Development of a double model slab tracking control system for the continuous reheating furnace

Yong, Zhi; Su, Zheng-Gang; Li, Guojun; Yang, Qiangda; Wei-jun, Zhang

doi:10.1016/j.ijheatmasstransfer.2017.05.093

Cited by 26 publications

(8 citation statements)

References 31 publications

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“…In [7], a nonlinear optimization problem is formulated through a genetic algorithms approach; the minimization of fuel cost and the satisfaction of a desired discharge temperature represent the control objectives. In [8], two models and two related tracking control systems are proposed. In [9], a mixed neural network/heat transfer model approach is exploited, achieving an integrated intelligent control method.…”

Section: Astesj Issn: 2415-6698mentioning

confidence: 99%

MPC-based energy efficiency improvement in a pusher type billets reheating furnace

Zanoli¹,

Cocchioni²,

Pepe³

2018

Adv. sci. technol. eng. syst. j.

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The research reported in this paper proposes an Advanced Process Control system, denoted "i.Process | Steel -RHF", oriented to energy efficiency improvement in a pusher type billets reheating furnace located in an Italian steel plant. A tailored control method based on a two-layer Model Predictive Control strategy has been created that involves cooperating modules. Different types of linear models have been combined and an overall furnace global linear model has been developed and included in the controller formulation. The developed controller allows handling all furnace conditions, guaranteeing the fulfillment of the defined specifications. The reliability of the proposed approach has been tested through significant simulation scenarios. The controller has been installed on the considered real plant, replacing local standalone controllers manually conducted by plant operators. Very satisfactory field results have been achieved, both on process control and energy efficiency improvement. Optimized trade-offs between energy saving, environmental impact decreasing, product quality improvement and production maximization have been guaranteed. Consequently, Italian energy efficiency certificates have been obtained. The formulated steel industry reheating furnaces control method has been patented.

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Section: Astesj Issn: 2415-6698mentioning

confidence: 99%

MPC-based energy efficiency improvement in a pusher type billets reheating furnace

Zanoli¹,

Cocchioni²,

Pepe³

2018

Adv. sci. technol. eng. syst. j.

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“…The goal is represented by the minimization of fuel costs while satisfying a desired discharge temperature; simulation results are shown. In [28], a double model slab tracking system for a walking beam continuous reheating furnace is developed. A ternary model is used to describe the heating process in the furnace.…”

Section: Introductionmentioning

confidence: 99%

Multi-Mode Model Predictive Control Approach for Steel Billets Reheating Furnaces

Zanoli

Pepe

Orlietti³

2023

Sensors

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In this paper, a unified level 2 Advanced Process Control system for steel billets reheating furnaces is proposed. The system is capable of managing all process conditions that can occur in different types of furnaces, e.g., walking beam and pusher type. A multi-mode Model Predictive Control approach is proposed together with a virtual sensor and a control mode selector. The virtual sensor provides billet tracking, together with updated process and billet information; the control mode selector module defines online the best control mode to be applied. The control mode selector uses a tailored activation matrix and, in each control mode, a different subset of controlled variables and specifications are considered. All furnace conditions (production, planned/unplanned shutdowns/downtimes, and restarts) are managed and optimized. The reliability of the proposed approach is proven by the different installations in various European steel industries. Significant energy efficiency and process control results were obtained after the commissioning of the designed system on the real plants, replacing operators’ manual conduction and/or previous level 2 systems control.

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“…With the rapid development of the iron and steel industry, the energy consumption and the level of emissions are increasing annually [1][2][3]. In particular, reheating furnaces are the main energy-and emission-intensive equipment used in the hot rolling process (producing final steel products from semi-finished materials) and significantly affect the energy consumption and emitting detrimental gases such as CO 2 , SO 2 , and NO x [4][5][6][7]. These emissions are generated because reheating furnaces for thermal input use fossil fuels such as coke oven gas (COG) or mixed gases in the integrated steel plant based on the blast furnace and natural gas (NG) or liquefied petroleum gas (LPG) in the mini steel plant based on the electric arc furnace [8,9].…”

Section: Introductionmentioning

confidence: 99%

Nitric Oxide Emission Reduction in Reheating Furnaces through Burner and Furnace Air-Staged Combustions

et al. 2021

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In this study, a series of experiments were conducted on a testing facility and a real-scale furnace, for analyzing the nitric oxide (NO) emission reduction. The effects of the temperature, oxygen concentration, and amount of secondary combustion air were investigated in a single-burner combustion system. Additionally, the NO-reduction rate before and after combustion modifications in both the burner and furnace air-staged combustion were evaluated for a real-scale reheating furnace. The air-to-fuel equivalence ratio (λ) of individual combustion zones for the furnace was optimized for NO reduction without any incomplete combustion. The results indicated that the NO emission for controlling the λ of a single-zone decreased linearly with a decrease in the λ values in the individual firing tests (top-heat, bottom-heat, and bottom-soak zones). Moreover, the multi-zone control of the λ values for individual combustion zones was optimized at 1.13 (top-preheat), 1.0 (bottom-preheat), 1.0 (top-heat), 0.97 (bottom-heat), 1.0 (top-soak), and 0.97 (bottom-soak). In this firing condition, the modifications reduced the NO emissions by approximately 23%, as indicated by a comparison of the data obtained before and after the modifications. Thus, the combined application of burner and furnace air-staged combustions facilitated NO-emission reduction.

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Development of a double model slab tracking control system for the continuous reheating furnace

Cited by 26 publications

References 31 publications

MPC-based energy efficiency improvement in a pusher type billets reheating furnace

MPC-based energy efficiency improvement in a pusher type billets reheating furnace

Multi-Mode Model Predictive Control Approach for Steel Billets Reheating Furnaces

Nitric Oxide Emission Reduction in Reheating Furnaces through Burner and Furnace Air-Staged Combustions

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