CONTENT

1. Introduction to Neural Networks 2-6

1.1 What is a neural network?
1.2 Historical background
1.3 Why use neural networks?
1.4 Neural networks ersus conentional co!"uters - a co!"arison
2. Hu!an and #rti$icial Neurones - inestigating the si!ilarities 6-%
2.1 How the Hu!an &rain 'earns?
2.2 (ro! Hu!an Neurones to #rti$icial Neurones
3. )echni*ues and a""lication +-13
I!"le!entation o$ #NN on ,teel -late -rocess .ontrol
3.1 Network /esign
3.2 Network -ro"erty
3.3 ,i!ulation
3.4 ,i!ulation $or &last (urnace
3.0 ,i!ulation $or other de"art!ents in steel "late $low "rocess
4. (uture sco"e 13-14
0. .onclusion 14
6. 1e$erences. 10
#""endi2 16-1+
1
Abstract:
With the adent o$ reolutionary steel !aking "rocess3 de!and $or better *uality o$ steel
"late has increased. 1eduction in re4ection o$ the $inal "roduct out"ut o$ steel "late "rocess
has been an area o$ concern. Neural network is a "ower$ul tool in achieing this target.
5anu$acturing "rocess o$ steel "lates inole arious co!"le2ities .)here are a""ro2i!ately
06 di$$erent grades o$ steel !anu$actured. -roducing steel "lates with better *uality standards
with higher acce"tance leel has been a challenge $or steel industries. Neural network with
its i!!ense "otential is a $easible tool $or reducing the re4ections in the out"ut o$ steel "lates.
#rti$icial neural network with hidden layers with the hel" o$ 5at 'ab so$tware is used to
a""ro2i!ate the $unction de"endency o$ the e$$ectie "ara!eters o$ steel "lates
2
1. Introduction:
1.1 What is a Neural Network?
#n #rti$icial Neural Network 7#NN8 is an in$or!ation "rocessing "aradig! that is ins"ired
by the way biological nerous syste!s3 such as the brain3 "rocess in$or!ation. )he key
ele!ent o$ this "aradig! is the noel structure o$ the in$or!ation "rocessing syste!. It is
co!"osed o$ a large nu!ber o$ highly interconnected "rocessing ele!ents 7neurones8
working in unison to sole s"eci$ic "roble!s. #NNs3 like "eo"le3 learn by e2a!"le. #n #NN
is con$igured $or a s"eci$ic a""lication3 such as "attern recognition or data classi$ication3
through a learning "rocess. 'earning in biological syste!s inoles ad4ust!ents to the
syna"tic connections that e2ist between the neurones. )his is true o$ #NNs as well.
1.2 Historical backround
Neural network si!ulations a""ear to be a recent deelo"!ent. Howeer3 this $ield was
established be$ore the adent o$ co!"uters3 and has suried at least one !a4or setback and
seeral eras.
5any i!"ortant adances hae been boosted by the use o$ ine2"ensie co!"uter e!ulations.
(ollowing an initial "eriod o$ enthusias!3 the $ield suried a "eriod o$ $rustration and
disre"ute. /uring this "eriod when $unding and "ro$essional su""ort was !ini!al3 i!"ortant
adances were !ade by relatiely $ew researchers. )hese "ioneers were able to deelo"
conincing technology which sur"assed the li!itations identi$ied by 5insky and -a"ert.
5insky and -a"ert3 "ublished a book 7in 19698 in which they su!!ed u" a general $eeling o$
$rustration 7against neural networks8 a!ong researchers3 and was thus acce"ted by !ost
without $urther analysis. .urrently3 the neural network $ield en4oys a resurgence o$ interest
and a corres"onding increase in $unding.
)he $irst arti$icial neuron was "roduced in 1943 by the neuro"hysiologist Warren 5c.ulloch
and the logician Walter -its. &ut the technology aailable at that ti!e did not allow the! to
do too !uch.
3
1.! Wh" use neural networks?
