Integrated gasoline blending and order delivery operations: Part I. short‐term scheduling and global optimization for single and multi‐period operations

Gasoline is one of the most valuable products in an oil refinery and can account for as much as 60–70% of total profit. Optimal integrated scheduling of gasoline blending and order delivery operations can significantly increase profit by avoiding ship demurrage, improving customer satisfaction, minimizing quality give‐aways, reducing costly transitions and slop generation, exploiting low‐quality cuts, and reducing inventory costs. In this article, we first introduce a new unit‐specific event‐based continuous‐time formulation for the integrated treatment of recipes, blending, and scheduling of gasoline blending and order delivery operations. Many operational features are included such as nonidentical parallel blenders, constant blending rate, minimum blend length and amount, blender transition times, multipurpose product tanks, changeovers, and piecewise constant profiles for blend component qualities and feed rates. To address the nonconvexities arising from forcing constant blending rates during a run, we propose a hybrid global optimization approach incorporating a schedule adjustment procedure, iteratively via a mixed‐integer programming and nonlinear programming scheme, and a rigorous deterministic global optimization approach. The computational results demonstrate that our proposed formulation does improve the mixed‐integer linear programming relaxation of Li and Karimi, Ind. Eng. Chem. Res., 2011, 50, 9156–9174. All examples are solved to be 1%‐global optimality with modest computational effort. © 2016 American Institute of Chemical Engineers AIChE J, 62: 2043–2070, 2016     

Inventory pinch algorithm for gasoline blend planning

Current gasoline blend scheduling practice is to optimize blend plans via fixed duration (e.g., days) multiperiod NLP or MINLP models and schedule blends via interactive simulation. Solutions of multiperiod models typically have different blend recipes for each time period. We introduce inventory pinch points and use them to construct an algorithm based on single‐period nonlinear model to minimize the number of different blend recipes. The algorithm optimizes multigrade blend recipes for each period delimited by the inventory pinch points and then uses a fine‐grid multiperiod fixed‐recipe MILP to compute blend volumes profile. If MILP is infeasible, a corresponding period between the pinch points is subdivided and recipes are reoptimized. In our case studies, solutions are computed in significant less time and are most often within 0.01% of the solutions by multiperiod MINLP. Reduced number of blend recipes makes it easier for the blend scheduler to create a schedule by interactive simulation. © 2013 American Institute of Chemical Engineers AIChE J, 59: 3748–3766, 2013     

Recipe determination and scheduling of gasoline blending operations

Gasoline is a major contributor to the profit of a refinery. Scheduling gasoline‐blending operations is a critical and complex routine task involving tank allocation, component mixing, blending, product storage, and order delivery. Optimized schedules can maximize profit by avoiding ship demurrage, improving order delivery, minimizing quality give‐aways, avoiding costly transitions and slop generation, and reducing inventory costs. However, the blending recipe and scheduling decisions make this problem a nonconvex mixed‐integer nonlinear program (MINLP). In this article, we develop a slot‐based MILP formulation for an integrated treatment of recipe, specifications, blending, and storage and incorporate many real‐life features such as multipurpose product tanks, parallel nonidentical blenders, minimum run lengths, changeovers, piecewise constant profiles for blend component qualities and feed rates, etc. To ensure constant blending rates during a run, we develop a novel and efficient procedure that solves successive MILPs instead of a nonconvex MINLP. We use 14 examples with varying sizes and features to illustrate the superiority and effectiveness of our formulation and solution approach. The results show that our solution approach is superior to commercial solvers (BARON and DICOPT). © 2009 American Institute of Chemical Engineers AIChE J, 2010     

Multiscale strategic planning model for the design of integrated ethanol and gasoline supply chain

The design and planning of an integrated ethanol and gasoline supply chain is addressed, and is composed of harvesting and production sites for ethanol, petroleum refineries, distribution centers where blending takes place, and the retail gas stations where blends of gasoline and ethanol are sold. We postulate a superstructure that combines all the components of the supply chain and different means of transportation, and model this multiscale design problem as a multiperiod MILP model. In order to identify regions where investments are needed and the optimal configuration of the network, a strategic planning model is considered in which gasoline stations are aggregated in different regions. A detailed formulation is considered where regions are disaggregated into gas stations to determine the retrofit projects for the selection of blending pumps over their expected life. Also, the application of these MILP models with two large‐scale problems are illustrated. © 2013 American Institute of Chemical Engineers AIChE J, 59: 4655–4672, 2013     

