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Processes 2016, 4(4), 53; doi:10.3390/pr4040053

Model Predictive Control of the Exit Part Temperature for an Austenitization Furnace

McKetta Department of Chemical Engineering, University of Texas at Austin, Austin, TX 78712, USA
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Academic Editor: Dominique Bonvin
Received: 9 August 2016 / Revised: 6 December 2016 / Accepted: 6 December 2016 / Published: 15 December 2016
(This article belongs to the Special Issue Real-Time Optimization)
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Abstract

Quench hardening is the process of strengthening and hardening ferrous metals and alloys by heating the material to a specific temperature to form austenite (austenitization), followed by rapid cooling (quenching) in water, brine or oil to introduce a hardened phase called martensite. The material is then often tempered to increase toughness, as it may decrease from the quench hardening process. The austenitization process is highly energy-intensive and many of the industrial austenitization furnaces were built and equipped prior to the advent of advanced control strategies and thus use large, sub-optimal amounts of energy. The model computes the energy usage of the furnace and the part temperature profile as a function of time and position within the furnace under temperature feedback control. In this paper, the aforementioned model is used to simulate the furnace for a batch of forty parts under heuristic temperature set points suggested by the operators of the plant. A model predictive control (MPC) system is then developed and deployed to control the the part temperature at the furnace exit thereby preventing the parts from overheating. An energy efficiency gain of 5.3 % was obtained under model predictive control compared to operation under heuristic temperature set points tracked by a regulatory control layer. View Full-Text
Keywords: model predictive control; energy efficiency; iron and steel; austenitization model predictive control; energy efficiency; iron and steel; austenitization
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MDPI and ACS Style

Ganesh, H.S.; Edgar, T.F.; Baldea, M. Model Predictive Control of the Exit Part Temperature for an Austenitization Furnace. Processes 2016, 4, 53.

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