Integrated Scheduling and Dynamic Optimization of Batch Processes Yisu Nie 1 Lorenz T. Biegler 1 John M. Wassick 2 Carlos M. Villa 2 1 Center for Advanced Process Decision-making Department of Chemical Engineering Carnegie Mellon University 2 The Dow Chemical Company March 14, 2012 Yisu Nie (Carnegie Mellon University) EWO meeting March 14, 2012 1 / 11
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Integrated Scheduling and Dynamic Optimization ofBatch Processes
Yisu Nie1 Lorenz T. Biegler1 John M. Wassick2 Carlos M. Villa2
1Center for Advanced Process Decision-makingDepartment of Chemical Engineering
Carnegie Mellon University
2The Dow Chemical Company
March 14, 2012
Yisu Nie (Carnegie Mellon University) EWO meeting March 14, 2012 1 / 11
IntroductionBackground and motivation
Current industrial practice for batch production
Development of a batch process
Product recipescale-up−−−−→ Process recipe
scheduling−−−−−→ Production process
− Lost productivity and lowered performance in unit operations− Schedules sensitive to uncertainties in manufacturingI Opportunities for process optimization
Optimizing the performance of a batch process in real-time
Approach An optimization-based framework with integrated
Scheduling: assignment of batch operationsOptimal control: execution of batch operations
Benefit + Adding value to existing assets+ Improving plant profitability and reliability
Steps Off-line ⇒ On-line
Integrated optimizer
Batch plant
Schedule
Control strategy
⇓Integrated optimizer
Batch plant
Schedule
Control strategy
Feedback
Yisu Nie (Carnegie Mellon University) EWO meeting March 14, 2012 2 / 11
IntroductionBackground and motivation
Current industrial practice for batch production
Development of a batch process
Product recipescale-up−−−−→ Process recipe
scheduling−−−−−→ Production process
− Lost productivity and lowered performance in unit operations− Schedules sensitive to uncertainties in manufacturingI Opportunities for process optimization
Optimizing the performance of a batch process in real-time
Approach An optimization-based framework with integrated
Scheduling: assignment of batch operationsOptimal control: execution of batch operations
Benefit + Adding value to existing assets+ Improving plant profitability and reliability
Steps Off-line ⇒ On-line
Integrated optimizer
Batch plant
Schedule
Control strategy
⇓Integrated optimizer
Batch plant
Schedule
Control strategy
Feedback
Yisu Nie (Carnegie Mellon University) EWO meeting March 14, 2012 2 / 11
Problem DescriptionIntegrated scheduling and dynamic optimization of batch plants
GivenI A batch plant with existing equipmentI A time horizon to make productsI Knowledge of process dynamics
DetermineI The optimal production scheduleI The optimal equipment control strategy
Yisu Nie (Carnegie Mellon University) EWO meeting March 14, 2012 6 / 11
Case StudyOptimal operating profiles for batch units
Optimal temperature profiles of Reactor 1
4.0 5.0 6.0 7.0 8.0 9.0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8Sca
led
tem
p.
Time(hr)
Event slot 1: Reaction 1Recipe
Integrated
0.4 0.6 0.8 1.0 1.2
2 2.2 2.4 2.6 2.8 3 3.2 3.4 3.6Sca
led
tem
p.
Time(hr)
Event slot 2: Reaction 2
0.4 0.6 0.8 1.0 1.2
3.8 4 4.2 4.4 4.6 4.8 5 5.2 5.4Sca
led
tem
p.
Time(hr)
Event slot 3: Reaction 2
0.6 0.9 1.2 1.5 1.8
5.6 5.8 6 6.2 6.4 6.6 6.8 7 7.2Sca
led
tem
p.
Time(hr)
Event slot 4: Reaction 2
Dynamic profiles also obtained for Reactor 2 and Distillation Column
Yisu Nie (Carnegie Mellon University) EWO meeting March 14, 2012 7 / 11
Industrial Application at DowOptimizing a real-world process with the integrated method
Methodology development
Main resultsI An integrated optimization formulation for batch scheduling and dynamic
optimization based on the state equipment networkI A proof-of-concept case study: verified benefits of the integration
Application at Dow: an alkoxylation process
Process characteristicsI Polymerization reactions in semi-batch stirred tank reactorsI Finishing train as a continuous processI Multiple products differ in composite monomers, molecular weights,
functionality, etc.
Yisu Nie (Carnegie Mellon University) EWO meeting March 14, 2012 8 / 11
Industrial Application at DowOptimizing a real-world process with the integrated method
Methodology development
Main resultsI An integrated optimization formulation for batch scheduling and dynamic
optimization based on the state equipment networkI A proof-of-concept case study: verified benefits of the integration
Application at Dow: an alkoxylation process
Process characteristicsI Polymerization reactions in semi-batch stirred tank reactorsI Finishing train as a continuous processI Multiple products differ in composite monomers, molecular weights,
functionality, etc.
Yisu Nie (Carnegie Mellon University) EWO meeting March 14, 2012 8 / 11