2015 Volume 55 Issue 4 Pages 845-850
Blast furnace system is one of the most complex industrial systems and, as such, there are still many unsolved theoretical and experimental difficulties, such as silicon prediction. For this reason, based on recursive updating algorithm, an adaptive least squares support vector machine (LS-SVM) predictor is presented for prediction task of silicon content in blast furnace (BF) hot metal. The predicator employs recursive updating algorithm to get the precise solution of the latest LS-SVM model and avoid the long process of running through the whole model. Theoretically, the computational complexity is reduced significantly from O(n3m + m4) to O(n3 + m3). Experiments on two different BF data sets demonstrate that the proposed adaptive LS-SVM predicator is suitable for the task of predicting BF ironmaking process for its high hitting percentage and time saving.
Blast furnace (BF) is a highly complex nonlinear system characterized by high temperature, high pressure, strong noise and distributed parameters. During the process of blast furnace ironmaking, the solid raw materials are charged layer by layer from the top of the BF. The compressed air and some auxiliary fuels are introduced through the tuyeres just equipped above the hearth. A large number of gas-solid, solid-solid and solid-liquid chemical reactions take place in different zones of the BF. Heat energy is produced to heat up the hearth to be nearly 2000°C. As the operation proceeds, the final product, hot metal, continuously trickles down into the hearth and is then tapped from below at a regular interval for steelmaking. The whole ironmaking period lasts 6–8 hours. Being one of the most complex industrial reactors, BF has long received broad interests both theoretically and experimentally due to its complexity and the important role of iron and steel industry on the national economy.
There are some open problems, such as the prediction of silicon content in BF hot metal, BF dynamics characterization, BF automation, etc., in the contemporary metallurgical field. Thereinto, special attention is placed to the silicon prediction in the present work. The silicon content in hot metal, as a chief indicator of the internal thermal state of BF, determines the quality of hot metal and fuel consumption in hot metal production. Thus, it needs to be controlled within acceptable bounds. To achieve this, some mathematical models1,2) have been constructed in the hope of providing more possibilities for controlling the BF system in stable operation state and also achieving pig iron with high quality. Since the BF process is nonlinear and multivariate essentially, these mathematical models seldom yield successful application in practice due to lack of fully understanding on the physical and chemical reactions in the BF process and weak real-time services. It seems very difficult to meet the increasing demand of the BF process stability and hot metal quality just depending upon mathematical models. Recently, thanks to the fast development of measurement instruments and sensor techniques, one is able to get a large amount of process data from the ironmaking BF. Since the measured data contain rich dynamic information about the BF system, the so-called data-driven modeling methods can describe the complex BF process. Today, as a BF system is concerned, data-driven modeling is being broadly investigated and exhibits great potential in describing the complex behavior of the BF process. Candidate data-driven modeling tools include state space,3) neural networks,4) genetic programming,5) partial least squares,6) fuzzy set,7) chaos,8) support vector machine (SVM),9,10,11) generalized Gaussian regularization network,12) and generalized autoregressive conditional heteroskedastic model.13) These data-driven methods are expected to be able to improve the BF model accuracy and also to shed more light on how to optimize the BF process operation in the future. Among these data-driven methods, SVM and regularization network are equivalent under some mild assumption.14) They have gained much attention because their capability to identify nonlinear system and avoid the problem of over fitting as well as ensure good generalization ability.15) However, most of these models are constructed based on fixed learning samples, which are not adequate for online use. To overcome this limitation, a recursive updating algorithm based adaptive LS-SVM predicator is presented, and further employed to predict the silicon content in BF hot metal in real-time. Experimental results indicate that the established adaptive LS-SVM predicator is a good candidate to predict the silicon content in BF hot metal with high hitting rate and less time cost. The possible application of this work is to aid the BF operators to judge the inner state of BF getting hot or chilling in time properly, which provides a guide for them to determine the direction of controlling BF in advance.
The remainder of the paper is organized as follows: Section 2 reviews the formulation of LS-SVM and presents the adaptive LS-SVM predictor, Section 3 performs the application and validation of the built adaptive LS-SVM predictor on two typical real BFs, together with the detailed analysis about the application results, Section 4 concludes this work.
As an interesting variant of classical SVM, LS-SVM proposed by Suykens et al.,16) based on the margin-maximization principle has remarkable generalization ability. The classical SVM formulation is modified at two points: first, the inequality constraints with the slack variable are replaced by the equality constraints with error variable; second, substitute the squared loss function for ε-insensitive loss function in the objective function as it is frequently used in training of neural networks.17) This reformulation greatly simplifies the problem since the solution is characterized by linear equations instead of quadratic programming in the case of classical SVM. LS-SVM is formulated as follows
(1) |
The corresponding Lagrangian is given as
(2) |
(3) |
(4) |
To track the status of time varying system, adaptive predictor as well as incremental predictor updates the training set continuously by adding the latest sampling data timely. The schematic diagram of adaptive and incremental predictor is exhibited in Fig. 1.
