Chapter 8 Process Optimisation
Chapter 8 Process Optimisation
Chapter 8 Process Optimisation
Process Optimization
Definition of Optimization
The more stages, the higher the capital cost and the
lower the operating cost.
Reflux Ratio
RR*
Features of Optimization Problem
objective function to be
minimised (or
maximised)
min f(xi)
xi vector of decision
variables to be chosen to
find the min. of f(x)
i = 1, 2, … i
Subject to
c(xi) = 0 g(xi) 0 in-equality
constraints
equality
constraints
Terminology
Objective function
Function that you wish to minimize or maximize, usually an
economic value eg. maximize profit, production rate,
throughput, minimize energy utilisation, cost
Decision variables
Variables that you can adjust (manipulate) or chose in order
to minimize or maximize the objective function
Variables can be:
Real eg. flow rates, concentration, temperature, pressure
Integers eg. No. of trays
Binary eg. Select/not select - plant process flowsheet
Constraints
Limitations on the free adjustment of decision variables.
They can be physical, economic, policy, or environmental
Constraints can be explicitly defined in terms of the decision
variables eg. flow rate > 0 or implicitly defined in terms of
other variables eg. product concentration > 95%
Linear Objective Function
Maximum objective function is desired.
f(x) f(x)
x xopt = xU x
f(x) f(x)
xL xopt x xopt = xU x
Chemical Contribution
Product Nitrogen Phosphate
(lb/bag) (lb/bag)
Super-gro 2 4
Crop-quick 4 3
The farmer requires at least 16 pounds of nitrogen and 24 pounds of phosphate. Super-gro
costs $6/bag, and Crop-quick costs $3/bag. The farmer wants to know how many bags of each
brand to be purchased in order to MINIMIZE the total cost of fertilizing.
Solution for Example 1
Step 1: Define the desicion variables
x1 = bags of Super-gro
x2 = bags of Crop quick
Inequality constraint
2x1 + 4x2 16 (nitrogen constraint)
4x1 + 3x2 24 (phosphate constraint)
4
2x1 + 4x2 = 16
2
2 4 6 8 10 12 14 x1
Step 6: Perform sensitivity analysis e.g. What if the cost of raw material is increased by 10%.
Example 2
Ready-Mixes produces both interior and exterior paints from two raw material,
M1 and M2. the following table provides the basic data of the problem
Profit per 5 4
ton ($1000)
A market survey indicate that’s the daily demand for interior paint cannot
exceed that for exterior paint by more than 1 ton. Also, the maximum
daily demand for interior paint is 2 tons. Determine the optimum (best)
product mix of interior and exterior paints that maximizes the total daily
profit.
Solution for Example 2
7
6
5
4 M1 const
3 M2 const
X1
2 Market limit
1 Demand limit
0
-1 0 1 2 3 4 5 6 7
-2
X2
Answer:
Example 3
During the 2002 Winter Olympics in Salt Lake City, Utah, a local plant
X received a rush order for 100 gals of A containing 4.0 vol%
alcohol. Although no 4% A was in stock, large quantities of A-4.5 with
4.5% alcohol at a price of $6.40/gal and A-3.7 with 3.7% alcohol
priced at $5.00/gal were available, as well as water suitable for
adding to the blend at no cost. The plant manager wanted to use at
least 10 gal of A-4.5. Neglecting any volume change due to mixing,
determine the gallons each of A 4.5, A-3.7, and water that should be
blended together to produce the desired order at the minimum cost.
Use 6 steps approach to solve optimization problem.
Solution to Example 3
Step 1: Define the decision variables
V4.5 = gallons of A-4.5
V3.7 = gallons of A-3.7
Vw = gallons of water
Equality constraints
0.045V4.5 + 0.037 V3.7 + 0.00VW = 0.04(100) = 4.00 (eq 2)
V4.5 + V3.7 + VW = 100 (eq 3)
Inequality constraints
V4.5 10
V3.7 0
VW 0
.
Step 4 : Simplification.
The problem can be reduced to two decision variables by solving (eq 3) for
V3.7,
V3.7 = 100 – V4.5 – VW (eq 4)
And substituting it into (eqs 1 and 2) to give the following restatement of this
problem:
The optimal volume of A-3.7 need only to be calculated from (eq 4), after the
optimal volumes of A-4.5 and water have been determined from (eq 5). Since
the objective function, the equality constraints, and the lower and upper bound
are all linear, this constitutes an LP problem.
Step 5 : Choose suitable optimization technique
With just two decision variables, the problem can be shown graphically on a plot of V
against cost as shown in the following figure.
Feasible region
80
V A4.5 constraint
V, gallons
60 VA4.5
VW
40 VA3.7
20
V A4.5 constraint
V A3.7 & V W 0
constraint
540 545 550 555 560 565 570 575
-20
Cost, $
With the constrained given, the optimal solution is when V4.5 is 37.5 gal,
V3.7 is 62.5 and V is 0 with the minimum cost at $552.50.
Example 4
A chemical plant makes three products
(E, F, G) and utilizes three raw materials Maximum
(A, B, C) in limited supply. Each of the Raw available, Cost,
three products is produced in a separate Material lb/day cent/lb
process (1, 2, 3); a schematic of the plant
is shown in Fig. 2. The available materials A 40,000 1.5
A, B and C do not have to be totally
consumed. Find the optimum production to B 30,000 2.0
maximize the total operating profit per day
in $/day C 25,000 2.5
Reactant
requirement (lb) Processing Selling price
Process Product per lb product cost of product
1 E 2/3 A, 1/3 B 1.5 cent/lb E 4.0 cent/lb E
2 F 2/3 A, 1/3 B 0.5 cent/lb F 3.3 cent/lb F
3 G 1/2 A, 1/6 B, 1/3 C 1.0 cent/lb G 3.8 cent/lb G
The reactions involving Process 1: A + B E
A, B and C Process 2: A + B F
Process 3: 3A + 2B + C G
are as follows:
A
1 E
2 F
B
3 G
C
Step 1 : Define the decision variable, XA, XB, Xc, XE, XF, XG
Step 2 : Define the objective function
Profit = Income – raw material cost – Processing cost
Income = 0.04 xE + 0.033 xF + 0.038 xG
Operating costs in $ per day include:
(a) Raw material costs : 0.015xA + 0.02xB + 0.025xC
(b) Processing costs: 0.015xE + 0.005xF + 0.01xG
Therefore
Max f(x) = (0.04xE + 0.033xF + 0.038xG) – (0.015xA + 0.02xB + 0.025xC + 0.015xE
+ 0.005xF + 0.01xG)
Step 4: Simplification
Not applicable
The optimization problem is comprised of a linear function and linear constrained, hence
linear programming would be the best technique. However, this problem cannot be solve
using graphical technique because it consists of more than 2 variables. Solve using
computation e.g. Excel Solver
The company has a daily budget of $45,000 for both plants combined. Based on past
sales, the company knows the maximum demand which is 6000 kg for NJ1 and 7000
kg for NJ2 daily. The selling price is $9/kg for NJ1 and $7/kg for NJ2. The company wants
to know how much of fertilizer per brand need to produce at each plant in order to
maximize profit.