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Abstract: An automatic control of a DRI plant has been performed in order to provide the best possible
working point, to obtain the target level 2 process set points (DRI metallization, carburation,
productivity) in function of Iron Ore and Reducing gas compositions. The target has been obtained by
means of a Process Reconstruction Model (PRM) that provides continuous static estimation of plant
measurements, efficiency analyses, virtual sensor and diagnostics. An Extended Kalman Filter (EKF) has
been used to provide continuous robust dynamic estimations of the output process measurements. Finally
the EKF feeds a Linear Quadratic Gaussian (LQG) regulator that performs, in real time, the calculation of
Optimal Controls (minimum energy, maximum gas quality level 1 set points), in function of level 2 sets.
The suite has been successfully applied to a DRI Energiron Plant.
Keywords: Process Reconstruction Model, Extended Kalman Filter, LQG, Real time, DRI Energiron
Plant, Automatic Process Control.
2.1 The PRM Virtual Sensor Iron Ore In Main Chemical Reactions
The software can envisage, through variation of degrees of Top
freedom on a selected and isolated system, the possible
presence of inconsistencies. For this reason, the first result of Pre Red - Fe 2 O3 H 2 l 2 FeO H 2O
® (1)
this kind of analysis is the detection of incorrect response Area ¯ Fe 2 O3 CO l 2 FeO CO 2
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August 25-28, 2013. San Diego, USA
[kmol/m3] outlet and inlet respectively, V the reactor volume temperatures of the gas, and finally by 8 parametric
[m3], Wgs represents the Water Gas Shift Reaction, St is the equations, referred to the kinetics Kj of the 8 reactions that
Steam Reforming reaction (Wgs and St are the AR reactions), take place in continuous process to follow the trajectory of
Cr represents the Cracking reaction, PH2 and PCO are the the reaction kinetic gains.
Pre Reduction reactions, RH2 and RCO represent the
Reduction Reactions and finally, Bou is the Boudouard 3.3 The EKF Estimator
reaction, all reaction in [kmol/m3s]. To complete the dynamic
system (6) we need now the calculation of the reaction The Kalman Filter theory brings to a solution of the optimal
chemical contributions, by means of the calculation of their state estimation problem, for a linear discrete time dynamic
kinetics: system described by the following equation:
Ei
§ · - x(k 1) f ( x(k ), u (k )) w(k )
R˜TR (Cc ) c ˜ (Cd ) d ® (10)
Rkin Ki ˜ e ˜ ¨¨ (Ca ) a ˜ (Cb ) b
Keqi TR
¸¸ (7) ¯ y (k ) h( x(k ), u (k )) v(k )
© ¹
In (7) the Keqi(TR) terms represent the equilibrium constants With f and h linear function of states and inlets; w, v additives
of the reactions calculated at the reaction temperature TR gaussian noise of states and measurements respectively with
[adim.] (for reactions with no mole production), Rkin are the known covariance matrix W = E(wwT) and V = E(vvT)
reaction contribution [kmol/m3s], Ei represent the Arrhenius respectively. For nonlinear systems a closed solution for the
coefficients of the reactions [kJ/kmol], (Ca)a are the chemical same problem doesn’t exists. In this case, a classical method
species concentration rising to the power of its mole to solve the problem is to linearize the system around the
contribution [kmol/m3]a, TR is the reaction temperature, or the actual estimation and to apply the Kalman Filter to the
temperature of both gas and solid flows at the Red & AR linearized system (Voros 2008).
Area [K], R is the gas Constant 8.314 [kJ/kmolK] and finally Let f and h be nonlinear function of the states, F(k), B(k) and
Ki are the Kinetic Constants to estimate [1/s]. The physical H(k) be the jacobian matrices of f and h, respectively,
model finally has been completed with the energy balance denoted by (Yang, 2011):
equations, taking in consideration the energy equilibrium at
the inlet (Red & AR Area) and outlet (Top) of the shaft for ª wf x ( k ), u ( k ) º ª wf x ( k ), u ( k ) º
F (k ) « » , B (k ) « » ,
¬ wx ( k ) ¼ ¬ wu ( k ) ¼
both gas and solid flows: xÖ ( k ), u ( k ) xÖ ( k ), u ( k )
(11)
x Qin QoutD ˜ A ˜ TR Tin ª wh x ( k ), u ( k ) º
TR ˜ Tin ˜ TR H (k ) « »
V V V ˜ U ˜ CP ¬ wx ( k ) ¼
( 'H Wgs ˜ Wgs 'H Cr ˜ Cr 'H St ˜ St 'H Bou ˜ Bou (8) xÖ ( k ),u ( k )
'H RH 2 ˜ RH 2 'H RCO ˜ RCO 'H PH 2 ˜ PH 2 'H PCO ˜ PCO ) /( U ˜ C P ) The solution is given by a recursive algorithm (table 1) that
x Qin Qout D ˜ A ˜ TTop Tox
can be easily described in the following steps:
TTop ˜ TR ˜ TTop
V V V ˜ U ˜ CP - Time update step that brings to the estimation of the
C pox ˜ qDRI DO ˜ Tox C pDRI ˜ q DRI ˜ TR
(9) current state and the state error covariance matrix P.
