No. 4

Automated system for modeling the movement of burden layers in the blast furnace

This paper examines the issues of constructing models of burden movement in a blast furnace, built on the principles of macromodeling using readily available data on the blast furnace process.

The developed models enhance the blast furnace master’s decision support system, integrating into the automated management system for resource efficiency in energy and metallurgical production.

The results of the automated system for the movement of burden layers in the blast furnace on experimental data are presented.

Keywords: blast furnace, blast furnace control, burden movement model, decision support systems.

Decision support system for the blast furnace master

The aim of the study being performed is to enhance the efficiency of operational management of the blast furnace process and, consequently, to reduce the consumption of the primary energy resource for the blast furnace process – coke, while ensuring compliance with technology requirements and planned productivity based on intelligent decision support for the furnace master using model-predictive control methods of the blast furnace process. The work presents the structure of the decision support system for the blast furnace master, including a description of the modules of software and hardware complex.

Keywords: decision support system, blast furnace, blast furnace operation management.

Development of an adaptive algorithm for limiting natural gas consumption on steam boilers

This article is aimed at analyzing and eliminating existing problems associated with modern automatic control systems (ACS) used in various industrial sectors. An adaptive algorithm for limiting GHG consumption has been developed. A program for a programmable logic controller (PLC) has been prepared. The program has been implemented into the existing system for automatic control of steam boiler modes (SAR PC). The algorithm was tested; conclusions were drawn about the impact of the changes made to the operation of the ACS PC.

Keywords: adaptive algorithm for limiting the opening of a natural gas valve, data analysis, steam boilers, steam load regulation, automatic control system.

Modeling of the control system for energy boiler unit with synthesis of an adaptive steam pressure regulator in the steam pipeline during sharp load variations

The article discusses control methods for the energy boiler unit. A critical issue is regulating steam pressure in the main steam pipeline during sharp load variations (for example, in a metallurgical plant, steam may be consumed by blast furnaces, blowers, turbo units, etc.). It is essential to consider the complex interconnected dynamic structure of the object. Identifying the fundamental characteristics of the steam boilers and the main steam pipeline based on operational data was conducted to create the system model. Nonlinear elements were introduced into the model to simulate real-world operation. A model of an automatic control system for the energy boiler unit was developed in the Simulink (MATLAB) modeling environment. Experiments were conducted to integrate various types of regulators into the system. Upon analyzing the simulation results of the existing system, the synthesis and implementation of an adaptive regulator were decided to track dynamic changes in the object and sharp load variations. A comparative analysis of the operation results of the PID and adaptive regulators was performed.

Keywords: automatic control system; energy boiler unit; thermal load regulation; steam pressure regulator in the main steam pipeline; adaptive regulator; control object identification; mathematical model; simulation model; nonlinear dynamic elements.

Algorithm for limiting the opening of a natural gas valve on a steam boiler during a sharp increase in steam pressure in the main steam pipeline

The article is devoted to the review and solution of current problems of modern automatic control systems (ACS) in the field of thermal power engineering. An algorithm for limiting the opening of the steam generator valve in the event of emergency situations has been developed, a program for a programmable logic controller (PLC) has been prepared, the program has been implemented in the existing system for automatic control of steam boiler modes (SAR PC), the algorithm has been tested, conclusions have been drawn about the impact of the changes made to the operation of the SAR PC.

Keywords: algorithm for limiting the opening of a natural gas valve, data analysis, steam boilers, steam load regulation, automatic control system.

Model-predictive control of complex pyrotechnological processes

The paper discusses the use of model-predictive control in solving the tasks of operational control of complex pyrotechnological processes. The blast furnace process control is considered as an example, where one of the central tasks is to maintain furnace thermal state. The use of model-predictive control methods allows finding optimal values of control parameters, that leads to increase in the overall efficiency of the process. This approach can be generalized to other complex technological systems with nonlinear, non-stationary, and stochastic characteristics.

Keywords: pyrotechnological processes, model-predictive control, blast-furnace process.

A new emitter in the form of an absolutely black body model of the АЧТ 75/50/600

The article presents a new development of JSC research-and-industrial enterprise «Etalon» – an emitter in the form of a model of a completely black body АЧТ 75/50/600.

Being a reference emitter in the form of a model of a completely black body of the second category, the АЧТ 75/50/600 competes adequately with other emitters of both domestic and foreign production in terms of its technical characteristics and operational capabilities. The article discusses its main features, technical characteristics, features of operation and exploitation. Its comparison with analogues of imported and domestic production is production.

Keywords: completely black body, black body, black body model, emitter, pyrometer.

Digital metrology as a response to the development of smart manufacturing

The importance of understanding the difference between Industry 4.0 and smart manufacturing sets the direction for future research. Comparing technologies such as artificial intelligence, big data analytics, and the Industrial Internet of Things provides insight into how each technology contributes to the development of smart manufacturing. Digital technologies such as artificial intelligence and big data analytics with measurement science («metrology») will enable smart manufacturing systems to improve quality and reduce errors. Considering the need to develop modern automated control and monitoring systems, this paper presents a scheme of characteristics and factors to be considered in the development of such measurement systems with self–calibration and metrological self-monitoring functions.

Keywords: intelligent manufacturing, digital technologies, metrological self-monitoring, self-calibration.