Advanced measurements and dynamic modelling for improved furnace operation and control (DYNAMO) : final report

Modern reheating furnace control systems currently use limited measurements of the furnace temperature coupled with simple empirical mathematical models to predict and following regulate stock temperatures. However existing measurement data capture only a small amount of information about the operating state of the furnace. In addition, the mathematical models used in existing reheating furnace control systems are relatively crude so that predictions of process parameters have only limited accuracy and the precision of the supervisory process control system is compromised. Therefore furnace operation will be improved using these advanced measurements and dynamic modelling for improved furnace operation and control. In the completed research, the specifications for different advanced furnace measurements and modelling were determined. Beyond the analysis of the state-of-the-art in furnace measurements and modelling the collection of the requirements for advanced furnace measurements was completed. This covered stock and gas temperature measurements, furnace atmosphere measurements and radiometric imaging. Such measurement technologies were installed and operated in different types of reheating furnaces. The resulting information was used for the development of improved furnace models. The necessary data for each of the furnaces selected was collected to allow the development of the "virtual furnace" model by a well-documented zone modelling approach. The virtual furnace models were adapted to the specific situation in industrial facilities. General conclusions regarding new measurement approaches, reheating furnace models and furnace control were collected.