Nirav J Bhavsar

Department of Chemical Engineering

DDU, Nadiad

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INTRODUCTION……..
Optimization is the act of obtaining the best result under
given circumstances.

The process of finding the conditions that give the

minimum or maximum value of a function.

The mathematical function represents the effort required to

get the best optimum result.

This is the mathematical discipline which is concerned with

finding the maxima and minima of functions, possibly
subject to constraints.
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INTRODUCTION……..
The optimum seeking methods are also known as
mathematical programming techniques and are generally
studied as a part of operations research.

Operations research is a branch of mathematics

concerned with the application of scientific methods and
techniques to decision making problems and with
establishing the best or optimal solutions.

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INTRODUCTION……..
Different methods that can be used under the umbrella
of Operation Research are,
 Mathematical modeling
Statistics
Algorithms
 to obtain an optimal or good decisions in complex problems
which are concerned with optimizing the maxima (profit,
faster assembly line, greater crop yield, higher bandwidth,
etc) or minima (cost loss, lowering of risk, etc) of some
objective function.

The aim behind using operations research is to obtain a

best possible solution of a mathematical problem to
improve or optimize the performance of the system.

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INTRODUCTION……..

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HİSTORİCAL DEVELOPMENT…
Isaac Newton (1642-1727)
(The development of differential calculus
methods of optimization)

Joseph-Louis Lagrange (1736-1813)

(Calculus of variations, minimization of functionals,
method of optimization for constrained problems)

Augustin-Louis Cauchy (1789-1857)

(Solution by direct substitution, steepest
descent method for unconstrained optimization)
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HİSTORİCAL
DEVELOPMENT…
Leonhard Euler (1707-1783)
(Calculus of variations, minimization of
functionals)

Gottfried Leibnitz (1646-1716)

(Differential calculus methods
of optimization)

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HİSTORİCAL
DEVELOPMENT…
George Bernard Dantzig (1914-2005)
(Linear programming and Simplex method (1947))

Richard Bellman (1920-1984)

(Principle of optimality in dynamic
programming problems)

Harold William Kuhn (1925-)

(Necessary and sufficient conditions for the optimal
solution of programming problems, game theory)
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HİSTORİCAL
DEVELOPMENT…
Albert William Tucker (1905-1995)
(Necessary and sufficient conditions
for the optimal solution of programming
problems, nonlinear programming, game
theory: his PhD student
was John Nash)

Von Neumann (1903-1957)

(game theory)

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FORMULATION OF PROBLEM..
Optimization : The process of finding the conditions that
give the maximum or minimum of a function subject to
constraints.

Basic components of an optimization problem : –

 An objective function expresses the main aim of the model
which is either to be minimized or maximized.
 A set of unknowns or variables which control the value of
the objective function.
A set of constraints that allow the unknowns to take on
certain values but exclude others.

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FORMULATION OF PROBLEM..
The optimization problem is then to:
find values of the variables that minimize
or maximize the objective function while
satisfying the constraints.

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OBJECTIVE FUNCTION….
Many optimization problems have a single objective
function (When they don't they can often be
reformulated so that they do).
The two interesting exceptions are:
1) No objective function.: The user does not particularly
want to optimize anything so there is no reason to
define an objective function. Usually called a
feasibility problem.
2) Multiple objective functions: In practice, problems
with multiple objectives are reformulated as single-
objective problems by either forming a weighted
combination of the different objectives or by treating
some of the objectives by constraints.
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STATEMENT OF OPTIMIZATION
PROBLEM…

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STATEMENT OF OPTIMIZATION
PROBLEM…
where
X is an n-dimensional vector called the design
vector
f(X) is called the objective function, and
gi(X) and lj(X) are known as inequality and equality
constraints, respectively.
This type of problem is called a constrained
optimization problem.
Optimization problems can be defined without
any constraints as well. Such problems are called
unconstrained optimization problems.
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STATEMENT OF OPTIMIZATION
PROBLEM…
If the locus of all points satisfying f(X) = a constant “c” is
considered.
It can form a family of surfaces in the design space called the
objective function surfaces.
 When drawn with the constraint surfaces as shown in the figure
we can identify the optimum point (maxima).
This is possible graphically only when the number of
design variable is two.
When we have three or more design variables because of
complexity in the objective function surface we have to
solve the problem as a mathematical problem and this
visualization is not possible.
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STATEMENT OF OPTIMIZATION
PROBLEM…

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VARIABLES AND CONSTRAINTS…
Variables
These are essential. If there are no variables, we cannot
define the objective function and the problem
constraints.
Constraints
Constraints are referred as limitations contained with
the system or process
Even though Constraints are not essential, it has been
suggested that almost all problems really do have
constraints.