Neural networks3 with their re!arkable ability to derie !eaning $ro! co!"licated or
i!"recise data3 can be used to e2tract "atterns and detect trends that are too co!"le2 to be
noticed by either hu!ans or other co!"uter techni*ues. # trained neural network can be
thought o$ as an :e2"ert: in the category o$ in$or!ation it has been gien to analyse. )his
e2"ert can then be used to "roide "ro4ections gien new situations o$ interest and answer
:what i$: *uestions.
;ther adantages include<
#da"tie learning< #n ability to learn how to do tasks based on the data gien $or
training or initial e2"erience.
,el$-;rganisation< #n #NN can create its own organisation or re"resentation o$ the
in$or!ation it receies during learning ti!e.
1eal )i!e ;"eration< #NN co!"utations !ay be carried out in "arallel3 and s"ecial
hardware deices are being designed and !anu$actured which take adantage o$ this
ca"ability.
(ault )olerance ia 1edundant In$or!ation .oding< -artial destruction o$ a network
leads to the corres"onding degradation o$ "er$or!ance. Howeer3 so!e network
ca"abilities !ay be retained een with !a4or network da!age.
1.# Neural networks $ersus con$entional co%&uters
Neural networks take a di$$erent a""roach to "roble! soling than that o$ conentional
co!"uters. .onentional co!"uters use an algorith!ic a""roach i.e. the co!"uter $ollows a
set o$ instructions in order to sole a "roble!. =nless the s"eci$ic ste"s that the co!"uter
needs to $ollow are known the co!"uter cannot sole the "roble!. )hat restricts the "roble!
soling ca"ability o$ conentional co!"uters to "roble!s that we already understand and
know how to sole. &ut co!"uters would be so !uch !ore use$ul i$ they could do things that
we don>t e2actly know how to do.
4
Neural networks "rocess in$or!ation in a si!ilar way the hu!an brain does. )he network is
co!"osed o$ a large nu!ber o$ highly interconnected "rocessing ele!ents7neurones8 working
in "arallel to sole a s"eci$ic "roble!. Neural networks learn by e2a!"le. )hey cannot be
"rogra!!ed to "er$or! a s"eci$ic task. )he e2a!"les !ust be selected care$ully otherwise
use$ul ti!e is wasted or een worse the network !ight be $unctioning incorrectly. )he
disadantage is that because the network $inds out how to sole the "roble! by itsel$3 its
o"eration can be un"redictable.
;n the other hand3 conentional co!"uters use a cognitie a""roach to "roble! soling? the
way the "roble! is to soled !ust be known and stated in s!all una!biguous instructions.
)hese instructions are then conerted to a high leel language "rogra! and then into !achine
code that the co!"uter can understand. )hese !achines are totally "redictable? i$ anything
goes wrong is due to a so$tware or hardware $ault.
Neural networks and conentional algorith!ic co!"uters are not in co!"etition but
co!"le!ent each other. )here are tasks are !ore suited to an algorith!ic a""roach like
arith!etic o"erations and tasks that are !ore suited to neural networks. @en !ore3 a large
nu!ber o$ tasks3 re*uire syste!s that use a co!bination o$ the two a""roaches 7nor!ally a
conentional co!"uter is used to su"erise the neural network8 in order to "er$or! at
!a2i!u! e$$iciency.
2. Hu%an and Arti'icial Neurones ( in$estiatin the si%ilarities
2.1 How the Hu%an )rain *earns?
5uch is still unknown about how the brain trains itsel$ to "rocess in$or!ation3 so theories
abound. In the hu!an brain3 a ty"ical neuron collects signals $ro! others through a host o$
$ine structures called dendrites. )he neuron sends out s"ikes o$ electrical actiity through a
long3 thin stand known as an a2on3 which s"lits into thousands o$ branches. #t the end o$
each branch3 a structure called a syna"se conerts the actiity $ro! the a2on into electrical
e$$ects that inhibit or e2cite actiity $ro! the a2on into electrical e$$ects that inhibit or e2cite
actiity in the connected neurones. When a neuron receies e2citatory in"ut that is
su$$iciently large co!"ared with its inhibitory in"ut3 it sends a s"ike o$ electrical actiity
down its a2on. 'earning occurs by changing the e$$ectieness o$ the syna"ses so that the
in$luence o$ one neuron on another changes.
