Enterprise-wide optimization of integrated planning and scheduling for refinery-petrochemical complex with heuristic algorithm

Lifeng Zhang, Haoyang Hu, Zhiquan Wang, Zhihong Yuan, Bingzhen Chen

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PDF(5870 KB)
Front. Chem. Sci. Eng. ›› 2023, Vol. 17 ›› Issue (10) : 1516-1532. DOI: 10.1007/s11705-022-2283-7
RESEARCH ARTICLE

Enterprise-wide optimization of integrated planning and scheduling for refinery-petrochemical complex with heuristic algorithm

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Abstract

This paper focuses on the integrated problem of long-term planning and short-term scheduling in a large-scale refinery-petrochemical complex, and considers the overall manufacturing process from the upstream refinery to the downstream petrochemical site. Different time scales are incorporated from the planning and scheduling subproblems. At the end of each discrete time period, additional constraints are imposed to ensure material balance between different time scales. Discrete time representation is applied to the planning subproblem, while continuous time is applied to the scheduling of ethylene cracking and polymerization processes in the petrochemical site. An enterprise-wide mathematical model is formulated through mixed integer nonlinear programming. To solve the problem efficiently, a heuristic algorithm combined with a convolutional neural network (CNN), is proposed. Binary variables are used as the CNN input, leading to the integration of a data-driven approach and classical optimization by which a heuristic algorithm is established. The results do not only illustrate the detailed operations in a refinery and petrochemical complex under planning and scheduling, but also confirm the high efficiency of the proposed algorithm for solving large-scale problems.

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Keywords

planning / scheduling / refinery-petrochemical / convolutional neural network / heuristic algorithm

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Lifeng Zhang, Haoyang Hu, Zhiquan Wang, Zhihong Yuan, Bingzhen Chen. Enterprise-wide optimization of integrated planning and scheduling for refinery-petrochemical complex with heuristic algorithm. Front. Chem. Sci. Eng., 2023, 17(10): 1516‒1532 https://doi.org/10.1007/s11705-022-2283-7

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Acknowledgements

The authors gratefully acknowledge the financial support from the National Key Research and Development Program of China (Grant No. 2018AAA0101602).

Nomenclature

Main units in refinery and petrochemical

Unit Abbreviation
Refinery units
Delayed coking unit DCU
Wax oil hydrotreating unit WHU
Hydrocracking unit HDT
Catalytic cracking unit CCU
Coking naphtha hydrotreating unit CNHT
Naphtha hydrotreating unit NHT
Dry liquefied gas desulfurization unit LDU
Liquefied gas separation unit LSU
Dry gas separation unit A DSU A
Continuous reformer CRU
Aromatics complex ARU
Naphtha n-isomer separation unit NSU
Jet fuel hydrogenation unit JHT
Diesel hydrocracking unit A DHT A
Diesel hydrocracking unit B DHT B
Gas fractionation unit GFU
Alkylation unit AKU
Hydrogen deep recovery device HDRU
Hydrogen recovery unit HRU
Dry gas separation unit B DSU B
Catalytic gasoline hydrogenation unit CHU
Jet fuel hydrogenation unit JHT
Coke hydrogen production unit CHP
Sulfur recovery unit SRU
Petrochemical units
Gasoline hydrogenation unit GHT
Butadiene extraction unit BEU
MTBE/butene-1 unit MTBE
Styrene unit STU
Full density polyethylene unit FDPE
Acrylonitrile butadiene styrene unit ABS
Acetonitrile unit ATU
methyl methacrylate unit MMA
Acrylonitrile polymerization unit APU
High density polyethylene unit HDPE
Polypropylene unit PP

Main products from refinery and petrochemical

Refinery product Petrochemical product
92# gasoline Pitch C5 C9+
95# gasoline PX Propylene Butadiene
98# gasoline Petroleum coke Styrene MMA
Jet fuel Butane Acetonitrile Acrylonitrile
Diesel Sulfur LLDPE HDPE
Liquefied petroleum gas (LPG) Ammonia PP
Benzene Fuel oil
Methylbenzene (PhMe)

Sets and indices

C Set for crude distillation units
O Set for crude oils
T Set for time periods
N Set for time plots in scheduling of ethylene cracking
J Set for time plots in scheduling of polymerization process
S Set for stream
R Set for raw materials
U Set for processing units
M Set for operation modes
I Set for intermediate stream tanks
P Set for products
K Set for cracking furnaces
Q Set for polymerization reactors
L Set for polymer products
G Set for grades of polymer products

