Solutions Metallurgical

Using model-based techniques, and intelligent data processing, Cybernetica’s solutions bring the knowledge about metallurgical processes from theory and written documents in the research offices into the production and control room, in the form of process monitoring, process parameter estimation, operator support systems, softsensing control, and ultimately full model-predictive control.

Metallurgical solutions

Operation of metallurgical processes typically includes a number of challenges, including:

Extreme temperatures
Aggressive liquid materials
Lining wear
Few measurements of the core process
Inhomogeneous raw materials

Experience

Cybernetica has experiences in the following process metallurgy areas:

Ladle refining
Electric arc furnaces
Electrolysis
Oxygen refining converters

We provide solutions for

Training simulators
Realtime process variable monitoring
Soft-sensor control
Modelbased predictive control

Services

Cybernetica has wide experience with industrial implementations, with over a hundred applications running online in our customers process plants. These applications run at different sites for different customers in a variety of fields. For each of them, we offer and deliver maintenance of the applications, upgrades and further development when needed. We also offer different consultancy services including simulation studies, software development and process optimizations.

Research and development is an important part of Cyberneticas strategy to stay at the forefront of our field, and we take part in several research projects focusing on metalurgical processes. In theese projects we are partnering with our customers, research institutions and other technology companies.

Case Aluminium electrolysis

Production of aluminium is a power consuming process where large amounts of electric power is needed. Alumina, processed from bauxite, reacts with anode carbon in Hall-Héroult electrolysis cells to produce the aluminium metal.

Case Electric arc smelting furnaces

A key challenge in large industrial submerged arc electric furnaces is the lack of direct measurements of the furance hearth. The operating conditions in the furnace hearth, typically consisting of a coke-bed or a crater are so harsh with extreme temperatures and aggressive chemical conditions that measurement equipment will not survive long enough to make proper measurements.

Case Metal refining processes

In metal refining the aim is to obtain the specification of one or several chemical components within product specifications, while at the same time obtain a product temperature within a preferred narrow window within a defined margin above the melting temperature. At the same time, production amounts should be optimized, at a lowest possible cost.

Implementation

Cybernetica employees have extensive experience in industrial implementation and commissioning of advanced process control (APC) applications based on model predictive control (MPC) technology.

Cybernetica develops, implements and commissions complete (“turn-key”) advanced process control applications based on Cybernetica CENIT. A comprehensive maintenance programme ensures all applications to perform at its best at all times.

Cybernetica CENIT

State-of the art nonlinear model predictive control
Mechanistic mathematical models
Industrially proven
Runs on a Windows server
OPC communication

Maintenance

Cybernetica’s maintenance programme ensures that all applications perform at their best at all times. Cybernetica rapidly responds to customer requests. Cybernetica CENIT has built-in functionality for reproduction and diagnosis of current or past process situations, facilitating efficient analyses of issues reported by the customer.

The most common and important issues are reported directly to the operators, enabling the operators to act when necessary.

Maintenance program

Prevents performance degradation
Quick response on request
Performance monitoring
Automatic reports to operator

Safe operation

Using model adaption, Cybernetica CENIT ensures that the industrial processes are safely controlled in spite of model uncertainty.

In addition to the inherent safety associated with the model predictive control methodology and the online model adaptation, CENIT includes functionality for fault detection and diagnosis.

Installation of Cybernetica CENIT requires no change in the existing safety systems. The integrity of the facility will not be impaired in any way.

Safety first

Advanced control with intrinsic safety
Fault detection
Diagnosis functionality
Safety integrity is retained