Self-optimizing control of a batch catalyst calcination furnace

In this paper, the efficiency improvement of a batch catalyst calcination furnace is studied. The aim is to minimize electric energy consumption while tracking a predefined temperature profile during the calcination process. The approach is based on the redesign of the furnace control structure. Already available measurements are three temperature sensors at three furnace sidewalls. The manipulated variable is the intake electric power which is converted to heat by the installed resistive heating elements. The process dynamics from measurement to inputs are modeled using system identification methods. The self-optimizing control methodology is applied to the developed process model. As a result, an optimal linear combination of the available measurements is found, to be used as the controlled variable. Holding the proposed controlled variable constant at the setpoint (or setpoint trajectory), will minimize electricity intake during the furnace operation. The new control structure is applied to the real process and the performance improvement is evaluated. Based on the results 14% energy saving is achieved.