Dynamic models and fault diagnosis‐based triggers for closed‐loop scheduling

Establishing an explicit feedback connection between production management and process control decisions is a key requirement for more nimble and cost effective process operations in today's variable market conditions. Past research efforts focused on embedding dynamic process information in the production scheduling problem. In this article, we propose a novel framework for closing the scheduling loop, based on considering the process‐level events and disturbances that impact the implementation of scheduling decisions. We emphasize the role of a comprehensive fault detection, isolation and reconstruction mechanism as a trigger for rescheduling decisions and for reflecting the process capabilities altered by these events in the rescheduling problem formulation. Our framework is agnostic to the process type, and we present two (continuous process, sequential batch process) case studies to demonstrate its applicability. © 2016 American Institute of Chemical Engineers AIChE J, 63: 1959–1973, 2017     

A multiscale decomposition method for the optimal planning and scheduling of multi-site continuous multiproduct plants

This paper addresses the solution of simultaneous scheduling and planning problems in a production–distribution network of continuous multiproduct plants that involves different temporal and spatial scales. Production planning results in medium and long-term decisions, whereas production scheduling determines the timing and sequence of operations in the short-term. The production–distribution network is made up of several production sites distributing to different markets. The planning and scheduling model has to include spatial scales that go from a single production unit within a site, to a geographically distributed network. We propose to use two decomposition methods to solve this type of problems. One method corresponds to the extension of the bi-level decomposition of Erdirik-Dogan and Grossmann (2008) to multi-site, multi-market networks. A second method is a novel hybrid decomposition method that combines bi-level and spatial Lagrangean decomposition methods. We present four case studies to study the performance of the full space planning and scheduling model, the bi-level decomposition, and the bi-level Lagrangean method in profit maximization problems. Numerical results indicate that in large-scale problems, decomposition methods outperform the full space solution and that as problem size increases the hybrid decomposition method becomes faster than the bi-level decomposition alone.     

Short‐term scheduling of a large‐scale oil‐refinery operations: Incorporating logistics details

Refineries are increasingly concerned with improving the scheduling of their operations to achieve better economic performances by minimizing quality, quantity, and logistics give away. In this article, we present a comprehensive integrated optimization model based on continuous‐time formulation for the scheduling problem of production units and end‐product blending problem. The model incorporates quantity, quality, and logistics decisions related to real‐life refinery operations. These involve minimum run‐length requirements, fill‐draw‐delay, one‐flow out of blender, sequence‐dependent switchovers, maximum heel quantity, and downgrading of better quality product to lower quality. The logistics giveaways in our work are associated with obtaining a feasible solution while minimizing violations of sequence‐dependent switchovers and maximum heel quantity restrictions. A set of valid inequalities are proposed that improves the computational performance of the model significantly. The formulation is used to address realistic case studies where feasible solutions are obtained in reasonable computational time. © 2010 American Institute of Chemical Engineers AIChE J, 2011     

A mathematical programming approach for cyclic production and cleaning scheduling of multistage continuous plants

The objective of this paper is to address the cyclic scheduling of cleaning and production operations in multiproduct multistage plants with performance decay. A mixed-integer nonlinear programming (MINLP) model based on continuous time representation is proposed that can simultaneously optimize the production and cleaning scheduling. The resulting mathematical model has a linear objective function to be maximized over a convex solution space thus allowing globally optimal solutions to be obtained with an outer approximation algorithm. Case studies demonstrate the applicability of the model and its potential benefits in comparison with a hierarchical procedure for the production and cleaning scheduling problem.     

Robust optimization and stochastic programming approaches for medium-term production scheduling of a large-scale steelmaking continuous casting process under demand uncertainty

Scheduling of steelmaking-continuous casting (SCC) processes is of major importance in iron and steel operations since it is often a bottleneck in iron and steel production. In practice, uncertainties are unavoidable and include demand fluctuations, processing time uncertainty, and equipment malfunction. In the presence of these uncertainties, an optimal schedule generated using nominal parameter values may often be suboptimal or even become infeasible. In this paper, we introduce robust optimization and stochastic programming approaches for addressing demand uncertainty in steelmaking continuous casting operations. In the robust optimization framework, a deterministic robust counterpart optimization model is introduced to guarantee that the production schedule remains feasible for the varying demands. Also, a two-stage scenario based stochastic programming framework is investigated for the scheduling of steelmaking and continuous operations under demand uncertainty. To make the resulting stochastic programming problem computationally tractable, a scenario reduction method has been applied to reduce the number of scenarios to a small set of representative realizations. Results from both the robust optimization and stochastic programming methods demonstrate robustness under demand uncertainty and that the robust optimization-based solution is of comparable quality to the two-stage stochastic programming based solution.     

