Optimal Setting and Control for Iron Removal Process Based on Adaptive Neural Network Soft-Sensor

Abstract

Satisfying the process technical requirements while optimizing the control of oxygen and zinc oxide is the main task for optimal operation of the iron removal process. However, due to the complicated mechanism and varied production conditions, the process is difficult to achieve optimal operation with the simple controller. The manual control, as a result, is extensively used in practice. In this paper, we develop an optimal setting and control (OSC) system for the iron removal process to achieve its technical requirements with minimal process consumptions. The OSC system is composed of a neural network soft-sensor, an optimal setting module, an optimal controller, and a fuzzy-logic-based compensator. First, we define the oxygen reaction efficiency (ORE) to measure the difference between the theoretical oxygen amount and its actual amount. Due to the ORE cannot be measured online and it varies with the production conditions, an adaptive weight radial basis function neural network soft-sensor is designed to estimate it. The adaptive weight adjusting method contributes to improve the adaptability of the soft-sensor, and its convergence is discussed. The optimal setting module provides the set-point of outlet ferrous ion concentration for the optimal operation of every reactor. The steady-state optimal control of oxygen and zinc oxide is then established, and the compensator compensates the control inputs utilizing the feedforward and feedback information. Finally, simulations validate that the ORE is important for the optimal control of the process. Furthermore, industrial experiments are presented to verify the effectiveness and potential of the proposed strategy.