Simultaneous mixed-integer dynamic optimization for environmentally benign electroplating

Hoist scheduling, especially cyclic hoist scheduling (CHS), is used to maximize the manufacturing productivity of electroplating processes. Water-reuse network design (WRND) for the electroplating rinsing system targets the optimal water allocation, such that fresh water consumption and wastewater generation are minimized. Currently, there is still a lack of studies on integrating CHS and WRND technologies for electroplating manufacturing. In this paper, a multi-objective mixed-integer dynamic optimization (MIDO) model has been developed to integrate CHS and WRND technologies for simultaneous consideration of productivity and water use efficiency for environmentally benign electroplating. The orthogonal collocation method on finite elements is employed to convert the MIDO problem into a mixed-integer nonlinear programming (MINLP) problem. The efficacy of the methodology is demonstrated by solving a real electroplating example. It demonstrates that the computational methods of production scheduling, process design, and dynamic optimization can be effectively integrated to create economic and environmental win-win situations for the electroplating industry.     

Integration of scheduling and control with online closed-loop implementation: Fast computational strategy and large-scale global optimization algorithm

In this paper, we propose a novel integration method to solve the scheduling problem and the control problem simultaneously. The integrated problem is formulated as a mixed-integer dynamic optimization (MIDO) problem which contains discrete variables in the scheduling problem and constraints of differential equations from the control problem. Because online implementation is crucial to deal with uncertainties and disturbances in operation and control of the production system, we develop a fast computational strategy to solve the integration problem efficiently and allow its online applications. In the proposed integration framework, we first generate a set of controller candidates offline for each possible transition, and then reformulate the integration problem as a simultaneous scheduling and controller selection problem. This is a mixed-integer nonlinear fractional programming problem with a non-convex nonlinear objective function and linear constraints. To solve the resulting large-scale problem within sufficiently short computational time for online implementation, we propose a global optimization method based on the model properties and the Dinkelbach's algorithm. The advantage of the proposed method is demonstrated through four case studies on an MMA polymer manufacturing process. The results show that the proposed integration framework achieves a lower cost rate than the conventional sequential method, because the proposed framework provides a better tradeoff between the conflicting factors in scheduling and control problems. Compared with the simultaneous approach based on the full discretization and reformulation of the MIDO problem, the proposed integration framework is computationally much more efficient, especially for large-scale cases. The proposed method addresses the challenges in the online implementation of the integrated scheduling and control decisions by globally optimizing the integrated problem in an efficient way. The results also show that the online solution is crucial to deal with the various uncertainties and disturbances in the production system.     

A discrete-time scheduling model for continuous power-intensive process networks with various power contracts

Increased volatility in electricity prices and new emerging demand side management opportunities call for efficient tools for the optimal operation of power-intensive processes. In this work, a general discrete-time model is proposed for the scheduling of power-intensive process networks with various power contracts. The proposed model consists of a network of processes represented by Convex Region Surrogate models that are incorporated in a mode-based scheduling formulation, for which a block contract model is considered that allows the modeling of a large variety of commonly used power contracts. The resulting mixed-integer linear programming model is applied to an illustrative example as well as to a real-world industrial test case. The results demonstrate the model's capability in representing the operational flexibility in a process network and different electricity pricing structures. Moreover, because of its computational efficiency, the model holds much promise for its use in a real industrial setting.     

Global optimization for scheduling refinery crude oil operations

In this work we present an outer-approximation algorithm to obtain the global optimum of a nonconvex mixed-integer nonlinear programming (MINLP) model that is used to represent the scheduling of crude oil movement at the front-end of a petroleum refinery. The model relies on a continuous time representation making use of transfer events. The proposed algorithm focuses on effectively solving a mixed-integer linear programming (MILP) relaxation of the nonconvex MINLP to obtain a rigorous lower bound (LB) on the global optimum. Cutting planes derived by spatially decomposing the network are added to the MILP relaxation of the original nonconvex MINLP in order to reduce the solution time for the MILP relaxation. The solution of this relaxation is used as a heuristic to obtain a feasible solution to the MINLP which serves as an upper bound (UB). The lower and upper bounds are made to converge to within a specified tolerance in the proposed outer-approximation algorithm. On applying the proposed technique to test examples, significant savings are realized in the computational effort required to obtain provably global optimal solutions.     

