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C. The impurities in
the iron like silica and alumina combine with the uxes
(limestone and dolomite) to form the slag. The molten
iron and slag collect at the bottom with the slag oating
on the molten iron. The slag layer plays an important
role in rening and purifying the hot metal produced.
The nal concentration of the hot metal with respect to
the impurities like silicon is the result of the equilibrium
between the iron phase and slag phase when the iron
droplets trickle down through the slag phase. The sulfur
present in the coke is also a very critical impurity and
should report to the slag rather than the hot metal.
0959-1524/00/$ - see front matter # 2000 Elsevier Science Ltd. All rights reserved.
PI I : S0959- 1524( 99) 00052- 9
Journal of Process Control 10 (2000) 509524
* Corresponding author. Tel.: +60-05-367-6901; fax:+60-05-367-7055.
E-mail address: chradha@kimia.eng.usm.my (V.R. Radhakrishnan)
2. Blast furnace variables and models
The important constituents of hot metal and slag
which ultimately aect their quality are shown in Table
1. For the ecient operation of the steel making process
the hot metal produced in the blast furnace has to meet
stringent specications with respect to composition and
temperature. In the particular integrated steel plant
studied in this paper the carbon content has to be within
5%, the silicon content less than 1.5%, the sulfur con-
tent less than 0.4% and the phosphorus content less
than 0.4%. Similarly the slag composition is also very
important from the point of view of its owability and
granulation characteristics.
The load variables which aect the controlled vari-
ables are shown in Table 2. This list was prepared by a
DELPHI technique by polling experienced blast furnace
operators, technologists, managers and research work-
ers. These load variables enter the process either from
the top with the solid charge or from the bottom with
the hot blast. The solid raw materials charged from the
top are normally preblended to reduce their variability.
The operation of the furnace so that it is maintained in
a very stable status is one of the primary objectives of
control.
The amounts of sulfur and silicon present in the pig
iron at the hearth of the blast furnace is the most critical
variable for the economics of the steel plant. These two
variables are also very sensitive to the upsets in the blast
furnace operation [1]. The variables which can be
manipulated in a blast furnace can be divided into two
classes. Those entering the system from the top and
those entering the system from the bottom. The
manipulated variables entering from the top are the ore/
coke ratio and the basicity ratio. The basicity ratio is
related to the amount of ux material limestone and
dolomite added per tonne of hot metal produced. The
manipulated variables from the bottom are the hot blast
temperature, humidity and the fuel/ore ratio. The
manipulated variables from the top aect the hot metal
compositions after a long period of the order of 68 h.
The manipulated variables entering from the bottom
have a relatively quick eect on the compositions.
In normal practice the composition of the hot metal
and slag as shown in Table 1 are measured by spectro-
scopic analysis of a sample of the hot metal or slag.
Since spectroscopic analysis is a laboratory technique
the value of the variables are not available for on line
control of the input variables of the blast furnace. The
tonnage of the hot metal and slag produced in each
tapping are also an information of great importance for
the scheduling of the steel plant operations. These mea-
surements also cannot be performed a priori and has to
be inferred from the ladle weights after the material is
poured. Because of the large hold up in the blast furnace
there is a very large time delay between the inputs and
the outputs. This causes considerable control diculties.
The only possible control actions to control the output
quality and quantity of the hot metal and slag from a
blast furnace is some form of model based predictive
control. For implementation of model based controls,
on-line measurements of the controlled variables are
required. The controlled variables in the present case
are the composition and tonnage variables which can-
not be measured on-line. An alternative method for on-
line measurement of variables is the so called soft sensor
techniques. In the soft sensor technique a variable which
cannot be directly measured is related by a suitable
model to several other process variables which are
amenable to on line measurements. These variables in
most cases are temperatures, pressures and ows which
can all be measured on-line by standard instrumenta-
tion. The complex relationship between the measured
variables and the variable of interest is modeled by a
suitable technique.
There have been many attempts made to model the
blast furnace processes. The complexity of the heat and
mass transfer processes coupled with a large number of
gassolid, solidsolid and solidliquid reactions, com-
bustion processes and inter phase mass transfer makes
the modeling of blast furnaces an extremely dicult
Fig. 1. The iron blast furnace.
