Integrated production scheduling and process control: A systematic review

Computers and Chemical Engineering

Volumn 71, Issue , 2014, Pages 377-390

  Baldea, Michael ^a   Harjunkoski, Iiro ^b  

^a The University of Texas at Austin   (United States)

^b ABB AG   (Germany)

Author keywords

Integrated scheduling and control; Process control; Production scheduling

Indexed keywords

DECISION MAKING; PRODUCTION CONTROL; SCHEDULING;

BUILDING BLOCKES; ECONOMIC BENEFITS; INTEGRATED PRODUCTION; INTEGRATED SCHEDULING; OPERATIONAL DECISIONS; PRODUCTION SCHEDULING; SCHEDULING AND CONTROLS; SYSTEMATIC REVIEW;

PROCESS CONTROL;

EID: 84929412724     PISSN: 00981354     EISSN: None     Source Type: Journal    
DOI: 10.1016/j.compchemeng.2014.09.002     Document Type: Review

References (90)

1. CONOPT. http://www.gams.com/dd/docs/solvers/conopt.pdf, last retrieved 8/3/2014.
2. CPLEX. http://www.gams.com/dd/docs/solvers/cplex.pdf, last retrieved 8/3/2014.
3. DICOPT. http://www.gams.com/dd/docs/solvers/dicopt.pdf, last retrieved 8/3/2014.
4. Allgor R.J., Barton P.I. Mixed-integer dynamic optimization I: problem formulation. Comput Chem Eng 1999, 23(4):567-584.
5. Amrit R., Rawlings J.B., Angeli D. Economic optimization using model predictive control with a terminal cost. Annu Rev Contr 2011, 35(2):178-186.
6. Baldea M., Daoutidis P. Dynamics and nonlinear control of integrated process systems 2012, Cambridge University Press, Cambridge.
7. Baldea M., Daoutidis P. A general analysis and control framework for process systems with inventory recycling. Int J Robust Nonlin Contr 2013, 10.1002/rnc.3029.
8. Baldea M., Touretzky C.R. Nonlinear model predictive control of energy-integrated process systems. Syst Contr Lett 2013, 62:723-731.
9. Bemporad A., Bozinis N.A., Dua V., Morari M., Pistikopoulos E.N. Model predictive control: a multi-parametric programming approach. Comput Aided Chem Eng 2000, 8:301-306.
10. Bemporad A., Morari M., Dua V., Pistikopoulos E.N. The explicit linear quadratic regulator for constrained systems. Automatica 2002, 38(1):3-20.
11. Bhatia T., Biegler L.T. Dynamic optimization in the design and scheduling of multiproduct batch plants. Ind Eng Chem Res 1996, 35(7):2234-2246.
12. Biegler L.T., Zavala V.M. Large-scale nonlinear programming using IPOPT: an integrating framework for enterprise-wide dynamic optimization. Comput Chem Eng 2009, 33(3):575-582.
13. Cao Y., Swartz C.L.E., Baldea M. Design for dynamic performance: application to an air separation unit. American Control Conference (ACC), 2011. IEEE 2011, 2683-2688.
14. Cao Y., Swartz C.L.E., Baldea M., Blouin S. Optimization-based assessment of design limitations to air separation plant agility in demand response scenarios. J Proc Contr 2014, submitted for publication.
15. Capón-García E., Guillén-Gosálbez G., Espuña A. Integrating process dynamics within batch process scheduling via mixed-integer dynamic optimization. Chem Eng Sci 2013, 102:139-150.
16. Chatzidoukas C., Kiparissides C., Perkins J.D., Pistikopoulos E.N. Optimal grade transition campaign scheduling in a gas-phase polyolefin FBR using mixed integer dynamic optimization. Comput Aided Chem Eng 2003, 14:71-76.
17. Chatzidoukas C., Perkins J.D., Pistikopoulos E.N., Kiparissides C. Optimal grade transition and selection of closed-loop controllers in a gas-phase olefin polymerization fluidized bed reactor. Chem Eng Sci 2003, 58(16):3643-3658.
18. Christofides P.D., Davis J.F., El-Farra N.H., Clark D., Harris K.R.D., Gipson J.N. Smart plant operations: Vision, progress and challenges. AIChE J 2007, 53(11):2734-2741. 1547-5905.
19. Chu Y., You F. Integration of scheduling and control with online closed-loop implementation: fast computational strategy and a large-scale global optimization algorithm. Comput Chem Eng 2012, 47:248-268.
