Design and Scheduling of

Flexible Processing Systems:

An Optimization Approach
Ana Paula Barbosa Pvoa
Centro de Estudos de Gesto, CEG-IST
Instituto Superior Tcnico
Iberian Conference in Optimization, Coimbra, Nov. 2006,

Ana Pvoa

Ana Pvoa

Overview
Objective
Flexible Processing Systems
Problems & Challenges
Systems Approach
Processes, Resources, Operating Conditions
Generic Problems Representations
Scheduling
Design
Supply Chains
Conclusions & Future Work

Iberian Conference in Optimization, Coimbra, Nov. 2006,

Objective

Develop generic models for the

design and scheduling of flexible
process systems

Solution of Real Problems

Flexible Process Systems

High variety of

Products
Low Volumes
Batch and Semi-

Continuous
Operations
Multipurpose

Resources

Raw Materials

Products

Flexible Process Systems

ProductA
R1

RV1

RV1
ST1

R2

Product A

RD1
RD2

RV2

FT1
RV2

RD3
Product B
RD1
D1

RV1

RV1
RD2

D2

RD2

RV2

Product C
RV2

RD3
Campaign 1

Campaign 2

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Flexible Process Systems : Design +

Operation
Supply Chain Planning

Supply Chain Structure

Plants & Distribution Capacities

Production Planning

Resources Requirements in
New Plants /Existing Plants

Production Scheduling and

Re-scheduling

Maintenance & New Resources

Productions Control

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Process Industries: Motivation

Utilities

Chemical

Oil/Gas

Pharma/Fine

Metals

Diversity of Applications
Complex Production Processes
Improvement of Processes Efficiency
Client Satisfaction

Enviro

Food

Decision
Support
Systems

Costs Reduction

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Problems & Challenges

How to design these plants?
How to manage the plants resources?
How to design and manage the associated

supply chains?
SYSTEMS APPROCH

OPTIMIZATION...

Iberian Conference in Optimization, Coimbra, Nov. 2006,

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The Model
Develop the model for the problem;
Parameters definition
Sets definition
Variables definition
Binary (ex. Use or not the resource ?)
Continuous (ex. Batch sizes ?)
Constraints definitions
Objective definition

Complex Optimization Problems

Mixed Integer Linear/Non-Linear
Formulations
(MILPs & MINLPs)
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Solution Methods
Heuristics generic rules used to
alternatives (FIFO, ).
Meta-Heuristics
algorithms (e.g.
annealing, Tabu search, Ant colony, ).

evaluate
simulate

Artificial Intelligence Ruled based

methods, agent
r
methods.

Constraint Programming

Mathematical Programming MILPs and MINLPs

models, use of optimization algorithms (e.g.
GAMS/CPLEX, XPRESS)

Combination of Methods (Hybrid)

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Key Components
Tasks activities that transform the materials:

Processing
Storage
Transport
Resources:
r
Processing and storage equipments,
Transport
Man-power
Utilities
Time :
External - Production versus external demand
Internal Production Planning & Scheduling

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Treatment of time
The activities (tasks) must occur such that

the problem objectives are attained and no

restrictions are violated

The use of the resources by the tasks and its

availability along time must be analyzed

Continuous Time

Discrete Time
Slot 1

1
0

T-2

T-1

T
H

Slot 2

Slot T-2

T-2

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Slot T-1

T-1

T
H

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Discrete vs. Continuous Time

Discrete Time
Tight mathematical formulations
Large models small discretisation of time
Processing times independent of the batches.
Continuous Time
Loose mathematical formulations
Smaller models less points within the time grid
Time grid points determined by the model
Processing times may be dependent of the batches

Iberian Conference in Optimization, Coimbra, Nov. 2006,

Problems Representation

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(Pantelides, 2004)

Problems are very complex and very diverse

need a diverse set of techniques to match
problem characteristics
OR
Distinctions between different industrial design
& scheduling problems are not really sharp
uniform representations can be used

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Scheduling
Given:

Process description
Plant flow-sheet
Resources suitability tasks / materials
Operating constraints
Production demands
Costs/Values
Times of operation

Determine:
Optimal operation: scheduling
So as to:
Optimize an objective function
Min. Delays / Max. Prod./ Min Makespan
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Process Description
State-Task Network, STN

(Kondili, Sargent & Pantelides, 1988, 1993)

States
A

Mixture 1
Tasks
Reactions

80%

3h
C

2h

P1

20%
Add

75%

25%
Mixture 2

1h

P2

Non ambiguities in the process description:

Sharing of intermediate products;
Different processing alternatives;
Recycles.

