Two-Layer Linear MPC Approach Aimed at Walking Beam Billets Reheating Furnace OptimizationReport as inadecuate

Two-Layer Linear MPC Approach Aimed at Walking Beam Billets Reheating Furnace Optimization - Download this document for free, or read online. Document in PDF available to download.

Journal of Control Science and Engineering - Volume 2017 2017, Article ID 5401616, 15 pages -

Research ArticleDipartimento di Ingegneria dell’Informazione, Università Politecnica delle Marche, Ancona, Italy

Correspondence should be addressed to Silvia Maria Zanoli

Received 23 September 2016; Revised 18 November 2016; Accepted 21 December 2016; Published 31 January 2017

Academic Editor: Shuyou Yu

Copyright © 2017 Silvia Maria Zanoli and Crescenzo Pepe. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.


In this paper, the problem of the control and optimization of a walking beam billets reheating furnace located in an Italian steel plant is analyzed. An ad hoc Advanced Process Control framework has been developed, based on a two-layer linear Model Predictive Control architecture. This control block optimizes the steady and transient states of the considered process. Two main problems have been addressed. First, in order to manage all process conditions, a tailored module defines the process variables set to be included in the control problem. In particular, a unified approach for the selection on the control inputs to be used for control objectives related to the process outputs is guaranteed. The impact of the proposed method on the controller formulation is also detailed. Second, an innovative mathematical approach for stoichiometric ratios constraints handling has been proposed, together with their introduction in the controller optimization problems. The designed control system has been installed on a real plant, replacing operators’ mental model in the conduction of local PID controllers. After two years from the first startup, a strong energy efficiency improvement has been observed.

Author: Silvia Maria Zanoli and Crescenzo Pepe



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