ADVANCED SIMULATION

AND CONTROL SYSTEMS

OF ENERGIRON PLANTS

Iouri Martynov - Executive Sales Manager

Danieli Centro Metallics
5th World DRI and Pellet Congress
26-27 April 2017, Dubai (UAE)
INDEX

1. OPERATION & CONTROL

OF DR PLANTS

2. THERMO-FLUID-DYNAMIC MODEL
OF THE REACTOR

3. ADVANCED LEVEL 2 SYSTEM

4. AUTOMATIC CONTROL
OF THE ENERGIRON PROCESS

5. TEST RESULTS
AT INDUSTRIAL PLANT

6. TRACKER

7. CONCLUSIONS
> The innovative HYL Direct
Reduction technology jointly
developed by Tenova and Danieli
> The most competitive and
environmentally clean solution for
EAF quality steel making
INDEX

1. OPERATION & CONTROL

OF DR PLANTS OPERATION & CONTROL
2. THERMO-FLUID-DYNAMIC MODEL
OF THE REACTOR OF DR PLANTS
3. ADVANCED LEVEL 2 SYSTEM

4. AUTOMATIC CONTROL
OF THE ENERGIRON PROCESS

5. TEST RESULTS
AT INDUSTRIAL PLANT

6. TRACKER

7. CONCLUSIONS
OPERATION & CONTROL
OF DR PLANTS

DESIGN

THERMO-FLUID-DYNAMIC SET PRODUCT QUALITY

MODEL OF REACTOR

DEFINE EQUIPMENT CHARACTERISTICS

PREDICT OPERATING PARAMETERS &

CONSUMPTION
OPERATION & CONTROL
OF DR PLANTS

DESIGN OPERATION

CONSISTENT PRODUCT QUALITY

ADVANCED LEV.2
CONTROL SYSTEM
MINIMUM CONSUMPTION

AUTO-ADJUSTMENT TO DIFFERENT
SURROUNDING CONDITIONS

X Traditionally, at each change of inputs, product

quality changes are detected few hours later (~5h)
INDEX

1. OPERATION & CONTROL

OF DR PLANTS THERMO-FLUID-DYNAMIC
2. THERMO-FLUID-DYNAMIC MODEL
OF THE REACTOR MODEL OF THE REACTOR
3. ADVANCED LEVEL 2 SYSTEM

4. AUTOMATIC CONTROL
OF THE ENERGIRON PROCESS

5. TEST RESULTS
AT INDUSTRIAL PLANT

6. TRACKER

7. CONCLUSIONS
THERMO-FLUID-DYNAMIC
MODEL OF THE REACTOR

> Reduction of
A SHAFT REACTOR IS iron oxide
THE CORE EQUIPMENT
OF A DR PLANT
> Autoreforming
> Reduction

> DRI
Carburization
Cooling
THERMO-FLUID-DYNAMIC
MODEL OF THE REACTOR

THE REACTOR MODEL IS Inside the reactor

USED DURING PROJECT
DESIGN STAGE TO SET
> Product quality (Met, C) > Flow patterns
> Equipment characteristics > Local
compositions
> Operating parameters &
consumptions > T profiles
> Reactions spatial
distribution
THERMO-FLUID-DYNAMIC
MODEL OF THE REACTOR

also validated through a

2-D AXIAL-
small scale experimental
SYMMETRIC
reactor at Danieli’s R&D
THE MODEL
BASIS GRANULAR Viscosity α solid
Non-Newtonian fluid
MATERIAL flow status

Brinkman equation
GAS MOTION
Continuity equations

GAS/SOLID Transport equations of

COMPOSITION, T species enthalpy

REDUCTION 2 interfaces shrinking core

KINETICS model
THERMO-FLUID-DYNAMIC
MODEL OF THE REACTOR

GAS GAS SOLID

DISTRIBUTION VELOCITY FLOW
The model couples flow fields
for solid & gas with kinetics TOP G ORE TOP G ORE
and thermal equations

RESULTS PG PG
1 – FLOW FIELD
> Gas flow distribution &
velocity
> Solid plug flow

NG NG

DRI DRI
THERMO-FLUID-DYNAMIC
MODEL OF THE REACTOR

The model couples flow fields

for solid & gas with kinetics
and thermal equations

RESULTS
H2 CO CH4
2 – GAS COMPOSITION
> Distribution of reductants
> CH4 reforming
> Partial CH4 cracking
> Use of oxidants for
autoreforming

