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研究生: 吳佳熹
Wu, Chia-Hsi
論文名稱: 以機器學習探討爐床碳磚異常侵蝕狀況之對策
Development of Strategies for Preventing Abnormal Carbon Brick Erosion in Blast Furnace Based on Machine Learning Approaches
指導教授: 黃致憲
Huang, Chih-Hsien
學位類別: 碩士
Master
系所名稱: 電機資訊學院 - 電機工程學系
Department of Electrical Engineering
論文出版年: 2022
畢業學年度: 110
語文別: 英文
論文頁數: 24
中文關鍵詞: 高爐爐床溫度主成分分析皮爾森相關係數機器學習長短期記憶
外文關鍵詞: blast furnace, hearth temperature, PCA, Pearson correlation coefficient, machine learning, random forest, LSTM
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  • 在工業鐵生產中高爐非常重要。它是鋼鐵持續生產的核心。高爐的使用壽命會直接反映在煉鋼的總成本上。它受多種原因影響,如冷卻板和高爐碳磚的厚度。其中碳磚厚度是最關鍵的。近十年來,中鋼4號高爐碳磚的侵蝕速度異常的快。這將大大縮短 4 號高爐的使用壽命。碳磚的厚度是根據爐床溫度經由特殊公式計算得出。當爐床溫度達到歷史高溫度時,意味著碳磚變薄了。在不影響鋼鐵產量的情況下控制高爐溫度並不容易。如果可以提前知道溫度趨勢。它將能夠隨著即將到來的情況改變操作方法。因此,本研究將提出機器學習模型來預測研究中的爐床溫度。
    在本研究中,主成分分析(PCA)和皮爾森相關係數用於驗證數據集的特徵數目。 PCA 可以顯示不同特徵數量數據的複雜性。此外,可以根據皮爾森係數刪除數據集中的高度相關的特徵。
    為了證明預測爐膛溫度的可能性。使用隨機森林訓練一個溫度分類器,可以對爐床溫度進行分類。分類器在測試集中達到 95% 的準確率。最後,基於LSTM建立了一個爐床溫度模型,利用高爐運行數據預測爐膛溫度。此外,為了優化溫度預測模型,本研究將提出一個新的訓練方法。此外,找出輸入和輸出長度的最佳組合,以減少模型的損失。該模型的 MSE 為 0.00939,而未經訓練以平均溫度計算的基準線為 0.0615。

    The blast furnace plays a very important role in industrial iron production. It is the heart of the consistent production of steel. The service life of the blast furnace is directly reflecting the total cost of steelmaking. It is affected by many reasons, like the cooling plate and the thickness of carbon bricks in the blast furnace. Among the reason carbon brick is the most critical ones. In the past decade, the carbon brick in blast furnace No.4 of China Steel Corporation has been eroded at an abnormal rate. It would dramatically reduce the life span of blast furnace No. 4. The thickness of the carbon bricks is calculated with a custom formula from the hearth temperature. When the hearth temperature hit a historical highest temperature means the carbon brick became thinner. It is not easy to control the temperature of blast furnace without affecting the iron production. If the temperature trend could be known in advance. It would be able to change the operating method with the upcoming situation. Therefore, a machine learning model would be proposed to predict the hearth temperature in the study.
    In this study, principal components analysis (PCA) and Pearson correlation coefficient are used to determine the feature number of the dataset. PCA could show the complexity of data with the different number of features. Furthermore, the high correlation features in the dataset could be deleted based on the Pearson coefficient.
    To demonstrate the possibility of predicting hearth temperature. A temperature classifier is trained with random forest which can classify the hearth temperature. The classifier achieves 95% accuracy in the test set. At last, a hearth temperature model was developed by LSTM which uses the operation data of blast furnace to predict the hearth temperature. In addition, to optimize the temperature prediction model, a different approach in the training process will be compared with common method in this study. Also, find out the best combination of input and output lengths to reduce the loss of the model. The MSE of the model is 0.00939 and the baseline which calculate with average temperature without training is 0.0615.

    致謝III List of Figures V List of Tables VI List of Symbols VII Chapter1 Introduction 1 Chapter2 Research method 3 2.1 The Dataset 3 2.1.1 Original dataset 3 2.1.2 Data preprocessing 4 2.1.3 The circulation of carbon brick thickness 5 2.1.4 Abnormal behavior of existing carbon brick 6 2.2 Statistical Analysis 8 2.2.1 Dimension reduction using principal components analysis (PCA) 8 2.2.2 Pearson correlation analysis for feature selection 9 2.3 Predicting the hearth temperature with machine learning models 9 2.3.1 Random Forest 9 2.3.2 Long short-term memory (LSTM) 10 2.3.3 Feature selection and training method 12 Chapter3 Result and Discussion 14 3.1 Result of statistical analysis 14 3.1.1 PCA with blast furnace operation data 14 3.1.2 Pearson correlation between each feature 15 3.2 Machine learning result 16 3.2.1 A temperature classifier using random forest 16 3.2.2 A temperature prediction model based on LSTM 18 Chapter4 Conclusion 23 Reference 24

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