MFA Control and Optimization
of Gas Mixing Process
|• Soft-sensor measurement of gas heating
value in CyboMax to monitor the gas quality.
||• Monitors heating value online to ensure
consistent gas quality for downstream processes.
|• MFA control of gas flow, gas differential
pressure, and mixed gas heating value.
||• Improved product quality, plant safety,
and production efficiency.
|• Easy integration and startup.
||• Return on investment in a few months.
Gas Heating Value Monitoring and Control Solution
Process: In an iron and
steel complex, operating units including blast furnaces,
basic oxygen furnaces (BOF), and coking ovens all produce
gases as byproducts. Many plants discharge these gases
into the atmosphere wasting valuable energy and causing
severe air pollution. A gas plant mixes these gases
to produce fuel for the furnaces in metal casting and
rolling mills. The quality of the mixed gas is measured
by its heating value. Gases with inconsistent heating
value can cause major control, quality, and production
problems due to over or under heating.
Challenges: Even during normal production,
gas supply and demand can change randomly. Major operating
units like blast furnaces and reheating furnaces may
go online and offline periodically causing huge disturbances
in gas flow, pressure and the heating value.
Heating Value: Online heating value
analyzers are available, but not usually used during
normal operations because they are difficult to maintain
and overly expensive.
Goals: Monitor and control the gas
heating value automatically in all operating conditions.
Solution: CyboSoft offers a turnkey
solution for heating value measurement and control.
Using our special soft-sensor technology, heating value
can be accurately calculated online. An offline heating
value analyzer can be used to calibrate the calculated
value. Using Model-Free
Adaptive (MFA) controllers, gas flow
and differential pressure loops can be effectively controlled.
MFA controllers are also used to handle
the constraints and protect the system from running
in vicious cycles. An MFA controller is used to control
the gas heating value by cascading with the gas flow
and pressure controllers.
Application Story: Ling-Yuan Iron and
Steel Company in China has deployed a heating value
monitoring and control system in its gas mixing facility.
A distributed control system (DCS) with CyboCon MFA
control software and CyboMax process monitoring and
optimization software are used.
CyboSoft Beijing implemented this turnkey system. The
trend chart above shows good control of the heating
value (red) when there are major gas disturbances from
blast furnaces and coking ovens. The user has certified
• Gas heating value within +/-100 Kcal/Nm3 specification.
• Improved product quality, plant safety, and
• Enables flexible production.