Effective control of a blast furnace (BF) process requires accurate estimates of key process indicators (KPIs), namely, productivity, coke rate, direct reduction per cent, adiabatic flame temperature, bosh gas volume and top gas utilization. Some of these KPIs are obtained directly from the measurements, and some are derived by carrying out material and energy balances on measurements of different feeds, their compositions and temperatures. Due to errors in the measurements, the estimates of the KPIs can be inconsistent or misleading, which may result in misinterpretation of the current state of the BF process. Hence, it is necessary to reconcile the measurement data before these are used either for interpreting the current furnace state directly or as an input to other models. In the proposed methodology, data reconciliation and gross error detection techniques are used to improve the accuracy of the estimates of process variables and parameters, by ensuring that they satisfy process constraints such as elemental balances of iron, nitrogen, carbon, oxygen and hydrogen. Since the BF is a fed‐batch process, a customized version of these techniques has been developed and applied real time to an operating BF. The method is shown to be useful in deriving consistent estimates of the hot metal production rate, identifying gross errors in the online gas analyser and for estimating unmeasured parameters, such as top gas flow rate, its moisture concentration and calorific value which are useful for the purpose of stove heating in the downstream process.
A novel raceway heat and material balance model is developed considering all physico-chemical phenomena surrounding the raceway of the blast furnace (BF). This model is unique, as it considers reactions based on thermodynamics and determines important parameters such as raceway adiabatic flame temperature (RAFT), bosh gas properties, raceway coke rate etc. Importantly, the model also predicts blowing parameters in case of known RAFT and permeability of the furnace. This paper focuses on the raceway regime only considering the effect of different injectants, H 2 , CO, CH 4 , CO 2 and coke oven gas (COG). Firstly, the paper describes the modelling approach, based on thermodynamic, heat and material balances. The first part of the paper quantifies the effect of injectants on the raceway keeping the blowing parameters constant, whereas second part presents the changes of raceway properties as well as blowing parameters keeping RAFT and permeability of the furnace constant.
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