Feedback control of a cupola - concepts and experimental results
- Idaho State Univ., Pocatello, ID (United States)
- Tenn. Technological Univ., Cookeville, TN (United States)
- Lockheed Martin Idaho Technologies Co., Idaho Falls, ID (United States)
- US Dept. of Energy Albany Research Center, Albany, OR (United States)
In this paper we present some final results from a research project focused on introducing automatic control to the operation of cupola iron furnaces. The main aim of this research is to improve the operational efficiency and performance of the cupola furnace, an important foundry process used to melt iron. Previous papers have described the development of appropriate control system architectures for the cupola. These results are summarized. Then we describe the experimental results obtained with the U.S. Department of Energy Albany Research Center`s research cupola. First, experimental data is used to calibrate the model, which is taken as a first-order multivariable system with time delay. Then relative gain analysis is used to select loop pairings to be used in a multi-loop controller. The resulting controller pairs meltrate with blast volume, iron temperature with oxygen addition, and carbon composition with percent coke. Special (nonlinear) filters are used to compute meltrate from actual scale readings of the amount of iron produced and to smooth the temperature measurement. The temperature and meltrate loops use single-loop PI control. The composition loop uses a Smith predictor to discount the deadtime associated with mass transport through the furnace. Experimental results validate the conceptual controller design and provide proof-of-concept of the idea of controlling a foundry cupola. Future research directions are discussed, including the concept of an integrated, intelligent industrial process controller, or I{sup 3}PC.
- Research Organization:
- Lockheed Martin Idaho Technologies Co., Idaho Falls, ID (United States)
- Sponsoring Organization:
- USDOE Assistant Secretary for Energy Efficiency and Renewable Energy, Washington, DC (United States)
- DOE Contract Number:
- FC07-94ID13321
- OSTI ID:
- 656072
- Report Number(s):
- CONF-981006-1; ON: DE98005086
- Resource Relation:
- Conference: 1998 AFS cupola conference, Cincinnati, OH (United States), Oct 1998; Other Information: PBD: Oct 1998
- Country of Publication:
- United States
- Language:
- English
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