| Company | Tomago |
| Location | Hunter Valley, New South Wales |
| Timeline | 2024 |
| Project Overview | Tomago Aluminium is one of Australia’s largest aluminium smelters, producing up to 590,000 tonnes per year—around 37% of the nation’s primary aluminium output—and exporting 90% of its product across the Asia‑Pacific region. As a critical industrial operation with a strong focus on reliability and a transition to 100% renewable electricity by 2035, the site is supported by Insulect‑supplied Qualitrol IDM+ solutions for digital fault recording, power quality monitoring, and FCAS performance monitoring. |
| Products |
Qualitrol IDM+
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Tomago Aluminium is one of Australia’s largest aluminium smelters, producing up to 590,000 tonnes of aluminium each year—around 37% of the nation’s total primary aluminium output. With 90% of production exported to the Asia‑Pacific region, the site is a critical part of both the Australian economy and the regional supply chain. Operating at this scale requires exceptionally reliable power and deep visibility into electrical performance, particularly as Tomago progresses toward its goal of operating on 100% renewable electricity by 2035. Insulect supported this requirement by supplying Qualitrol IDM+ monitoring solutions.
Aluminium smelting is one of the most energy‑intensive industrial processes, where even brief electrical disturbances can impact production, equipment life, and operational safety. Tomago required a monitoring system capable of capturing faults, disturbances, and power quality issues in real time, while also supporting compliance with grid requirements and FCAS participation. As the site continues to evolve toward a renewable‑powered future, understanding how the power system behaves under changing grid conditions became increasingly important.
Insulect supplied and supported the implementation of the Qualitrol IDM+ platform, delivering Class A power quality monitoring alongside digital fault recording and dynamic disturbance recording. The system also provides FCAS generation performance monitoring, giving Tomago clear visibility of its response to grid events. By integrating the IDM+ solution into the smelter’s electrical network, Insulect enabled high‑resolution data capture across critical operating conditions, supporting both real‑time decision‑making and long‑term analysis.
The IDM+ system provides Tomago with detailed insight into power quality, fault events, and system disturbances, helping operators identify issues quickly and respond with confidence. Accurate monitoring supports equipment protection, reduces the risk of unplanned outages, and assists with regulatory and market compliance. The ability to analyse trends over time also supports better asset management and informed planning as the site transitions toward renewable energy supply.
With Insulect’s monitoring solution in place, Tomago Aluminium operates with improved visibility and confidence across its electrical network. The smelter is better equipped to manage disturbances, protect critical assets, and support reliable, large‑scale production. This project demonstrates Insulect’s ability to support energy‑intensive industrial operations with advanced monitoring solutions that underpin reliability today while supporting the transition to a cleaner energy future.