Schematic diagrams of the adaptive and incremental predicator.
This paper employs Sherman-Morrison-Woodbury formula to deduce the recursive updating method for LS-SVM regression based on which we design the adaptive LS-SVM predicator for the online prediction task. Indeed, similar work has been carried out by Mika et al. to develop efficient algorithm for kernel Fisher discriminants.18)
Lemma 1. Sherman-Morrison-Woodbury formula18)
Let M be a symmetric invertible matrix given by
(5) |
(6) |
The recursive update algorithm is used to incorporate new training sample, which is crucial for adaptive learning problem. Given a training set
(7) |
(8) |
(9) |
(10) |
(11) |
(12) |
(13) |
(14) |
(15) |
The following adaptive LS-SVM predicator is presented based on recursive updating algorithm.
The merit in speed is due to the efficient matrix inversion using Lemma 1. Whenever a new training sample is available, there is no need to solve the linear Eqs. (4) all over again. Direct computation of the inverse of saddle point matrix requires O(n3) operations. Suykens et al.16) proposed to use Conjugate Gradient method based iterative method for the solution of Eq. (4) which also requires O(n3) operations. Whereas adaptive LS-SVM predicator only needs O(n2) operations except for the first training process. It should be pointed out that the computation of the inverse of saddle point matrix requires O(n3) in the first training process. Once the initial inverse of saddle point matrix is given, the inverse of updated saddle point matrix, and subsequently, the solution of Eq. (4), i.e., α and b can be computed efficiently using the adaptive LS-SVM predicator when a new training sample (x, y) is available. Compared with the traditional algorithms, the total computational complex is reduced from O(n3m + m4) to O(n3 + m3) for n training samples and m test samples. The proposed algorithm is significantly efficient in the case of many test samples.
BF is a typical multi-input and multi-output system. Since the silicon content in hot metal is very important, it is natural to take it as the BF output.3,4,8,9,11) Generally, the variables involved in the compressed air, the charged solid raw materials and some other hot metal components are thought to be the most relevant ones. They are selected as input variables. Here, to make the proposed adaptive LS-SVM predictor more convincing, two groups of experimental data sets about these related variables are collected from a medium-sized BF with the inner volume of about 2500 m3 and a pint-sized BF with the inner volume of about 750 m3, labeled as BF(a) and (b) respectively. For the BF(a), totally 20 candidate variables listed in Table 1, including blast volume, blast temperature etc. are selected as input variables. While for the BF(b), there are only 6 relevant variables collected due to the weak measurement condition in this BF, which are selected as input variables. The 6 variables are also exhibited in Table 1 with marked * sign. It should be pointed out that too many input variables may increase the complexity of model while too few inputs will reduce the accuracy of model. A tradeoff should be taken between the model complexity and accuracy when we select the inputs. So there is much work worth investigating in the future, like input variables selection, to improve the performance of the model. The iron ore used for BF(a) is the Baiyunebo mineral in Baotou, which contains materials such as rare earth elements, niobium and other metals. The complex ingredients of the iron ore make the ironmaking process extremely unstable. The prediction of silicon content in BF hot metal also becomes more difficult.11,19)
Variable name | Unit |
---|---|
Blast volume* | m3/min |
Blast temperature* | °C |
Blast pressure | kPa |
Pulverized coal injection* | t |
Oxygen enrichment percentage | wt% |
Coke load of ingredients | wt% |
Coke rate | Kg/t |
Feed speed* | mm/h |
Furnace top temperature | °C |
Basicity of ingredients | wt% |
Smelting intensity | t/m3 ·d |
The latest silicon content* | wt% |
Sulfur content | wt% |
Furnace top pressure | kPa |
Gas permeability* | m3/min ·kPa |
Slag basicity | wt% |
CO percentage in top gas | wt% |
CO2 percentage in top gas | wt% |
H2 percentage in top gas | wt% |
Utilization coefficient | t/m3 ·d |
There are 700 observed data points in all. The sampling interval is about 1.5 h for the BF(a) and about 2 h for the BF(b). In the field of machine learning, the number of training samples should be equal to or greater than the number of the learning parameters that specify a predictive model. On the other hand, evaluating results on large test set is more convincing than those on small test set. According to the above two points, in the current work, the first 200 sampling points are put into the following training set and the residual 500 points into the test set.