510 V.R. Radhakrishnan, A.R. Mohamed / Journal of Process Control 10 (2000) 509524
problem. Peacey and Davenport [2] have presented a
very extensive steady state heat and mass balance model
of the blast furnace. Their model can be used for deter-
mining the required raw material rates for a given hot
metal production rate. The hot metal and slag tempera-
tures, o gas rate and analysis and slag production can
also be calculated from their model. However this
model cannot predict the HM and slag compositions
which are the required inputs for their model. Ufret and
Williams [1] have in their model combined the heat bal-
ances, mass balances and kinetic data with empirical
relations for phase equilibrium in the hot metal -slag
system. The model consists of 10 state variables. The
blast furnace is divided into four cells, the stack, bosh,
hearth and molten metal pool. The model uses empirical
relationships to dene the activity coecients of the
dierent components, the kinetic parameters, and the
temperature dependence of phase solubility. These
equations are complex nonlinear relationships. The
resulting set of dierential and algebraic equations are
solved numerically. Their model can predict the mate-
rial and blast requirements as well as silica and sulfur
concentrations in the hot metal. Their model was not
capable of predicting various other parameters like
production rate of hot metal and slag and slag basicity.
For modeling such complex systems neural network is
an attractive technique. There has been several success-
ful attempts at modeling metallurgical systems using
neural networks [3,4]. In the present work 33 measur-
able variables related to the blast furnace operation and
burden compositions are related by NN techniques to
six variables related to the hot metal and nine variables
related to the slag (Table 3).
3. Neural networks
Neural networks can be thought of as a nonlinear
mapping between a set of inputs and a set of outputs. In
a neural network the inputs and outputs are connected
through a series of nodes arranged in several layers (Fig.
2). Because of this complex connectivity between the
nodes the NN model is able to perform the mapping
with excellent accuracy. A feedforward neural network
essentially consists of a number of nodes interconnected
as shown in Fig. 2. The inputs x
i
are connected to the
nodes in the input layer. The outputs y
p
are taken from
Table 2
Preliminary list of input variables
Sinter Coke Iron
Ore
Limestone Mn
Ore
Hot
blast
Cold
blast
Fe% * * * * *
Iron oxides% * * *
SiO
2
% * * * * *
CaO% * * * *
Al
2
O
3
% * * * * *
MgO% * * * *
K
2
O * *
S% *
MnO% * * *
C% * *
Caloric value *
Basicity * *
Quantity (tons/h) * * * *
Pressure * *
Di., pressure * *
Temperature * *
Steam rate * *
Oxygen% * *
Table 1
Important quality variables of hot metal and slag
No. Variable Mean Median Standard
deviation
Pseudo standard
deviation
Skew Kurtosis Standard error
of estimate
Hot metal
1 Quantity (tonnes) 377.65 408.09 122.65 72.33 0.88 0.11 28.67
2 Temperature (
C. The HMT
results look less coincident because of the large numer-
ical value of this parameter.
A Neural Network based model is valid only so long
as the system as represented by the training data has not
changed. If the system has changed then the model will
no longer be valid. In the case of a blast furnace this is
not a major problem since the furnace operates in a
stable regime with essentially constant raw material
Fig. 8. Sensitivity of output variables to changes in Fe% in coke ash:
(a) slag quantity, (b) Mn% in hot metal, (c) hot metal quantity, (d) hot
metal temperature, (e) Si% in hot metal, (f) S% in hot metal.
Fig. 9. Sensitivity of output variables to changes in CaO% in coke
ash: (a) slag quantity, (b) S% in hot metal, (c) Mn% in hot metal, (d)
Si % in hot metal, (e) hot metal quantity, (f) hot metal temperature.