20. Chu Y., You F. Integration of production scheduling and dynamic optimization for multi-product CSTRs: Generalized Benders decomposition coupled with global mixed-integer fractional programming. Comput Chem Eng 2013, 58:315-333.
21. Chu Y., You F. Moving horizon approach of integrating scheduling and control for sequential batch processes. AIChE J 2014, 60:1654-1671.
22. Congalidis J.P., Richards J.R., Ray W.H. Feedforward and feedback control of a solution copolymerization reactor. AIChE J 1989, 35(6):891-907.
23. Daoutidis P., Kravaris C. Dynamic output feedback control of minimum-phase nonlinear processes. Chem Eng Sci 1992, 47:837.
24. Daoutidis P., Kravaris C. Dynamic output feedback control of minimum-phase multivariable nonlinear processes. Chem Eng Sci 1994, 49:433-447.
25. Davis H.T., Thomson K.T. Linear algebra and linear operators in engineering: with applications in mathematica®, volume 3 2000, Academic Press.
26. Davis J.F., Edgar T.F., Porter J., Bernaden J., Sarli M. Smart manufacturing, manufacturing intelligence and demand-dynamic performance. Comput Chem Eng 2012, 47:145-156.
27. Downs J.J., Vogel E.F. A plant-wide industrial process control problem. Comput Chem Eng 1993, 17(3):245-255.
28. Du J., Park J., Harjunkoski I., Baldea M. Time scale bridging approaches for integration of production scheduling and process control. Comput Chem Eng 2014, submitted for publication.
29. Edgar T.F. Control and operations: when does controllability equal profitability?. Comput Chem Eng 2004, 29(1):41-49.
30. Edgar T.F., Davis J.F.S Design for energy and the environment: Proceedings of the seventh international conference on the foundations of computer-aided process design chapter Smart process manufacturing-A vision of the future 2009, 149-165. CRC Press, Boca Raton, FL.
31. El-Halwagi M.M. Process integration. Process systems engineering 2006, Elsevier Academic Press.
32. Ellis M., Durand H., Christofides P.D. A tutorial review of economic model predictive control methods. J Proc Contr 2014, 10.1016/j.jprocont.2014.03.010.
33. Engell S. Feedback control for optimal process operation. J Proc Contr 2007, 17(3):203-219.
34. Engell S. Online optimizing control: The link between plant economics and process control. Comput Aided Chem Eng 2009, 27:79-86.
35. Engell S., Harjunkoski I. Optimal operation: Scheduling, advanced control and their integration. Comput Chem Eng 2012, 47:121-133.
36. Engell S., Kowalewski S., Schulz C., Stursberg O. Continuous-discrete interactions in chemical processing plants. Proc IEEE 2000, 88(7):1050-1068.
37. Flores-Tlacuahuac A., Grossmann I.E. Simultaneous cyclic scheduling and control of a multiproduct CSTR. Ind Eng Chem Res 2006, 45:6698-6712.
38. Floudas C.A., Lin X. Continuous-time versus discrete-time approaches for scheduling of chemical processes: a review. Comput Chem Eng 2004, 28(11):2109-2129.
39. Gallestey E., Stothert A., Castagnoli D., Ferrari-Trecate G., Morari M. Using model predictive control and hybrid systems for optimal scheduling of industrial processes. Automatisierungstechnik 2003, 51(6):285-293.
40. Grossmann I.E. Enterprise-wide optimization: a new frontier in process systems engineering. AIChE J 2005, 51(7):1846-1857.
41. Harjunkoski I., Nyström R., Horch A. Integration of scheduling and control-Theory or practice?. Comput Chem Eng 2009, 33(12):1909-1918.
42. Harjunkoski I., Maravelias C.T., Bongers P., Castro P., Engell S., Grossmann I.E., Hooker J., Méndez C., Sand G., Wassick J. Scope for industrial applications of production scheduling models and solution methods. Comput Chem Eng 2014, 62:161-193.