Logarithm-transform piecewise linearization method for the optimization of fasoline blending processes

Gasoline blending is a key process in a petroleum refinery, as it can yield 60%–70% of a typical refinery's total revenue. This process not only exhibits non-convex nonlinear blending behavior due to the complicated blend mechanism of various component feedstocks with different quality properties, but also involves global optimum searching among numerous blending recipes. Since blend products are required to meet a series of quality requirements and highly-sensitive to the proportion changes of blending feedstocks, global optimization methods for NLP problems are often difficult to be applied because of heavy computational burdens. Thus, piecewise linearization methods are naturally proposed to provide an approximate global optimum solution by adding binary variables into the models and converting the original NLP problems into MILP ones. In this paper, Logarithmtransform piecewise linearization(LTPL) method, an improved piecewise linearization, is proposed. In this method a logarithm transform is applied to convert multi-variable multi-degree constraints into a series of single-variable constraints. As a result, the number of 0–1 variables is greatly reduced. In the final part of this paper, an industrial case study is conducted to demonstrate the effectiveness of LTPL method. In principle, this method would be useful for blending problems with complicated empirical or theoretical models.     

汽油调合调度优化

采用连续时间建模方法,建立了一种新的汽油非线性调合和调度集成优化的混合整数非线性规划（MINLP）模型,克服了当前在油品调合调度中采用线性调合模型或者将非线性调合过程和调度分开优化的缺陷。针对建立MINLP模型的特点,将原MINLP问题转化为求解一系列的混合整数线性规划（MILP）模型,避免了直接求解MINLP模型的复杂性。最后以某大型炼油企业为例,验证了模型和算法的实用性。     

Inventory pinch gasoline blend scheduling algorithm combining discrete- and continuous-time models

This work introduces multi-period inventory pinch-based algorithm to solve continuous-time scheduling models (MPIP-C algorithm), a three level method which combines discrete-time approximate scheduling with continuous-time detailed scheduling and with inventory pinch-based optimization of operating states. When applied to gasoline blending, the top level computes optimal recipes for aggregated blends over periods initially delineated by inventory pinch points. Discrete-time middle level uses fixed blend recipes to compute an approximate schedule, i.e. what, when, and how much to produce; it also allocates swing storage and associated product shipments with specific storage. Continuous-time model at the third level computes when exactly to start/stop an operation (blend, tank transfer, shipment). MPIP-C algorithm solves linear or nonlinear problems 2–3 orders of magnitude faster than full-space models.     

Improved continuous-time model for gasoline blend scheduling

This work introduces a reduced-size continuous-time model for scheduling of gasoline blends. Previously published model has been modified by (i) introducing new model features (penalty for deliveries in order to reduce sending material from different product tanks to the same order, product and blender-dependent minimum setup times, maximum delivery rate from component tanks, threshold volume for each blend), (ii) by reducing the number of integer variables, and (iii) by adding lower bounds on the blend and switching costs, which significantly improve convergence. Nonlinearities are introduced by ethyl RT-70 equations for octane blending. Medium-size linear problems (two blenders, more than 20 orders, 5 products) are solved to optimality within one or two minutes. Previously unsolved large scale blending problems (more than 35 orders, 5 product, 2 or 3 blenders) have also been solved to less than 0.5% optimality gap.     

A multi-level simulation approach for the crude oil loading/unloading scheduling problem

An integrated approach for refinery production scheduling and unit operation optimization problems is presented. Each problem is at a different decision making layer and has an independent objective function and model. The objective function at the operational level is an on-line maximization of the difference between the product revenue and the energy and environmental costs of the main refinery units. It is modeled as an NLP and is constrained by ranges on the unit's operating condition as well as product quality constraints. The production scheduling layer is modeled as an MILP with the objective of minimizing the logistical costs of unloading the crude oil over a day-to-week time horizon. The objective function is a linear sum of the unloading, sea waiting, inventory, and setup costs. The nonlinear simulation model for the process units is used to find optimized refining costs and revenue for a blend of two crudes. Multiple linear regression of the individual crude oil flow rates within the crude oil percentage range allowed by the facility is then used to derive linear refining cost and revenue functions. Along with logistics costs, the refining costs or revenue are considered in the MILP scheduling objective function. Results show that this integrated approach can lead to a decrease of production and logistics costs or increased profit, provide a more intelligent crude schedule, and identify production level scheduling decisions which have a tradeoff benefit with the operational mode of the refinery.     