Efficient multi-product multi-BOM batch scheduling for a petrochemical blending plant with a shared pipeline network

We present an effective scheduling heuristic for realistic production planning in a petrochemical blending plant. The considered model takes into account orders spanning a multi-product portfolio with multiple bills of materials per product, that need to be scheduled on shared production facilities including a complex pipeline network. Capacity constraints, intermediate storage restrictions, due dates, and the dedication of resources to specific product families have to be respected. The primary objective of the heuristic is to minimize the total order tardiness. Secondary objectives include the minimization of pipeline cleaning operations, the minimization of lead times, and the balanced utilization of filling units.The developed algorithm is based on a dynamic prioritization-based greedy search that schedules the orders sequentially. The proposed method can schedule short to mid-term operations and evaluate different plant configurations or production policies on a tactical level. We demonstrate its performance on various real-world inspired scenarios for different scheduling strategies.Our heuristic was used during the construction phase of a new blending plant and was instrumental in the optimal design of the plant.     

A THRESHOLD-ACCEPTING METAHEURISTIC METHOD FOR SCHEDULING THE OPERATIONS OF DEHYDRATION PLANTS

Dehydration plants are broadly characterized by a multi-product nature chiefly attributed to the utilization of different raw materials to be processed sequentially so that demand constraints are met. Processing of raw materials is implemented through a series of preprocessing operations that together with drying constitute the production procedure of a pre-specified programme. The core of the manufacturing system that a typical dehydration plant involves, is scheduling of operations so that demand is fulfilled within a pre-determined time horizon imposed by production planning. The typical scheduling operation that dehydration plants involve can be formulated as a general job shop scheduling problem. The aim of this study is to describe a new metaheuristic method for solving the job shop scheduling problem of dehydration plants, termed as the Backtracking Adaptive Threshold Accepting (BATA) method. Our effort focuses on developing an innovative method, which produces reliable and high quality solutions, requiring reasonable computing effort. The main innovation of this method, towards a typical threshold accepting algorithm, is that during the optimization process the value of the threshold is not only lowered, but also raised or backtracked according to how effective a local search is. BATA is described in detail while a characteristic job shop scheduling case study for dehydration plant operations is presented.     

ENVIRONMENTALLY CONSCIOUS HOIST SCHEDULING FOR ELECTROPLATING FACILITIES

Hoist scheduling in electroplating operations has long been considered a key factor for improving the production rate. It has recently been recognized that hoist scheduling can also play an important role in waste minimization. In this work, a new hoist scheduling method is introduced for simultaneously achieving both the economic and environmental goals. A two-step dynamic optimization algorithm is introduced for identifying an optimal hoist schedule that can minimize the quantity and toxicity of wastewater streams from an electroplating line without loss of production rate. To improve computational efficiency, an engineering approach is adopted to reduce the number of binary decision variables in the optimization problem. An application to an actual electroplating process shows a significant reduction of both chemical and water consumption, which equates to a simultaneous realization of wastewater reduction and increase of profits.     

ENVIRONMENTALLY CONSCIOUS HOIST SCHEDULING FOR ELECTROPLATING FACILITIES

Hoist scheduling in electroplating operations has long been considered a key factor for improving the production rate. It has recently been recognized that hoist scheduling can also play an important role in waste minimization. In this work, a new hoist scheduling method is introduced for simultaneously achieving both the economic and environmental goals. A two-step dynamic optimization algorithm is introduced for identifying an optimal hoist schedule that can minimize the quantity and toxicity of wastewater streams from an electroplating line without loss of production rate. To improve computational efficiency, an engineering approach is adopted to reduce the number of binary decision variables in the optimization problem. An application to an actual electroplating process shows a significant reduction of both chemical and water consumption, which equates to a simultaneous realization of wastewater reduction and increase of profits.     

