Design And Application Of Operation Management And Optimization System For Sintering Comprehensive Stockyard

In iron and steel enterprises, sintering comprehensive stockyard is used to store raw materials, and normally cover large area, in order to guarantee routine large-scale production. Because the production process is complicated, and the production cost is large, it is of great significance to establish an efficient sintering comprehensive stockyard operation management and optimization system for production cost savings. Currently, the operating procedure of sintering comprehensive stockyard has not been fully optimized. In the aspect of storage configuration, there exist problems such as confusion storage mode, low utilization rate of stockyard and low stability of raw materials. In the aspect of inventory management, the procurement of raw materials is unreasonable, which results in too much or too little inventory. In the aspect of stockyard management, there exist mistakes of stacker reclaimers’job, inaccurate information of stockyard and other problems. In response to these issues, this paper conducts research on job management and optimization of sintering comprehensive stockyard, the main research work and innovations are as follows:(1) Fuzzy multiple criteria optimization method based on analytic hierarchy process for storage location choiceThe supply of raw materials in iron and steel enterprises always shows its complexity because of large variety of sources and composition, large purchase quantity, and serious impacts coming from production. So it is a combination of qualitative and quantitative multi-objective optimization problem for the evaluation of raw materials storage solutions. Conventional optimization algorithms can hardly improve the stockyard utilization and the materials ingredients stability fundamentally. Based on the analysis on the situation of raw materials storage, this paper establishes a storage locations optimization model, which aims at stockyard utilization and materials ingredients stability. Firstly, seven optimization criterions are established based on the main factors affecting storage locations configuration. Secondly, the weight values of various criteria are determined by using analytic hierarchy process method. Finally, the method with triangular fuzzy numbers is used to represent the weight values and the desired values, in order to improve the reasonability of optimization results. The running results show that, the system established can achieve the desired optimization goal, and reduce the cost of enterprise management greatly.(2) Prediction method based on multi-model integration for iron mine powders inventoriesDue to the difference of origin and grade, raw materials have different price, show importance in different degrees in batching process. However, in the formation process of powder, the proportions of different kinds of raw materials are nearly unchanged. Hence there is certain regularity about the changes of the total raw materials inventory, as well as the changes of the special kinds of raw materials with different importance. This paper proposes a prediction method based on gray system model and time series model to predict raw materials inventory. Firstly, as gray system can reflect the overall trend of the data sequence, gray prediction model for inventory is established by filtering, statistics, cumulation, or regression based on historical inventory data. Secondly, because of the advantage in reflecting fluctuations of the data sequence, according to the timing analysis of the data sequence, the time series model is applied. Finally, the integrated prediction model is established based on information entropy for raw materials inventory. This integrated model can fully reflect the advantages of different types of models, predict the raw material inventory accurately, and provide a reliable basis for the following optimization of raw materials inventory.(3) Raw material inventory optimization algorithm for sinter material plant based on GA-PSOThe goal of stockyard inventory prediction is to prevent the occurrence of the raw materials shortage, so as to ensure the continuity of production. At the same time, inventory optimization aims to reduce the cost of purchasing inventory. The two aspects constitute the raw materials inventory optimization management for stockyard. The constraints of raw materials inventory and procurement cost are the bottleneck of liquidity in iron and steel enterprises. According to the characteristics of procurement and consumption of raw materials in sintering comprehensive stockyard, this paper establishes an optimization model for raw materials inventory, which targets on minimum inventory costs, and builds the detailed model of the objective function and the constraints. Firstly, a standard PSO algorithm is proposed based on fitness function. Secondly, GA algorithm is applied to improved PSO algorithm and the detailed algorithm parameters are designed. Lastly, the optimization results of GA-PSO algorithm and standard PSO algorithm are compared. Further more, the actual production data of sintering comprehensive stockyard in a steel enterprise are used for simulation, and the results show that this inventory optimization model combined with GA-PSO algorithm has achieved the optimization of raw materials inventory costs, which provides decision support for the procurement plan in iron and steel enterprises.(4) The design and industrial applications of the job management and optimization system for sintering comprehensive stockyardBased on the analysis of system software and hardware structure of a360m2sintering production line, and the actual situation of the industrial field, the job management and optimization system for sintering comprehensive stockyard is established. What’s more, the implementation process of application software modules, the optimization control algorithm and the data communication technology of this system are introduced. After the analysis of the actual operation of the system results, it is found that this system can realize the comprehensive optimization of procurement costs and stability of raw materials supply, and achieve the goal of optimization configuration of the stockyard storage locations, improve the stockyard utilization and raw materials stability. That makes significant economic benefits.