5


.o!"onents o$ a neuron

)he syna"se

2.2 +ro% Hu%an Neurones to Arti'icial Neurones
We conduct these neural networks by $irst trying to deduce the essential $eatures o$ neurones
and their interconnections. We then ty"ically "rogra! a co!"uter to si!ulate these $eatures.
Howeer because our knowledge o$ neurones is inco!"lete and our co!"uting "ower is
li!ited3 our !odels are necessarily gross idealisations o$ real networks o$ neurones.
. )he neuron !odel
!. Techni,ues and a&&lication
I!"le!entation o$ #NN on ,teel -late -rocess .ontrol
)he "roble! can be $or!ulated in si!ilar a""roach as in an ;"erations 1esearch !odel.
)here are certain controllable "ara!eters which are key decisions to be taken $or the
o"ti!u! "rocess out"ut . )hese controllable "ara!eters are actually altered in the "rocess o$
6
Network 1
&last (urnace
In"ut 7=ncontrollable8 "ara!eters A 423
;ut"ut 7.ontrollable8 "ara!eters A 3
!anu$acturing di$$erent grades o$ steel "late !aking or to get di$$erent s"eci$ications. )here
are certain constrains in the "rocess $low which needs to be considered while taking the key
decisions and there are arious resource sti"ulations in these constraints which are the
uncontrollable "ara!eters. )he -late !anu$acturing "rocess is considered $ro! the &last
(urnace to -late 5ill and se"arate networks are trained $or di$$erent "rocess de"art!ents as
shown.



7
Network 2
;2ygen &lown .onerters
In"ut 7=ncontrollable8 "ara!eters A 363
;ut"ut 7.ontrollable8 "ara!eters A 14
Network 3
.ontinuous .ast
In"ut 7=ncontrollable8 "ara!eters A293
;ut"ut 7.ontrollable8 "ara!eters A 2
Network 4
-late 5ill
In"ut 7=ncontrollable8 "ara!eters A2%3
;ut"ut 7.ontrollable8 "ara!eters A %

-rocess (low .hart
!.1 Network -esin
#ll the networks are trained and si!ulated in the Neural Network )oolbo2 o$ 5atlab
so$tware. @ach network has one in"ut layer3 one hidden layer 3 one out"ut layer and the layer
details are as $ollows.
18 )he nu!ber o$ neurons in the in"ut layer is e*ual to the nu!ber o$ training in"ut and these
are the uncontrollable "ara!eters $or the de"art!ent in the "rocess $low.
28 )he nu!ber o$ neurons in the out"ut layer is e*ual to the nu!ber o$ target "ara!eters and
these are the controllable "ara!eters on which the decision is to be taken.
8
38 )he nu!ber o$ neurons in the hidden layer has been ke"t e*ual to the nu!ber neurons in
the in"ut layer.
Network )y"e B (eed $orward &ack -ro"agation
)rans$er (unction B
'ayer 1 B tansig3 'ayer 2 B "urelin
!.2 Network .ro&erties
18 &last (urnace B Network No 1
Neural Network ob4ect<
#rchitecture<
Nu! In"uts< 1 nu! 'ayers< 2 bias .onnect< C1? 1D in"ut .onnect< C1? 6D layer
.onnect< C6 6? 1 6D out"ut .onnect< C6 1D target .onnect< C6 1D nu! ;ut"uts< 17read-
only8 nu! )argets< 17read-only8 nu! In"ut /elays< 6 7read-only8 nu! 'ayer /elays< 6
7read-only8
,ub ob4ect structures<
in"uts< E121 cellF o$ in"uts layers< E221 cellF o$ layers out"uts< E122 cellF
containing 1 out"ut targets< E122 cellF containing 1 target biases< E221 cellF
containing 2 biases in"ut Weights< E221 cellF containing 1 in"ut weight layer Weights<
E222 cellF containing 1 layer weight
$unctions< ada"t (cn< >trains> init (cn< >initlay> "er$or! (cn< >!se> train (cn< >trainl!>
-ara!eters<
#da"t -ara!< ."asses init -ara!< 7none8 "er$or! -ara!< 7none8 train -ara!<
.e"ochs3 .goal3 .!a2G$ail3 .!e!Greduc3 .!inGgrad3 .!u3 .!uGdec3 .!uGinc3 .!uG!a23
.show3 .ti!e
Weight and bias alues<
IW< E221 cellF containing 1 in"ut weight !atri2
9
'W< E222 cellF containing 1 layer weight !atri2
b< E221 cellF containing 2 bias ectors
;ther<
=ser data< 7user stu$$8
!.! Network Trainin
)raining in"uts 7controllable "ara!eters8 are a""lied to the in"ut layer o$ the network3 and
desired out"uts are co!"ared at the out"ut layer. )he di$$erence between the out"ut o$ the
$inal layer and the desired out"ut is back-"ro"agated to the "reious layer7s83 usually
!odi$ied by the deriatie o$ the trans$er $unction3 and the connection weights are nor!ally
ad4usted using the /elta 1ule. )his "rocess "roceeds $or the "reious layer7s8 until the in"ut
layer is reached.
