Refining Process Control Using Similar-Past Performance Matching
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Solution Overview
Problem
Existing refining process control methods fail to consider the influence of varying conditions and environments in refining facilities, leading to inconsistent process outcomes due to suboptimal target change curves.
Innovation Solution
A refining process control device and method that utilizes a model calculation unit, refining performance database, and operation amount determination unit to analyze past similar processes, adjusting operation amounts based on input information and environmental factors to achieve consistent process results.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a target change curve is set based on past satisfactory process performance, then the control process becomes simpler, but the manufacturing precision deteriorates due to not considering varying process conditions and environment
Solution Approach 1:
The patent applies dynamics by transitioning from a static target change curve to a dynamic control approach where the target values are continuously adjusted based on real-time process conditions. The control device dynamically modifies operation amounts according to varying molten iron conditions, temperature, component concentrations, and facility state, enabling the system to adapt to changing conditions while maintaining high precision control.
Solution Approach 2:
The patent implements parameter changes by adjusting multiple process parameters (oxygen flow rate, lance height, gas flow rate, charge amount) based on calculated reaction amounts and state amounts. The control device modifies these parameters dynamically according to the actual process state, transforming fixed target curves into adaptive parameter adjustments that respond to real-time conditions.
2Adaptability or versatility
If the operation amount is determined by an infinite number of combinations of process parameters, then the adaptability to different conditions improves, but the device complexity increases due to difficulty in control
Solution Approach 1:
The patent applies feedback by continuously monitoring process parameters (temperature, component concentrations, exhaust gas flow rate) and using this information to adjust operation amounts. The control device calculates reaction amounts and state amounts based on actual measurements, then feeds this information back to modify subsequent operation amounts, creating a closed-loop control system that handles complexity through systematic feedback.
Solution Approach 2:
The patent replaces complex mechanical control adjustments with computational methods. Instead of manually adjusting multiple parameters based on experience, the control device uses calculation units to compute optimal operation amounts based on mathematical models of the refining process, substituting mechanical trial-and-error control with computational optimization.
3Ease of operation
If the same process pattern is used for all charges, then the ease of operation improves, but the manufacturing precision deteriorates due to variations in molten iron conditions and facility state
Solution Approach 1:
The patent transforms static process patterns into dynamic control strategies where the same basic refining pattern is executed with dynamically adjusted operation amounts. The control device maintains the overall process structure while continuously adapting specific parameters (oxygen flow rate, gas flow rate, charge timing) based on real-time conditions, achieving both pattern consistency and result precision.
Data Source
AI summary
A refining process control device includes: a past similar performance extraction unit configured to extract, from the refining performance database, a performance value of a past refining process in which a refining condition being a refining process condition acquired before the start of the refining process and including a result of an immediately preceding refining process in the refining facility, is similar to a refining process condition as a calculation target and the evaluation value is high; and an operation amount determination unit configured to determine an initial operation amount at the start of a refining process based on the performance value of the past refining process extracted by the past similar performance extraction unit, and determine an operation amount based on a change amount of the initial operation amount after the start of the refining process.