Workshop 01 - Introduction to Process

Optimization in Excel®

Jorge Mario Gómez R., Ph.D.

Associate Professor
 OPTIMIZATION OF CHEMICAL
PROCESSES WORSHOP
Contents
INTRODUCTION: Optimization MICROSOFT OFFICE EXCEL®
of Chemical Processes • Workshop 01 - Introduction to
Workshop Process Optimization in
• Program Excel®
• Game rules • Problem
• Grading matrices • Problem formulation
• Solution
PROCESS OPTIMIZATION • Bonus
• Optimization software
• The six steps used to solve REFERENCES
optimization problems
• Class of Optimization Problem
• Mathematical Programming in
Process System Engineering

Department of Chemical Engineering / Process Optimization Workshop / IQUI – 3042

 PROGRAM

Department of Chemical Engineering / Process Optimization Workshop / IQUI – 3042

 GAME RULES

• 3 Exams
– Theoretical
– Practical
• Bonuses
• No activities to the e-mail
• 30% of the whole course

Department of Chemical Engineering / Process Optimization Workshop / IQUI – 3042

 PROCESS OPTIMIZATION

Optimization: given a system or process, find the best

solution to this process within constraints [1].

This task requires the following elements:

• Sets
• Parameters
• Variables
• Constraints
• Objective function

Department of Chemical Engineering / Process Optimization Workshop / IQUI – 3042

 The 6 steps used to solve an opt. problem

Using mathematical
expressions, develop a
Specify the objective valid process or
Make a list of the
function in terms of the equipment model that
variables and
variables defined in the relates the input-output
parameters
first step variables of the process.
(Get the number of
degrees of freedom)

If the problem
Check the answers, and Apply a suitable formulation is too large
examine the sensitivity optimization technique in scope:
of the result to changes to the mathematical Break it up into
in the models and statement of the manageable parts or
assumptions problem Simplify the objective
function and model

Modified from Table 1.1 in [1]

Department of Chemical Engineering / Process Optimization Workshop / IQUI – 3042
 Degrees of Freedom

The degrees of freedom in a model is the number of variables that can

be specified independently and is defined as follows:

𝑁𝐹 = 𝑁𝑣 − 𝑁𝐸
 𝑁𝐹 = 𝑑𝑒𝑔𝑟𝑒𝑒𝑠 𝑜𝑓 𝑓𝑟𝑒𝑒𝑑𝑜𝑚
 𝑁𝑣 = 𝑡𝑜𝑡𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑣𝑎𝑟𝑖𝑎𝑏𝑙𝑒𝑠 𝑖𝑛𝑣𝑜𝑙𝑣𝑒𝑑 𝑖𝑛 𝑡𝑕𝑒 𝑝𝑟𝑜𝑏𝑙𝑒𝑚
 𝑁𝐸 = 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑖𝑛𝑑𝑒𝑝𝑒𝑛𝑑𝑒𝑛𝑡 𝑒𝑞𝑢𝑎𝑡𝑖𝑜𝑛𝑠 (𝑖𝑛𝑐𝑙𝑢𝑑𝑖𝑛𝑔 𝑠𝑝𝑒𝑐𝑖𝑓𝑖𝑐𝑎𝑡𝑖𝑜𝑛𝑠)

A degrees-of-freedom analysis separates modeling problems into three

categories :
• 𝑁𝐹 = 0: 𝑇𝑕𝑒 𝑝𝑟𝑜𝑏𝑙𝑒𝑚 𝑖𝑠 𝑒𝑥𝑎𝑐𝑡𝑙𝑦 𝑑𝑒𝑡𝑒𝑟𝑚𝑖𝑛𝑒𝑑
• 𝑁𝐹 > 0: 𝑇𝑕𝑒 𝑝𝑟𝑜𝑏𝑙𝑒𝑚 𝑖𝑠 𝑢𝑛𝑑𝑒𝑡𝑒𝑟𝑚𝑖𝑛𝑒𝑑
• 𝑁𝐹 < 0: 𝑇𝑕𝑒 𝑝𝑟𝑜𝑏𝑙𝑒𝑚 𝑖𝑠 𝑜𝑣𝑒𝑟𝑑𝑒𝑡𝑒𝑟𝑚𝑖𝑛𝑒𝑑

Department of Chemical Engineering / Process Optimization Workshop / IQUI – 3042

 Classes of optimization problems

Optimization

NLP
Mixed Integer
(Continuous)

MINLP
Differentiable Nondifferentiable

MILP
Convex Nonconvex

IP
LP QP

Figure 1.1 in [2]

