炼钢流程生产作业计划编制相关基础问题研究

发布时间：2018-05-30 09:22

  本文选题：炼钢厂 + 开浇决策　； 参考：《重庆大学》2016年博士论文

【摘要】：炼钢流程是钢铁生产的关键环节,生产作业计划是其生产运行控制的依据。合理的生产作业计划可以降低物耗与能耗成本、增加收益、稳定质量,并直接提升企业的核心竞争力。为此,通过对炼钢流程生产作业计划相关的连铸机开浇决策、生产运行稳定顺行高效等基础性问题的深入研究,以提升和发挥炼钢厂制造执行系统MES(Manufacturing Execution System,MES)的生产计划调度功能,最终实现以信息化为基础的生产运行优化控制模式取代传统的人工经验控制模式,成为钢铁企业广泛关注并亟待解决的重要课题。由于炼钢流程是一个由多阶段大型高温生产单元所构成的、离散与连续工序相混杂的系统,具有多目标、多约束、动态变化等复杂系统特征,而在不同的炼钢厂由于工艺流程方面的各自不同特点,致使建立统一且有效的生产作业计划模型难度较大,而经简化抽象建立的通用性模型或算法与炼钢厂的现实生产需求之间通常存在较大的差异。对炼钢流程生产作业计划编制相关问题的研究综述和炼钢厂制造执行系统应用情况的调研可见,已有研究对于连铸机开浇、连连浇决策问题、多目标要求下的连铸机组浇开浇优化问题,能动态反映炼钢厂现实生产稳定性特征的仿真方法问题等方面认识不足、手段有限;炼钢厂MES系统的生产计划调度功能与生产管理要求之间尚存在不适应性,影响了炼钢厂“有序、稳定、高效”的生产目标的实现。有鉴于此,以现实生产为背景,提出开展“炼钢流程生产作业计划编制相关基础性问题研究”的博士论文课题,主要围绕炼钢厂的连铸机开浇/连浇决策、连铸机组浇开浇多目标优化、生产运行的仿真优化手段等问题开展建模、优化求解算法与生产组织运行优化分析等研究工作,为炼钢流程生产作业计划已有研究成果的有效应用提供更可靠的前提条件,并为炼钢厂生产管控人员对生产稳定控制的认识提供一种新的仿真分析手段。论文的主要创新点及研究结论概述如下:1)建立了连铸机开浇决策的混合整数规划模型,并基于MATLAB软件的YALMIP优化工具进行模型求解。为了通过生产物流稳定顺行来降低生产成本,针对炼钢厂连铸机开浇时是否连浇及开浇时间确定问题,以控制积压液态金属量成本最小和连续浇铸的连续化程度收益最大为目标,在综合考虑进铁量、安全生产线液态金属量(简称安全在线金属量)、金属损耗、浇铸钢水量等涉及铁钢资源平衡的各因素之间的相互关系以及时间与生产线液态金属量(简称在线金属量)约束的条件下构建了连铸机开浇决策的混合整数规划模型,并设计相应的模型求解方法。2)构建了连铸机的开浇炉次与时间决策的多目标优化模型,并设计了改进的非支配排序遗传算法-INSGAII算法。针对现实连铸机开浇决策中需同时确定炉次选择、排序与开浇时间的多目标优化难题,以炼钢厂生产批量计划执行情况的总惩罚、生产线积压液态金属量、优质铁水非有效利用量最小为目标函数,构建了连铸机的开浇炉次与时间决策的多目标优化模型;基于非支配排序遗传算法设计了改进的NSGAII算法进行模型求解,以预选池内选择的炉次序号为基因的编码方式来减小模型解的无效搜索空间,采取调整传统精英解集计算顺序、限定计算拥挤距离个体数目的改进措施来减轻计算负荷,利用对pareto解进行模糊选优的方法来确定最终优化解。3)建立了炼钢厂生产线金属量控制的系统动力学仿真模型,并以某炼钢厂的实际生产数据对模型进行仿真分析,来动态反映炼钢厂现实生产的稳定性特征。基于系统工程的思想方法,在综合考虑生产作业计划需求流量、生产线金属量的目标库存、实际库存、库存偏差等信息,以及相关物质流影响的基础上,建立了以炼钢厂生产线金属量为控制水平变量的系统动力学仿真模型。4)以某炼钢厂生产条件为对象的优化模型应用测试表明:(1)炼钢厂连铸机的开浇时间决策优化模型可以实现连铸机浇次开浇时间的科学计算,有助于稳定各班次之间的生产条件,降低生产线上的积压液态金属量,编制出合理的炼钢厂生产作业计划;(2)连铸机开浇炉次与时间多目标决策模型有利于连铸机上各炉次浇铸周期的稳定控制,并有利于在炼钢流程切实推行计划管理,改进的非支配排序遗传算法的效率优于传统的非支配排序遗传算法与强度pareto进化算法。系统动力学模型仿真研究表明:(1)有生产作业计划指导下炼钢-连铸区域的运行状态明显较无作业计划指导的铁水预处理区更稳定,因此,炼钢厂应实行按全流程的生产作业计划的运行管控;(2)当加快生产节奏提高连铸机的拉速时,在线金属量应同步提高,否则会因为在线金属量的降低,而导致生产不稳定。5)为进一步检验所建立的多目标开浇决策与系统动力学模型的实用性,进行了联合仿真实验研究。通过将前者决策结果作为后者输入参数,并以实例炼钢厂的生产数据为依据,分别对连铸机的开浇时间、品种钢比例、连铸机数量等指标与炼钢厂各区域在线金属量的影响关系进行联合仿真实验,仿真研究表明:在进铁流量一定的情况下,(1)推迟开浇时间或者增大品种钢比例会使在线金属量增高;(2)增加连铸机数量会降低炼钢厂各区域在线金属量;(3)在进铁流量存在差异情况下,平稳进铁较随机进铁更有利于在线金属量的稳定控制。综上所述,本文所建立的炼钢厂连铸机开浇时间决策优化模型、连铸机开浇炉次与时间决策的多目标优化模型,为科学确定炼钢厂连铸机的开浇时间与开浇炉次提供了新的技术手段,为炼钢流程生产作业计划编制的假设条件问题提供了科学决策方法;所建炼钢厂生产线金属量控制的系统动力学模型,以及针对多目标开浇决策与系统动力学模型的联合仿真实验研究,为深入认识炼钢厂生产线上液态金属量动态变化特性提供了新方法,给炼钢厂生产运行的稳定控制提供了有效的仿真分析手段。
[Abstract]:The steelmaking process is the key link in the steel production, and the production operation plan is the basis for its production control. The reasonable production operation plan can reduce the cost of material consumption and energy consumption, increase the income, stabilize the quality, and directly improve the core competitiveness of the enterprise. In order to improve and exert the production planning and scheduling function of MES (Manufacturing Execution System, MES) in the steelmaking plant, the production operation and operation system based on the information based production and operation optimization control mode is finally realized and the traditional artificial experience control model is replaced by the iron and steel enterprise. Because the steelmaking process is a multi stage large and high temperature production unit, the discrete and continuous processes are mixed with complex systems, which have complex system characteristics such as multi-objective, multi constraint, dynamic change and so on. In different steelworks, the different characteristics of process flow are caused by different characteristics of different steelmaking plants. It is difficult to establish a unified and effective production operation plan model, and there is a large difference between the general model or algorithm established by simplified abstract and the actual production demand of the steelmaking plant. A survey on the related problems of the production planning of steelmaking process and the investigation of the application of the manufacturing execution system of the steelmaking plant In view, there have been research on