518 V.R. Radhakrishnan, A.R. Mohamed / Journal of Process Control 10 (2000) 509524
qualities over fairly long periods of time. When impor-
tant changes like furnace relining, changes in the fur-
nace injectant composition or changes in the source and
quality of raw materials takes place then the neural
network has to be retrained for the new set of condi-
tions. The training can be incorporated in the model in
what is known as an Adaptive NN, but this has not
been found necessary for a Blast Furnace model since
the system is stable over long periods.
9. Expert system control of silica and sulfur in the hot
metal
The control of silicon and sulfur at stable low values
is critical for the successful operation of the furnace.
The two group of variables which aect the amount of
silica and sulfur in the hot metal are the burden vari-
ables and the blast variables. Some of the important
interactions of these variables on the hot metal silica
and sulfur can be summarized as follows.
9.1. Manipulated variables aecting silica in hot metal
i. Decreased blast temperature lowers the Si in hot
metal.
ii. Decreased coke/ore ratio decreases the Si in hot
metal.
iii. Decreased fuel to ore ratio lowers the Si in hot metal.
iv. Increased blast humidity lowers Si in hot metal.
v. Decreased slag acidity lowers the Si in hot metal.
Decreased blast temperature, lower coke/ore ratio
and lower fuel/ore ratio reduce the energy supply to the
furnace. By introducing more water the energy demand
for dissociating the water is increased. Decreased acidity
reduces the silica concentration in slag and hence
increases the mass transfer from the hot metal to the
slag. Decreasing the slag acidity requires increase in the
limestone in the charge. The rst, third and fourth
actions are implemented at the bottom of the furnace
with the blast. A control action taken through the hot-
blast aects the hot metal silica almost immediately.
The second and fourth actions are implemented by
changing the burden composition from the top of the
furnace. These changes aects the hot metal silica after
a considerable delay of the order of 4 to 6 h. The hydro-
carbon fuel injection produces a complex change in silica
rst decreasing it and then increasing it. Hence it is not a
preferred method of controlling the hot metal silica.
9.2. Manipulated variables aecting the hot metal sulfur
The sulfur concentration in the hot metal is the result
of the complex phase equilibrium between the slag and
the iron phases. Thermal conditions in the hearth, and
Fig. 10. Model validation of hot metal variables: &Experimental, Model: (a) hot metal quantity, (b) hot metal temperature, (c) Si% (d) S%, (e)
Mn%, (f) C%.
V.R. Radhakrishnan, A.R. Mohamed / Journal of Process Control 10 (2000) 509524 519
the compositions of the metal and slag as well as the
reducing conditions in the hot metalslag interphase all
have profound eect on the hot metal sulfur concentra-
tion. Venkatadri and Gupta [8] have presented equations
relating the hot metal sulfur content with the process
variables. According to their ndings the important
eects on hot metal sulfur are
1. Higher basicity ratio of the slag decreases the sul-
fur in the hot metal. The basicity ratio is dened as
(CaO+0.5MgO)/(SiO
2
+0.33Al
2
O
3
).
2. Higher carbon monoxide partial pressure in the
hearth increases the hot metal sulfur.
3. Higher hot metal/slag temperature decreases the
hot metal sulfur.
4. Silicon, phosphorus and carbon in the hot metal
decrease the hot metal sulfur while Mn increases
the hot metal sulfur.
The basicity ratio of the slag can be manipulated by
changing the limestone addition rate. However since
this is implemented from the furnace top its eect will
Fig. 11. Model validation of slag variables: &Experimental, Model: (a) slag quantity, (b) TiO
2
, (c) SiO
2
, (d) Al
2
O
3
, (e) CaO, (f) MgO, (g) K
2
O,
(h) FeO, (i) basicity.
520 V.R. Radhakrishnan, A.R. Mohamed / Journal of Process Control 10 (2000) 509524
be felt after about 4-6 h. The carbon monoxide pressure
on the interface is directly related to the blowing pres-
sure. However the allowable changes in blowing pres-
sure is only small since furnace productivity and stable
operation are aected by this variable. The eect of
temperature on hot metal sulfur is exactly opposite to
its eect on the hot metal silicon. In view of these con-
siderations only limited manipulation of the sulfur is
possible using the blast variables. The major adjustment
to the sulfur has to be obtained by the limestone addi-
tion rate.