Department of Chemical Engineering / Process Optimization Workshop / IQUI – 3042
 Classes of optimization problems

Mixed Integer

MINLP MILP IP

𝑚𝑖𝑛𝑥,𝑦 𝑓 𝑥, 𝑦
𝑠. 𝑡. 𝑕 𝑥, 𝑦 = 0
𝑔 𝑥, 𝑦 ≤ 0
𝑥 ∈ 𝑅𝑛 , 𝑦 ∈ *0,1+𝑡

Figure 1.1 in [2]

Department of Chemical Engineering / Process Optimization Workshop / IQUI – 3042
 Classes of optimization problems

NLP
(Continuous)

Differentiable Nondifferentiable

Convex Nonconvex

LP QP 𝑚𝑖𝑛𝑥∈𝑅𝑛 𝑓 𝑥
𝑠. 𝑡. 𝑕 𝑥, 𝑦 = 0
𝑔 𝑥, 𝑦 ≤ 0

Figure 1.1 in [2]

Department of Chemical Engineering / Process Optimization Workshop / IQUI – 3042
 Convex functions

A twice-differentiable function f of a differentiable function of

a single variable defined on the interval I is:
• Concave if and only if f"(x) ≤ 0 for all x in the interior of I.
• Convex if and only if f"(x) ≥ 0 for all x in the interior of I.

Department of Chemical Engineering / Process Optimization Workshop / IQUI – 3042

 Convex vs Non-Convex Optimization

- With a convex objective

and a convex feasible region
there can be only one
optimal solution, which is
globally optimal.

-NCOPs may have multiple

feasible regions and multiple
locally optimal points within
each region.

Department of Chemical Engineering / Process Optimization Workshop / IQUI – 3042

 Classes of optimization problems

LP MILP QP NLP MINLP

Process Model Building X X
Process Design & Synthesis
Heat Exchangers X X X X
Mass Exchangers X X X X
Separations X X X
Reactors X X X
Flowsheeting X X
Process Operations
Scheduling X X X
Supply Chain X X X
Real-Time Optimization X X X
Process Control
Model Predictive Control X X
Nonlinear MPC X X
Hybrid MPC X

Table 1.1 in [2]

Department of Chemical Engineering / Process Optimization Workshop / IQUI – 3042
 Optimization Software

Worksheets [Solver de Excel, OpenOffice, etc.]:

• LP, MILP, NLP, MINLP.
• Small and simple models
• It is impractical and inefficient.

Traditional Programming Languages [Fortran, C++]:

• All types of problem.
• For large-size models.
• It is impractical for programming.
• It has more emphasis on programming than model.

Department of Chemical Engineering / Process Optimization Workshop / IQUI – 3042

 Optimization Software

Specialized Programming Languages [Matlab,

Mathematica]:
• LP, NLP, MILP.
• Moderate size problems.
• Low speed and efficiency.

Mathematical Programming Languages [GAMS, AMPL]:

• All types of problem.
• All sizes of problem.
• High speed.
• Emphasis on the modeling of the problem.

Department of Chemical Engineering / Process Optimization Workshop / IQUI – 3042

 MICROSOFT OFFICE EXCEL®

“Use Solver to determine the maximum or minimum value of

one cell by changing other cells” [3]

• Limited the problems size.

• Generalized Reduced Gradient (GRG) Nonlinear: Use for
problems that are smooth nonlinear.
• LP Simplex: Use for problems that are linear.
• Evolutionary: Use for problems that are non-smooth.
• Low computational performance.
• Ideal for quick solutions to small problems.

Department of Chemical Engineering / Process Optimization Workshop / IQUI – 3042

 MICROSOFT OFFICE EXCEL®
Workshop 1 - Problem
Suppose we want to assign streams to heat exchangers and the cost
(in $) of doing so is listed in the following matrix:

Exchanger Number
1 2 3 4
A 94 1 54 68
Stream

B 74 10 88 82
C 73 88 8 76
D 11 74 81 21

Each element in the matrix represents the cost of transferring stream

to an exchanger. The problem is to assign each stream to a heat
exchanger. How can the cost be minimized if each stream goes to
only one exchanger?

Reference [1], Section 7.9, Page 252.