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.     

Simultaneous subtour elimination model for single-stage multiproduct parallel batch scheduling with sequence dependent changeovers

In this paper a mixed-integer linear programming (MILP) model is presented to minimize makespan of single-stage multiproduct parallel batch production with sequence dependent changeovers. The computational inefficiency and suboptimal problems are addressed by the tight and rigorous formulation of the proposed model. Subtours (subcycles) are eliminated simultaneously so that the optimal solution is obtained in one step. The proposed model is tested with two examples. The results show that the model obtains the global optimal solutions with significant improvement in solution time.     

Scheduling of displacement batch digesters using discrete time formulation

This paper provides mathematical programming based optimization model and computational results for short-term scheduling of displacement batch digesters in a pulp industry. The scheduling problem involves development of an optimal solution that yields the best sequence of operations in each of the parallel batch digesters sharing common resources. The constraints are imposed on meeting the demand of pulp of different qualities within a specified time horizon. The problem comprises of both fixed-time and variable time durations of the tasks, different storage policies, zero-wait and finite wait times, and handling of shared resources. The scheduling problem is formulated using a state-task-network (STN) representation of production recipes, based on discrete time representation resulting in a mixed-integer linear programming (MILP) problem which is solved using GAMS software. The basic framework is adapted from the discrete-time model of Kondili et al. (Comput. Chem. Eng., 1993, 17, 211–227). Different case studies involving parallel digesters in multiple production lines are considered to demonstrate the effectiveness of the proposed formulation using two different objective functions.     

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.     

Simultaneous mixed-integer dynamic scheduling of processes and their energy systems

Increasingly volatile electricity prices make simultaneous scheduling optimization desirable for production processes and their energy systems. Simultaneous scheduling needs to account for both process dynamics and binary on/off-decisions in the energy system leading to challenging mixed-integer dynamic optimization problems. We propose an efficient scheduling formulation consisting of three parts: a linear scale-bridging model for the closed-loop process output dynamics, a data-driven model for the process energy demand, and a mixed-integer linear model for the energy system. Process dynamics is discretized by collocation yielding a mixed-integer linear programming (MILP) formulation. We apply the scheduling method to three case studies: a multiproduct reactor, a single-product reactor, and a single-product distillation column, demonstrating the applicability to multiple input multiple output processes. For the first two case studies, we can compare our approach to nonlinear optimization and capture 82% and 95% of the improvement. The MILP formulation achieves optimization runtimes sufficiently fast for real-time scheduling.     

Integrated process design,scheduling, and model predictive control of batch processes with closed-loop implementation

Simultaneous evaluation of multiple time scale decisions has been regarded as a promising avenue to increase the process efficiency and profitability through leveraging their synergistic interactions. Feasibility of such an integral approach is essential to establish a guarantee for operability of the derived decisions. In this study, we present a modeling methodology to integrate process design, scheduling, and advanced control decisions with a single mixed-integer dynamic optimization (MIDO) formulation while providing certificates of operability for the closed-loop implementation. We use multi-parametric programming to derive explicit expressions for the model predictive control strategy, which is embedded into the MIDO using the base-2 numeral system that enhances the computational tractability of the integrated problem by exponentially reducing the required number of binary variables. Moreover, we apply the State Equipment Network representation within the MIDO to systematically evaluate the scheduling decisions. The proposed framework is illustrated with two batch processes with different complexities.     

