Conversion of Iterative Balance Models to Directly Calculating Explicit Models for Real-time Process Optimization and Scheduling

Optimal utilization of complex processes involves real-time operational optimization and scheduling, especially in cases where the production line consists of both continuous and batch operated unit processes. This kind of real-time optimization requires process models which can be computed significantly faster than real-time. Iterative balance calculation is typically far too slow for these cases. This paper presents a method for converting an iterative balance model to a directly calculating model suitable for on-line process optimization. The approach is demonstrated with the first unit process in the copper smelting line, the flash smelting furnace (FSF). The method consisted of formulating an equation group based on the constrained FSF HSC-Sim model and solving the unknown parameters and static states with use of a symbolic calculation software. The solution was implemented as a function whose calculation time fulfilled the requirements for scheduling use.