CP ˜V ˜ U CP ˜V ˜ U The evaluation is an ‘a priori’ estimation for the next
step.
In (8) the Tin term represents the gas temperature at the inlet
(Red & AR Area) [K], Qin and Qout are the gas mass flow - Measurement update step that brings to the feedback
inlet and outlet the reactor [kg/s], . is the heat transfer correction. The evaluation is an ‘a posteriori’
coefficient between gas and solid bed at inlet point [W/m2K], estimation for the current step.
A represents the equivalent area for the heat exchange [m2], ! The following scheme represents the previous algorithm:
is the gas inlet density [kg/m3], Cp represents the gas heat
capacity [kJ/kgK], û+i represent the heat of reactions Table 1. Predictor - Corrector
[kJ/kmol], In (9) the TTop is the gas temperature at the Top Time Update (step k) - Predictor
[K], Tox is the iron ore pellets temperature at inlet (Top) [K], Future - xÖ ( k 1) f ( xÖ (k ), u (k ))
Cpox and CpDRI represent the heat capacity of the solid bed at ® (12)
state ¯ yÖ (k ) h( xÖ (k ))
the inlet (for pellets the inlet is the Top zone) and at the Red
Future
& AR Area [kJ/kgK], qDRI is the solid flow [kg/s], DO P ( k 1) F ( k ) ˜ P ( k ) ˜ F ( k )T W (13)
covariance
represents the oxygen mass flow, passing from solid to
Measurement Update (step k+1) – Corrector
gaseous phase during the reduction process [kg/s].
Kalman K ( k ) P (k ) ˜ H (k )T ˜
The physical model of the shaft finally has been synthesized Filter Gain ( H (k ) ˜ P(k ) ˜ H (k )T V ) 1 (14)
using a system of 15 dynamic equations that represent the Innovation K (k ) ˜ ( y(k ) h( xÖ(k ))) (15)
complete evolution of the shaft state, considering both the estimation xÖ (k 1) f ( xÖ (k ), u (k ))
field measurements and the estimated reaction kinetics. The (16)
correction K (k ) ˜ ( y ( k ) h( xÖ (k )))
system is composed by 5 dynamic chemical equations that
covariance
describe the complete evolution trajectory of the 5 chemical P ( k ) ( I K ( k ) ˜ H ( k )T ) ˜ P ( k ) (17)
correction
gas species concentrations Cj, 2 dynamic energy equation
referred to the energy balance of the mass/gas system at the The next predicted state and state error covariance matrix at
shaft inlet/outlet that describe the tracking of the TR and TTop step k, xÖ(k+1) and P(k+1) respectively, are computed in the
first step and then in the measurement update at step k+1, the
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IFAC MMM 2013
August 25-28, 2013. San Diego, USA
next estimated step xÖ(k+1), is obtained by means of the - A Reformer Unit that converts Steam and Natural gas into
corrective term called innovation, calculated by the Kalman Reducing (Bustle) gas, a gas mix rich in H2 and CO.
Filter Gain K(k). - A Dewatering Unit that removes H2O from the recirculating
process gas.
3.4 EKF with Parametric Estimation - A Compressor Unit that rises up the pressure of the
recirculating process gas.
In this application we need to estimate not only the state - A CO2 Removing Plant Unit that removes the CO2 from the
trajectory but also parameters represented by the reaction recirculating process gas.
kinetics. This kinetics must be represented as state variable
- A Heater Unit that rises the Process Gas temperature up to
too (Voros 2008), with no dynamic (constant states). The
the process request value before entering the Reactor Unit.
dynamic states represented by 5 chemical concentration
trajectory and by 2 temperature trajectory have been - A Flare Unit that bursts the bleed to maintain the pressure in
augmented by 8 static parametric equations representing the the circuit when regulations take place and to keep in control
kinetics. the Inert gas specie concentration (Nitrogen N2) in the
process gas loop (minimum bleed required).