Department of Chemical Engineering / Process Optimization Workshop / IQUI – 3042
 MICROSOFT OFFICE EXCEL®

How to load the Solver Add-in program

Department of Chemical Engineering / Process Optimization Workshop / IQUI – 3042

 MICROSOFT OFFICE EXCEL®

How to load the Solver Add-in program

Department of Chemical Engineering / Process Optimization Workshop / IQUI – 3042

 MICROSOFT OFFICE EXCEL®

How to load the Solver Add-in program

Department of Chemical Engineering / Process Optimization Workshop / IQUI – 3042

 MICROSOFT OFFICE EXCEL®
Workshop 1 – Problem formulation

Sets:
𝑆 = *𝐴, 𝐵, 𝐶, 𝐷+: Streams, index 𝑖
𝐸 = *1,2,3,4+: Heat exchangers, index 𝑗
Parameters and scalars:
𝐶𝑖,𝑗 : Cost of assigning stream 𝑖 to heat
exchanger 𝑗, [$]
Variables:
𝑥𝑖,𝑗 ∈ 0,1 : 1 if the stream 𝑖 is assigned to heat
exchanger 𝑗, 0 otherwise, [-]
𝑇: Total operation cost, [$]

Department of Chemical Engineering / Process Optimization Workshop / IQUI – 3042

 MICROSOFT OFFICE EXCEL®
Workshop 1 – Problem formulation

Constraints:
Eq1. Just one stream must be assigned to each heat exchanger, [-]:
4
𝑖=1 𝑥𝑖,𝑗 = 1, ∀𝑗 ∈ 𝐸
Eq2. Just one heat exchanger must be assigned to each stream, [-]:
4
𝑗=1 𝑥𝑖,𝑗 = 1, ∀𝑖 ∈ 𝑆
Eq3. Variable nature:
𝑥𝑖,𝑗 ∈ 0,1
Objective function
Minimize the whole operation cost, [$]

4 4

min 𝑇 = 𝐶𝑖,𝑗 𝑥𝑖,𝑗

𝑖=1 𝑗=1
Department of Chemical Engineering / Process Optimization Workshop / IQUI – 3042
MICROSOFT OFFICE EXCEL®
Workshop 1 – Problem formulation

Department of Chemical Engineering / Process Optimization Workshop / IQUI – 3042

MICROSOFT OFFICE EXCEL®
Workshop 1 – Problem formulation

Department of Chemical Engineering / Process Optimization Workshop / IQUI – 3042

MICROSOFT OFFICE EXCEL®
Workshop 1 – Problem solution

Department of Chemical Engineering / Process Optimization Workshop / IQUI – 3042

MICROSOFT OFFICE EXCEL®
Workshop 1 – Problem solution

Department of Chemical Engineering / Process Optimization Workshop / IQUI – 3042

 MICROSOFT OFFICE EXCEL®
Bonus 1.1
Bonus 1.1
The Fresh Milk cooperative supplies milk in gallon jugs from its two
warehouses located in Buffalo (New York) and Williamsport
(Pennsylvania). It has a capacity of 2000 gallons per day at Buffalo and
1600 gallons per day at Williamsport. It delivers 800 gallons/day to
Rochester (New York). Syracuse (New York) requires 1440 gallons/day and
the remainder (1360 gallons) are trucked to New York City. The cost to
ship the milk to each of the destinations is different and is given in the
following table. Establish the shipping strategy for minimum cost.

Parcial 1. 2013-10
Department of Chemical Engineering / Process Optimization Workshop / IQUI – 3042
 MICROSOFT OFFICE EXCEL®
Bonus 1.2
Bonus 1.2
In the “Optibeer” brewery are four different kinds of beers: light,
lager, ale and premium. Each kind of beer uses different amounts of
the four main components of beer: water, malt, hops and yeast. Each
kind of beer has a different utility in dollars.
Maximize the revenue of the “Optibeer” brewery based on the fact
that each raw material has certain availability.
Required amount of component in each beer (lb/L)
Light Lager Ale Premium Availability (lb)
Water 7 6 5 4 Unlimited
Malt 1 1 0 3 50
Hops 2 1 2 1 150
Yeast 1 1 1 4 80
Utility ($/L) 6 5 3 7
Adapted from Reference [4]
Department of Chemical Engineering / Process Optimization Workshop / IQUI – 3042
 REFERENCES

[1] E. Thomas F, D. Himmelblau, and L. Lasdon, OPTIMIZATION OF

CHEMICAL PROCESSES, Second Edition. New York: McGraw-Hill, 2001.
[2] B. Lorenz T., NONLINEAR PROGRAMMING: Concepts, Algorithms, and
Applications to Chemical Processes. Philadelphia, 2010.
[3] Microsoft, “Define and solve a problem by using Solver.” [Online].
Available: http://office.microsoft.com/en-us/excel-help/define-and-
solve-a-problem-by-using-solver-HP010342416.aspx?CTT=1.
[4] Ecker; Kupferschmid, 1988.

Department of Chemical Engineering / Process Optimization Workshop / IQUI – 3042