Effect of Blending Procedure on Tensile and Degradation Properties of Toughened Biodegradable Poly(lactic acid) Blend with Poly(trimethylene terephthalate) and Reactive Compatibilizer

This research focuses on brittleness improvement of biodegradable poly(lactic acid) (PLA) by reactive melt blending with poly(trimethylene terephthalate) (PTT). First, PLA is simultaneously blended with PTT and a reactive compatibilizer, poly(ethylene‐co‐glycidyl methacrylate) (PEGMA), (one‐step blending procedure). In the PLA/PTT/PEGMA blend, PEGMA mainly disperses in the PLA matrix phase, and the blend shows unimproved tensile properties. To increase the reaction between PTT and PEGMA, PEGMA is sequentially blended with PTT then PLA (two‐step blending procedure). This procedure is effective in drastically enhancing elongation at break of the blend. The strain at break of the blend formed by two‐step blending is significantly improved because the blending procedure affects the blend morphology. PLA‐g‐PEGMA‐g‐PTT graft copolymer is formed at the interface between PLA and PTT during reactive melt blending with PEGMA when the two‐step blending procedure is employed as a blending method which is confirmed by Fourier transform infrared spectroscopy and viscosity measurement. Such features bring about craze formation during tensile test and this is the reason why the toughening is achieved by the two‐step blending procedure.     

Reduction of the elongation at break of thermoplastic polyolefins through melt blending with polylactide and the influence of the amount of compatibilizers and the viscosity ratios of the blend components on phase morphology and mechanics

The objective of this work is the synthesis of a polypropylene/ethylene‐propylene‐rubber (TPO)/polylactide (PLA)/compatibilizer (PVM) blend to reduce the elongation at break of TPO by blending TPO with brittle PLA. Three TPO types with different viscosities were melt blended with PLA and an ethylene/n‐butylacrylate/glycidyl methacrylate terpolymer (PVM) as reactive compatibilizer. All blends had a constant PLA amount of 30 wt%. Two parameters were varied in the experiments, viscosity of the TPO types, and amount of PVM used in the blends. Both parameters played important roles in reducing the nominal elongation at break compared to pure TPO foils and influencing the phase morphology of extruded blend foils. The nominal elongation at break could be reduced by 100‐150% through blending TPO with PLA and PVM. Characterization regarding the blend morphology, especially the size and shape of the dispersed PLA phase in the TPO matrix was done by Environmental Scanning Electron Microscopy (ESEM) images. Investigations of the morphology showed that size and shape of dispersed PLA phases are dependent on the viscosity ratios of the blend components and on the amount of compatibilizer in the blend. AFM images of the polymer blends reveal soft rubbery layers around the dispersed PLA phases. POLYM. ENG. SCI., 56:905–913, 2016. © 2016 Society of Plastics Engineers     

Composite planning and scheduling algorithm addressing intra‐period infeasibilities of gasoline blend planning models

Multi‐period planning models result in solutions which are feasible at the boundaries of the periods but may be infeasible within the periods. The composite algorithm presented here (i) solves coarse multi‐period MILP model structure for production planning; (ii) sequences operations via a genetic algorithm to minimise switching; (iii) verifies schedule feasibility via agent‐based simulation and local logical decision making; and (iv) if infeasible, re‐partitions the time horizon into multi‐periods and resolves from (i) until feasible. Application of the algorithm to gasoline blending illustrates its effectiveness in computing feasible plans and schedules for such systems. © 2012 Canadian Society for Chemical Engineering     

Preparation and Characterization of Human Milk Fat Substitutes Based on Triacylglycerol Profiles

Human milk fat substitutes (HMFS) having similarity in (TAG) composition to human milk fat (HMF) were prepared by Lipozyme RM IM‐catalyzed interesterification of lard blending with selected oils in a packed bed reactor. Four oil blends with high similarity in fatty acid profiles to HMF were first obtained based on the blending model and then the blending ratios were screened based on TAG composition similarity by enzymatic interesterification in a batch reactor. The optimal ratio was determined as lard:sunflower oil:canola oil:palm kernel oil:palm oil:algal oil:microbial oil = 1.00:0.10:0.50:0.13:0.12:0.02:0.02. This blending ratio was used for a packed bed reactor and the conditions were then optimized as residence time, 1.5 h; reaction temperature, 50 °C. Under these conditions, the obtained product showed high degrees of similarity in fatty acid profile with 39.2 % palmitic acid at the sn‐2 position, 0.5 % arachidonic acid (n‐6) and 0.3 % docosahexaenoic acid (n‐3) and the scores for the degree of similarity in TAG composition was increased from 58.4 (the oil blend) to 72.3 (the final product). The packed bed reactor could be operated for 7 days without significant decrease in activity. The final product presented similar melting and crystallization profiles to those of HMF. However, due to the loss of tocopherols during deacidification process, the oxidative stability was lower than that of the oil blend. This process for the preparation of HMFS from lard with high similarity in TAG composition by physical blending and enzymatic interesterification, as optimized by mathematical models in a packed bed reactor, has a great potential for industrialization.     