Kj 0 (18)
Introducing the parameters in the state equation (10):
- x( k 1) f ( x (k ), u (k ),T ( k )) w(k )
® (19)
¯ y (k ) h( x (k ), u ( k ),T (k )) v( k )
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IFAC MMM 2013
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(a)
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IFAC MMM 2013
August 25-28, 2013. San Diego, USA
The dynamic system model aided by the PRM (for the laboratory measurements (circles) before and after regulation
effective quantities of reactants and plants indicators) and the (regulation time: 2012, September 23, 1:00am). The regulator
EKF (with the estimation of kinetics and anti-windup for let to the stability of the plant response reducing the mean
state correction) lets to the determination of the whole shaft error of lab measurements and estimation from set required.
state trajectory (Fig. 5, Fig. 7a). The formalization of the state Finally in figure 7d is reported the energy consumption
trajectory lets the application of the LQG controller. The comparison: Natural gas consumption (upper line) and the
figure 7 shows the response in closed loop of the plant whole specific energy consumption (lower line), before and
applying the LQG controller to track a new plant working after the regulation. As we can expect from the theory, the
point. The example reports a variation in the product quality LQG regulates the process following both the management
requests by the plant management: the request was the requests (for the variation of metallization in this case) the
augment of metallization +1[%] maintaining carburation and different response time of the equipment and the minimum
productivity. transformation cost (medium saving 0.1Gcal/t on 2.4Gcal/t
total consumption). The correct estimation of the shaft states
lets the control loop to act on the main gas flows, taking in
accounts the process time response.
6. CONCLUSIONS
This paper presents the first automatic process controller
realized for a DRI Energiron plant, developed on level 2 by
means of a Grey Box model (PRM) an optimal state
estimator (EKF) and an optimal regulator (LQG). The
(a) process control variables (level 1 set points) are automatic
calculated on line in function of the process target requests
(level 2 set points: DRI metallization, DRI carburation and
DRI productivity). The input/output plant values and the
mass/energy balances are calculated in real time by the PRM,
in function of accessible plant measurements. The EKF use
the physical shaft model and the PRM measurements, virtual
measurements and balances to generate an optimal estimation
of the shaft state. The LQG regulator performs the calculation
(b) of the optimal level 1 set point input trajectories to manage
the plant from the current working point to a new one, to
realize the new process targets. The application of automatic
control on line lets to a mean energy saving of about 4% on
total consumption and a stabilization of the plant response
too. Stabilization brings also to an overall correct plant
managing with the reduction of trip events and unwanted
stops. Operators are supplied with a multi-purpose instrument
capable to manage in automatic the process for any kind of
(c) quality charged, setting the optimal reducing gas composition
and temperature, pointing both the process target and the
minimum transformation cost.
7. REFERENCES
Skogestad, S., Postlethwhite, I. (2001), Multivariable
Feedback Control, John Wiley & Sons.
6LPRQ ' 2SWLPDO 6WDWH (VWLPDWLRQ .DOPDQ +’
and Nonlinear Approaches, John Wiley & Sons.
(d) Yang, X., Marjanovic, O. (2011), LQG Control with EKF for
Power System with Unknown Time-Delays, Paper of the
Fig. 7: (a) LQG result for a new working point with 18th IFAC World Congress, Milano.
augmented metallization (+1[%]) with same carburation and Di Giorgio, F.M., Martinis, A., and others (2011), Driving
productivity. New level 1 set points for Reducing (Bustle) Process Optimization via the Energiron Advanced L2
and Reformed gas (b), and for Natural gas (c). (d) Whole Control, METEC InSteelCon 2011, Paper of 6th
plant Natural gas consumption response. European Coke Iron Making Congress, Dusseldorf.
Voros, J., Mikles, J., Cirka L. (2008), Parameter Estimation
The LQG produced directly the new working point sets
of Nonlinear Systems, Acta Chimica Slovaca, Vol. 1, No.
(shaded lines on Fig 7b, 7c). The level 1 accepts the sets and
1, 2008,309-320.
controls directly the process flows (continuous lines on Fig
7b, 7c). The result of the control action is reported in figure
7a with the new quality set reached (EKF continuous line) vs.
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