Balancing the fuel gas network in an integrated steel plant using advanced data validation and reconciliation of measurements

Energy costs constitute about 20–25 % of the total production cost in an integrated steel plant. Energy efficiency is, therefore, essential for economic profitability. Production processes in this steel plant require, among other things, fuel gas networks that have to reliably supply a wide variety of fuel gas grades and blends to many process consumers. Due to the complex nature of production scheduling, these fuel gases must always be available when needed. The reliability of energy efficiency calculations can be increased by using the advanced data validation and reconciliation method in fuel gas network balancing. The measurement system of the fuel gas network in a selected integrated steel plant was identified. After determining measurement redundancy from the point of view of the advanced data validation and reconciliation method, it was used to assess the credibility of the measurements. Mass and energy balance equations were formulated for the analysed fuel gas network, and exemplary calculations for advanced measurement validation were performed. To evaluate the redundant measurement system as a whole, the relative information entropy – Kullback-Leibler divergence has been applied. The calculation results showed that due to the usually greater uncertainty of measurements in industrial conditions, it was found necessary to use the advanced data validation and reconciliation method in balancing the fuel gas network. The literature review shows that the article presents the first application of the advanced data validation and reconciliation of measurement for the fuel gas network of an integrated steel plant.