Blast Furnace DCS Control Solution
The process for producing blast furnaces is consecutive, where the first generation of blast furnaces (from commencement of work to stopping work for major maintenance) can continue production over a dozen years. Short disruptions in between will result in immeasurable losses during the production process. This would raise the reliability requirements required for the control system. HollySys combines the characteristics of the blast furnace iron-smelting system and the different requirements of the user based on the HOLLiAS MACS automation control system to provide targeted and customised solutions to its clients.
The HOLLiAS MACs of the HollySys system is designed based on the concept of a safety system, ensuring product reliability in terms of hardware and software.
In terms of overall power consumption during sintering processes, nearly 50% of heat energy are emitted into the atmosphere as sensible heat via sintered flue gas and coolant exhaust. The energy conservation potential is huge. As the world’s energy sources become scarce, waste heat recovery in the iron and steel industry can save a lot of energy and reduce power consumption during the production process. As the waste-heat recovery (WHR) technology soared, especially with breakthroughs in flash power and admission condensing steam turbine technologies, WHR efficiency has significantly improved.
1) Data Acquisition System (DAS)
(2) Modular Control System (MCS)
(3) Sequence control system (SCS)
(4) Steam turbine accident trip system (ETS)
As automation level requirements increase, better control can be achieved for changing the speed of steam turbines for economical and reliable operations. The DEH has functions that achieve process control commencement, automatic regulation, parameter control, protection, monitoring, and testing.
Integrated control of air separation units and compressors
Air separation units (ASU) and compressors shall be treated as a single controlled entity, where its advantages are mainly presented in the following points:
Parallel monitoring of steam turbine and ASU is done from an independently established IO control station that is separate from the ASU system, as shown in the following network architecture diagram:
The control interlock logic includes:
Leveraging on its experience in the design and implementation of over 1000 DEH equipment and the practical application of blast furnace blower, HollySys has established a complete package of integrated control solution for turbine blower system. With the turbine and blower treated as a single controlled entity, its strengths are mainly shown in the following ways: standardised human-machine interface for ease of operations by operator; flexible configuration, which facilities functional expandability; fast system dynamic response, which facilities high accuracy; convenient maintenance.
Turbine blower integration control solution allows for the ease of adjusting the change in blower speed, wind volume, and wind pressure with few occurrences of overshooting. With high control accuracy added into the picture, the automation level of blast furnace blower operations can be increased. Its effects are mainly shown in the following technological indicators:
Integrated control solutions include:
The key auxiliary equipment controls include: steam turbine oil jacking pump control, lubricant AC electric pump control, lubricant DC electric pump control, power oil pump control, jigger motor control, condensate pump control, and water-jet pump control.