A digital control system designed for ore thermal furnaces producing metallurgical silicon

Abstract

This paper considers the key control issues related to non-adjustable parameters in the production of metallurgical silicon in ore thermal furnaces. A series of experiments has been conducted to confirm the possibility of introducing the electrode off-position control. Thus, additional control parameters were introduced in the process control system. The electrode positioning algorithm was tested and adjusted to minimize electrode bending and reduce the risk of breakage and to minimize end cracking and spalling during restarting in the current production environment. An integrated 3D model of the thermal field distribution has been developed and built that accounts for the charcoal moisture content, the position of the electrodes and the power emitted as the charge gets hot. Substantiation is given to the application of this adaptive adjustment algorithm to control the changing parameters as determined by the process conditions, such as the moisture content of the charge, the position of the electrode, the power mode of the furnace. The authors propose to expand the existing control system by adding a digital module, i.e. due to the integration of electrode off-position signals and the use of the adaptive adjustment algorithm and avoiding using any additional corrective signals. This research was carried out as part of the Governmental Assignment No. 075-03-2020-127/1 for the year of 2020, Project No. FSRW-2020-0014. Subject: A crossdisciplinary approach to the comprehensive exploitation of natural resources and conservation. Area (a 2020 topic): “Comprehensive processing of minerals and man-made materials and gasification of solid hydrocarbons: A review and concept elaboration”. As greenhouse gases and carbon are produced as a result of electrode destruction, it is proposed to use the method of gasification and dispose of the heat produced.