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Process + Resources + Production

States
A

Mixture 1
Tasks
Reaction

80%

3h

320 t

C
400t

2h

P1

20%
Add

75%

600t

25%
Mixture 2

1h

P2

125 t
1450t

How long it takes to produce ?

(adapted, Shah, 2004)

Global Model
Process
Multipurpose Resources
Time representation
Operating Costs
Operating modes
Operating constraints
Demand

Constraints & Objective

Function Linear

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(Kondili et al, 1988, Shah et al 1993)

Tasks, States, STN

Capacity & Suitability
Discrete, Fixed Times
Batch linear function
Periodic e non periodic
Cleaning, etc.
Intervals, Fixed Values

MILP
Problem

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Scheduling

Batch de P2

Batch de P1

Answer : 26 hours
(adapted, Shah, 2003)

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STN Restrictions
Tasks are always associated to materials that
suffer transformation.
Tasks associated to a dingle equipment.
Each resource is treated independently and non
uniformly
Generalizations
constraints

implies

the

addition

of

Generic Models but with some complexity

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10

Resource -Task Network, RTN

(Pantelides, 1994)

Uniform treatment of all resources

- Materials
- Processing & Storage equipment
- Utilities & Man-power
- Connections
- Transport resources

Resources

Tasks

Classified accordingly to its

functionality
All resources of the same class
have the same functionality

Abstract operation that

consumes & produces
resources

Iberian Conference in Optimization, Coimbra, Nov. 2006,

Resource-Task Network, RTN

Reaction A

21

(Pantelides, 1994)

Reactor

B
A

Reaction A

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Reaction

B with cleaning
Cleaning
Reactor clean

Reactor dirty

Reaction

GENERIC & SIMPLE MODELS

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11

Formulations: STN versus RTN

)

MaxPR = Rr ,H +1 Rs,0 . vr + r ,t . vr
t

rRP

s.t.

s.t.
t
W
1 j ,t = 1,...,H

iI j t' =t pi +11 i, j,t'

0 S st C s

0 Rrt Rrtmax

r , t = 1,..., H

s , t = 1,..., H

VijminWijt Bijt Wijt Vijmax

0 U ut U umax

Vkrmin N kt kt N kt Vkrmax

i, j Ki , t = 1,..., H

u, t = 1,..., H

U ut = ( uiWijt + ui Bijt )
i

MaxPR = S s,H +1 S s,0 . vs + Ds,t . vs

t

sSP

k , r PEk , t = 1,..., H

Rr ,t = R
+
( kr N k ,t + kr k ,t ) + rt
s,t 1
k =0

u , t = 1,..., H

r , t = 1,...,H + 1

jki

S s,t = S s,t 1 + is Bi, j ,t + is Bi, j ,t Ds,t + Rs,t

i
iT
jK
iT
jK
s

s , t = 1,...,H + 1

Rrt , N kt , kt , rt

S st ,Wijt , Bijt , Dst , Rst

Iberian Conference in Optimization, Coimbra, Nov. 2006,

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Scheduling: Caima Pulp Mill

(Castro, Barbosa-Pvoa e Matos, 2002)
S tream 3

S plitte r

Digester

S tream 4

Four Digesters
operating in batch mode
(D3, D4, D5 e D6)

S tream 2
S tream 1

He a t E xcha nge r

Vapor resource limitation

What is the optimal digesters sequence that

maximizes production while account for vapor
limitations?
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12

Scheduling: Caima Pulp Mill

(Castro, Barbosa-Pvoa e Matos, 2002)

Process:
1
2
3
4
5
6

Chip filling;
Acid filling
Heating ( 55C to 130C)
Cooking
Degasification (high & low pressure)
Blowing

Cyclic Operation sequence that is repeated

Iberian Conference in Optimization, Coimbra, Nov. 2006,

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Scheduling: Caima Pulp Mill

(Castro, Barbosa-Pvoa e Matos, 2002)

