The multivariable model-based control of the non-alumina electrolyte variables in aluminum smelting cells

This paper investigates the application of multivariable model-based control to improve the regulatory control of electrolyte temperature, aluminum fluoride concentration, liquidus temperature, superheat, and electrolyte height. Also examined are therappropriateness of different control structures and the possible inclusion of recently developed sensors for alumina concentration and individual cell duct flowrate, temperature, and heat loss. For the smelter in this study, the maximum improvement possible with a multivariable model-based controller is predicted to be 30–40% reduction in standard deviation in electrolyte temperature, aluminum fluoride concentration, liquidus temperature, and superheat, and around half this for electrolyte height. Three control structures were found to be appropriate; all are different than the existing control structure, which was found to be suboptimal. Linear Quadratic Gaussian controllers were designed for each control structure and their predicted performance compared. Comalco Research.