Heuristic Method for the Optimal Synthesis and Design of Batch Plants Considering Mixed Product Campaigns

Abstract

In this paper, a heuristic method is presented for the simultaneous solution of the synthesis and design problems of batch plants. A detailed nonlinear program (NLP) model is developed that considers a superstructure to represent all the configuration options for the plants. Usually, similar works in this area assume as a hard constraint the use of single-product campaigns. In this work, mixed campaigns are introduced to pose problems where this is a significant condition. Specific scheduling constraints are formulated, and a resolution strategy is presented to solve the problem. This formulation is valid for multiproduct batch plants and a special type of multipurpose plants where products follow different production paths sharing some but not all the stages. The approach is implemented for a Torula yeast, brandy, and bakery yeast production plant. To assess the method, different mixed campaigns are modeled. Economical and synthesis, design, and operational results are also reported.

A modeling strategy for integrated batch process development based on mixed-logic dynamic optimization

“…Hybrid discrete/continuous models have been widely used in DO problems for determining the optimal control profiles of individual processing units along time [14,15]. The optimization of dynamic control trajectories in given chains of process stages has been also applied in the context of batch process synthesis [26,30,27], batch plant design [38,51], and short-term scheduling [39,40,41,42], among others.…”

Multiperiod design and planning of multiproduct batch plants with mixed‐product campaigns

“…In this formulation, the designer proposes a set of possible MPCs according to some criteria. Corsano et al15 presented a heuristic procedure for determining possible campaigns, and then for each campaign a NLP problem was modeled and solved. Unlike that procedure, in this work, all the possible campaigns are simultaneously considered.…”

“…Multiperiod optimization models for design and planning in the chemical industry have received considerable attention in the last years 1–15. Often, taking into account the model complexity, these problems have been solved through decomposition approaches.…”

“…Finally, Corsano et al15 presented a work, where synthesis, design, and scheduling are simultaneously considered in a NLP model. They develop a heuristic procedure to decompose the problem, where in the first step the optimal structure of the plant is obtained.…”

Processes Integration: Multiplant Complex vs Multipurpose Plant Assessment

“…These constraints are established for two consecutive products to ensure that the production processes of two different products do not overlap in the same unit. A detailed description of these scheduling constraints can be found in work by Corsano et al 14 Once all of the proposed mixed-product campaign models are solved, the best economical solution is chosen as the optimal plant design, operation, and scheduling solution.…”