Parameters

Xp,t Price of product p at time t
Xq,l,g,t Price of grade g in polymer l from reactor q at time t
Xc,o,t Price of crude oil o for CDU c at time t
X r,tpur Price of raw material r at time t
V c,oinv Inventory cost of crude oil o in CDU c
V pinv Inventory cost of product p
V q,l,ginv Inventory cost of grade g in polymer l from reactor q
V c,opro Process cost of crude oil o in CDU c
V uop Operation cost of unit u
V kop Operation cost of furnace k
V qop Operation cost of reactor q
V kcn Clean up cost of furnace k
V i,ii,kch Changeover cost from intermediate i to ii in furnace k
V q,l,g,g ch Changeover cost from grade g to g' in polymer l from reactor q
A cmin Minimum capacity of CDU c
A cmax Maximum capacity of CDU c
V c,omin Minimum purchase amount of crude oil o to CDU c
V c,omax Maximum purchase amount of crude oil o to CDU c
I c,o0 Initial inventory of crude oil o to CDU c
I c,omin Minimum inventory of crude oil o to CDU c
I c,omax Maximum inventory of crude oil o to CDU c
x c,o,smin Minimum cut point for stream s of crude oil o from CDU c
x c,o,smax Maximum cut point for stream s of crude oil o from CDU c
ar,u Constant inlet ratio of raw material r to unit u
A umin Minimum capacity of unit u
A umax Maximum capacity of unit u
x u,m,sfixed Constant yield of stream s in mode m in unit u
I i0 Initial inventory of intermediate i
H Time length of each time period
F i,k,n,t r at e,min Minimum flowrate of intermediate i to furnace k in slot n at time t
F i,k,n,t r at e,max Maximum flowrate of intermediate i to furnace k in slot n at time t
T k,n,tmax Maximum operation time for furnace k in slot n at time t
ai,k,s Coefficient of yield of stream s from intermediate i in furnace k
bi,k,s Coefficient of yield of stream s from intermediate i in furnace k
ci,k,s Coefficient of yield of stream s from intermediate i in furnace k
x q,l,gmin Minimum yield of grade g of polymer l from reactor q
x q,l,gmax Maximum yield of grade g of polymer l from reactor q
T q,l,g,gcha,fixed Constant changeover time from grade g to g' of polymer l in reactor q
A qrate,min Minimum capacity of reactor q
A qrate,max Maximum capacity of reactor q
d q.l,g,t m in Minimum demand of grade g of polymer l from reactor q at time t
d q,l,g,t m ax Maximum demand of grade g of polymer l from reactor q at time t
d p,tmin Minimum demand of product p at time t
d p,tmax Maximum demand of product p at time t

Binary variables

y c,o,tpur Purchase decision of crude oil o for CDU c at time t
y c,o,tpro Process decision of crude oil o for CDU c at time t
y u,m,tmode Assignment of operation mode m to unit u at time t
y i,k,n,t a ss i Assignment of intermediate i to furnace k in plot n at time t
y i,ii,k,n,tch Assignment of changeover from intermediate i to ii for furnace k in plot n at time t
y k,n,tcn Assignment of clean up operation to furnace k in plot n at time t
y q,l,g,j,tassi Assignment of grade g to polymer l from reactor q in plot j at time t
y q,l,g,g,j,t c h Assignment of changeover from grade g to g' of polymer l from reactor q in plot j at time t

Continuous variables

z Total profit as the objective function
F c,o,tpro Process flowrate of crude oil o for CDU c at time t
F c,o,tpur Purchase amount of crude oil o for CDU c at time t
Ic,o,t Inventory amount of crude oil o for CDU c at time t
xc,o,s,t Cut point of stream s from crude oil o for CDU c at time t
xc,o,s,t Yield value of stream s from crude oil o for CDU c at time t
F c,s,tout Outlet flowrate of stream s from CDU c at time t
Fc,s,u,t Outlet flowrate of stream s from CDU c to unit u at time t
Fc,s,p,t Outlet flowrate of stream s from CDU c to product p at time t
F u,tin Inlet flowrate to unit u at time t
Fi,u,t Outlet flowrate of intermediate i to unit u at time t
Fr,u,t Outlet flowrate of raw material r to unit u at time t
Fu,s,u,t Outlet flowrate of stream s from unit u’ to unit u at time t
F u,m,tin Inlet flowrate to mode m in unit u at time t
F u,s,tout Outlet flowrate of stream s from unit u at time t
Fu,s,p,t Outlet flowrate of stream s from unit u to product p at time t
Fu,s,i,t Outlet flowrate of stream s from unit u to intermediate i at time t
Ii,t Inventory amount of intermediate i at time t
Fk,s,i,t Outlet flowrate of stream s from furnace k to intermediate i at time t
Fi,k,t Outlet flowrate of intermediate i to furnace k at time t
Fi,q,j,t Outlet flowrate of intermediate i to reactor q in slot j at time t
T k,n,tst Start time of slot n in furnace k at time t
T k,n,tend End time of slot n in furnace k at time t
T k,n,tdur Duration time of slot n in furnace k at time t
T k,n,tope Total operation time for furnace k in slot n at time t
F i,k,n,t r at e Outlet flowrate of intermediate i to furnace k in slot n at time t
xi,k,s,n,t Yield of stream s from intermediate i in furnace k in slot n at time t
F k,s,n,t o ut Outlet flowrate of stream s from furnace k in slot n at time t
T q,j,tst Start time of slot j in reactor q at time t
T q,j,tend End time of slot j in reactor q at time t
T q,j,tdur Duration time of slot j in reactor q at time t
xq,l,g,j,t Yield of grade g in polymer l in reactor q in slot j at time t
T q,j,tcha Changeover time of reactor q in slot j at time t
F q,j,tin Inlet flowrate to reactor q in slot j at time t
Fr,q,j,t Inlet flowrate to reactor q from raw material r in slot j at time t
F q,l,g,j,tout Outlet flowrate of grade g in polymer l from reactor q in slot j at time t
F q,l,g,t s al e Sale amount of grade g in polymer l from reactor q at time t
Iq,l,g,t Inventory amount of grade g in polymer l from reactor q at time t
F p,tsale Sale amount of product p at time t
Ip,t Inventory amount of product p at time t

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