Efficient scheduling method of complex batch processes with general network structure via agent‐based modeling

A novel efficient agent‐based method for scheduling network batch processes in the process industry is proposed. The agent‐based model is based on the resource‐task network. To overcome the drawback of localized solutions found in conventional agent‐based methods, a new scheduling algorithm is proposed. The algorithm predicts the objective function value by simulating another cloned agent‐based model. Global information is obtained, and the solution quality is improved. The solution quality of this approach is validated by detailed comparisons with the mixed‐integer programming (MIP) methods. A solution close to the optimal one can be found by the agent‐based method with a much shorter computational time than the MIP methods. As a scheduling problem becomes increasingly complicated with increased scale, more specifications, and uncertainties, the advantages of the agent‐based method become more evident. The proposed method is applied to simulated industrial problems where the MIP methods require excessive computational resources. © 2013 American Institute of Chemical Engineers AIChE J, 59: 2884–2906, 2013     

A nested online scheduling and nonlinear model predictive control framework for multi-product continuous systems

In the pursuit of integrated scheduling and control frameworks for chemical processes, it is important to develop accurate integrated models and computational strategies such that optimal decisions can be made in a dynamic environment. In this study, a recently developed switched system formulation that integrates scheduling and control decisions is extended to closed-loop operation embedded with nonlinear model predictive control (NMPC). The resulting framework is a nested online scheduling and control loop that allows to obtain fast and accurate solutions as no model reduction is needed and no integer variables are involved in the formulations. In the outer loop, the integrated model is solved to calculate an optimal product switching sequence such that the process economics is optimized, whereas in the inner loop, an NMPC implements the scheduling decisions. The proposed scheme was tested on two multi-product continuous systems. Unexpected large disturbances and rush orders were handled effectively.     

Homotopy continuation enhanced branch and bound algorithms for strongly nonconvex mixed-integer nonlinear optimization

Large-scale strongly nonlinear and nonconvex mixed-integer nonlinear programming (MINLP) models frequently appear in optimization-based process synthesis, integration, intensification, and process control. However, they are usually difficult to solve by existing algorithms within acceptable time. In this study, we propose two robust homotopy continuation enhanced branch and bound (HCBB) algorithms (denoted as HCBB-FP and HCBB-RB) where the homotopy continuation method is employed to gradually approach the optimum of the NLP subproblem at a node from the solution at its parent node. A variable step length is adapted to effectively balance feasibility and computational efficiency. The computational results from solving four existing process synthesis problems demonstrate that the proposed HCBB algorithms can find the same optimal solution from different initial points, while the existing MINLP algorithms fail or find much worse solutions. In addition, HCBB-RB is superior to HCBB-FP due to much lower computational effort required for the same locally optimal solution.     

Design,synthesis and scheduling of multipurpose batch plants via an effective continuous-time formulation

Design, synthesis and scheduling issues are considered simultaneously for multipurpose batch plants. An earlier proposed continuous-time formulation for scheduling is extended to incorporate design and synthesis. Processing recipes are represented by the State-Task Network (STN). The superstructure of all possible plant designs is constructed according to the potential availability of all processing/storage units. The proposed model takes into account the trade-offs between capital costs, revenues and operational flexibility. Computational studies are presented to illustrate the effectiveness of the proposed formulation. Both linear and nonlinear models are included, resulting in MILP and mixed-integer nonlinear programming (MINLP) problems, respectively. The MILP problems are solved using a branch and bound method. Globally optimal solutions are obtained for the nonconvex MINLP problems based on a key property that arises due to the special structure of the resulting models. Comparisons with earlier approaches are also presented.     

Sustainable scheduling of batch processes under economic and environmental criteria with MINLP models and algorithms

We address the bi-criterion optimization of batch scheduling problems with economic and environmental concerns. The economic objective is expressed in terms of productivity, which is the profit rate with respect to the makespan. The environmental objective is evaluated by means of environmental impact per functional unit based on the life cycle assessment methodology. The bi-criterion optimization model is solved with the ε-constraint method. Each instance is formulated as a mixed-integer linear fractional program (MILFP), which is a special class of non-convex mixed-integer nonlinear programs. In order to globally optimize the resulting MILFPs effectively, we employ the tailored reformulation-linearization method and Dinkelbach's algorithm. The optimal solutions lead to a Pareto frontier that reveals the tradeoff between productivity and environmental impact per functional unit. To illustrate the application, we present two case studies on the short-term scheduling of multiproduct and multipurpose batch plants.     

