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.     

改进生物地理学优化算法及其在汽油调合调度中的应用

汽油调合和调度优化问题中含有典型的非线性约束(NLP)问题。针对一般智能优化算法在解决此类优化问题中易陷于局部极值,提出了一种改进的生物地理学优化算法(HMBBO)。该算法设计了一种基于种群个体差异信息的启发式变异算子,弥补了Gauss变异、Cauchy变异算子缺乏启发式信息的不足,以解决原算法在局部搜索时易出现的早熟问题,提高算法的全局搜索能力,并且采用非线性物种迁移模型以适应不同的自然环境。采用4个测试函数进行仿真,结果表明:HMBBO算法与标准BBO算法、基于Gauss变异及基于Cauchy变异的BBO算法比较,其收敛速度和全局寻优能力有明显改善。汽油调合和调度优化实例表明,该算法能够快速有效地找到全局最优解。     

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 cost‐effective model for the gasoline blend optimization problem

Gasoline blending is a critical process with a significant impact on the total revenues of oil refineries. It consists of mixing several feedstocks coming from various upstream processes and small amounts of additives to make different blends with some specified quality properties. The major goal is to minimize operating costs by optimizing blend recipes, while meeting product demands on time and quality specifications. This work introduces a novel continuous‐time mixed‐integer linear programming (MILP) formulation based on floating time slots to simultaneously optimize blend recipes and the scheduling of blending and distribution operations. The model can handle non‐identical blenders, multipurpose product tanks, sequence‐dependent changeover costs, limited amounts of gasoline components, and multi‐period scenarios. Because it features an integrality gap close to zero, the proposed MILP approach is able to find optimal solutions at much lower computational cost than previous contributions when applied to large gasoline blend problems. © 2016 American Institute of Chemical Engineers AIChE J, 62: 3002–3019, 2016     

Multi‐period planning,design, and strategic models for long‐term,quality‐sensitive shale gas development

In this work we address the long‐term, quality‐sensitive shale gas development problem. This problem involves planning, design, and strategic decisions such as where, when, and how many shale gas wells to drill, where to lay out gathering pipelines, as well as which delivery agreements to arrange. Our objective is to use computational models to identify the most profitable shale gas development strategies. For this purpose we propose a large‐scale, nonconvex, mixed‐integer nonlinear programming model. We rely on generalized disjunctive programming to systematically derive the building blocks of this model. Based on a tailor‐designed solution strategy we identify near‐global solutions to the resulting large‐scale problems. Finally, we apply the proposed modeling framework to two case studies based on real data to quantify the value of optimization models for shale gas development. Our results suggest that the proposed models can increase upstream operators’ profitability by several million U.S. dollars. © 2016 American Institute of Chemical Engineers AIChE J, 62: 2296–2323, 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     

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     

A bio-inspired algorithm based on membrane computing and its application to gasoline blending scheduling

For the purpose of applying membrane computing as a global optimization technique, a bio-inspired algorithm based on membrane computing (BIAMC) is proposed to solve both constrained and unconstrained problems. The membrane structure used in BIAMC is a network of membranes that is inspired by the Golgi apparatus. In the process of approaching to the optimum solution, the objects containing a tentative solution are evolved by the rewriting rule in the parallel identical membranes and synthesized by the novel rules of target indication, transition and abstraction in the membrane of quasi-Golgi. The information transfers according to directions defined by the communication rule. Eight well-known unconstrained and constrained functions are used for performance testing. Then we apply the proposed algorithm with two schemes to solving a typical nonlinear optimization of gasoline blending and scheduling problem. The results show that the proposed approach can find optimal or close-to-optimal solutions efficiently.     

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。     

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     

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     

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     

Optimization of short-time gasoline blending scheduling problem with a DNA based hybrid genetic algorithm

Gasoline blending is a key process in the petroleum refinery industry posed as a nonlinear optimization problem with heavily nonlinear constraints. This paper presents a DNA based hybrid genetic algorithm (DNA-HGA) to optimize such nonlinear optimization problems. In the proposed algorithm, potential solutions are represented with nucleotide bases. Based on the complementary properties of nucleotide bases, operators inspired by DNA are applied to improve the global searching ability of GA for efficiently locating the feasible domains. After the feasible region is obtained, the sequential quadratic programming (SQP) is implemented to improve the solution. The hybrid approach is tested on a set of constrained nonlinear optimization problems taken from the literature and compared with other approaches. The computation results validate the effectiveness of the proposed algorithm. The recipes of a short-time gasoline blending problem are optimized by the hybrid algorithm, and the comparison results show that the profit of the products is largely improved while achieving more satisfactory quality indicators in both certainty and uncertainty environment.     