43. Heidarinejad M., Liu J., Christofides P.D. Economic model predictive control of nonlinear process systems using Lyapunov techniques. AIChE J 2012, 58(3):855-870.
44. Henze G.P. Model predictive control for buildings: a quantum leap?. J Build Perform Simulat 2013, 6(3):157-168.
45. Ierapetritou M.G., Wu D., Vin J., Sweeney P., Chigirinskiy M. Cost minimization in an energy-intensive plant using mathematical programming approaches. Ind Eng Chem Res 2002, 41(21):5262-5277.
46. Kadam J., Marquardt W. Integration of economical optimization and control for intentionally transient process operation. Assess Future Direct Nonlinear Model Predictive Contr 2007, 419-434.
47. Kelly J.D., Mann J.L. Crude-oil blend scheduling optimization: An application with multi-million dollar benefits-Part 1. Hydrocarbon Process 2003, 82(6):47-54.
48. Khalil H.K. Nonlinear systems 2002, Prentice Hall, Upper Saddle River, NJ.
49. Kokotovic P.V., Khalil H.K., O'Reilly J. Singular perturbations in control: analysis and design 1986, Academic Press, London.
50. Kopanos G.M., Pistikopoulos E.N. Reactive scheduling by a multiparametric programming rolling horizon framework: a case of a network of combined heat and power units. Ind. Eng. Chem. Res. 2014, 53(11):4366-4386.
51. Kumar A., Daoutidis P. Dynamics and control of process networks with recycle. J Proc Contr 2002, 12:475-484.
52. Liu J., Munoz de la Pena D., Christofides P.D. Distributed model predictive control of nonlinear process systems. AIChE J 2009, 55(5).
53. Ma J., Qin S.J., Salsbury T., Xu P. Demand reduction in building energy systems based on economic model predictive control. Chem Eng Sci 2012, 67(1):92-100.
54. Ma Y., Borrelli F., Hencey B., Coffey B., Bengea S., Packard A., Wetter M., Haves P. Model predictive control for the operation of building cooling systems. IEEE Trans Cont Syst Technol 2012, 20(3):796-803.
55. Mahadevan R., Doyle F.J., Allcock A.C. Control-relevant scheduling of polymer grade transitions. AIChE J 2002, 48:1754-1764.
56. Maravelias C.T. General framework and modeling approach classification for chemical production scheduling. AIChE J 2012, 58(6):1812-1828.
57. Maravelias C.T., Sung C. Integration of production planning and scheduling: overview, challenges and opportunities. Comput Chem Eng 2009, 33(12):1919-1930.
58. Mayne D.Q., Rawlings J.B., Rao C.V., Scokaert P.O. Constrained model predictive control: stability and optimality. Automatica 2000, 36:789-814.
59. Méndez C.A., Cerdá J., Grossmann I.E., Harjunkoski I., Fahl M. State-of-the-art review of optimization methods for short-term scheduling of batch processes. Comput Chem Eng 2006, 30(6):913-946.
60. Méndez C.A., Grossmann I.E., Harjunkoski I., Kaboré P. A simultaneous optimization approach for off-line blending and scheduling of oil-refinery operations. Comput Chem Eng 2006, 30(4):614-634.
61. Mendoza-Serrano D.I., Chmielewski D.J. HVAC control using infinite-horizon economic MPC. 51st IEEE conference on decision and control 2012 Dec., 6963-6968.
62. Miller J., Luyben W.L., Blouin S. Economic incentive for intermittent operation of air separation plants with variable power costs. Ind Eng Chem Res 2008, 47(4):1132-1139.
63. Mitra K., Gudi R.D., Patwardhan S.C., Sardar G. Resiliency issues in integration of scheduling and control. Ind Eng Chem Res 2010, 49(1):222-235.
64. Mouret S., Grossmann I.E., Pestiaux P. Time representations and mathematical models for process scheduling problems. Comput Chem Eng 2011, 35(6):1038-1063.
65. Nie Y., Biegler L.T., Wassick J.M. Integrated scheduling and dynamic optimization of batch processes using state equipment networks. AIChE J 2012, 58(11):3416-3432.
66. Nyström R.H., Franke R., Harjunkoski I., Kroll A. Production campaign planning including grade transition sequencing and dynamic optimization. Comput Chem Eng 2005, 29(10):2163-2179.