)raining -ara!eters<
)raining (unction B trainl!3 @"och 7set alue8 A1663 Hoal 7set alue8 A63 -er$or!ance
(unction - 5,@
)raining $or each network was done with batches o$ 0 sets o$ data and with 1666 set o$ data
within the s"eci$ied range. )he training is done in such a way that the new set o$ "rocess
"redictions can be a""ro"riate done during the si!ulation and the details o$ releant
"ara!eters $or training can be better understood by going through the subse*uent section on
si!ulation.
!.# /i%ulation
,i!ulation hel"s us to $ind out the a""ro"riate "ara!eters o$ a new steel "late with di$$erent
s"eci$ication.
@ach de"art!ent in the $lowchart is taken one at a ti!e. ,i!ulation is done with 10 sets new
data $or which re*uired ariable "ara!eter in "roduct s"eci$ication is already deter!ined as
"er custo!er re*uire!ent and an attribute o$ acce"tance o$ 166I is taken. )he identi$ied
uncontrollable "ara!eters are listed in )able-I. )he a""ro"riate resources to be utiliJed with
their corres"onding re$erence nu!bers are also !entioned
!.0 /i%ulation 'or )last +urnace
10
&last (urnace being a de"art!ent catering to arious other "roduct re*uire!ents other than
steel "lates3 the custo!er s"eci$ication is not included. )he arious target "ara!eters re*uired
$or Hot !etal3 &last (urnace slag3 &last (urnace gas and the "ara!eters relating to the $ed
!aterials are taken as uncontrollable 71e$ )able No.BI8.
.are needs to be taken $or a""ro"riateness o$ "osted data while si!ulating the de"art!ent
under consideration. )he "ara!eters like the Hot 5etal s"eci$ication $or &last (urnace
7"reious de"art!ent83 considered as targeted alue3 can now be taken in actual obtained
alue $or the subse*uent "rocesses3 i$ the test results are known by that ti!e. ,i!ulation $or
other de"art!ents in steel "late $low "rocess
(or the &last (urnace3 .ontinuous cast and -late 5ill de"art!ents the arious releant
resource sti"ulations are considered along with the $ollowing
18 )he arious ele!ents in "ercentage3 which constitute the che!ical co!"osition3 are the
ariables and the e2"ected alues in the "rocessed "roduct need to be !entioned in the
uncontrollable "ara!eter.
28 ,o!e o$ the !echanical "ro"erties like =),3 K, L @longation are o$ ariable ty"e while
the I!"act or the bend is attribute where the acce"tance is taken as "ercentage.
38 (or internal de$ects3 the non destructie testing by =ltrasonic the acce"tance is taken as
"ercentage.
)he network out"ut and targeted alue is "lotted on gra"h $or select "ara!eters are dis"layed
in (ig.
#. +uture sco&e:
)here are large sets o$ "rocess data in thousands aailable in the conentional "lants like the
steel "lants and these hae the "otential to train the e$$icient network. In steel !anu$acturing
the data within the "roduct is in ery s!all ranges and batch training o$ 0 sets at a ti!e is
$ound ery e$$ectie. Within a "roduct $a!ily 7e.g. steel "late83 the !ore the data aailability
$or each "roduct3 the network beco!es !ore e$$icient. &atch training o$ 0 sets each is
a""licable in this case also.
