CBB 4333 Process Optimisation USING MICROSOFT EXCEL SOLVER

Dr Murni Melati Universiti Teknologi PETRONAS Sept 2012

OUTCOME
At the end of the lab session, one should be able to:

appreciate the application of optimisation

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CASE STUDY ON MAXIMISATION OF REFINERY PROFIT

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OPERATION OF REFINERY
A schematic of a refinery is shown below, the objective is to maximise the profit of the refinery
Cost($/bbl) 24 crude #1 15 crude #2 Volume percent yield Crude 1 Crude 2 Gasoline kerosene Fuel oil Residual Processing cost ($/bbl) 80 5 10 5 0.5 44 10 36 10 1
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Refinery

Product Gasoline Kerosene Fuel oil Residual

Price($/bbl) 36 24 21 10

maximum allowable production (bbl/day) 24000 2000 6000

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MODEL DEVELOPMENT
Step 1- Define variables: x1=bbl/day of crude 1 consumed x2=bbl/day of crude 2 consumed x3=bbl/day of gasoline produced x4=bbl/day of kerosene produced x5=bbl/day of fuel oil produced x6=bbl/day of residual produced

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MODEL DEVELOPMENT
Step 2 Formulate equations
a) Equations : Gasoline 0.8 x1 0.44 x2 x3 Kerosene 0.05 x1 0.1x2 x4 Fuel oil 0.1x1 0.36 x2 x5 Residual 0.05 x1 0.1x2 x6 b) Inequaliti es : Gasoline x3 24000 ; or 0.8 x1 0.44 x2 24000 Kerosene x4 2000 ; or 0.05 x1 0.1x2 2000 Fuel oil x5 6000 ; or 0.1x1 0.36 x2 6000 Although not explicitly stated, all variables are non negative x1, x2 , x3 , x4 , x5 , x6 0
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FORMULATION
Step 3 Formulate objective function
Maximise f ( x) profit income raw material cost processing cost Income : 36 x3 24 x4 21x5 10 x6 ($ / day) Raw material cost : 24 x1 15 x2 Processing cost : 0.5 x1 x2 ($ / day) ($ / day)

f ( x) 36 x3 24 x4 21x5 10 x6 24 x1 15 x2 0.5 x1 x2 f ( x) 36 x3 24 x4 21x5 10 x6 24.5 x1 16 x2 Obviously the dimensiona lity of the problem can be reduced by eliminatin g variables x3 , x4 , x5 and x6 via the equality constraint s, leaving only two variables x1 and x2 f ( x) 8.1x1 10.8 x2
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LP model for the example problem

The full version LP Objective: maximise f ( x) 36 x3 24 x4 21x5 10 x6 24.5 x1 16 x2 Subject to : 0.8 x1 0.44 x2 x3 0.05x1 0.1x2 x4 0.1x1 0.36 x2 x5 0.05x1 0.1x2 x6 x3 24000 x4 2000 x5 6000 x1 , x2 , x3 , x4 , x5 , x6 0
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The reduced version LP Objective : maximise f ( x) 8.1x1 10.8 x2 Subject to : 0.8 x1 0.44 x2 24000 0.05 x1 0.1x2 2000 0.1x1 0.36 x2 6000 x1 , x2 0 Let us represent the LP model graphically

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Assignment 2
1. Plot the constraints and feasible region for the LP problem. Show the details of the working. 2. Solve for the maximum profit for the refinery . 3. Provide some analysis on the solution.

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FEASIBLE REGION
x2 60

Crude 2 (in 1000 bbl)

0.8 x1 0.44 x2 24000 0.05 x1 0.1x2 2000

( A) ( B) (C )

40

0.1x1 0.36 x2 6000 x1 , x2 0

20
Feasible region

20

40

60

x1

Crude 1 (in 1000 bbl)

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SOLVING USING CONTOUR PLOT

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maximise f ( x) 8.1x1 10.8 x2

f 3 8.1x1 10.8 x2

s.t. 0.8 x1 0.44 x2 24000 0.05 x1 0.1x2 2000 0.1x1 0.36 x2 6000 ( A) ( B) (C )

Crude 2 (in 1000 bbl)

20 2 C 3 10
f 1 180,000

f 3 286,740

x1 , x2 0

f 2 243,000

A 4

10

20

30

Crude 1 (in 1000 bbl)