Detailed Model (gPROMS)

Cooking Operation modeling
Optimal
Sequence
RTN Model Scheduling
Time Discretisation

Iberian Conference in Optimization, Coimbra, Nov. 2006,

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13

Cooking Process, RTN

R1
D3

S1

D4

S1

D5
D6

S1
S1

(Castro, Barbosa-Pvoa e Matos, 2002)

R2

R3

k=1

S2

k=2

S3

k=3-10

k=1

S2

k=2

S3

k=3-10

k=1

S2

k=2

S3

k=3-10

k=1

S2

k=2

S3

k=3-10

S8
S8
S8
S8

D3

k=14

S11

k=13

S10

k=12

S9

k=11

D4

k=14

S11

k=13

S10

k=12

S9

k=11

D5

k=14

S11

k=13

S10

k=12

S9

k=11

D6

k=13

S11

k=13

S10

k=12

S9

k=11

R6

R4

R5

Heating phase simplification K=3-10

Iberian Conference in Optimization, Coimbra, Nov. 2006,

Heating Phase, RTN

27

(Castro, Barbosa-Pvoa e Matos, 2002)

H 0 (3,3)

S3

Ana Pvoa

H 1 (3,3)
H 1 (4,3)

S5

H 0 (3 ,4 )

H 1 (5,3)

H 1 (3,4)

S6

H 0 (3 ,5 )

H 1 (6,3)

S7

H 0 (3 ,6 )

H 1 (3,6)

H 1 (3,4)

S5

H 0 (4 ,3 )

H 1 (4,3)

H 1 (5,4)

S6

H 0 (4 ,5 )

H 1 (6,4)

S4

H 1 (3,5)

S8

D3

H 0 (4,4)
S3

D4

D5

H 1 (4,4)
S4

H 1 (4,5)

S7

H 0 (4 ,6 )

H 1 (4,6)

H 1 (3,5)

S5

H 0 (5 ,3 )

H 1 (5,3)

H 1 (4,5)

S6

H 0 (5 ,4 )

S4

H 1 (5,4)

H 0 (5,5)

S3

D6

S8

S8
H 1 (5,5)

H 1 (6,5)

S7

H 0 (5 ,6 )

H 1 (5,6)

H 1 (3,6)

H 1 (6,3)

S5

H 0 (6 ,3 )

H 1 (4,6)

S6

H 0 (6 ,4 )

H 1 (5,6)

S7

H 0 (6 ,5 )

S4

H 1 (6,4)

S8

S3

H 0 (6,6)

H 1 (6,5)
H 1 (6,6)

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14

Scheduling: Caima Pulp Mill

(Castro, Barbosa-Pvoa e Matos, 2002)

Optimal Sequence
13 t/h

14 t/h

Optimal Sequence

D3-D4-D5-D6

D3-D6-D4-D5

Cycle Time (min.)

605

595

Scenarios Study

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Optimal Scheduling for 14 ton/hr

(Castro, Barbosa-Pvoa e Matos, 2002)
Chip filling

Acid filling

Steam sharing

Heating till 90C (H0)

Final heating (H1)

Cooking

HP Degassing

LP Degassing

Blowing

D6

D5

D4

D3

200

400

600

800

1000

1200

1400

1600

1800

2000

2200

2400

2600

2800

3000

Time (min)

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15

Flexible Systems Scheduling

(Shah, 1998, Floudas & Lin, 2004, Mendez et al., 2005)

Generic & Flexible Representations

Detailed Models

BUT IS MISSING .
Dynamic Scheduling treatment
Uncertainty study
Explore more efficient solution methods complex

problems

Real cases solution

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Design / Retrofit
Given:
Process Description
Plant Superstructure : Equipment & Topology
Equipment Suitability Tasks/Materials
Operational constraints
Demands
Operating & Investment Costs/Values
Operation times
Determine:
Plant design : Equipment & Topology
Optimal Operation : scheduling
So as to:
Optimize and Objective Function
Min. Costs / Max. Profit
Iberian Conference in Optimization, Coimbra, Nov. 2006,

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Design / Retrofit

(Barbosa-Pvoa e Macchietto, 1994)