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     

A projection‐based method for production planning of multiproduct facilities

An algorithm is presented for identifying the projection of a scheduling model's feasible region onto the space of production targets. The projected feasible region is expressed using one of two mixed‐integer programming formulations, which can be readily used to address integrated production planning and scheduling problems that were previously intractable. Production planning is solved in combination with a surrogate model representing the region of feasible production amounts to provide optimum production targets, while a detailed scheduling is solved in a rolling‐horizon manner to define feasible schedules for meeting these targets. The proposed framework provides solutions of higher quality and yields tighter bounds than previously proposed approaches. © 2009 American Institute of Chemical Engineers AIChE J, 2009     

Moving horizon closed‐loop production scheduling using dynamic process models

The economic circumstances that define the operation of chemical processes (e.g., product demand, feedstock and energy prices) are increasingly variable. To maximize profit, changes in production rate and product grade must be scheduled with increased frequency. To do so, process dynamics must be considered in production scheduling calculations, and schedules should be recomputed when updated economic information becomes available. In this article, this need is addressed by introducing a novel moving horizon closed‐loop scheduling approach. Process dynamics are represented explicitly in the scheduling calculation via low‐order models of the closed‐loop dynamics of scheduling‐relevant variables, and a feedback connection is built based on these variables using an observer structure to update model states. The feedback rescheduling mechanism consists of, (a) periodic schedule updates that reflect updated price and demand forecasts, and, (b) event‐driven updates that account for process and market disturbances. The theoretical developments are demonstrated on the model of an industrial‐scale air separation unit. © 2016 American Institute of Chemical Engineers AIChE J, 63: 639–651, 2017     

A novel approach to scheduling multipurpose batch plants using unit‐slots

Several models for scheduling multipurpose batch plants exist in the literature. The models using unit‐specific event points have shown better solution efficiency on various literature examples. This article presents a novel approach to scheduling multipurpose batch plants, which uses unit‐slots instead of process‐slots to manage shared resources such as material storage. We develop two slightly different models that are even more compact and simpler than that of Sundaramoorthy and Karimi, Chem Eng Sci. 2005;60:2679–2702. Although we focus on material as a shared resource, our multi‐grid approach rationalizes, generalizes, and improves the current multi‐grid approaches for scheduling with shared resources. Our models allow nonsimultaneous transfers of materials into and out of a batch. We show by an example that this flexibility can give better schedules than those from existing models in some cases. Furthermore, our approach uses fewer slots (event‐points) on some examples than even those required by the most recent unit‐specific event‐based model. Numerical evaluation using literature examples shows significant gains in solution efficiency from the use of unit‐slots except where the number of unit‐slots required for the optimal solution equals that of process slots. We also highlight the importance of constraint sequencing in GAMS implementation for evaluating mixed‐integer linear programming based scheduling models fairly. © 2009 American Institute of Chemical Engineers AIChE J, 2010     

A data‐driven multistage adaptive robust optimization framework for planning and scheduling under uncertainty

A novel data‐driven approach for optimization under uncertainty based on multistage adaptive robust optimization (ARO) and nonparametric kernel density M‐estimation is proposed. Different from conventional robust optimization methods, the proposed framework incorporates distributional information to avoid over‐conservatism. Robust kernel density estimation with Hampel loss function is employed to extract probability distributions from uncertainty data via a kernelized iteratively reweighted least squares algorithm. A data‐driven uncertainty set is proposed, where bounds of uncertain parameters are defined by quantile functions, to organically integrate the multistage ARO framework with uncertainty data. Based on this uncertainty set, we further develop an exact robust counterpart in its general form for solving the resulting data‐driven multistage ARO problem. To illustrate the applicability of the proposed framework, two typical applications in process operations are presented: The first one is on strategic planning of process networks, and the other one on short‐term scheduling of multipurpose batch processes. The proposed approach returns 23.9% higher net present value and 31.5% more profits than the conventional robust optimization method in planning and scheduling applications, respectively. © 2017 American Institute of Chemical Engineers AIChE J, 63: 4343–4369, 2017     

Planning and scheduling of flexible process networks under uncertainty with stochastic inventory: MINLP models and algorithm

The tactical planning and scheduling of chemical process networks consisting of both dedicated and flexible processes under demand and supply uncertainty is addressed. To integrate the stochastic inventory control decisions with the production planning and scheduling, a mixed‐integer nonlinear programming (MINLP) model is proposed that captures the stochastic nature of the demand variations and supply delays using the guaranteed‐service approach. The model takes into account multiple tradeoffs and simultaneously determines the optimal selection of production schemes, purchase amounts of raw materials, sales of final products, production levels of processes, detailed cyclic production schedules for flexible processes, and working inventory and safety stock levels of all chemicals involved in the process network. To globally optimize the resulting nonconvex MINLP problems with modest computational times, the model properties are exploited and a tailored branch‐and‐refine algorithm based on the successive piecewise linear approximation is proposed. To handle the degeneracy of alternative optima in assignment configurations of production scheduling, three symmetry breaking cuts are further developed to accelerate the solution process. The application of the model and the performance of the proposed algorithm are illustrated through three examples with up to 25 chemicals and 16 processes including at most 8 production schemes for each flexible process. © 2012 American Institute of Chemical Engineers AIChE J, 59: 1511–1532, 2013