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Expert systems are computer programs that contain expert knowledge stored in a knowledge base. This information or knowledge can be used to examine plant data and form conclusions about the way the plant, or piece of equipment within that plant is performing. The advantage of this approach is that it does not require detailed mathematical understanding of plant operation in order to provide important information to plant engineers. Steelmaking processes generate fume that must be captured and controlled to prevent emissions to atmosphere. This is done with large extraction fans and bag filter cleaning systems. The operation of these systems is critical to ensure good environmental performance of the steelmaking process and optimisation is necessary to ensure that the fume extraction systems are run economically. Fume capture also helps to recycle the metallic oxides back into the steelmaking process. Owing to the complexity of large extraction systems it is important to pre-empt plant malfunction so that site engineers are aware of potential problems that may cause system failure or fugitive particulate emissions to atmosphere. A prototype expert system has recently been installed at a local electric arc based steelworks. The model accesses real-time data from the melting shop, extraction system and bag filter plant and is able to perform the two roles of information and advice.  Real-time data are displayed as dynamic plant mimics so that site engineers are able to see the condition of the extraction system without need to be on plant. An expert system containing a knowledge base of plant rules informs engineers of any plant operational anomalies. Typical expert rules might check for the correct operation of dampers controlling the filter cleaning sequences, or to check for damaged filter bags that might eventually cause roof emissions. The installation of this prototype expert system, has shown potential savings of over £60,000p/a based on energy costs alone. | |
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