Integrated Optimization Strategies for Dynamic Process Operations

Process systems engineering faces increasing demands and opportunities for better process modeling and optimization strategies, particularly in the area of dynamic operations. Modern optimization strategies for dynamic optimization trace their inception to the groundbreaking work Pontryagin and his coworkers, starting 60 years ago. Since then the application of large-scale non-linear programming strategies has extended their discoveries to deal with challenging real-world process optimization problems. This study discusses the evolution of dynamic optimization strategies and how they have impacted the optimal design and operation of chemical processes. We demonstrate the effectiveness of dynamic optimization on three case studies for real-world reactive processes. In the first case, we consider the optimal design of runaway reactors, where simulation models may lead to unbounded profiles for many choices of design and operating conditions. As a result, optimization based on repeated simulations typically fails, and a simultaneous, equationbased approach must be applied. Next we consider optimal operating policies for grade transitions in polymer processes. Modeled as an optimal control problem, we demonstrate how product specifications lead to multistage formulations that greatly improve process performance and reduce waste. Third, we consider an optimization strategy for the integration of scheduling and dynamic process operation for general continuous/batch processes. The method introduces a discrete time formulation for simultaneous optimization of scheduling and operating decisions. For all of these cases we provide a summary of directions and challenges for future integration of these tasks and extensions in optimization formulations and strategies.

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