Abstract: Methods and systems for substantially optimizing plant operations within a manufacturing environment. The method can include separating the manufacturing environment into two or more individual modules, wherein each individual module contains a fundamental principles-based model, and wherein the totality of the individual modules represents the entire manufacturing environment. Each individual module can be independently parameterized upon said module reaching steady state, wherein inter-module data flow can be provided to at least one of the individual modules during parameterization, and wherein an output of the parameterization comprises an individual, calibrated steady-state model of each individual module. A reduced order model can be derived from each parameterized module, and the reduced order models can be assembled to provide a facility reduced order model. The facility reduced order model can then be solved to provide improved or new operating conditions or operating condition targets.

Abstract: Methods and systems for substantially optimizing plant operations within a manufacturing environment. The method can include separating the manufacturing environment into two or more individual modules, wherein each individual module contains a fundamental principles-based model, and wherein the totality of the individual modules represents the entire manufacturing environment. Each individual module can be independently parameterized upon said module reaching steady state, wherein inter-module data flow can be provided to at least one of the individual modules during parameterization, and wherein an output of the parameterization comprises an individual, calibrated steady-state model of each individual module. A reduced order model can be derived from each parameterized module, and the reduced order models can be assembled to provide a facility reduced order model. The facility reduced order model can then be solved to provide improved or new operating conditions or operating condition targets.

Abstract: A method for separating carbon and iron bearing particles from zinc and lead bearing particles contained in an aqueous slurry of blast furnace dust and the recovery and reuse of the carbon and iron bearing particles as charge material in a blast furnace is described.An aqueous slurry of blast furnace flue dust is collected in a thickener. The thickened aqueous slurry is strained to remove large foreign matter and make a size separation at about 4 mm. The plus 4 mm particles are generally wasted. The aqueous slurry containing the minus 4 mm particles is fed into at least one hydrocyclone where a size separation is made at between about 3 and 5 microns. A substantial portion of the carbon and iron bearing particles report to the hydrocyclone underflow and a substantial portion of the zinc and lead bearing particles report to the hydrocyclone overflow. The carbon and iron bearing particles are passed to a preparation plant to be prepared for reuse in the blast furnace.