11
,till the "rocess $low can be !ade !ore detailed by taking all the o"erations which are
releant to the "rocess. 7e.g. -ara!eters $or argon rinsing is not taken in the aboe case study
o$ steel "late.8
#.1+ile 1anae%ent /"ste%
# $ile !anage!ent syste! based on the steel "late !aking "rocess releance can
be designed $or each grade o$ steel "late with se"arate sets o$ three $iles o$ trained networks
and one trained network $or blast $urnace. (or si!ulation based on the re$erence o$ grade and
"rocess de"art!ent3 a""ro"riate network in the releant $older should get selected. )he in"ut
alues can be $ed through $ront end inter$ace so$tware and this gets "rocessed at the back end
so$tware. )he network out"ut can be obtained back in the $ront end again.
;nce the so$tware is in its i!"le!entation "hase3 eery network out"ut as si!ulation results
is "ro"osed to be "re$erably etted by the "lant e2"erts till a consistent con$idence leel is
attained. )he actual obtained alues and !aintained alues in "ro"er $or!at o$ controllable
and uncontrollable "ara!eter should go as training to the network as eternal "rocess.
0. Conclusion:
# "ersistent a""roach using #NN is a $easible tool to reduce the nu!ber o$ re4ections $ro! a
!anu$acturing "rocess. I$ a "rocess is ca"able o$ "roducing a "roduct with *uality
con$or!ance o$ at least 2 sig!a leels3 then it i!"lies it has "otential to achiee si2 sig!a
leels within a reasonable ti!e "eriod. )here is "ossibility o$ reducing the de$ects3 which got
into "roduct because o$ one or !ore "ara!eters. )he real challenge is to list all the releant
"ara!eters and analyJe which "ara!eters are in the hands o$ the "roduction "ersonnel and
which "ara!eters can not be controlled. /uring training the hu!an interention $or altering
12
(ile Network
.onerter
(ile Network
.ontinuous .ast
(ile Network
-late 5ill
.onerter
(ile Network
&last (urnace
1. (older $or Hrade I, 2662
(ile Network
.onerter
(ile Network
.ontinuous .ast
(ile Network
-late 5ill
.onerter
2. (older #,)5 - # - 365
(ile Network
.onerter
(ile Network
.ontinuous .ast
(ile Network
-late 5ill
.onerter
06. (older ,#I' HI))@N
696#1
In&ut and Out&ut Inter'ace 'or /i%ulation
+i 1.! +I*E 1ANA2E1ENT /3/TE1 +O4 NE54A* NETWO46 +O4 /TEE* .*ATE/
(ile Network
.onerter
(ile Network
.ontinuous .ast
(ile Network
-late 5ill
.onerter
1aster Network /et
All 2rades
the weights and biases reduces i$ all the releant uncontrolled "ara!eters at the in"ut and
re*uisite nu!ber controllable "ara!eters are taken into consideration (or any 5anu$acturing
-rocess the aailable in$or!ation can be conerted into nu!erical data and organiJed data
handling with a "ro"er training !ethodology will eole an a""ro"riate correlation between
the arious controllable and uncontrollable "ara!eters aailable as historical data. )his
correlation will be a boon $or the old and conentional "lants i$ they are willing to record all
the releant "ara!eters een $ro! now onwards.
4e'erences:
1. &hat3 N. M.3 -. #. 5inder!an3 ). N. 5c#oy3 and N. Wang3 1996. O5odeling .he!ical
-rocess ,yste!s ia Neural .o!"utation3P I@@@ .ontrol ,yste!s 5agaJine3 "". 24-36.
2. @. 1.3 and .. #. Massiliadis3 1990. O#rti$icial Intelligance< ,tarting to 1ealiJe Its -ractical
-ro!ise3P Chemical Engineering Progress3 "". 22-36.
3. (an3 H. ).3 and Wu3 ,. 5.3 19903 .ase studies on !odelling !anu$acturing "rocesses using
arti$icial neural networks. Nournal o$ @ngineering $or Industry3 11%3 412-41%.