H2O CO2 N2
THERMO-FLUID-DYNAMIC
MODEL OF THE REACTOR

The model couples flow fields

for solid & gas with kinetics
and thermal equations

RESULTS
3 – SOLID WEIGHT FRACTIONS
> Pellet humidity in heat
balance
> Hematite to Wustite quick
(~0.5h)
> Wustite to iron close to
PG inlet (high T, less oxidants)
> Met > 96% achievable Hematite Wüstite Iron
THERMO-FLUID-DYNAMIC
MODEL OF THE REACTOR

The model couples flow fields

for solid & gas with kinetics
and thermal equations

RESULTS
4 – DRI CHARACTERIZATION
> Metallization
> Carbon content (Fe3C)
> Temperature profile

Temperature °C Metallization Carbon

THERMO-FLUID-DYNAMIC
MODEL OF THE REACTOR

The model is able to fully

characterize the DRI product.
Reactor design and process
parameters can be accurately
defined to get the desire
productivity and DRI quality.
At the same time, heat losses
and overall energy efficiency are
calculated.

THE REACTOR MODEL

IS SUCCESFULLY USED
TO FINELY TUNE THE
DESIGN PARAMETERS
FOR EACH PLANT
INDEX

1. OPERATION & CONTROL

OF DR PLANTS ADVANCED
2. THERMO-FLUID-DYNAMIC MODEL
OF THE REACTOR LEVEL 2 SYSTEM
3. ADVANCED LEVEL 2 SYSTEM

4. AUTOMATIC CONTROL
OF THE ENERGIRON PROCESS

5. TEST RESULTS
AT INDUSTRIAL PLANT

6. TRACKER

7. CONCLUSIONS
ADVANCED LEVEL 2 SYSTEM

LEVEL 2 RUNS ON LINE, BASED ON THE CONTINUOUS COMMUNICATION WITH DCS

DATA COLLECTING AND

PRODUCTION ANALYSIS
> OWS: Operator workstation ADVANCED LEVEL 2
PRM – EKF - LQG
> PWS: Process Workstation
OPTIMAL DYNAMIC CONTROL PWS OWS OWS

> PRM (Process Reconstruction Model)

performs a continuous completion of the
raw data and efficiency analysis of the
process
> EKF (Extended Kalman Filter) Estimator:
Performs estimations from data produced PWS
by the PRM at each step (minute)
> LQG (Linear Quadratic Gaussian)
Regulator: Performs the calculation of the
Optimal Lev1 set points at each step, in
function of the Lev2 set points requests
(DRI met, DRI carb, Productivity), by
means of the EKF results
INDEX

1. OPERATION & CONTROL

OF DR PLANTS AUTOMATIC CONTROL
2. THERMO-FLUID-DYNAMIC MODEL
OF THE REACTOR OF THE ENERGIRON
3. ADVANCED LEVEL 2 SYSTEM PROCESS
4. AUTOMATIC CONTROL
OF THE ENERGIRON PROCESS

5. TEST RESULTS
AT INDUSTRIAL PLANT

6. TRACKER

7. CONCLUSIONS
AUTOMATIC CONTROL OF THE
ENERGIRON PROCESS

EKF + LQG
MANUAL SET REAL TIME PREDICTION OF PRODUCT QUALITY
POINTS set points BASED ON ACTUAL OPERATING PARAMETERS
DRP PLANT
> Time saving
> Consistent product quality & consumptions
MEASURE IN inlets outlets
> Autopilot mode

inlets In DRP
outlets inlets inlets
PROCESS DRP LEVEL 2
RECONSTRUCTOR REPORT
MODEL GENERATOR
outlets outlets Out DRP
inlets outlets

calculated calculated Out DRP

compensation calculated
LEV 2 PC
PWS
inlets actual inlets OWS
REPORTS
outlets est est
actual Out Kalman

DRP-SHAFT DRP PLANT

KALMAN FILTER LQG
opt sets Out LQG
calculated actual actual

previous
AUTOMATIC CONTROL OF THE
ENERGIRON PROCESS

EKF + LQG
MANUAL SET REAL TIME PREDICTION OF PRODUCT QUALITY
POINTS set points BASED ON ACTUAL OPERATING PARAMETERS
DRP PLANT
> Time saving
> Consistent product quality & consumptions
MEASURE IN inlets outlets
> Autopilot mode

inlets In DRP
outlets inlets inlets
PROCESS DRP LEVEL 2
RECONSTRUCTOR REPORT
MODEL GENERATOR
outlets outlets Out DRP
inlets outlets

calculated calculated Out DRP

compensation calculated
LEV 2 PC
PWS
inlets actual inlets OWS
REPORTS
AUTOPILOT MODE outlets est est
actual Out Kalman