State-Task Network, STN

2h
S1

T1

2h
0.6

S3
0.6

S4

T2

S6

S1/V1

T3

0.4

maximal State-Task Network, mSTN

0.4
4h

2h
S2

T4

S5

T1/R1

S2/V2

T4/R3

T2/R1

S6/V6
S5/V5

T3/R3
S4/V4

Equipment Network, Flowsheet

Only feasible configurations
V1

V2

Precise representation of :

V5

R1
R1

R3

V4

- all transfers
- all material locations
- any storage policies

V6

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Equipment-Process Modeling

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(Barbosa-Pvoa & Macchietto, 1997)

Equipment State- Task Network (eSTN)

( i.e. Reactor R1)
( i.e. Connection)

R1_Sujo_S3
Limpeza

T1

C_Limpa

C_Suja

tr_S3

R1_Limpo

tr_S4

R1_Sujo_S4
T2

tr_gua

- eTask (process, storage, services & Transfers)

- eState (connections / units)

Define allowable states of each piece of equipment /

connection (eStates)
Define allowable transformations between equipment
states caused by process, transfers, storage and
cleaning tasks (eSTN Tasks)

Representing:
-precedence constraints
-sequence dependencies
-cleaning requirements

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17

Design - Modeling
Process Networks
products recipes (ex. make A)
ancillary operations (ex. clean)

Equipment Network
- Units
- Connections

Flowsheet

(Barbosa-Pvoa, 1994)

STN

Equipment / Process
Units / Tasks-States (Suitability)
Connections / States
mSTN
*

Operational Pre-conditions
- Equipment States
- Product precedence orders
- Cleaning needs

eSTN
*

- generated automatically
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Model Characteristics

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(Barbosa-Pvoa and Machietto, 1994)

Process Representation, STN;

Resources with Discrete & Continuous Capacity;
Plant Topology
Time Discretisation;
Short-term & Periodic Operation;
Multipurpose Resources
Fixed Processing Times;
Non-preemptive Operations;
Generic Storage Policies;
Operating demands;
Utility circuits;
Multi-product operation.

Objective
Function

MILP
Problem

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18

Retrofit: Example

(Barbosa-Pvoa, 1994)

Expand Existence Capacity ???

If Profitable???

How to expand ???

How much it costs ???

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Retrofit: Example

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(Barbosa-Pvoa, 1994)

Process Representation (STN)

RMA

RML
0.2

RMP
0.5

R_INTA
0.5
RMD

0.1
0.33
0.2
0.34
10 h
0.8
5h
0.4
SEP_A
R_INTB
IMPB
INTA
WASH_B
INTC
R_INTC 10 h
0.8
0.9
0.2
0.33
0.2
0.1
0.2
WA
WB
15 h

10 h
IMPA

RMW
IMPC
0.1
PROC

0.9

0.9
0.1

WASH_C
5h

WC

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19

Retrofit: Example

(Barbosa-Pvoa, 1994)

Superstructure Flowsheet
(in black existing plant in red possible additions)
F_RMA

RC1
F_RML

F_RMP
F_RMW
F_RMD

RA1
RC2

VB1

Sep1
RA2

VA1
Sep2

RC3

WB1

RA3
RB1

WC1

VwA

VB2

RC4

RA4
RA5

Sep3

VA2

WB2

RC5

RB2
WC2

VwB

VwC

VC2
VC1

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Retrofit: Example

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(Barbosa-Pvoa, 1994)

Optimal Structure
F_RMA
RC1
F_RML

F_RMP
F_RMW

F_RMD
F_RMD

RA1
VB1

Sep1
RA2

VA1
VwA

RC2
RC3

WB1
RB1

WC1
RC4
RC5
VwB

VwC
VC2

VC1

Profit = (> 20%)

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20

Retrofit: Example

R_INTA
100
IMPA
100

Reactor RA1
Reactor RA2

Filter WB
Reactor RC1
Reactor RC2
Reactor RC3
Reactor RC4
Reactor RC5
Filter WC
250

Tank VB1

SEP_A
200

R_INTA
78

IMPA
78

R_INTA
100

R_INTA
100
SEP_A
178

SEP_A
200

R_INTB
300

Reactor RB

Tank VA1

R_INTA
100
R_INTA
100

SEP_A

Separator Sep1

(Barbosa-Pvoa, 1994)