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VARIABLES AND CONSTRAINTS…
In many practical problems, one cannot choose the design
variable arbitrarily.
Design constraints are restrictions that must be satisfied
to produce an acceptable design and classified as,

 Behaviour constraints: Constraints that represent limitations on

the behaviour or performance of the system are termed
behaviour or functional constraints.

 Side constraints: Constraints that represent physical limitations

on design variables such as manufacturing limitations.

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CONSTRAINT SURFACE…
Consider the optimization problem presented earlier with
only inequality constraints gi(X) .

The set of values of X that satisfy the equation gi(X) forms a

boundary surface in the design space called a constraint
surface.

The constraint surface divides the design space into two

regions: one with gi(X) < 0 (feasible region) and the other in
which gi(X) > 0 (infeasible region).

The points lying on the hyper surface will satisfy g i(X) =0.

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 The figure shows a hypothetical two-dimensional design space
where the feasible region is denoted by hatched lines.

Behavior
constraint
Infeasible g2  0
region

Side
constraint Feasible region
g3 ≥ 0 Behavior

. constraint
g1 0

. Bound
acceptable point.

Free acceptable point

Free unacceptable point Bound
unacceptable point.

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Formulation of design problems as mathematical
programming problems

 The following steps summarize the procedure used to

formulate and solve mathematical programming
problems.
1. Analyze the process to identify the process variables
and specific characteristics of interest i.e. make a list
of all variables.
2. Determine the criterion for optimization and specify
the objective function in terms of the above variables
together with coefficients.

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 3. Develop a process model in terms of mathematical
expressions that relates the input-output variables of
the process and associated coefficients.
a) Include both equality and inequality constraints
b) Use well known physical principles
c) Identify the independent and dependent variables to get the number of
degrees of freedom

3. If the problem formulation is too large in scope:

a) break it up into manageable parts/ or
b) simplify the objective function and the model
4. Apply a suitable optimization technique for
mathematical statement of the problem.
5. Perform sensitivity analysis to examine the sensitivity of
the result with possible changes in the coefficients in
the problem and the assumptions.
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APPLICATION OF OPTIMIZATION……..
Optimization : The process of finding the conditions
that give the maximum or minimum of a function
subject to constraints.

Design, construction and maintenance of engineering

systems involve decision making both at the
managerial and the technological level

Goals of such decisions :

 To minimize the effort required or
 To maximize the desired benefit

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APPLICATION OF OPTIMIZATION……..
Optimization problems arise in almost all fields
where numerical information is processed
Science, Engineering, Mathematics,
Economics & Commerce, etc.
In Science, optimization problems arise in:
Data fitting, variation principles, solution of differential
and integral equations by expansion methods, etc.

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APPLICATION OF OPTIMIZATION……..
• Engineering applications in design problems
usually have constraints in the sense that
variables cannot take arbitrary values.
 For example, while designing a bridge, an

engineer will be interested in minimizing the

cost, while maintaining a certain minimum
strength for the structure.
 Optimizing the surface area for a given volume of
a reactor is another example of constrained
optimization.

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APPLICATION OF OPTIMIZATION……..
Chemical process industries consist of several
“unit operations” and “unit processes” e.g.,
Heat exchanger
Distillation column
Batch reactor
Packed bed reactor

It is essential to run the plant at an optimum

condition to obtain the maximum profit with
minimum environmental impact.

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APPLICATION OF OPTIMIZATION……..
The real driving force for process optimization is
efficiency.
Chemical companies realize that if they can run
the plant more efficiently, it will improve their
bottom line (least production/profit)
The process can be optimized by considering the
individual unit one by one, or by considering
many units at a time e.g.,
Water distribution system with pumps and pipe line
Heat exchanger network
 Reactor network.