> LQG outputs: successfully tested at DRP-SHAFT DRP PLANT

industrial plant in operation KALMAN FILTER LQG
opt sets Out LQG
> Next step: implement permission to calculated actual actual

control the process previous

INDEX

1. OPERATION & CONTROL

OF DR PLANTS TEST RESULTS
2. THERMO-FLUID-DYNAMIC MODEL
OF THE REACTOR AT INDUSTRIAL PLANT
3. ADVANCED LEVEL 2 SYSTEM

4. AUTOMATIC CONTROL
OF THE ENERGIRON PROCESS

5. TEST RESULTS
AT INDUSTRIAL PLANT

6. TRACKER

7. CONCLUSIONS
TEST RESULTS
AT INDUSTRIAL PLANT

ANALYSIS PERFORMED ON
LINE AT INDUSTRIAL PLANT
BY EKF + LQG ON
DRP PROCESS DATA

ORIGINAL
WORKING 190 t/h; 94% Met; 2.4%C
POINT

> iron ore feed mix change

VARIABLES (+10% new pellet)
> metallization increase

TEST
48 h
DURATION
TEST RESULTS
AT INDUSTRIAL PLANT

EKF OUTPUT
> Deviation from target in the
observed period:
±0.25% DRI Met

LQG OUTPUT
> new profile set generated
> new working point was set ORIGINAL WORKING TARGETED WORKING GAP REAL
from Kalman + LQG POINT POINT FINAL MEASURE –
SET POINT
> target achieved with great
accuracy 190 t/h 190 t/h 0.00%

94% Met 95% Met -0.40%

2.4% C 2.4% C +0.04%

TEST RESULTS
AT INDUSTRIAL PLANT

The new Set Points profile LQG

event brings to an effective mean
NATURAL GAS SAVING
of 0.05 Gcal/tDRI,
on a 2.5Gcal/TDRI
mean consumption

The Mean Gap between actual

and previous values is about
0.05 Gcal/tDRI,
obtained by the application of the
LQG Set Points
TEST RESULTS
AT INDUSTRIAL PLANT

THE EKF + LQG IS ABLE TO

CORRECTLY DETECT CHANGES

IN OPERATING PARAMETERS
(ORE FEED MIX, ….)

CONTINUOUSLY REFRESH
THE SET POINT TO
CONSISTENTLY MAINTAIN
THE PRODUCTION TARGET

OPTIMIZE THE OVERALL

ENERGY EFFICIENCY
INDEX

1. OPERATION & CONTROL

OF DR PLANTS TRACKER
2. THERMO-FLUID-DYNAMIC MODEL
OF THE REACTOR

3. ADVANCED LEVEL 2 SYSTEM

4. AUTOMATIC CONTROL
OF THE ENERGIRON PROCESS

5. TEST RESULTS
AT INDUSTRIAL PLANT

6. TRACKER

7. CONCLUSIONS
TRACKER

A 1D REACTOR MODEL
HAS BEEN IMPLEMENTED
IN A TRACKING SOFTWARE
> Every minute it reads the
necessary input from the PRM
and solves a set of equations
> Predicts product quality
and gas analysis
> Provides real time profiles of
the reactor working parameters
> Continuous monitoring with
< 3 seconds elaboration

REAL-TIME INSIGHT OF WHAT IS

HAPPENING INSIDE THE REACTOR
INDEX

1. OPERATION & CONTROL

OF DR PLANTS CONCLUSIONS
2. THERMO-FLUID-DYNAMIC MODEL
OF THE REACTOR

3. ADVANCED LEVEL 2 SYSTEM

4. AUTOMATIC CONTROL
OF THE ENERGIRON PROCESS

5. TEST RESULTS
AT INDUSTRIAL PLANT

6. TRACKER

7. CONCLUSIONS
CONCLUSIONS

DURING DESIGN STAGE

2D AXIAL SYMMETRIC MODEL OF THE REACTOR ALLOWS TO
> Optimize the reactor
> Define main equipment’s characteristics
> Predict operating parameters & consumptions
> Define the optimum operation set point in terms of
> Metallization
> Carbon content
> Energy consumption
CONCLUSIONS

ADVANCED LEVEL 2 SYSTEM

INNOVATIVE TOOL
> Auto-adjustment of DRP operating parameters
> Avoid the typical delay between detection of DRI quality changes and modification on
operating parameters
> Minimize the try and error approach
> Realize process on-line diagnostic to catch the presence of non normal operative
conditions
> helpful to detect instrument faults
> helpful to program maintenance activities
> Can also be used offline to estimate the behavior of the reactor
ADVANCED SIMULATION
AND CONTROL SYSTEMS
OF ENERGIRON PLANTS

Iouri Martynov - Executive Sales Manager

Danieli Centro Metallics
5th World DRI and Pellet Congress
26-27 April 2017, Dubai (UAE)