the problem of continuous casting casting, continuous casting decision, optimization of casting cast in cast in continuous casting machine under multi objective requirements, lack of knowledge and limited means, which can dynamically reflect the practical production stability characteristics of the steelworks, and the means are limited, and the production planning and scheduling function of the steelworks MES system is still between the requirements of production management. The existence of inadaptability affects the realization of the production target of "orderly, stable and efficient" in the steelmaking plant. In order to provide more reliable precondition for the effective application of the existing research results of the steelmaking process production operation plan, it provides more reliable prerequisite for the effective application of the existing research results of the steelmaking process production operation plan, and the stable control for the production management and control personnel of the steelmaking plant. The main innovation and research conclusions of this paper are summarized as follows: 1) 1) the mixed integer programming model of casting casting decision making is established, and the model is solved based on the YALMIP optimization tool of the software. In order to reduce the production cost through the stable production of the production logistics, the continuous caster of the steelmaking plant is made. In order to control the minimum cost of the backlog of liquid metal and the maximum yield of continuous casting, the aim is to control the minimum cost of the backlog of liquid metal and the continuity of continuous casting. The factors involved in the balance of iron and steel resources are considered in the comprehensive consideration of the amount of iron intake, the liquid metal content of the safety production line, the metal loss and the casting amount of the steel. The relationship between the time and the time and the liquid metal content of the production line (on the line metal amount) constrains the mixed integer programming model of the casting casting decision of the continuous casting machine, and the corresponding model solving method.2 is designed. The multi-objective optimization model of the time decision of the open casting furnace and the time of the continuous casting machine is constructed, and the improved non support is designed. According to the -INSGAII algorithm of sorting genetic algorithm, it is necessary to determine the multi-objective optimization problem in the decision making of the real caster casting at the same time, the total penalty of the sequencing and opening time, the total penalty of the production batch plan in the steelmaking plant, the backlog of liquid metal and the minimum non effective utilization of the high quality iron water as the objective function, and the continuous casting is constructed. The multi-objective optimization model of the timing and time decision of the open casting furnace is made. Based on the non dominated sorting genetic algorithm, an improved NSGAII algorithm is designed to solve the model. The invalid search space of the model solution is reduced by the encoding method of the selected furnace sequence number in the pre selected pool to reduce the invalid search space of the model solution, and the calculation order of the traditional elite solution set is adjusted and the calculation support is limited. In order to reduce the number of individual numbers, to reduce the calculation load and to determine the final optimal solution by using the method of fuzzy optimization of Pareto solution to determine the final optimal solution.3), the system dynamics simulation model of the metal quantity control of the production line of the steelmaking plant is established, and the simulation analysis of the mould type is carried out with the actual production data of a steelmaking plant to dynamically reflect the steelmaking plant. Based on the thought method of the system engineering, based on the