A THRESHOLD-ACCEPTING METAHEURISTIC METHOD FOR SCHEDULING THE OPERATIONS OF DEHYDRATION PLANTS

ABSTRACT

Dehydration plants are broadly characterized by a multi-product nature chiefly attributed to the utilization of different raw materials to be processed sequentially so that demand constraints are met. Processing of raw materials is implemented through a series of preprocessing operations that together with drying constitute the production procedure of a pre-specified programme. The core of the manufacturing system that a typical dehydration plant involves, is scheduling of operations so that demand is fulfilled within a pre-determined time horizon imposed by production planning. The typical scheduling operation that dehydration plants involve can be formulated as a general job shop scheduling problem. The aim of this study is to describe a new metaheuristic method for solving the job shop scheduling problem of dehydration plants, termed as the Backtracking Adaptive Threshold Accepting (BATA) method. Our effort focuses on developing an innovative method, which produces reliable and high quality solutions, requiring reasonable computing effort. The main innovation of this method, towards a typical threshold accepting algorithm, is that during the optimization process the value of the threshold is not only lowered, but also raised or backtracked according to how effective a local search is. BATA is described in detail while a characteristic job shop scheduling case study for dehydration plant operations is presented.     

Integration of production planning and scheduling: Overview, challenges and opportunities

We review the integration of medium-term production planning and short-term scheduling. We begin with an overview of supply chain management and the associated planning problems. Next, we formally define the production planning problem and explain why integration with scheduling leads to better solutions. We present the major modeling approaches for the integration of scheduling and planning decisions, and discuss the major solution strategies. We close with an account of the challenges and opportunities in this area.     

A state-space model for chemical production scheduling

We express a general mixed-integer programming (MIP) scheduling model in state-space form, and show how common scheduling disruptions, which lead to rescheduling, can be modeled as disturbances in the state-space model. We also discuss how a wide range of scheduling models, with different types of decisions and processing constraints, can be expressed in state-space form. The proposed framework offers a natural representation of dynamic systems, thereby enabling researchers in the chemical process control area to study scheduling problems. It also facilitates the application of known results for hybrid systems, as well as the development of new tools necessary to address scheduling applications. We hope that it will lead to the development of scheduling solution methods with desired closed-loop properties, a topic that has received no attention in the process operations literature.     

Integrated Optimization Strategies for Dynamic Process Operations

Process systems engineering faces increasing demands and opportunities for better process modeling and optimization strategies, particularly in the area of dynamic operations. Modern optimization strategies for dynamic optimization trace their inception to the groundbreaking work Pontryagin and his coworkers, starting 60 years ago. Since then the application of large-scale non-linear programming strategies has extended their discoveries to deal with challenging real-world process optimization problems. This study discusses the evolution of dynamic optimization strategies and how they have impacted the optimal design and operation of chemical processes. We demonstrate the effectiveness of dynamic optimization on three case studies for real-world reactive processes. In the first case, we consider the optimal design of runaway reactors, where simulation models may lead to unbounded profiles for many choices of design and operating conditions. As a result, optimization based on repeated simulations typically fails, and a simultaneous, equationbased approach must be applied. Next we consider optimal operating policies for grade transitions in polymer processes. Modeled as an optimal control problem, we demonstrate how product specifications lead to multistage formulations that greatly improve process performance and reduce waste. Third, we consider an optimization strategy for the integration of scheduling and dynamic process operation for general continuous/batch processes. The method introduces a discrete time formulation for simultaneous optimization of scheduling and operating decisions. For all of these cases we provide a summary of directions and challenges for future integration of these tasks and extensions in optimization formulations and strategies.     

Multi‐stage adjustable robust optimization for process scheduling under uncertainty

Variations in parameters such as processing times, yields, and availability of materials and utilities can have a detrimental effect in the optimality and/or feasibility of an otherwise “optimal” production schedule. In this article, we propose a multi‐stage adjustable robust optimization approach to alleviate the risk from such operational uncertainties during scheduling decisions. We derive a novel robust counterpart of a deterministic scheduling model, and we show how to obey the observability and non‐anticipativity restrictions that are necessary for the resulting solution policy to be implementable in practice. We also develop decision‐dependent uncertainty sets to model the endogenous uncertainty that is inherently present in process scheduling applications. A computational study reveals that, given a chosen level of robustness, adjusting decisions to past parameter realizations leads to significant improvements, both in terms of worst‐case objective as well as objective in expectation, compared to the traditional robust scheduling approaches. © 2016 American Institute of Chemical Engineers AIChE J, 62: 1646–1667, 2016     

