future generations to lead the operations and address the needs of the industry?
  • How can we deploy Industry 4.0 to help our industry reach our operational goals?
  • The industry relies on Automation to eliminate mundane tasks as well as improve safety where operators are in the line of fire and the need for human intervention. Can we optimize Automation in new technologies?
  • How to ensure that we can streamline supply chain and responsible sourcing? How to balance strategic supply imperatives with cost reduction, just-in-time sourcing and logistics for raw material?
  • What else can procurement people do to maximize profitability? In terms of logistics, transportation, taxes, and supply versus demand?