MWPCA blast furnace anomaly monitoring algorithm based on Gaussian mixture model

doi:10.11949/0438-1157.20201708

Abstract

Abstract:

Large-scale blast furnaces are important equipment in the steel manufacturing process. Due to the complex operation of the blast furnaces and the many interference factors, abnormal furnace conditions often occur. In order to monitor the abnormal furnace conditions in time and ensure the blast furnace is running smoothly, this paper develops an algorithm based on the principal component analysis and gaussian mixture model to monitor the abnormal process of the blast furnace. Due to the non-Gaussian distribution and time-varying characteristics of blast furnace operating data, the Gaussian mixture model is used to improve the T² statistics of the traditional PCA monitoring model, so that the algorithm can adapt to the unique distribution characteristics of blast furnace data. And the sliding window mechanism is added to give the algorithm the ability to update in real time. Subsequently, the algorithm was applied to the real blast furnace data of a large iron and steel group in South China. The effectiveness of the algorithm was tested and compared with the basic algorithm to prove the improvement of the algorithm's ability to monitor blast furnace anomalies.

Key words: blast furnace, process systems, principal component analysis, Gaussian mixture model, process monitoring, algorithm

摘要：

大型高炉是钢铁制造过程中的重要装备，由于高炉运行过程复杂，干扰因素繁多，经常会有异常炉况发生。为及时监测异常炉况、保证高炉顺行，本文利用高炉运行数据，开发了一种基于MWPCA和高斯混合模型的算法对高炉异常过程进行监测。由于高炉运行数据存在非高斯分布和时变的特点，利用高斯混合模型改进了传统PCA监测模型的T²统计量，使算法可以适应高炉数据的独特分布特征，并加入了滑窗机制，使算法具有实时更新的能力。随后，将算法应用在华南某大型钢铁集团的真实高炉数据上，检测了算法的有效性，并将其与基础算法进行了对比分析，证明了算法在高炉异常监测能力上有所提高。

关键词: 高炉, 过程系统, 主元分析, 高斯混合模型, 过程监测, 算法

CLC Number:

ZHU Xiongzhuo, ZHANG Hanwen, YANG Chunjie. MWPCA blast furnace anomaly monitoring algorithm based on Gaussian mixture model[J]. CIESC Journal, 2021, 72(3): 1539-1548.

朱雄卓, 张瀚文, 杨春节. 基于高斯混合模型的MWPCA高炉异常监测算法[J]. 化工学报, 2021, 72(3): 1539-1548.

Figures/Tables 13

Fig.1 General blast furnace fault monitoring methods

Table 1 A list of variables for the dataset

序号	变量	单位	序号	变量	单位	序号	变量	单位
1	富氧率	％	13	冷风流量	10⁴ m³/h	25	实际风速	m/s
2	高炉渗透系数		14	炉腹煤气量	m³	26	冷风温度	℃
3	CO体积	％	15	理论燃烧温度	℃	27	顶温东北	℃
4	H₂体积	％	16	炉顶压力(1)	kPa	28	顶温西南	℃
5	CO₂体积	％	17	炉顶压力(2)	kPa	29	顶温西北	℃
6	标准风速	m/s	18	炉顶压力(3)	kPa	30	顶温东南	℃
7	富氧流量	m³/h	19	炉顶压力(4)	kPa	31	顶温下降管	℃
8	炉腹煤气指数		20	富氧压力	MPa	32	热风温度	℃
9	鼓风动能	kJ	21	冷风压力(1)	MPa	33	设定喷煤量	t/h
10	阻力系数		22	冷风压力(2)	MPa	34	本小时喷煤量	t
11	鼓风湿度		23	热风压力(1)	MPa	35	上小时喷煤量	t
12	全压差	MPa	24	热风压力(2)	MPa

Fig.2 General blast furnace fault monitoring methods

Fig.3 Distribution histogram of key index

Table 2 A list of variables for the dataset

变量	p	正态分布假设
热风压力	<0.001	拒绝
全压差	<0.001	拒绝
理论燃烧温度	<0.001	拒绝
鼓风动能	<0.001	拒绝

Table 3 Data mean and standard deviation of the two groups

变量	7月1日均值	7月20日均值	7月1日标准差	7月20日标准差
热风压力/MPa	0.393	0.389	0.006	0.017
全压差/MPa	165.974	161.558	6.433	7.636
理论燃烧温度/℃	2262.765	2277.597	8.345	23.872
鼓风动能/kJ	135.888	138.128	9.264	11.450

Fig.4 Iteration flow chart of GMM model

Fig.5 Samples and the coverage of T2 statistics

Fig.6 Samples and the coverage of GMM-T2 statistics

Fig.7 Monitoring results of Gaussian test

Fig.8 Monitoring results of moving windows were not added

Fig.9 Monitoring results after moving windows were added

Table 4 Comparison of different algorithms

统计量	误报率	故障报警持续时间	故障的报警起始时刻
$T 2$ 统计量	5.74%	186个时刻	1859时刻
MAX-T²统计量	1.14%	173个时刻	1861时刻
主元凸包算法	1.14%~5.74%	173~186个时刻	1859~1861时刻
两阶段PCA算法	3.40%	117个时刻	1896时刻
KPCA算法	4.33%	184个时刻	1860时刻
GMM-T²统计量	0.24%	189个时刻	1861时刻

Table 4 Comparison of different algorithms

统计量	误报率	故障报警持续时间	故障的报警起始时刻
$T 2$ 统计量	5.74%	186个时刻	1859时刻
MAX-T²统计量	1.14%	173个时刻	1861时刻
主元凸包算法	1.14%~5.74%	173~186个时刻	1859~1861时刻
两阶段PCA算法	3.40%	117个时刻	1896时刻
KPCA算法	4.33%	184个时刻	1860时刻
GMM-T²统计量	0.24%	189个时刻	1861时刻

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