R_INTB
R_INTB
R_INTB
R_INTB
300
300
300
160
WASH_B
WASH_B
WASH_B
WASH_B
WASH_B
375
375
350
375
200
R_INTC
R_INTC
R_INTC
R_INTC
R_INTC
100
100
30
100
100
R_INTC
R_INTC
R_INTC
R_INTC
R_INTC
R_INTC
30
100
30
30
100
100
R_INTC
R_INTC
R_INTC
R_INTC
R_INTC
R_INTC
100
100
100
100
100
100
R_INTC
R_INTC
R_INTC
R_INTC
R_INTC
R_INTC
100
100
100
100
100
100
R_INTC
R_INTC
R_INTC
R_INTC
R_INTC
R_INTC
230
230
230
230
230
230
WASH_C WASH_C WASH_C WASH_C WASH_C WASH_C WASH_C WASH_C WASH_C WASH_C WASH_C WASH_C
267
222
400
222
400
222
400
222
400
222
367
333

0
150
0
0

10

15

20

25

30

35

40

45

50

55

60

Tempo de Cycle (hr)

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Design & Retrofit - RTN

Generic Models

Plants Topology
Multipurpose Resources
Operating Constraints
Discrete & Continuous Capacities
Cyclic & Short Term Operation
Time
Discrete (Pinto, Barbosa-Pvoa e Novais, 2005)
Continuous (Castro, Barbosa-Pvoa e Novais, 2005)

Investment in the models applications

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21

Design of Flexible Systems

(Barbosa-Pvoa, 2006)

Details models but exists space for much more :

Multi-level models (design, planning & scheduling)

Multi-objective models
Uncertainty modeling
Explore more efficient solution methods

Explore the solutions of real cases

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Supply Chain
Optimization
Distribution

Production

Integration
Demand

Supply

Return

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Optimization Opportunities
The supply chains are difficult to understand
Decisions are frequently based on common

sense

Optimization tools allow the possibility of

looking in an integrated form to:

Design & Operational decisions

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Supply Chains
Previous representations can be extended

to the supply chain

Knowledge obtained within the design and

scheduling problems should be used.

Models
Detailed and able to capture interactions
Deal with uncertainty
Dynamic & Flexible
Extensible
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23

Supply Chains Operation

(Amaro e Barbosa-Pvoa, 2004, 2006)

TOPOLOGY
Chain Structure
Transportation Network

OPERATION

Model
(MILP)

ChainSTN

Tasks
Materials flows

MARKET ASPECTS
Supply/Demand
Constraints Iberian Conference in Optimization, Coimbra, Nov. 2006,

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Closed Loop Supply Chain with return of non-conform

products: Pharmaceutical Industry
(Amaro e Barbosa-Pvoa, 2006)
Products
White

Final

IP1
IP2
IP3
Europe

AP

BC1

.
.
.

IP4

Europe

WH1

PC
SC
EC

WSH1

I1
I3

WH2

SP

I2

BC2

Ii

Plants: I1, I2, I3

Airport and Sea Port

Africa

WSH2

Distribution Sites

WH3
Europe

Burning Centers
Forward flows
(white/ final Products)
Reverse flows
(Recycle, Remanufacturing, Burning)

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Closed Loop Supply Chain with return of non-conform

products: Pharmaceutical Industry
(Amaro e Barbosa-Pvoa, 2006)

Main Operations
Production intermediate medicines production (not for sale)
involves essentially operations like:
sterilization,
components calibration,
mixing, etc.
Customization considers operations as:
filling,
blistering,
packing, etc.
Distribution and Supply considers operations as:
storing,
distribution.
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Closed Loop Supply Chain with return of non-conform

products: Pharmaceutical Industry
(Amaro e Barbosa-Pvoa, 2006)
BF3

BF1 BF2 BF3 BF4

I1

BF4

I2

BF2
RF2

BF3
RF3

BC 2

BF3
RF3

BF4
RF4

I1
BFi

BF4
RF4

BF1
RF1

BF2
RF2

I2
RFi

BFi

Ws

RC RM

Transporte

BF3
RF3

I3
BFi

RFi

Valncia-U

I 1 Produo

Scenario 1 no recover,
Burning (SC1)

I3

BC 1

BF1
RF1

BF1 BF2 BF3 BF4

RFi

BF4
RF4

Scenario 2 recover,
without minimums (SC2)
with minimums (SC3)

Transporte

Mercado

(Outras Indstrias)

BC 1

BC 2

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Return with and without Recover

(Amaro e Barbosa-Pvoa, 2006)

G lo b a l P la n n in g P ro fit
C a se I - 5% P rio r T rim e stre

Profit (thousands of m.u.)