The values of the hot metal and silica compositions
and temperatures predicted by the neural network
model were combined with the blast furnace charge
calculation model, and a set of rules for changing the
blast temperature, blast rate, blast pressure, coke rate
and limestone rate for implementing the supervisory
control. The values of the manipulated variables so
obtained were downloaded to the furnace control sys-
tems. The general structure of the control system is
represented in Fig. 12. The furnace control is made up
of two basic systems. The Programmable Logic Control
System (PLC) for the charge control, and the Dis-
tributed Control System (DCS) based stove controls.
The existing supervisory system consists of a charge
calculation model for determining the burden and blast
rates. The inputs to the charge calculation model are the
burden component analysis, the targeted hot metal
analysis and hot metal production, blast temperature
and humidity, quantity, analysis and properties of the
injectants and the required slag basicity. On the basis of
a complex set of material and energy balances the model
calculates the required tonnage of each of the burden
components and the blast requirements. The model also
predicts the tuyere ame temperature, blast furnace gas
composition and the quantity of blast furnace gas pro-
duced. This model is based on the current average
values of the variables and is a steady state model. The
model outputs are downloaded to the PLC and DCS
control systems to be used as their setpoints.
The second level supervisory control reported in this
paper is used as an adjunct to the steady state charge
calculation model. This system consists of two basic
elements the neural network based estimator and the
rule based expert system (Fig. 12). The inputs to the
neural network estimator are the burden parameters
and blast parameters shown in Table 3. The neural net-
work acts as a soft sensor and outputs the estimated
Fig. 12. Blast furnace supervisory control system.
V.R. Radhakrishnan, A.R. Mohamed / Journal of Process Control 10 (2000) 509524 521
values of Si, S and other constituents in the hot metal. If
the predicted values of Si and S compositions in the hot
metal are outside their allowable bands then the expert
system calculates the required changes in the operating
conditions. These changes are used to upgrade the
values calculated by the charge calculation model and
can be considered as the dynamic ne tuning of the
steady state calculations. The neural network estimator
is activated once every 30 min. If the Si and S values are
beyond their tolerance changes are introduced in the
blast temperature, blast humidity, coke/HM ratio and
limestone/HM ratio. The changes in the blast conditions
produce immediate eect on the hearth conditions. The
burden changes however aects the hearth conditions
after considerable delay of the order of 46 h. Hence the
blast conditions are adjusted for immediate changes and
in parallel the burden conditions are adjusted to eect
permanent changes. As discussed earlier the blast tem-
perature and humidity aects both Si and sulfur in the
hot metal. Decreased blast temperature and increased
humidity brings down the hearth temperature which
reduces the HM silica. However a reduction in hearth
temperature aects the HM sulfur adversely, since it
increases it. Sulfur is reduced by decreasing the blast
pressure which decreases the carbon monoxide partial
pressure in the hearth. However due to operational
constraints the maximum allowable change in the
blowing pressure was limited to 0.1 atm. The coke/
HM ratio and the limestone/HM ratio bring about per-
manent changes in the hot metal Si and S, respectively. On
the basis of these considerations a rule based expert
system was developed based on the eects of these
variables on the hot metal silicon and sulphur. [811]
The general algorithm for the expert system is shown in
Fig. 13. The expert system also includes condential
empirical details of the particular steel plant which are
not included in this paper. The expert system is acti-
vated once in half an hour. This period was chosen
arbitrarily and could be less or more. The hot metal Si
and S compositions and temperature are estimated by
the neural network and down loaded to the expert sys-
tem. The expert system compares the predicted values
with the target values and if they are outside the toler-
ances then calculates the recommended corrective
actions. The corrective actions are arranged in a hier-
archy. Firstly correction is done for silicon and sulfur
using the blast variables and then permanent correc-
tions using the burden variables are performed. The Si is
rst corrected using the blast moisture and then the
blast temperature. All changes recommended by the
expert system have upper and lower bounds decided by
the furnace constraints. The changes required for the Si
correction may further deteriorate the sulfur, since the
eects on the two constituents of the blast variables are
opposite. The estimated values of the sulfur given by the
neural network model is corrected for the suggested
changes in the blast conditions used for the Si correc-
tion. An attempt is made to correct for this sulfur by
adjusting the blast pressure. However very little change
in this variable is permissible. After the blast variables
are adjusted the new value of coke rate required to bring
about permanent correction in the Si as well as the
basicity and the required limestone rate to correct the
sulfur are calculated. The blast changes are downloaded
to the stove control DCS systems and the burden variables
are down loaded to the skip control PLC systems.