Inventory pinch based,multiscale models for integrated planning and scheduling‐part I: Gasoline blend planning

A two‐level algorithm to compute blend plans that have much smaller number of different recipes, much shorter execution times, and the same cost as the corresponding multiperiod mixed‐integer nonlinear programming is introduced. These plans become a starting point for computation of approximate schedules, which minimize total number of switches in blenders and swing tanks. The algorithm uses inventory pinch points to delineate time periods where optimal blend recipes are likely constant. At the first level, nonlinear blend models are optimized via nonlinear programming. The second level uses fixed recipes (from the first level) in a multiperiod mixed‐integer linear programming to determine optimal production plan followed by an approximate schedule. Approximate schedules computed by the multiperiod inventory pinch algorithm in most of the case studies are slightly better than those computed by global optimizers (ANTIGONE, GloMIQO) while requiring significantly shorter execution times. Such schedules provide constraints for subsequent detailed scheduling in Part II. © 2014 American Institute of Chemical Engineers AIChE J, 60: 2158–2178, 2014     

Preparation of PVDF/poly(tetrafluoroethylene‐co‐vinyl alcohol) blend membranes with antifouling propensities via nonsolvent induced phase separation method

Poly(vinylidene fluoride) (PVDF) was blended with a new amphiphilic copolymer, poly(tetrafluoroethylene‐co‐vinyl alcohol) [poly(TFE‐VA)], via non‐solvent induced phase separation (NIPS) method to make membranes with superior antifouling properties. The effects of the VA/TFE segment ratio of the copolymer and the copolymer/PVDF blend ratio on the properties of the prepared membranes were studied. Membranes with similar water permeabilities, surface pore sizes, and rejection properties were prepared and used in bovine serum albumin (BSA) filtrations with the same initial water flux and almost the same operating pressure, to evaluate the sole effect of membrane material on fouling propensity. While the VA/TFE segment ratio strongly affected the membrane antifouling properties, the effects of the copolymer/PVDF blending ratio were not so drastic. Membrane surface hydrophilicity increased, and BSA adsorption and fouling decreased upon blending a small amount of amphiphilic copolymer with a high VA/TFE segment ratio with PVDF (copolymer/PVDF blending ratio 1:5). © 2016 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2016 , 133, 43780.     

Optimization models for planning shale gas well refracture treatments

Refracturing is a promising option for addressing the characteristically steep decline curves of shale gas wells. In this work we propose two optimization models to address the refracturing planning problem. First, we present a continuous‐time nonlinear programming model based on a novel forecast function that predicts pre‐ and post‐treatment productivity declines. Next, we propose a discrete‐time, multi‐period mixed‐integer linear programming (MILP) model that explicitly accounts for the possibility of multiple refracture treatments over the lifespan of a well. In an attempt to reduce solution times to a minimum, we compare three alternative formulations against each other (big‐M formulation, disjunctive formulation using Standard and Compact Hull‐Reformulations) and find that the disjunctive models yield the best computational performance. Finally, we apply the proposed MILP model to two case studies to demonstrate how refracturing can increase the expected recovery of a well and improve its profitability by several hundred thousand USD. © 2016 American Institute of Chemical Engineers AIChE J, 62: 4297–4307, 2016     

Inventory pinch based,multiscale models for integrated planning and scheduling‐part II: Gasoline blend scheduling

Integration of planning and scheduling optimizes simultaneous decisions at both levels, thereby leading to more efficient operation. A three‐level discrete‐time algorithm which uses nonlinear models and integrates planning and detailed scheduling is introduced: first level optimizes nonlinear blend models via multiperiod nonlinear programming (NLP), where period boundaries are initially determined by the inventory pinch points; second level uses fixed recipes (from the first level) in a multiperiod mixed‐integer linear program to determine first an optimal production plan and then to optimize an approximate schedule which minimizes the total number of switches in blenders and swing tanks; third level computes detailed schedules that adhere to inventory constraints computed in the approximate schedule. If inventory infeasibilities appear at the second or the third level, the first‐level periods are subdivided and blend recipes are reoptimized. Algorithm finds the same or better solutions and is substantially faster than previously published full‐space continuous‐time model. © 2014 American Institute of Chemical Engineers AIChE J, 60: 2475–2497, 2014     