A time scale-bridging approach for integrating production scheduling and process control

In this paper, we propose a novel framework for integrating scheduling and nonlinear control of continuous processes. We introduce the time scale-bridging model (SBM) as an explicit, low-order representation of the closed-loop input–output dynamics of the process. The SBM then represents the process dynamics in a scheduling framework geared towards calculating the optimal time-varying setpoint vector for the process control system. The proposed framework accounts for process dynamics at the scheduling stage, while maintaining closed-loop stability and disturbance rejection properties via feedback control during the production cycle. Using two case studies, a CSTR and a polymerization reactor, we show that SBM-based scheduling has significant computational advantages compared to existing integrated scheduling and control formulations. Moreover, we show that the economic performance of our framework is comparable to that of existing approaches when a perfect process model is available, with the added benefit of superior robustness to plant-model mismatch.     

Optimal planning and scheduling of batch plants with operational uncertainties: An industrial application to Baker's yeast production

In this work, the mixed integer linear programming (MILP) model developed in Orçun et. al 1996 for optimal planning and scheduling of batch process plants under uncertain operating conditions is further improved to deal also with discrete probability functions. Furthermore, the logic behind integrating the processing uncertainties within the MILP model is implemented on the variations in the production volumes that can be faced in some batch processes such as Baker's yeast production. The modified model is tested on Baker's yeast production plant data to illustrate the effect of uncertainties on the production planning and scheduling. The results show that the plant production will be improved by 20% when the optimal production planning and scheduling is utilized by fine tuning the degree of risk the management can resist. An example on how a process design engineer may utilize such an MILP model for optimal planning and scheduling of batch process plant and identify plant problems, such as the bottleneck operations, is also included. A simulation type analysis on how to improve the processing site, i.e. the effect of introducing an extra operator to the bottleneck operation, is also demonstrated in this work using the available plant data.     

Sequential methodology for integrated optimization of energy and water use during batch process scheduling

Though commonly encountered in practice, energy and water minimization simultaneously during batch process scheduling has been largely neglected in literature. In this paper, we present a novel framework for incorporating simultaneous energy and water minimization in batch process scheduling. The overall problem is decomposed into three parts - scheduling, heat integration, and water reuse optimization - and solved sequentially. Our approach is based on the precept that in any production plant, utilities (energy and water) consumption is subordinate to the production target. Hence, batch scheduling is solved first to meet an economic objective function. Next, alternate schedules are generated through a stochastic search-based integer cut procedure. For each resulting schedule, minimum energy and water reuse targets are established and networks identified. As illustrated using two well-known case studies, a key feature of this approach is its ability to handle problems that are too complex to be solved using simultaneous methods.     

Chemical supply chain modeling for analysis of homeland security events

The potential impacts of man-made and natural disasters on chemical plants, complexes, and supply chains are of great importance to homeland security. To be able to estimate these impacts, we developed an agent-based chemical supply chain model that includes: chemical plants with enterprise operations such as purchasing, production scheduling, and inventories; merchant chemical markets, and multi-modal chemical shipments. Large-scale simulations of chemical-plant activities and supply chain interactions, running on desktop computers, are used to estimate the scope and duration of disruptive-event impacts, and overall system resilience, based on the extent to which individual chemical plants can adjust their internal operations (e.g., production mixes and levels) versus their external interactions (market sales and purchases, and transportation routes and modes). To illustrate how the model estimates the impacts of a hurricane disruption, a simple example model centered on 1,4-butanediol is presented.     

Time representations and mathematical models for process scheduling problems

During the last 15 years, many mathematical models have been developed in order to solve process operation scheduling problems, using discrete or continuous-time representations. In this paper, we present a unified representation and modeling approach for process scheduling problems. Four different time representations are presented with corresponding strengthened formulations that rely on exploiting the non-overlapping graph structure of these problems through maximum cliques and bicliques. These formulations are compared, and applied to single-stage and multi-stage batch scheduling problems, as well as crude-oil operations scheduling problems. We introduce three solution methods that can be used to achieve global optimality or obtain near-optimal solutions depending on the stopping criterion used. Computational results show that the multi-operation sequencing time representation is superior to the others as it allows efficient symmetry-breaking and requires fewer priority-slots, thus leading to smaller model sizes.