A mathematical approach for retrofit and optimization of total site steam distribution networks

This paper presents a generic mathematical model for retrofitting the steam power plants in an industrial site. The industrial sector under review consists of one steel mill, one oil refinery, and several petrochemical plants, where only small-scale steam integration has been implemented before this study. The relevant unit models in a typical steam power plant are established, and the steam plant retrofit problem is formulated as a mixed-integer nonlinear program (MINLP). Feasible retrofit alternatives suggested by experienced field engineers are investigated in sequence to examine the revenue of those possible modifications. The first scenario examines operational optimization of existent plants; the second option allows installation of one new turbine and replacement of several boilers and turbines with lower efficiency; the third scenario considers using a steam ejector to upgrade the disqualified import steam in the oil refinery. The significant merits from these three retrofit alternatives show that the proposed MINLP formulation has been a great help to enhance the inter-plant steam integration in an industrial sector.     

A multiobjective optimization framework for multicontaminant industrial water network design

The optimal design of multicontaminant industrial water networks according to several objectives is carried out in this paper. The general formulation of the water allocation problem (WAP) is given as a set of nonlinear equations with binary variables representing the presence of interconnections in the network. For optimization purposes, three antagonist objectives are considered: F(1), the freshwater flow-rate at the network entrance, F(2), the water flow-rate at inlet of regeneration units, and F(3), the number of interconnections in the network. The multiobjective problem is solved via a lexicographic strategy, where a mixed-integer nonlinear programming (MINLP) procedure is used at each step. The approach is illustrated by a numerical example taken from the literature involving five processes, one regeneration unit and three contaminants. The set of potential network solutions is provided in the form of a Pareto front. Finally, the strategy for choosing the best network solution among those given by Pareto fronts is presented. This Multiple Criteria Decision Making (MCDM) problem is tackled by means of two approaches: a classical TOPSIS analysis is first implemented and then an innovative strategy based on the global equivalent cost (GEC) in freshwater that turns out to be more efficient for choosing a good network according to a practical point of view.     

Reduction of water usage in industry by using the MINLP coordinates technique

Natural resources are limited, so we need to handle them carefully. Wastewater also belongs as a significant natural resource. The re-usage of wastewater is to save fresh water and for the preparation of raw materials or/and utilities. The wastewater re-usage distribution can be optimised using mixed-integer nonlinear programming (MINLP), as a tool in combinations using the coordinates technique. The main goal of this MINLP coordinates technique was: i) wastewater and condensate, as produced during different industrial processes, could be collected for: utilities for steam-generation, and the preparations of raw materials; ii) wastewater and condensate could be collected within the main reservoir; iii) distributions from the main reservoir could be used with including different alternatives, which can reduce pollution, based on the re-usage of wastewater. Alternatives included in the optimization model represent potential solutions, which need to be evaluated on appropriate way.The MINLP coordinates technique for wastewater re-usage distribution was tested on existing formalin and methanol industrial processes, thus allowing the saving of water and generated by 280 kEUR/a profit.     

Systematic incorporation of inherent safety in hazardous chemicals supply chain optimization

Increasing globalization has made many chemical supply chains large, interdependent and complex. Process incidents often affect the reliability of a supply chain and can cause large disruptions at different segments of the industry. We propose an optimization-based framework that systematically takes into account the trade-offs between process safety and supply chain economics for decision-making. We quantify the hazard at various supply chain echelons in the form of a safety index that takes both fire and toxic hazards into account. A mixed-integer nonlinear programming (MINLP)-based model is developed to either maximize profit for specified hazard limits, or to minimize hazard in a supply chain with multiple production plants, technological options, warehouses and distribution nodes. The MINLP model is used to generate trade-off optimal solutions for various toxic and fire hazard limits. The framework is demonstrated by applying it to an end-to-end ammonia supply chain case study which resulted in several non-intuitive observations regarding hazardous supply chain design and optimization.     

ECO-design of reuse and recycling networks by multi-objective optimization

An ECO-optimized reuse of process liquors addresses the financial gain and the effective use of resources. In processes that have a potential for process liquor recovery, the minimization of both economic and environmental burdens can be realised by an ECO-optimal design of reuse and recycling network (RRN).In this paper, a procedure for synthesizing such an RRN for a metal finishing process is investigated. The simultaneous analysis of environmental impact sensitivity (SAEIS) based on a superstructure approach, combined with multi-objective optimization is performed by mixed-integer nonlinear programming (MINLP). This allows an “eco–eco” trade-off i.e. total annualized cost and environmental impacts are minimized simultaneously. By varying the weighting factor, different RRN alternatives were generated. A replacement of the standard and closed-loop system by these solutions, even for the environmentally friendliest case, yielded a reasonable cost saving on raw material's inputs.