US 12,259,712 B2
Method and system for ironmaking plant optimization
Manendra Singh Parihar, Pune (IN); Venkataramana Runkana, Pune (IN); Sri Harsha Nistala, Pune (IN); and Rajan Kumar, Pune (IN)
Assigned to TATA CONSULTANCY SERVICES LIMITED, Mumbai (IN)
Filed by Tata Consultancy Services Limited, Mumbai (IN)
Filed on Sep. 28, 2022, as Appl. No. 17/936,207.
Claims priority of application No. 202121047962 (IN), filed on Oct. 21, 2021.
Prior Publication US 2023/0130462 A1, Apr. 27, 2023
Int. Cl. G05B 19/4155 (2006.01)
CPC G05B 19/4155 (2013.01) [G05B 2219/31372 (2013.01)] 17 Claims
OG exemplary drawing
 
1. A processor implemented method for optimization of an ironmaking plant, comprising:
collecting data from a plurality of data sources of the ironmaking plant as input data, via one or more hardware processors;
pre-processing the input data to generate a pre-processed data, via the one or more hardware processors, comprising conditioning the input data to satisfy one or more pre-defined data quality requirements;
obtaining, via the one or more hardware processors, a simulated data using the pre-processed data and a plurality of soft sensors, wherein the simulated data is integrated with the pre-processed data to obtain an integrated data;
determining, via the one or more hardware processors, a first set of parameters using the integrated data and a plurality of data-driven models, for a plurality of pre-ironmaking units of the ironmaking plant;
obtaining, via the one or more hardware processors, a second set of parameters by combining the integrated data with the first set of parameters;
forecasting, via the one or more hardware processors, a set of key performance indicators (KPIs) using the second set of parameters and the plurality of data-driven models of the ironmaking plant;
determining a stability score of a blast furnace of the ironmaking plant, using the forecasted set of KPIs, the integrated data, and a plurality of stability score soft-sensors, via the one or more hardware processors, wherein the stability score represents a determined operating stability of the blast furnace;
monitoring for deviation of one or more of the forecasted KPIs or the stability score, from a corresponding pre-determined threshold, via the one or more hardware processors;
configuring optimization of one or more of the forecasted KPIs, using the determined stability score as a constraint, if the deviation from the pre-determined threshold is detected, via the one or more hardware processors, wherein the optimization of the one or more of the plurality of KPIs comprises identifying a plurality of optimum set points;
generating one or more recommendations based on the configured optimization of the one or more KPIs, via the one or more hardware processors; and
controlling the ironmaking plant based on the set points.