Mei C., Zhou J., Peng X. Simulation and Optimization of Furnaces and Kilns for Nonferrous Metallurgical Engineering

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10 Multi-objective Systematic Optimization of FKNME  

Measurement and control layer is also called digital direct control level (DDC), in

general, it is composed of field computer control system (DCS), programmable logic

controller (PLC), measurement, control network and so on. Its main tasks are:

on-time measuring relational infor-

mation and transmitting that to

supervision and scheduling layer;

receiving control orders from super-

vision and scheduling layer and

controlling objects according to them.

Supervision and scheduling layer,

in general, is composed of a special

computer system, short-range or

remote communication network and

its application software. Its main

tasks are: providing accurate field

production data for the information

management and decision-making

layer on time; receiving, explaining

and executing orders from the decision-making layer; according to the production

plan, condition of raw materials, condition of production equipments and orders

from decision-making layer, organizing production and executing optimal

scheduling, so as to make full use of the production resource; condition

monitoring and analysis, fault diagnosis, online adjusting and self-learning setting

of control laws and control parameters, assistant decision-making and producing

the optimal operation strategy; sending the control signal to the measurement and

control layer.

Information management and decision-making layer generally is composed of

the computer management information system network and decision support

system. Its tasks include: receiving data from the scheduling layer; based on these,

predicting the development trend of important technology parameters, making

optimal decisions so as to make production run in good state; sending orders to the

scheduling layer; sharing related information of every links of production

processes; managing the information about personnel, finance, marketing,

equipment and production by means of a computer, doing statistical analysis on

the related data, displaying and/or printing relational reports.

To sum up, the connections among layers of the integrated system for monitoring,

control and management are reflected in the information integration and exchanging.

There are obvious forward information flow and feedback information flow between

different layers. Meanwhile there are also relative independent information

closed-loop circulation, which can run as a local information system. Hence, every

layer of the system possesses good openness and expansibility.

Fig. 10.11 Integrated system for monitoring,

control and management

  Xiaoqi Peng, Yanpo Song, Zhuo Chen and Junfeng Yao

10.4.4.2



Example: nickel smelting workshop computer information integrated

network system

Based on nickel smelting process intelligent decision support system, technology

parameters online monitoring system and workshop computer management

network, a nickel smelting workshop computer information integrated network

system was developed, which gathers the functions of management,

decision-making and technology parameters’ online monitoring in integral whole.

By using it, the overall optimal decision-making of the production process in

smelting workshop was achieved; meanwhile, the computerized management of

production cost, production equipments and personnel matters were also realized.

Therefore, it increased significantly the level of management and decision-making

of the workshop, and laid a physical and technical foundation for developing the

computer integrated management system of the whole factory.

The structure of the smelting workshop computer information network system

is shown in Fig. 10.12.The system adopts a two-level radial topological structure

Fig. 10.12 Topo of smelting workshop computer information network

10 Multi-objective Systematic Optimization of FKNME  

and a Novell net operation system, all application software are driven by menu

and with prompt of Chinese character, so it possesses characteristics of simple

structure, good compatibility and easy operation and maintenance.

Workstation No.1 is a super workstation, it is also used as a mothball server. It

is used to administer and maintain network. The Network operation system and

application software are preinstalled in its hard disk, related data are copied termly

from special server to it. Once the special server breaks down, super workstation

can immediately be put into use as a server, so as to ensure the normal operation

of network.

Workstation No.2 adopts an industrial control computer, which connects with

smelting workshop technology parameters monitoring network. Data of each

monitoring spot are send to workstation No.2 through communication routes and

intelligent communication card, and workstation No.2 sends the processed data to

the network server, which provides data service for other workstations in the

network.

Other workstations adopt compatible microcomputer.

The main software of system includes:

a) Nickel smelting process energy saving and intelligent decision support

system;

b) Realtime displaying software of production technology parameters;

c) Management software for production technology, quality, personnel matters,

cost, equipment and so on.

System functions include:

a) Nickel smelting process energy saving and intelligent decision support

system: taking energy saving as the goal, performing adaptive optimal

decision-making for overall nickel production process of the“submerged arc

furnace-converter-slag cleaning furnace”.

b) Realtime displaying software of production technology parameters: using

realtime measured data of technology parameters in the server disk, displaying

time-varying curves of several key parameters such as transformer-oil temperature

of the submerged arc furnace and slag cleaning furnace, working out the current

and voltage of each electrode, the blast pressure and so on, and ringing the limit

alarm for them in time.

c) Management software for production and quality: managing routine

production data and statistics reports, performing general production statistics

analysis using computer.

d) Cost management software: performing production cost statistics, calculation

and analysis, outputting related cost report forms and analysis charts.

e) Equipment management software: managing information of equipments in

smelting workshop.

f) Spare parts management software: managing information of spare parts.

  Xiaoqi Peng, Yanpo Song, Zhuo Chen and Junfeng Yao

g) Personnel matters management software: managing information of personnel

matters.