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APPLICATION OF OPTIMIZATION……..
Optimization in chemical process industries
 concludes the selection of equipment and operating
conditions for the production of a given material
 So that the profit will be maximum.
• This could be interpreted as meaning the
maximum output of a particular substance
for a given capital expense.
 This is a mathematical problem of evaluating the
appropriate values of a set of variables to maximize a
dependent variable

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APPLICATION OF OPTIMIZATION……..
The minimum investment for a specified production
rate
This may be considered to be one of locating a
minimum value.
However, in terms of profit, both types of problems
are maximization problems

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APPLICATION OF OPTIMIZATION……..

These solutions of both is generally accomplished by

means of an economic balance (trade-off)
Between the capital and operating costs.
Such a balance can be represented as the capital, the
operating cost, and the total cost are plotted against
“f”,
Which is some function of the size of the equipment

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CAPITAL-OPERATING COST TRADE-OFF…..

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EXAMPLES OF APPLICATIONS OF
OPTIMIZATION…
Typical projects in which optimization has been used
in chemical processes and plants.
1. Determining the best sites for plant location.

2. Routing tankers for the distribution of crude and refined

products.

3. Sizing and layout of a pipeline.

4. Designing equipment and an entire plant.

5.Scheduling maintenance and equipment replacement.

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EXAMPLES OF APPLICATIONS OF
OPTIMIZATION…
6. Operating equipment, such as tubular reactors, columns,
and absorbers.

7. Evaluating plant data to construct a model of a process.

8. Minimizing inventory charges.

9. Allocating resources or services among several processes.

10. Planning and scheduling construction.

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CHEMICAL PROCESS INDUSTRIES

Flow Sheet structure

Best Individual step/equipment
Interconnection between each step

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 Process Simulation….
Simulation
Mathematical Model (Equation)
Chapter 1

Running Existing Process Plant

Carrying Material or Energy Balance
Formulation of New Plant
Modification in an existing plant
Expansion in an existing plant
Cost Reduction
Maximization of profit

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 Process Modeling
Deterministic Process
Output = (Input)
Chapter 1

Stochastic Process
Output = (Input, + + + +)

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Deterministic Vs. Stochastic.
Deterministic Process: Output of the process strongly
depend on the input of the process. There is no
randomness in the process. E.g. Dynamic model,
static model.
Stochastic process: It contains the stochastic variable
or random variable. Effect of such variable does not
affect the output(Not always).

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 Type of Model…
Distributed parameter model
Lumped parameter model
Chapter 1

Static model / Steady state model

Dynamic model / Unsteady state model
Deterministic model / Rigid model
Stochastic model / Probabilistic model
Black box model

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 Terminologies in Modeling…
Independent variables
Dependent variables
Chapter 1

Parameters
Initial condition
Boundary conditions

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Terminology in Optimization
Decision Variables:
 Independent variables
Objective Function:
 Mathematical model equation relating decision variables
Constraints: limitation on value of decision variables
 Equality constraints
 Inequality constraints
Linear Programming:
 Objective function and constraints both are linear in nature
Non Linear Programming
 Quadratic programming : II order obj. func. And I order Const.
 Mixed integer programming : Discrete and cont. Decision variables
 Mixed Integer non linear programming : Chemical Engineering Process

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 Optimization…
Cost effective and efficient solution to a problem of
chemical process.
Chapter 1

DESIGN
CONSTRUCTION
OPERATIONS
ANALYSIS
SALES
TRANSPORTATION
SAFETY
CONTROL
LABOR

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 Why to be optimized?
1. Improved yields/Conversion, reduced pollutants
Chapter 1

2. Reduced energy consumption

3. Higher processing rates

4.Reduced maintenance, fewer shutdowns

5. Better understanding of process (simulation) to

minimize the expansion

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 Best Example of optimization..
Reliance work culture.
Chapter 1

Design variables and Operating

Variables are coupled.

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 Classification of Optimization
Chapter 1

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 Prior to Plant Operations High Uncertainty

Project & product CAD Module

evaluation
Budget allocation
New Facility creation
Chapter 1

Optimum control of
Optimum V, XA,
T,P,Q
cost

Hierarchy of levels of Optimization

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Nirav J Bhavsar 45
Chapter 1

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 Optimize for Cost…
Sales Limited by production
Sales limited by market
Chapter 1

Large unit throughput

Higher cost of Raw material and energy
Product quality exceeds product specifications
Losses of valuable components through waste
stream
Higher labor cost

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 Optimization in Chemical
Industries…
Determining the best sites for plant location.
Routing tankers for the distribution of refined products.
Chapter 1

Sizing and layout of a pipeline.

