Optimal operation of an industrial blast furnace (BF) ironmaking process largely depends on a reliable measurement of molten iron quality (MIQ) indices, which are not feasible using the conventional sensors. This paper proposes a novel data-driven robust modeling method for the online estimation and control of MIQ indices. First, a nonlinear autoregressive exogenous (NARX) model is constructed for the MIQ indices to completely capture the nonlinear dynamics of the BF process. Then, considering that the standard least-squares support vector regression (LS-SVR) cannot directly cope with the multioutput problem, a multitask transfer learning is proposed to design a novel multioutput LS-SVR (M-LS-SVR) for the learning of the NARX model. Furthermore, a novel M-estimator is proposed to reduce the interference of outliers and improve the robustness of the M-LS-SVR model. Since the weights of different outlier data are properly given by the weight function, their corresponding contributions on modeling can properly be distinguished, thus a robust modeling result can be achieved. Finally, a novel multiobjective evaluation index on the modeling performance is developed by comprehensively considering the root-mean-square error of modeling and the correlation coefficient on trend fitting, based on which the nondominated sorting genetic algorithm II is used to globally optimize the model parameters. Both experiments using industrial data and industrial applications illustrate that the proposed method can eliminate the adverse effect caused by the fluctuation of data in BF process efficiently. This indicates its stronger robustness and higher accuracy. Moreover, control testing shows that the developed model can be well applied to realize data-driven control of the BF process.

Blast furnace (BF) in ironmaking is a nonlinear dynamic process with complicated physical-chemical reactions, where multiphases and multifields interactions with long time delay phenomena take place during its operation. In BF operation, the molten iron temperature as well as the Si content ([Si]), the phosphorus content ([P]), and the sulfur content ([S]) is the most essential quality (MIQ) indices. The measurement, modeling, and control of these indices have always been important issues in metallurgic engineering and automation. This paper proposes a novel data-driven nonlinear state-space modeling method for the prediction and control of multivariate MIQ indices by integrating hybrid modeling and control techniques together. First, to improve modeling efficiency, a data-driven hybrid method that combines canonical correlation analysis and correlation analysis is established to identify the most influential controllable variables as the modeling inputs from multitudinous factors. Then, a Hammerstein model for the prediction of MIQ indices is established using the Least squares support vector machine-based nonlinear subspace identification method. Such a model is further simplified by using piecewise cubic Hermite interpolating polynomial method. Compared with the original Hammerstein model, it has been shown that this simplified model can not only significantly reduce the computational complexity, but can also exhibit a good reliability and accuracy for a stable prediction of MIQ indices. In order to verify the practicability of the developed model, it is applied to the design of a genetic algorithm based nonlinear predictive controller for the multivariate MIQ indices by directly taking the established model as a predictor. Industrial experiments show the advantages and effectiveness of the proposed approaches.

This article proposes a multiobjective operation optimization method based on reinforcement self-learning and knowledge guidance for quality assurance and consumption reduction of wastewater treatment process (WWTP) with nonstationary time-varying dynamics. First, operation optimization models are developed by online sequential random vector functional-link (OS-RVFL) neural network, which can realize online sequential learning of model parameters. Then, a knowledge base is established to store typical optimization cases for knowledge guiding the subsequent optimizations. Based on it, a reinforcement self-learning-based multiobjective particle swarm optimization (RSL-MOPSO) algorithm is proposed to perform optimization calculation. In this algorithm, reinforcement self-learning is used for interaction learning between environment and action in optimization, and the particle motion trend of algorithm is adjusted according to the feedback information of the optimization process. The effects of wastewater state parameters on particles are recorded and reused to improve the solution quality and calculation efficiency of optimization. Moreover, to make good use of the information of the previous optimizations and balance the coordination between global search in the early stage and local search in the later stage, a selective information feedback mechanism is further proposed to ensure the diversity and convergence of the algorithm. Finally, prediction-based intelligent decision making is performed to select the final optimization solution as the final setpoints for the lower-level controllers from the Pareto frontier with considering specific technical requirements. Data experiments show that the proposed method can effectively reduce energy consumption and ensure effluent quality.

The automatic control of blast furnace (BF) ironmaking process has always been an important yet arduous task in metallurgic engineering and automation. In this article, a novel Kalman filter-based robust model-free adaptive predictive control (MFAPC) method is proposed for the direct data-driven control of molten iron quality in BF ironmaking. First, a compact-form dynamic linearization-based extended MFAPC method for multivariable molten iron quality control is proposed by generalizing the existing single-variable MFAPC method to multivariable systems. Based on it, a Kalman filter-based robust MFAPC is further proposed considering the problems of data loss and measurement noise in quality detection. Specifically, the robust mechanism in the robust MFAPC combines a novel dynamic linearization method with a concept termed Pseudo-Jacobian matrix to predict the missing data during data loss. After that, a Kalman filter is constructed based on a prediction model to filter the measurement noise. The stability of the proposed control method is analyzed, and various data experiments using actual industrial data are performed to verify the effectiveness of the proposed methods. Note to Practitioners —The extremely complicated dynamics of blast furnace ironmaking process make the model-based controllers difficult to realize in practice. In this article, a novel robust model-free adaptive predictive control method is proposed for direct data-driven control of multivariate molten iron quality in the ironmaking process. This method directly uses the process input and output data to design the multivariable quality controller online by the compact-form dynamic linearization technology and the internal multilayer prediction mechanism, thus avoids the drawback of model-based controllers in troublesome process modeling. Moreover, the proposed method can effectively avoid the influence of data loss and measurement noise on the controller performance with the designed Kalman filter-based robust mechanism. The superiority and practicability of the proposed method are verified using various experiments against actual industrial data.