comprehensive consideration of the production plan demand flow, the target inventory of the metal quantity of the production line, the actual inventory, the inventory deviation, and the influence of the related material flow, the system dynamics imitation is established with the control level variable of the production line metal quantity of the steelmaking plant. True model.4) the application test of optimization model based on the production conditions of a steelmaking plant shows that: (1) the optimization model of casting time decision optimization model of continuous casting machine in steelmaking plant can realize the scientific calculation of casting time in cast in place of continuous casting machine, help to stabilize production conditions between various flights, reduce the backlog of liquid metal in production line, and make reasonable The production operation plan of the steelmaking plant; (2) the multi-objective decision model of the continuous casting furnace time and time is beneficial to the stability control of the casting cycle of the continuous casting machine, and is beneficial to the practical implementation of the plan management in the steelmaking process. The efficiency of the improved non dominated sorting genetic algorithm is better than the traditional non dominated sorting genetic algorithm and the strength Pareto. The simulation study of system dynamics model shows that: (1) the operation state of the steelmaking and continuous casting area under the guidance of production operation plan is more stable than that without the guidance of the operation plan. Therefore, the steelmaking plant should carry out the operation control of the production operation plan according to the whole process; (2) when the production rhythm is accelerated, the continuous casting machine should be increased. At the speed, the on-line metal amount should be increased synchronously, otherwise the production is unstable due to the reduction of the metal content on the line, which leads to the production of unstable.5). A joint simulation experiment is carried out to study the practicability of the multi target opening decision and the system dynamics model established by the further inspection. Based on the production data of the factory, the simulation experiments are carried out on the relationship between the opening time of the continuous casting machine, the proportion of variety steel, the quantity of continuous casting machine and the influence of the on-line metal quantity in the various regions of the steelmaking plant. The simulation study shows that (1) the delayed opening time or the increase of the ratio of the variety of steel to the on-line metal under the certain flow rate of the iron intake (2) (2) increasing the number of continuous casting machines will reduce the online metal content in each area of the steelmaking plant; (3) in the case of difference in the flow of iron, the steady intake of iron is more favorable to the stable control of the online metal quantity than the random incoming iron. The multi-objective optimization model of decision making provides a new technical means for determining the opening time of the continuous casting machine and the opening of the open cast furnace for the scientific determination of the steelmaking plant. It provides a scientific decision method for the hypothetical conditions of the production planning of the steelmaking process, the system dynamics model of the metal quantity control of the production line of the steelmaking plant, as well as the multi-objective opening. The joint simulation experiment of casting decision and system dynamics model provides a new method to understand the dynamic change characteristics of liquid metal content on the production line of steelmaking plant, and provides an effective simulation analysis method for the stable control of the production operation of the steelmaking plant.
【学位授予单位】：重庆大学
【学位级别】：博士
【学位授予年份】：2016
【分类号】：TF758
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本文编号：1954769