67. Oldewurtel F., Ulbig A., Parisio A., Andersson G., Morari M. Reducing peak electricity demand in building climate control using real-time pricing and model predictive control. 49th IEEE conference on decision and control 2010, 1927-1932.
68. Pannocchia G., Rawlings J.B., Mayne D.Q., Mancuso G. Whither discrete time model predictive control?. IEEE Trans Automat Contr 2014.
69. Park J., Du J., Baldea M., Harjunkoski I. Integration of scheduling and control using internal coupling models. Proceedings of ESCAPE 24 2014, 529-534.
70. Pattison R.C., Baldea M. Optimal design of air separation plants with variable electricity pricing. Foundations of Computer Aided Process Design (FOCAPD) 2014, 393-398.
71. Paulus M., Borggrefe F. The potential of demand-side management in energy-intensive industries for electricity markets in Germany. Appl Energy 2011, 88(2):432-441.
72. Poncet A., Stothert A. Scheduling of industrial production processes. US Patent App. 11/586,713 2006.
73. Prata A., Oldenburg J., Kroll A., Marquardt W. Integrated scheduling and dynamic optimization of grade transitions for a continuous polymerization reactor. Comput Chem Eng 2008, 32(3):463-476.
74. Qin S.J., Badgwell T.A. A survey of industrial model predictive control technology. Contr Eng Prac 2003, 11(7):733-764.
75. Rawlings J.B., Stewart B.T. Coordinating multiple optimization-based controllers: new opportunities and challenges. J Proc Contr 2008, 18(9):839-845.
76. Rosenthal R.E. GAMS - a user's guide 2014, GAMS Development Corporation, Washington, DC.
77. Seborg D.E., Edgar T.F., Mellichamp D.A., Doyle F.J. Process dynamics and control 2010, Wiley.
78. Shobrys D.E., White D.C. Planning, scheduling and control systems: why cannot they work together. Comput Chem Eng 2002, 26(2):149-160.
79. Skogestad S. Control structure design for complete chemical plants. Comput Chem Eng 2004, 28:219-234.
80. Soroush M., Chmielewski D.J. Process systems opportunities in power generation, storage and distribution. Comput Chem Eng 2013, 51:86-95.
81. Subramanian K., Maravelias C.T., Rawlings J.B. A state-space model for chemical production scheduling. Comput Chem Eng 2012, 47:97-110.
82. Sundaramoorthy A., Maravelias C.T. Computational study of network-based mixed-integer programming approaches for chemical production scheduling. Ind Eng Chem Res 2011, 50(9):5023-5040.
83. Terrazas-Moreno S., Flores-Tlacuahuac A., Grossmann I.E. Simultaneous cyclic scheduling and optimal control of polymerization reactors. AIChE J 2007, 53(9):2301-2315.
84. Terrazas-Moreno S., Flores-Tlacuahuac A., Grossmann I.E. Lagrangean heuristic for the scheduling and control of polymerization reactors. AIChE J 2008, 54(1):163-182.
85. Touretzky C.R., Baldea M. Nonlinear model reduction and model predictive control of residential buildings with energy recovery. J Proc Contr 2013, 24:723-739.
86. Touretzky C.R., Baldea M. Integrating scheduling and control for economic MPC of buildings with energy storage. J Proc Contr 2014, 10.1016/j.jprocont.2014.04.015.
87. U.S. Department of Energy Advanced Manufacturing Office, Innovative Process and Materials Technologies, 2013. http://www1.eere.energy.gov/manufacturing/innovation/rd/innovative_manufacturing.html#IMIProjects2.
88. Westerberg A.W. A retrospective on design and process synthesis. Comput Chem Eng 2004, 28(4):447-458. 0098-1354.
89. Zhuge J., Ierapetritou M.G. Integration of scheduling and control with closed loop implementation. Ind Eng Chem Res 2012, 51(25):8550-8565.
90. Zhuge J., Ierapetritou M.G. Integration of scheduling and control for batch processes using multi-parametric model predictive control. AIChE J 2014, 10.1002/aic.14059.