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Zhifeng Zhang, Jue Tang, Mansheng Chu, Xinjing Shi, and Quan Shi, Prediction of blast furnace gas utilization rate based on mechanism and data-driven approaches, Int. J. Miner. Metall. Mater., (2026). https://doi.org/10.1007/s12613-026-3466-x
Zhifeng Zhang, Jue Tang, Mansheng Chu, Xinjing Shi, and Quan Shi, Prediction of blast furnace gas utilization rate based on mechanism and data-driven approaches, Int. J. Miner. Metall. Mater., (2026). https://doi.org/10.1007/s12613-026-3466-x
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基于机理与数据驱动融合的高炉煤气利用率预测

摘要: 煤气利用率是评价高炉能量利用与还原过程的重要指标,其变化受到原料条件、布料制度和操作状态等多因素耦合影响,并具有明显的时间滞后和状态累积特征。针对炉内隐含状态难表征问题,本文构建了基于机理与数据驱动融合的高炉煤气利用率预测方法。首先,结合高炉工艺理论对缺失和异常数据进行处理,并建立料批识别与计算模型、无钟炉顶布料模型及炉身镜像模型,提取炉料组成、区域矿焦比、有效炉内料批及状态变化等机理特征。随后将其与状态变量、操作变量及多尺度时滞特征融合,采用LightGBM和多折时序交叉验证筛选出关键输入特征。在此基础上,构建GBDT-Mamba-TCN分层预测模型,将非线性特征编码、长时依赖建模与短时残差校正协同融合,实现对高炉煤气利用率的高频次预测。消融测试表明,引入机理特征后模型在0.3%误差容限内的命中率由 76.27%提高至 92.05%。系统投产以后,生产期平均高炉煤气利用率由45.62%提高至46.90%,同期燃料比月度对比下降约 6 kg/t。结果表明,该方法能够将高炉生产中难以直接表征的炉内隐含状态信息显式化,为高炉煤气利用率提前预报提供有效支撑。

 

Prediction of blast furnace gas utilization rate based on mechanism and data-driven approaches

Abstract: As a key indicator in blast furnace production, the stability of the blast furnace gas utilization rate directly affects the economic benefits of ironmaking enterprises. To this end, this study proposes a blast furnace gas utilization rate prediction method that integrates mechanism modeling with data-driven approaches. First, the operational data from the blast furnace process were collected. Abnormal and missing data were preprocessed by combining big data techniques with process theory. Mechanism-derived features were constructed from multiple mechanistic models to capture the time-lag effects and state-accumulation characteristics of the blast furnace operation, including the burden composition, regional ore-to-coke ratio, and state transitions. After integrating these mechanism-derived features with the time-series features, a light gradient boosting machine combined with time-series cross-validation was employed to select the 18 features most relevant to the blast furnace gas utilization rate. These selected features were further analyzed in detail from a process perspective and were confirmed to be suitable as inputs to the model. Finally, a blast furnace gas utilization rate prediction model was developed by integrating a gradient boosting decision tree, Mamba, and a temporal convolutional network. By leveraging the strengths of these algorithms, the model effectively captures the time-lag effects, state-accumulation effects, and short-term fluctuations in the blast furnace operation. The superiority of the proposed model and the effectiveness of the constructed features were verified through ablation experiments. The results show that the model achieves a prediction hit rate of approximately 92% within an error margin of ±0.3%. After industrial deployment, the model delivered an increase of approximately 1 percentage point in the blast furnace gas utilization rate, which translated into enhanced economic returns for the company.

 

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