Conference Paper

Forecasting of Basic Oxygen Furnace Gas Production Through Echo State Neural Networks

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Abstract

Sustainability and competitiveness of integrated steelworks is correlated to the reuse of internal resources and efforts are spent to intensify such reuse. Off-gases coming from main production steps are valuable by-products due to their energy content. In particular, Basic Oxygen Furnace Gas is characterized by a significant net calorific value and can be used to replace natural gas for feeding internal processes that produce heat, steam or electricity. Optimized reuse of these gases allows achieving significant economic and environmental advantages. However, forecasting the amount and the features of these gases in the next future is a challenging task and an optimal management is a difficult goal to achieve. Currently, Basic Oxygen Furnace Gas is distributed to the network depending on the current demand of gas. In order to avoid flaring, due to the reaching of maximal capacity of the gasholder, a Basic Oxygen Furnace Gas production and energy demand forecast is necessary in order to optimize its use. The paper describes a hybrid data-driven model forecasting the amount and the features of Basic Oxygen Furnace Gas. The main aspects related to the involved processes have been considered and, consequently, a careful selection of input variables has been pursued. Echo State Neural Networks are exploited and the model has been trained and tested by exploiting real industrial data. The obtained accuracy is acceptable for optimization purposes.

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... power plants) and do not dynamically forecast the off-gases (and related energy carriers) production and request. The new DSS is composed of different units: a model library, which is able to forecast the production and the demand of off-gases and related energy carriers by the different producers or users in the whole steelmaking plant, as for instance described in [13][14][15][16]; an optimization tool, containing different optimization techniques in order to offline and online optimize the distribution of off-gases in steelworks; a graphical user interface in order to easy visualize the results of the different units of the DSS also in the form of key performance indicators [17,18]. ...
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The European steel industry is constantly promoting developments, which can increase efficiency and lower the environmental impact of the steel production processes. In particular, a strong focus refers to the minimization of the energy consumption. This paper presents part of the work of the research project entitled “Optimization of the management of the process gas network within the integrated steelworks” (GASNET), which aims at developing a decision support system supporting energy managers and other concerned technical personnel in the implementation of an optimized off-gases management and exploitation considering environmental and economic objectives. A mathematical model of the network as a capacitated digraph with costs on arcs is proposed and an optimization problem is formulated. The objective of the optimization consists in minimizing the wastes of process gases and maximizing the incomes. Several production constraints need to be accounted. In particular, different types of gases are mixing in the same network. The constraints that model the mixing make the problem computationally difficult: it is a non-convex quadratically constrained quadratic program (QCQP). Two formulations of the problem are presented: the first one is a minimum cost flow problem, which is a linear program and is thus computationally fast to solve, but suitable only for a single gas network. The second formulation is a quadratically constrained quadratic program, which is slower, but covers more general cases, such as the ones, which are characterized by the interaction among multiple gas networks. A user-friendly graphical interface has been developed and tests over existing plant networks are performed and analyzed.
... For this feature and for their fast training stage, they have been applied with success in different fields. In GASNET, ESNs are exploited for models that forecast the produced blast furnace gas (BFG) or the recoverable basic oxygen furnace gas (BOFG) in terms of gas volume flowrate and heating power that is computed after the prediction of the content of carbon monoxide and hydrogen by specialized ESN [50,51]. The simplified structure of these models is reported in Figure 3: here, inputs are highlighted in red, auxiliary outputs in green and final outputs in dark blue; the other blocks are the model "active" parts and the core is represented by the purple blocks of ESNs. ...
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The European Steel industry is spending considerable efforts in order to improve the can increase efficiency and lower the environmental impact of the steel production processes. In particular, the European iron and steel sector is strongly committed toward the reduction of energy consumptions and CO 2 emissions. Process gases are a very valuable resource: possibilities exist to consider these gases as an intermediate by-product for the production of other valuable energy carriers or products with an associated environmental benefit. Therefore, the process gas networks, especially inside the integrated steelworks, have a fundamental function, as they allow meeting the demand of many processes and producing energy through dedicated facilities. They can also support the production processes by internal electric energy generation and often by supplying energy outside the plant boundaries. On the other hand, such networks are very complex systems interacting with many different production steps and the management of such complex systems is a very difficult task, where many often-counteracting factors need to be jointly taken into account. This paper presents the first outcomes of the research project entitled “Optimization of the management of the process gas network within the integrated steelworks (GASNET)”, which aims at developing a Decision Support System helping the energy managers and other concerned technical personnel to implement an optimized off-gases management and exploitation considering environmental and economic objectives. A series of Key Performance Indicators has been elaborated, in order to monitor the efficiency of the gas management and the objectives of the optimization have been defined. The overall structure of the project and the ongoing work will also be outlined in the paper.
... For this feature and for their fast training stage, they have been applied with success in different fields. In GASNET, ESNs are exploited for models that forecast the produced blast furnace gas (BFG) or the recoverable basic oxygen furnace gas (BOFG) in terms of gas volume flowrate and heating power that is computed after the prediction of the content of carbon monoxide and hydrogen by specialized ESN [50,51]. The simplified structure of these models is reported in Figure 3: here, inputs are highlighted in red, auxiliary outputs in green and final outputs in dark blue; the other blocks are the model "active" parts and the core is represented by the purple blocks of ESNs. ...
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