Designing equipment and an entire plant
Scheduling maintenance and equipment replacement.
Operating conditions in equipment, such as tubular reactors,
columns, and absorbers.
Minimizing inventory charges.
Allocating resources or services among several processes.
Planning and scheduling construction.

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 Optimization in Design…
Optimization of volume/residence time
Kinetics plays major role
Chapter 1

Optimization of parameters
Temp, pressure, agitator speed
Optimization of construction cost and commissioning
Optimization after taking all costs into consideration
Social, economical, cultural, environmental

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 Optimization in Operations…
Maximum conversion and yield
Parameter optimization
Chapter 1

 Temperature and pressure

 Pressure and volume
 Concentration
 Flow rate
 Agitator speed

Minimum expenditure
Minimum pollution load
Minimum risk
Minimum cycle time/ production time

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 Optimization in Continuous Operations…
Parameter optimization at design stage
Parameter optimization at control stage
Chapter 1

Model based predictive control

 Constrained optimization
 Multivariable scenario

 Look into the future with the help of model

 Takes care of some problems related to data

Data reconciliation
Development of filters like Kalman filter

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Types of Optimization….
Optimization in the chemical field can be divided
into two classes:
1. Static optimization
2. Dynamic optimization

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Static optimization….
Static optimization is the establishment of the
most suitable steady-state operation conditions of
a process.

These include the optimum size of equipment

and production levels, in addition to
temperatures, pressures, and flow rates

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Static optimization….
Plant design (sizing and layout).
Operation (best steady-state operating
condition).
Parameter estimation (model fitting).
Allocation of resources.
Choice of controller parameters (e.g. gains, time
constants) to minimise a given performance index
(e.g. overshoot, settling time, integral of error
squared).

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Static optimization….
Steady-state optimization is applicable to
continuous processes,
which attain a new steady state after a change
in manipulated inputs within an acceptable
time interval.

The goal of static optimization is to develop and

realize an optimum model for the process.

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Dynamic optimization….
Dynamic optimization the establishment of the best
procedure for correcting:
The fluctuations in a process used in the static
optimization analysis.
 It requires knowledge of the dynamic characteristics of
the equipment
Also useful in predicting the best solution in which a
change in the process conditions can be corrected.
In reality, it is an extension of the automatic control
analysis of a process.

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Dynamic optimization….
As mentioned earlier, static optimization is applicable to
continuous processes
Which attain a new steady state after a change in
manipulated inputs within an acceptable time interval.
Static optimization gives the optimal choice at a single
instant or single point of time.
Dynamic optimization is an unsteady-state optimization
which give the optimal choice over a period of time.
For example, during travelling with food, how much food is
to be consumed today and how much to be saved for
tomorrow.

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Dynamic optimization….
The objective is not only to maintain a process at an
optimum level under steady-state conditions
But also to seek the best path for its transition from one
steady state to another.
The optimality function then becomes a time
function
The objective is to maximize or minimize the time-
averaged performance criterion.

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Dynamic optimization….
The goal of control in this case is to select at any
instant of time a set of manipulated variables
That will cause the controlled system to behave in an
optimum manner in the face of any set of disturbances.

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 Dynamic Optimization..
Determination of a control signal u(t) to transfer a
dynamic system from an initial state to a desired final
Chapter 1

state to satisfy a given performance index.

 Optimal plant start-up and/or shut down.
 Minimum time problems

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 Optimization in Chemical Industries….
Chapter 1

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Mathematical Programming
Recognize decision-making situations which that
may benefit from an optimization modeling
approach.
Formulate algebraic models for linear
programming problems.
Constricting a model to represent the system
under study
Deriving a solution from the model
Testing the model and solution derived from it.
Establishing control over the solution
Putting the solution to implementation
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Mathematical Programming
The essential characteristics of all decisions are:
 Objective
 Alternatives

 Influencing factor

Various optimizing methods are there:

 Linear programming ( LP)
 Non linear programming (NLP)

 Multi Integer Programming (MIP)

 Multi Integer linear programming (MILP)
 Multi Integer Non-linear programming (MINLP)

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Linear programming
If the objective function and all constraints are linear
functions of the decision variables
For example,
 No squared terms,
 No trigonometric functions,

 No ratios of variables,

Then the problem is called a Linear Programming

(LP) problem.