4. Hra!ckow3 5. Nansen3 ). -o""e3 .. ,chQ$$ner and H. ,Rrgel 7199%8. Neural networks $or
"rocess control in steel !anu$acturing. In< -roc. I@@@ I.#,,- 9%3 100-10+.
0. Na!es #. (ree!an L /aid 5.ska"ura3 Neural network algorith!s3 and "rogra!!ing
7 -#< -earson education #sia3 266283 ". 1%31+392396
6. N.&. ;lieira et al.3 :=se o$ Neural Networks in the -late -roduction ,cheduling at
=,I5IN#,3: ,e!inSrio de 'a!inaTUo 7-orto #legre< #ssociaTUo &rasileira de 5etais3
199283 "". 319-339.
%. 5aha4an3 5.3 O ,tatistical Vuality .ontrol P 3 /han"at 1ai L .o. 7-8 'td. 2660.3 "". 064
069.
+. 5ukesh3 /.3 199%. OHate ,tatistics? )ry Neural Networks3P .he!ical @ngineering
-rogress3 "". 96-164.
9. N. -ort!ann et al.3 :#""lication o$ Neural Networks in 1olling 5ill #uto!ation3: Iron
and ,teel @ngineer 728 7199083 "". 33-36.
16. -ort!ann3 N.(.3 /. 'indho$$3 H. ,Rrgel3 and ;. Hra!ckow 719908. #""lication o$ neural
networks in rolling !ill auto!ation. Iron and steel engineer3 %27283 33-36.
13
11. 1Rscheisen3 5.3 1. Ho$!ann and M. )res" 719928. Neural control $or rolling !ills<
incor"orating do!ain theories to oerco!e data de$iciency. In< -roc. NI-, 43 609-666.
12. ,essel!ann3 1.3 (. Wahlers3 H. WRrcher3 and ). -o""e 719908. ;"ti!iJation o$ the
electrode control syste! with neural networks. In< -roc. 0th @uro". ,teel .ongress3 266-2%1
13. ,chlang3 5.3 ). -o""e3 and ;. Hra!ckow 719968. Neural networks $or steel
!anu$acturing. I@@@ @2"ert Intelligent ,yste!s3 117483 +-16.
A&&endi7:
Table I
BLAST FURNACE
Controllable (Target) Uncontrollable ( Input )
Operation 1 Top Preure at! "#$ to 1#%
Iron ore
1 Fe & '(#)!in
Para!eter ) Blat ti!e *r +) ) SiO) & )#%,-."#%
/ Te!perature C 1%"".1'"" / P & "#1!a0
( Al)O/-SiO) & "#$$!a0
% Si1e !! 1" to ("
Li!etone
' CaO & /2#%,-.1
3 SiO) & '#%,-."#)%
$ 4gO & $#%,-."#%
2 Si1e !! ' to %"
4anganee Ore
1" 4n & /"!in
11 SiO) & /"!in
1) Al)O/ & %!a0
1/ P & "#/!a0
1( Si1e !! )% to $"
Sinter
1% Fe & %"4in
1' FeO & 1"
13 SiO) & '#""
1$ Al)O/ & /#""
12 CaO & 1(.1%
)" 4gO & ( to %
)1 Cao-SiO) Baicit5 )#" to )#1
Co6e Anal5i
))
Blat
No# 1 to 3 Furnace Re7
)/ A* & 1% to 1'
)( 84 & "#/ to "#(
)% 4 & %,-."#%
)' S & "#% to "#'
)3 C & 3% to $"
Blat Furnace 9a
( Targete: )
)$ CO & )% TO )'
)2 CO) & 1% TO 1'
/" N) & %% TO %3
/1 ;) & ) TO /
14
Blat Furnace Slag
( Targete: )
/) SiO) & /) to //
// Al)O) & 12 to )"
/( CaO & /1 to //
/% 4gO & 2 to 1"
/' 4nO & < 1
/3 CaO-SiO) Baicit5 "#2$
;ot 4etal
/$ Si & "#% to "#$
/2 4n & "#$ to 1
(" S & "#"( !a0
(1 P & "#)"
(Targete:) () C & (#""
Co%&arison ra&h:
15