To obtain deeper understanding on the selected data sets, some of the important statistical properties such as mean, standard deviation, etc., should be calculated. The results are shown in Table 2. Here, Pseudo standard deviation (PSD) defined to be (quantile(75%)-quantile(25%))/ 1.35 is more robust than the standard deviation, i.e. less vulnerable to outliers. PSD tests the normality of the data with PSD>, = and < Std being light tailed distribution, normal distribution and heavy tailed distribution respectively. The coefficient of variation (CV) is defined as the ratio of the standard deviation to the mean, i.e.
(16) |
BFs | Set | Max | Min | Mean | Std | PSD | CV | Skew | Kurtosis |
---|---|---|---|---|---|---|---|---|---|
(a) | Train | 1.080 | 0.280 | 0.567 | 0.161 | 0.148 | 0.285 | 0.820 | 3.328 |
Test | 1.110 | 0.130 | 0.590 | 0.185 | 0.185 | 0.314 | 0.512 | 2.780 | |
(b) | Train | 1.060 | 0.240 | 0.455 | 0.115 | 0.089 | 0.252 | 1.609 | 8.132 |
Test | 0.960 | 0.220 | 0.441 | 0.111 | 0.089 | 0.251 | 1.298 | 5.413 |
Std: standard deviation; PSD: pseudo standard deviation; CV: coefficient of variation.
Time series of the silicon content in hot metal (I) and the blast volume (II) in the BFs(a) and (b), e.g., (a-I) indicates the silicon series in the BF(a).
To construct the LS-SVM predictor, it is necessary to determine the type of kernel function, the related kernel parameters, and the parameter v in Eq. (4) in advance. In this current work, the Gaussian radial basis function is specified as the kernel function for its extensive applications20) and good performance in the BF modeling,10,11,21) which is defined to be
(17) |
BF | Methods | H (%) | S (%) | R | RMSE | CPU (sec) |
---|---|---|---|---|---|---|
(a) | Adaptive predictor | 81.4 | 90.8 | 0.7312 | 0.1267 | 7.7500 |
Incremental predictor | 81.4 | 90.8 | 0.7312 | 0.1267 | 397 | |
Fixed predictor | 70.8 | 84.2 | 0.5653 | 0.1545 | 0.1563 | |
AOSVR predictor | 71.0 | 86.4 | 0.6124 | 0.1495 | 171.3125 | |
(b) | Adaptive predictor | 84.4 | 92.6 | 0.4244 | 0.1033 | 12.5625 |
Incremental predictor | 84.4 | 92.6 | 0.4244 | 0.1033 | 361.0156 | |
Fixed predictor | 79.6 | 89.4 | 0.2564 | 0.1204 | 0.0938 | |
AOSVR predictor | 86.2 | 92.2 | 0.1241 | 0.1257 | 472.0313 |
• the percentage of hitting the target
(18) |
(19) |
• the percentage of prediction success
(20) |
(21) |
• the root mean square error
(22) |
• the correlation coefficient between the actual values and the predicted values
(23) |
All simulations are implemented in MATLAB 7.8 environment on a PC with Intel Core2Duo processor 2.1 GHz and 2 GB RAM. When an observed sample is available the adaptive LS-SVM predicator simply updates the previous solution to the new one to adapt to the change of BF ironmaking system, so it is much faster than incremental LS-SVM predicator. In terms of other quality index, adaptive LS-SVM predicator and incremental LS-SVM predicator, which employs iteration method, i.e., Conjugate Gradient method to solve the saddle point system Eq. (8), are always the same. This indicates that the proposed adaptive LS-SVM predicator is numerically stable and robust from the perspective of experiment. The adaptive LS-SVM always outperforms AOSVR predictor except the percentage of hitting the target, i.e., H(%) on BF(b). Furthermore, the performance of adaptive LS-SVM predicator is much better than fixed LS-SVM predicator on all criteria except the time cost.
The work presents an effective adaptive LS-SVM predicator with high hitting percentage and time saving for the task of BF silicon content prediction. Experiments demonstrate that adaptive LS-SVM predicator can be used for real-time prediction application. It is worth pointing out that as more and more observed data are available, the scale of training set will increase accordingly, and so is the training time. To overcome the above problem, we may use some decremental techniques such as sliding window etc., which will be our future investigation.
The authors would like to thank Dr. Zhaozhu Li for helpful discussions about this paper. This work was supported by National Natural Science Foundation of China under Grant No. 11326203, 61201455, 61403419, Natural Science Foundation of Shandong Province under Grant No. ZR2013FQ034 and Fundamental Research Funds for the Central Universities under Grant No. 13CX02008A and 14CX02017A.