From 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 online
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.