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 441

Simulation and Optimization on the Furnaces and Kilns for Nonferrous Metallurgical Engineering

Index

Absorptivity29

Activation energy39

Activation temperature39

Anisotropic12

Ar(Archimedes number)236

Arrhenius law39

Artificial intelligence model, AI model 101

Average particle size243

Barreiros52

Bath smelter2

BET surface area58

Beta function45

Biot-Savart law62

Black box model7

Blast smelting furnace236

Boiler102

Boundary condition137

Boussinesq16

Bubble assemblage model, BAM model 261

Bubble clouds259

Bubble phase259

Bubbling bed model259

Bubbling fluidized bed236

CAD (computer-aided design)318

CFD (Computational fluid dynamics)6

Chaos271

Circulating fluidized bed236

Critical fluidization velocity236

Cumulatine probability function33

Damkohler number46

Damping function22

Dense phase236

Diffusion term

17

Dilute phase236

Dilute phase model244

Direct exchanging area31

Discrete transfer radiation model, DTRM 34

Dissipation rate

Dissipation rate of turbulent kinetic energy

252

Dissipation term17

Double delta function45

Dynamic simulation127

Eddy-break-up model, EBU model45

Effective radiation31

Electric cleaning furnace193

Electric smelting furnace175

Electrical conduction equation153

Electrode paste176

Elkem-D178

Elkem-S177

Elkem-3X178

Elkem-T178

  Index

Emissivity29

Emulsion phase258

Enthalpy transport equation28

Equivalent magnetic dipole method 68

ESCIMO (engulfment-stretching-

coherence-interdiff-usion-interaction

-moving observer model)45

Enthalpy28

Euler coordinates244

Evans formula168

Expert system8

Favre-averaging13

Fenimore mechanism54

Fick’s law39

Field model50

Fixed beds302

FKNME (furnace and kilns for nonferrous

metallurgical engineering)1

Flash (smelting) furnace213

Flow field11

Fluidized roaster235

Frequency factor39

Furnace and kilns1

Fuzzy neural network analysis116

Fuzzy simulation104

Gas-particle two-phase flows235

Gaseous combustion42

Generalized fluidization90

General Navier-Stokes equations13

Gibb model51

Grey box model8

Heat conduction equation133

High temperature erosion306

Hologram simulation5

Hybrid models

Integrated system for monitoring, control

and management330

Intelligent decision support system,

IDSS320

Intelligent fuzzy analysis107

Isotropic

Jet flow12

-k model16

Kolmogorov-Prandtl expression17

Kronecker number13

Lagrange coordinates253

Lagrangian method244

Laplace force147

Large eddy simulation, LES70

Lillebuen formula168

Logarithmic probability distribution240

Low - Reynolds - number

-k models21

Magnetic attenuation factor67

Magnetic dipole68

Magnetic field69

Magnetic shielding factor67

Magnus force96

Magnussen soot model47

Mathematic simulation99

Mathematical model8

Mathematical model building83

Matte69

Mixed-is-burnt model43

Mixture fraction42

Mechanism analysis7

Monochromatic radiation heat flux30

Monte Carlo method28

Moving bed236

Index 

Multi-field coupling87

Multi-fluid model245

Multi-purpose synthetic optimization309

Navier-Stokes equations70

Neural network model119

model53

Non-homoge nous turbulent flow19

Normal distribution model239

Non-slip model245

Nukiyawa-Tanasawa distribution function

242

Nusselt number22

Oil combustion52

Online optimization system327

Optical thickness34

Optimization5

Optimization methods309

Particle group trajectory model245

PSIC method48

Particle source terms247

Physical property16

Potential field136

Prandtl number19

Pre-exponential factor39

Probability density function44

Probability density function models (PDF

models)287

Pseudo-partial-premix-PDF model 287

Quality control functions305

Radiation coefficient36

Radiation model28

Random cumulative33

Rate coefficient51

Rate constant39

Rate equations267

Raw coal (dry and ash free)48

Reaction rate51

Reaction rate constant268

Recirculation flow12

Relaxation time96

Renormalization group (RNG)

-k

model25

Reynolds stress16

Reynolds stresses model26

Robl formula168

Robust16

Rosin-Rammler distribution241

Runge-Kutta integration method254

Scattering35

Schmidt number308

SER tubes276

Sherwood number260

Shrinking core model268

Side ledge thickness157

Simple homogeneous reaction model

268

SIMPLE scheme279

Simulation5

Simulation test319

Single-phase fluid246

Slag21

Small-slip model245

Soderberg electrode176

Source term56

Standard wall function288

Suspension flow250

Terminal velocity236

The Reynolds-averaging13

Thermal system of the furnaces and kilns 3

  Index

Three ĀhighsāPreface

Tower trays216

Tower type zinc distillation furnace213

Transport equation17

Turbulent diffusion245

Turbulent diffusion time46

Turbulent dynamic viscosity202

Turbulent kinematic viscosity93

Turbulent models15

Turbulent Prandtl number19

Turbulent thermal diffusivity202

Turbulent diffusivity41

Turbulent drift247

Turbulent flow11

Turbulent fluidized bed236

Turbulent kinetic energy16

Turbulent viscosity93

Two-equation model18

Two Ālowsā Preface

Two-phase simple bubble model258

Unit output functions300

Unit output rate300

Vertical shaft furnace236

Viscosity13

Viscous stresses

Viscous stresses tensor13

Weibull probability distribution function

241

Zeldovich mechanism55

Zone method301