Modeling and optimization methods of integrated production planning for steel plate mill with flexible customization

With diversified requirements and varying manufacturing environments, the optimal production planning for a steelmill becomes more flexible and complicated. The flexibility provides operators with auxiliary requirements through an implementable integrated production planning. In this paper, a mixed-integer nonlinear programming (MINLP) model is proposed for the optimal planning that incorporates various manufacturing constraints and flexibility in a steel plate mill. Furthermore, two solution strategies are developed to overcome theweakness in solving the MINLP problem directly. The first one is to transformthe original MINLP formulation to an approximate mixed integer linear programming using a classic linearization method. The second one is to decompose the originalmodel using a branch-and-bound based iterative method. Computational experiments on various instances are presented in terms of the effectiveness and applicability. The result shows that the second method performs better in computational efforts and solution accuracy.     

Multiple and nonuniform time grids in discrete-time MIP models for chemical production scheduling

The modeling of time plays a key role in the formulation of mixed-integer programming (MIP) models for scheduling, production planning, and operational supply chain planning problems. It affects the size of the model, the computational requirements, and the quality of the solution. While the development of smaller continuous-time scheduling models, based on multiple time grids, has received considerable attention, no truly different modeling methods are available for discrete-time models. In this paper, we challenge the long-standing belief that employing a discrete modeling of time requires a common uniform grid. First, we show that multiple grids can actually be employed in discrete-time models. Second, we show that not only unit-specific but also task-specific and material-specific grids can be generated. Third, we present methods to systematically formulate discrete-time multi-grid models that allow different tasks, units, or materials to have their own time grid. We present two different algorithms to find the grid. The first algorithm determines the largest grid spacing that will not eliminate the optimal solution. The second algorithm allows the user to adjust the level of approximation; more approximate grids may have worse solutions, but many fewer binary variables. Importantly, we show that the proposed models have exactly the same types of constraints as models relying on a single uniform grid, which means that the proposed models are tight and that known solution methods can be employed. The proposed methods lead to substantial reductions in the size of the formulations and thus the computational requirements. In addition, they can yield better solutions than formulations that use approximations. We show how to select the different time grids, state the formulation, and present computational results.     

Disjunctive modeling for optimal control of hybrid systems

In this contribution, a novel approach for the modeling and numerical optimal control of hybrid (discrete–continuous dynamic) systems based on a disjunctive problem formulation is proposed. It is shown that a disjunctive model representation, which constitutes an alternative to mixed-integer model formulations, provides a very flexible, intuitive and effective way to formulate hybrid (discrete–continuous dynamic) optimization problems. The structure and properties of the disjunctive process models can be exploited for an efficient and robust numerical solution by applying generalized disjunctive programming techniques. The proposed modeling and optimization approach will be illustrated by means of optimal control of hybrid systems embedding linear discrete–continuous dynamic models.     

反渗透海水淡化系统的优化设计

对反渗透海水淡化过程的设计进行了研究。首先对过程的每个单元给出了单元操作模型和相关的经济模型。通过一定的变量将这些模型相互关联,组成系统模型。系统模型主要考虑了一级流程和二级流程。将年费用最小定为目标函数,并满足过程热力学、设备选型、设计要求等约束。系统的设计问题可表达为一个混合整数非线性规划(MINLP)。当产品水的设计要求不同,给水浓度不同时,采用本文的设计方法分别得出了不同的最优设计方案。这个方法可用于海水、苦咸水淡化的工程设计,也可用于高浓度含盐废水的脱盐工艺设计。     

Optimal storage design for a multi-product plant: A non-convex MINLP formulation

We discuss a tank design problem for a multi product plant, in which the optimal cycle time and the optimal campaign size are unknown. A mixed-integer nonlinear programming (MINLP) formulation is presented, where non-convexities are due to the tank investment cost, storage cost, campaign setup cost and variable production rates. The objective of the optimization model is to minimize the sum of the production cost per ton per product produced. A continuous-time mathematical programming formulation is proposed and several extensions are discussed. The model is implemented in GAMS and computational results are reported for the two global MINLP solver BARON and LINDOGlobal as well as several nonlinear solvers available in GAMS.