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Linear programming
Linear Programming is a technique or determining an
optimum schedule of independent activities in view of
available resources.
Programming (Planning) word refers to the process of
determining a particular plan of action from different
alternatives.
The word linear stands for indicating that all
relationship involved in a particular problem are
linear.

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Linear programming
Linear programming deals with optimization
 Either maximization or minimization
It is function of decision variables known as objective
function.
The objective function may be :
 Profit, cost, production capacity or any other measure of
effectiveness, which is to be obtained in the best possible or
optimal manner.

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Linear programming
Linear programming deals with set of linear
equations known as restriction or constraints:
 Constraints may be market, demand, production process and
equipment.
 It is also imposed by Storage capacity, manpower, money and

R/M availability.

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Linear programming
Formulation of LP model:
 Study the situation and find the decision variable
 Assume suitable symbols for variable quantities

 Express the feasible alternative mathematically in terms of

variables.
 Evaluate the objective function and express it as a linear

function of variables
 Mention the influencing factor or constraints and express

them also as linear equation in terms of variables.

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Linear programming
LPs are much easier to solve than problems involving
nonlinear functions.
Various methods are available to solve them like:
 Graphical
 Simplex

 Big M Method

There are various software solver tools are also

available.

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 EXAPLES

1.A company is manufacturing products Y and Z. One unit of

products Y requires 4.8 minutes of machining and 10 minutes
of assembly time. The profit for product Y is 0.7 Rs per unit.
The product Z requires 6 minutes of machining time and 5
minutes of welding time for manufacturing one unit. Profit for
Z is Rs 0.9 per unit. The capacity of the machining dept.
available for these products is 1400 minutes per week . The
welding dept. has an idle capacity of 800 minutes/week and
assembly dept. has 1800 minutes/week. Formulate the LPP
model so as to maximize the profit.

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2. A small scale industrialist produces four types of
pharmaceutical products M1, M2, M3, and M4 made of
Menthol and dextromethorphan. The content of
Menthol and dextromethorphan required for each
product and number of man-weeks required for each
product is as follows.

M1 M2 M3 M4 Availabilit
y
Menthol 6 5 3 2 100
dextrome 3 4 9 2 75
thorphan
Man- 1 2 1 2 20
weeks
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3. A garden shop wishes to prepare a supply of special
fertilizer at a minimal cost by mixing two fertilizers, A
and B. The mixture is to contain: at least 45 units of
phosphate at least 36 units of nitrate at least 40 units
of ammonium. Fertilizer A costs the shop Rs.97 per
Kg. Fertilizer B costs the shop 190 per Kg. fertilizer A
contains 5 units of phosphate and 2 units of nitrate
and 2 units of ammonium. Fertilizer B contains 3
units of phosphate and 3 units of nitrate and 5 units
of ammonium. How many Kg of each fertilizer should
the shop use in order to minimize their cost?

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4. Consider two different types of food stuff, say F 1 and
F2 . Assume that these foodstuff contain vitamins
V1, V2, &V3 respectively .Minimum daily
requirements of these vitamins are1 mg of V 1,50 mg
of V2 & 10 mg of V3.Suppose that the foodstuff F1
contain1mg of V1,100 mg of V2 &10 mg of V3.
Whereas foodstuff F2 contain 1 mg of V1,10 mg of V2
&100 mg of V3. Cost of one unit of foodstuff F1 is Rs.1
and that of F2 is Rs.1.5. find the minimum cost diet
that would supply the body at least minimum
requirements of each vitamin by using Graphical
method.
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A firm manufactures two items. It purchases casting which are
then machined, bored and then polished. Casting for item A and
B cost Rs.2 and Rs.3 respectively and sold at Rs.5 and Rs.6 each
respectively. Running cost of three machines are Rs.20, Rs.14, &
Rs.17.5 per hour respectively. Capacities of the machines are :
Formulate the LPP model so as to maximize the profit.

Part - A Part – B
Machining capacity 25 / hr 40 / hr
Boring capacity 28 / hr 35 / hr
Polishing capacity 35 / hr 25 / hr
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