Graphical solution to the problem indicates that optimum value of the profit occurs roughly at x*1 = 26,000 bbl/day x*2 = 7,000 bbl/day f(x*) = 286,200 $/day
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SOLVING USING CONTOUR PLOT

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maximise f ( x) 8.1x1 10.8 x2

f 3 8.1x1 10.8 x2

s.t. 0.8 x1 0.44 x2 24000 0.05 x1 0.1x2 2000 0.1x1 0.36 x2 6000 ( A) ( B) (C )

Crude 2 (in 1000 bbl)

20 2 C 3 10
f 1 180,000

f 3 286,740

x1 , x2 0

f 2 243,000

A 4

10

20

30

Crude 1 (in 1000 bbl)

Graphical solution to the problem indicates that optimum value of the profit occurs roughly at x*1 = 26,000 bbl/day x*2 = 7,000 bbl/day f(x*) = 286,200 $/day
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Building Model in Excel

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Set Target and Changing Cells

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Solving using Solver

1

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CASE STUDY ON MAXIMISATION OF PROFIT FOR MULTI-PRODUCT PLANT (mass balance)

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OPERATION OF MULTI-PRODUCT PLANT

A schematic of a refinery is shown below, the objective is to maximise the profit of the multi-product plant

reactant s: A, B, C products: E, F, G process units: 1, 2, 3

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MODEL DEVELOPMENT
Step 1- Define variables: Let x1, x2, x3 - mass input flows of A to each process x4,x5,x6, and x7 - individual reactant flows of B and C x8, x9 and x10 - the three mass product flows (E, F, G) x11 and x12 - total amounts of A and B and C is the same as x7 A total of 12 variables

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MODEL DEVELOPMENT
Step 2 Formulate equations a) Linear mass balances:
A x11 x1 x2 x3 B x12 x4 x5 x6 x1 0.667 x8 x2 0.667 x9 x3 0.5 x10 x4 0.333x8 x5 0.333x9 x6 0.167 x10 x7 0.333x10
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MODEL DEVELOPMENT
Step 2 Formulate equations a) Inequalities:
Suppose that the supply of reactant was limited

x11 40,000 x12 30,000 x 7 25,000

Constraints on production of E, F, and G in order to satisfy market demand or sales constraints.

x 8 20,000 x 9 25,000 x10 30,000

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FORMULATION
Step 3 Formulate objective function
Maximise f ( x) profit income raw material cost processing cost Income : Processing cost : 0.04 x8 0.0033 x9 0.038 x10 ($ / day ) 0.015 x8 0.005 x9 0.01x10 ($ / day )

Raw material cost : 0.015 x11 0.02 x12 0.025 x7 ($ / day ) f ( x) 0.025 x8 0.028 x9 0.028 x10 0.015 x11 0.02 x12 0.025 x7

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LP model for the example problem

The full version LP Objective: maximise f ( x) 0.025x8 0.028x9 0.028x10 0.015x11 0.02 x12 0.025x7 Subject to : x11 x1 x2 x3 ; x12 x4 x5 x6 ; x1 0.667 x8 ; x2 0.667 x9 ; x3 0.5 x10 ; x4 0.333x8 ; x5 0.333x9 ; x6 0.167 x10 ; x7 0.333x10 ; x11 40,000, x12 30,000, x 7 25,000 x 8 20,000, x 9 25,000, x10 5,000
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The reducedversion LP Objective: maximise f ( x) 0.025x8 0.028x9 0.028x10 0.015x11 0.02 x12 0.025x7 Subject to : x11 0.667 x8 0.667 x9 0.5 x10 ; x12 0.333x8 0.333x9 0.167 x10 ; x7 0.333x10 ; x11 40,000, x12 30,000, x 7 25,000 x 8 20,000, x 9 25,000, x10 5,000
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Building Model in Excel & Solving

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RECAP

appreciate the application of optimisation

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REFERENCES
1. Edgar T. F. and Himmelblau, Optimization of Chemical Processes, McGraw Hill, 2001. 2. Biegler, L.T., Grossmann E.I. and Westerberg, A.W., Systematic Methods of Chemical Process Design, Prentice Hall, 1997. 3. Lecture notes, MSc Process Integration, UTP-University of Manchester

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