In order to achieve full utilization of resources and ensure the smooth operation of the production process,non-ferrous metallurgical processes often employ multiple cascaded large-scale tanks/reactors for production.This brings significant challenges to optimizing and controlling the plant-wide process.This article proposes a hierarchical coordinated optimization and control framework for non-ferrous metallurgical processes with cascaded reactors.For the optimization of set-points for various reactors,a hierarchical coordinated optimization method is designed.This method comprises a global multi-objective coordinated optimization layer and local optimization layers.By employing a hierarchical coordination mechanism between the global coordinated layer and the local optimization layers,it enables the achievement of optimal operation for the plant-wide process.For the different controlled variables with different sampling frequencies,model predictive controllers and fuzzy control based on the T-S fuzzy logic are designed.A data-driven error compensation model is created to calibrate the models for achieving better set-point tracking control performance.To enhance the performance of the optimization control,an adaptive feedforward correction method is proposed.It optimizes the set-points of subsequent reactors based on measured feedback values,enabling the production process to continue optimal operation even after operation condition changes.Through a case study of the zinc flotation process,the effectiveness of the proposed coordinated optimization and control methods is validated.It improves the accuracy of predicting concentrate grade and accomplishes the optimal operation of the process.
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