非金属汽油辛烷值改进剂工业应用分析

针对FCC汽油降烯烃后辛烷值低影响企业高辛烷值汽油调和的问题,室内评价了不同FCC汽油馏分对WK-602型辛烷值改进剂的感受性及与其它调和组分的相互作用。结果表明WK-602可有效提高汽油辛烷值,基础汽油的辛烷值愈低作用效果愈明显,添加量每增加0.5%,RON值可提高0.7~1个单位,与其它高辛烷值组分/添加剂的互溶性好,无消极作用;工业放大应用显示WK-602与高辛烷值组分/添加剂混合分散均匀,调和生产的97#车用汽油指标满足质量标准要求。应用WK-602辛烷值改进剂调和生产93#、97#汽油产品的经济效益良好。     

The effect of the addition of poly(styrene‐co‐glycidyl methacrylate) copolymer on the properties of polylactide/poly(methyl methacrylate) blend

The effect of the addition of poly(styrene‐co‐glycidyl methacrylate) P(S‐co‐GMA) copolymer on the properties of melt blended polylactide/poly(methyl methacrylate) (PLA/PMMA) 80/20 (wt %) composition was studied. In the literature high ductility levels were achieved by melt blending PLA with different additives. However, the gained ductility was counter balanced with drastic drops in strength and modulus values. The novelty of this work was the preparation of PLA‐based blends with polylactide content higher than 75 wt % which showed an impact resistance value improvement of about 60% compared with the neat PLA and maintained similar tensile strength and modulus values as well as glass transition temperature to neat PLA. The addition of only 3 pph of copolymer to PLA/PMMA blend improved the impact resistance almost 100%. The chemical reaction between PLA/PMMA blend and P(S‐co‐GMA) copolymer were analyzed by FTIR, rotational rheometry, and GPC/SEC. Phase structure and morphology were studied by Differential Scanning Calorimetry and Scanning Electronic Microscopy. Tensile and impact properties as well as thermal stability were also studied. Results showed that as the amount of copolymer in the blend was increased then higher was average molecular weight and polydispersity index. After the addition of P(S‐co‐GMA) copolymer to the PLA/PMMA blend the impact resistance, elongation at break and thermal stability were improved while tensile strength and elastic modulus remained almost unaltered. © 2016 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2016 , 133, 43935.     

Gasoline permeation resistance of the as‐blow‐molded and annealed polyethylene,polyethylene/polyamide,and polyethylene/modified polyamide bottles

An investigation of the gasoline permeation resistance of the as‐blow‐molded and annealed polyethylene, polyethylene (PE)/polyamide (PA), and polyethylene/modified polyamide (MPA) bottles is reported. The gasoline permeation resistance improves dramatically after blending PA and MPA barrier resins in PE matrices during blow‐molding, and the order of barrier improvement corresponds to the order of barrier improvement of the barrier resins added in PE. Somewhat unexpectedly, the gasoline permeation rates of the annealed PE and/or PE/PA bottles annealed at 90°C or higher temperatures increase significantly with the annealing temperature and time. On the contrary, the gasoline permeation resistance of the annealed PE/MPA bottles increase significantly as the annealing temperature and/or time increase. For instance, the gasoline permeation rate of the PE/MPA bottle annealed at 120°C for 32 h is about 190 times slower than that of the as‐blow‐molded PE bottle. Further investigations found that, after blending the MPA and PA barrier resins in PE matrices, the relatively nonpolar hydrocarbon components present in the gasoline fuels were significantly blocked, without permeation during the permeation tests, in which the as‐blow‐molded PE/MPA bottle inhibited the permeation of hydrocarbon components more successfully than did the as‐blow‐molded PE/PA bottle. In contrast, the amounts of polar components that permeated through the as‐blow‐molded PE/PA and PE/MPA bottles were very small and about the same as the amount that permeated through the as‐blow‐molded PE bottle. Possible mechanisms accounting for these interesting behaviors are proposed in this study. © 2001 John Wiley & Sons, Inc. J Appl Polym Sci 81: 2827–2837, 2001