Accurate process control through automation is the key to achieving efficient and stable operation of a blast furnace. In this study, we developed an automatic control system of hot metal temperature (HMT). To cope with the slow and complex process dynamics of the blast furnace, we constructed a control algorithm that predicts eight-hour-ahead HMT using a two-dimensional (2D) transient model and calculates optimal target pulverized coal ratio (PCR) and pulverized coal flow rate by non-linear model predictive control (NMPC). An evaluation in a real plant showed that the developed control system suppressed the effects of disturbances, such as changes in the coke ratio and blast volume, on the HMT. The root mean square (RMS) of the control deviation of HMT was successfully reduced by 1.6 °C compared to the conventional manual operation.

To achieve the automation of blast furnace operation, an automatic control system for hot metal temperature (HMT) was developed. Nonlinear model predictive control (NMPC) which predicts up to ten-hour-ahead HMT and calculates appropriate control actions of pulverized coal rate (PCR) was constructed. Simulation validation showed that the NMPC algorithm generates control actions similar to those by the operators and that HMT can be maintained within ±10 °C of the set point. The automatic control system using NMPC was then implemented in an actual plant. As a result, the developed control system suppressed the effects of disturbances, such as the changes in the coke ratio and blast volume, and successfully reduced the average control error of HMT by 4.6 °C compared to the conventional manual operation. The developed control system has contributed to the reduction of reducing agent rate (RAR) and CO2 emissions.