C a se II - 10% P rio r T rim e stre

18500
1 8 09 3

18000
17500

18 0 73
17 8 8 2

1 77 1 3

1 7 83 7

1 7 2 96

The increase of non conform

products
recovery reduces the chain
profit.

17000
16500

S c1

S c2a

Recovery of medicines is more

favourable
than the non-recovery situation.

S c2b

O p e ra tio n a l S c e n a rio s

R everse Logistic - Global "P rofit"

S c1

Sc2a

Sc2b

Costs

-200000
-400000
-600000

Ca se I - 5% Prior Trim e stre

Ca se II - 10% Prior Trim e stre

-800000

O pe rational Sce narios

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Planning & Scheduling

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51

(Amaro e Barbosa-Pvoa, 2006)

Planning (Antibiotics) 3 months

Formulao:

IP1

IP2

Costumizao:

PF1, EECF1,
EF1

PF2,
EECF2

Scheduling 5 days

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Design of a recovery network of an industrial

(Duque, Barbosa-Pvoa e Novais, 2005, 2006)
polluted waste
Process
Utilidade 1
Electricidade

Utilidade 1
Electricidade

Utilidade 2
gua
5%

S1 57%
S2

38%

S1 25%
Diluio, T199% S3
(1 dia)
S2
1%
WT1

75%

Super-estructure

99%
Secagem, T2
S4
(2 dias)
1%
WT2

+ Environmental data

Optimize the network maximizing the profit accounting for :

- Demands within intervals
- Environmental Impacts (CTAM, CTWM, SMD)

Design of a recovery network of an industrial

(Duque, Barbosa-Pvoa e Novais, 2005, 2006)
polluted waste

Simplified super-structure

Optimal Network

27

Design of a recovery network of an industrial

(Duque, Barbosa-Pvoa e Novais, 2005, 2006)
polluted waste

Operation

Supply Chains
(Goetschalckx et al. 2002, Shah, 2004)

Area with a great potential.

There is some work done but there is space
for much more:

Improve existing structures

Integrated different decision levels
Explore environmental impacts
Economic details
Uncertainty
Deal with complexity & different scales
.
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Optimization is a possible Solution

STNs

mSTNs eSTNs

RTNs

Resources
Characteristics

Products demands

Operational
Characteristics

Objectives
Structural / Operational

Topological
Characteristics

Economic Parameters

Flexible Systems
ChainNet

Design
+
Retrofit
+
Scheduling

Mathematical
Formulation

Conclusions
Design & Scheduling

Detailed models
Solutions of some real cases
There is space for more

Supply Chains

Detail models are appearing

Great complexity in the modeling & solution
There is space for more

Optimization

Possible Solution
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Future
Fill the GAP between research & its application
Explore solution methods more efficiently :

Hybrid methods
Heuristics + MILPs
Meta-Heuristics + MILPS
Constraint Programming + MILPs
Integrated different decision levels
Explore environmental impacts
Uncertainty

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60

Thanks
Augusto Novais, INETI
Henrique Matos, DEQB, IST
PhDs
Carlos Vieira, MSc
Cristina Amaro, MSc
Elisa Cunha, PhD
Isabel Salema, MSc
Joaquim Duque
Marta Gomes, MSc
Pedro Castro, PhD
Susana Relvas
Tnia Pinto, MSc

MScs
Ana Mestre
Fernando Miranda, MSc
Joo Teles
Jos Matos, MSc
Nuno Sade, MSc
Pedro Oliveira
Ricardo Mateus, MSc
Sofia Pinheiro, MSc
Vernica Becken
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30

Design and Scheduling of

Flexible Processing Systems:
An Optimization Approach
Ana Paula Barbosa Pvoa

Centro de Estudos de Gesto, CEG-IST

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