Design And Development Of Dynamic Model Software For Shaft Furnace Reduction Roasting Process

The shaft furnace reduction roasting process is to provide the magnetite ore which is the production of the gas-based reduction of hematite ore with high temperature. Its effect is relative to the evaluation index of mineral processing-metal recovery and concentrated ore grade. The reduction roasting process is completely complex and its main characteristics can be listed as follows:strong coupling, strong nonlinear and the frequently varied operation condition. So, it focuses much more on the performance of the control strategies and optimal control algorithms. All these control strategies and algorithms should be validated before applying to the real industry processes. Unfortunately, the real experiment is expensive and the devices can’t be carried into the laboratory. So it is necessary to develop the simulation software to test those control strategies and algorithms in the laboratory.Supported by State Key Laboratory of Synthetical Automation for Process Industries "973Basic Research"-Complex Manufacturing Process Integration Control Theory and Technology Basic Research, the author builds the mechanism model of the process. Based on this model, dynamic model software is developed with the program Integrated Object Simulation Platform for the verification of control strategies and optimal control algorithms. The details are as follows:(1) The completely dynamic mechanism model of the shaft furnace reduction roasting process is built. By analyzing the process,3major physical and chemical processes are clarified as follows:combustion process, heat transfer process and reduction reaction. According to the spatial distribution of these physical and chemical processes, the space of the shaft furnace can be separated as combustion chamber, preheating zone, heating zone and reducing zone. Then the corresponding mechanism dynamic model is built for each "zone". Meanwhile, the simple models of valves and inverters are also built in order to accomplish the simulation of the whole reduction roasting process.(2) Based on the dynamic mechanism model, the dynamic model software is designed and developed. This program contains3major parts:the dynamic model bases and their corresponding visual components, the human-computer interface and variable database. Various functions are developed for this program, such as real-time simulation, process monitoring,boundary online modification, real-time curves, monitoring index and control loop information. (3) According to the function tests, this program meets the design requirements. Then several steady state tests are applied with the dynamic model, and various dynamic tests are applied by using the dynamic model software. The simulation data of the steady state experiments are coincident with the real data. Experimental data from the dynamic tests prove that the transient time and dynamic trend are similar to the real process.