The Neural Network based expert system was imple-
mented on a trial basis. The linkages between the con-
trol systems are shown in Fig. 12. As a safety measure
the linkage between the expert system and the DCS/
PLC systems was not implemented on-line. The expert
system recommendation was down loaded to DCS/PLC
system only after the approval of the plant engineer.
This did not create any diculty because this loop was
quite slow being implemented only once in half an hour.
As a trial case the system was tried over 30 taps over 5
days. In all the cases the expert system recommendation
was reasonable and was approved by the engineer. The
results of the trial run over 30 taps with the results for
Fig. 13. Expert system algorithm.
522 V.R. Radhakrishnan, A.R. Mohamed / Journal of Process Control 10 (2000) 509524
the earlier 30 taps are shown in Figs. 14 and 15. In Fig.
14 the Si in HM for the dierent taps are shown while
Fig. 15 presents similar results for sulfur. In Fig. 14 the
Silicon content was quite consistent even without the
expert system during the rst 19 taps. However from the
20th to the 26th tapping the silicon became very high.
This type of behavior was common in the particular
blast furnace. The reason for the inconsistent silica
behavior was traced to the particular nature of the
hematite ore body which supplied the iron ore to the
Fig. 14. Comparison of Si% in hot metal before and after the implementation of the expert system.
Fig. 15. Comparison of S% in hot metal before and after the implementation of the expert system.
V.R. Radhakrishnan, A.R. Mohamed / Journal of Process Control 10 (2000) 509524 523
blast furnace sinter plant. While the iron content of the
ore body was very high it had pockets of high silica
content. Since the ore was directly used for sintering
without any homogenisation the silica content of the
hot metal was quite unpredictable without the control.
However with the expert system these wide variations
were adequately controlled.
There was a dramatic improvement in both Si and S
by the implementation of the estimator based expert
system. The values of the measured and standard
deviation for Si and S before and after the implementa-
tion is shown in Table 4. Not only was the average Si
brought down by about 19% but equally importantly
the standard deviation of Si was reduced from 0.258 to
0.073. This attests to a very constant Si in the HM
which is very benecial for the subsequent steel making
process. In the case of S the mean decreased from
0.0318 to 0.021 and the standard deviation from 0.01 to
0.0023. The lower improvement is sulfur is expected
since much of the sulfur correction was through the
burden variables which take 46 h to take eect. For a
longer period of testing over 90 days the average value
of silicon was maintained at 1.07 while the standard
deviation became lower at 0.068. For sulfur the average
was 0.023 and the standard deviation 0.0022. Thus it
was seen that the model was able to operate over a
longer period without drift if the furnace is in stable
operation and there are no substantial changes in the
raw material quality.
10. Conclusions
A neural network based soft sensor was developed for
online estimation of the composition variables in the
hot metal and slag in a blast furnace. By careful selection
of the input variables for the model and their statistical
analysis a model with accuracy better than 3% could be
developed. The model could be eectively used for
online control of Si and S in the hot metal. An expert
system based on theoretical and empirical blast furnace
knowledge together with the neural network estimator
can be eectively used for improved control of the blast
furnace.
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Table 4
Silicon and sulphur in hot metal
Silicon Sulphur
Without neural network
expert control
With neural network
expert control
Without neural network
expert control
With neural network
expert control
Mean 1.195 1.068 0.0318 0.021
Standard deviation 0.258 0.073 0.01 0.0023
524 V.R. Radhakrishnan, A.R. Mohamed / Journal of Process Control 10 (2000) 509524