BASIC INTRODUCTION

ON

PROCESS OPTIMIZATION
29/SEP/2020

AHMED MOHAMED SHAFIK ALI ATTIA

PEC PROCESS & OPERATIONS ENGINEERING EXPERT

PROFESSIONALCHE@GMAIL.COM Ahmed Mohamed Shafik Ali Attia

 SAFETY MOMENT

https://www.youtube.com/watch?v=grOA7iUIxGY

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Ahmed Mohamed Shafik Ali Attia
 OBJECTIVE

UNDERSTAND THE REQUIREMENT FOR PROCESS

OPTIMIZATION BASICS AND TECHNIQUES.

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Ahmed Mohamed Shafik Ali Attia
 AGENDA

 INTRODUCTION TO OPTIMIZATION.
 OPTIMIZATION FRAMEWORK.
 BASIC CONCEPTS IN OPTIMIZATION.
 LINEAR PROGRAMMING IN CHEMICAL ENGINEERING.
 APPLICATION OF OPTIMIZATION.
 SOFTWARE TOOLS FOR OPTIMIZATIONS.
 CASE STUDY.

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Ahmed Mohamed Shafik Ali Attia
 Vision of Optimization in Chemical Engineering

• The optimization involves the application of mathematical techniques & tools to find
out the best possible solution from several available alternatives.

• Maximum ROI – Return On Investment

• Higher productivity @ lowest applicable cost.

• Eliminate losses

• Utilize lower cost feed stock @ acceptable quality.

• Maximize the operating capacity of process equipments

• Design & operate the plant @ the most optimum condition - max production rate

PEC = Max profit, min waste generation & impact on environment

Ahmed Mohamed Shafik Ali Attia
 Optimization – Definition

• Origin: Latin word “ Optimus” means “best”.

• Optimization: is the science of making best possible decisions

• By performing optimization, we aim to obtain the best result

under given circumstances

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Ahmed Mohamed Shafik Ali Attia
 Why we need to run Optimization studies?

1) Improve the process to realize optimum system potential.

2) Attain new or most efficient designs, maximize profits, reduce cost of

production, minimize loses & impact to event.

3) Utilize feedstock, energy, utilizing in the most efficient way (e.g. Heat
Integration).

4) Reduce waste generation, minimize the environmental Impact.

5) Determine the most desirable operating conditions and safe operation.

6) Meet product specification and max profit.

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Ahmed Mohamed Shafik Ali Attia
 Optimization Benefits

Improved plant performance such as

• Yield
• Availability
• Reduce energy consumption
• Reduce maintenance cost
• Reduce failure in equipment
• Minimize the unplanned shutdown

Example: To Optimize a distillation column performance, we will consider

Feed tray location, Reflux ratio, Reboiler duty.

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Ahmed Mohamed Shafik Ali Attia
 Optimization – Examples

• Design of HEX network (Heat Integration).

• Real time optimization of a distillation column.

• Model predictive control.

• Operations planning & scheduling.

• Pipeline sizing, Reactor sizing, Distillation column (CAPEX/OPEX).

• Predictive Maintenance (Machine Learning Applications) – Downtime

Planning.

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Ahmed Mohamed Shafik Ali Attia
 Optimization – Examples / Refinery

The objectives of refinery optimization (TARGET – Maximize Profit) include:

• Minimize crude OPEX at refinery
• Optimize refinery crude mix
• Optimize offspec generation and optimize overall product mix and dispatch
• Minimize quality giveaway
• Optimize fuel consumption, minimize losses
• Optimize utilization of the assets
• Optimize inventory management
• Optimize capacity utilization and shutdown planning
• Optimize unit operations maintaining highest standards of safety, catalyst life and activity,
etc.
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Ahmed Mohamed Shafik Ali Attia
 Optimization Framework
• All optimization problems are stated in some standard form.

• You have to identify the essential elements of a given problem

and translate them into a prescribed mathematical form.

• Requirements for application of optimization problem:

1.The design variables.

2.The constraints.

3.The objective (Target) function (Max / Min).

4.The process model.

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Ahmed Mohamed Shafik Ali Attia
 Optimization Framework – Design Variables

You need to know the design variables that affect the system.

• Example: reactor temp, feed rate, No. of trays In column, reflux ratio, Batch
time and reactor yield.

• A practical problem may involve many design variables

• Some of these maybe highly sensitive and heavily influence the process being
optimized. Choose these as design variables and others (not so sensitive
variables) maybe kept constant.

Note: If all the design variables are fixed, there is No scope for optimization.

Thus one or more variables must be relaxed so that the system becomes an Under
Determined System which has at least principle infinite no. of SOLUTIONS.

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Ahmed Mohamed Shafik Ali Attia
 Optimization Framework – Objective Function

A suitable objective function (cost function) is defined in terms of design

variables and often prices parameters.

The objective function may be technical or economic, which needs to be

either maximum or minimum

 Examples of economic objectives:-

1. Max profit.
2. Minimize cost of production.
 Examples of technical objectives:-
1. Maximize reactor yield.
2. Minimize size of equipment.
PEC 3. Minimize environmental impact.
Ahmed Mohamed Shafik Ali Attia
 Optimization Framework – Objective Function

Note:- technical objectives (Target) are ultimately related to economics

In practical process plant there would be multi objective functions to be

optimized in one case only, therefore, there are more than one objective
functions.

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Ahmed Mohamed Shafik Ali Attia
 Optimization Framework – Constraints
The constraints requests some additional relationships among the
design variables and process parameters.
The constraints originates because design variables must satisfy
certain physical phenomena & certain resource limitation.

Example: Variable bounds: 0<x<1 (Don’t exceed the range at any

direction) (Max / Min)
• Equality constraints: Sum of mole fraction should be unity such as
for component balance equation in distillation column.

• In equality constraints: In packed reactor, process temp should be

less than the catalyst deactivation temp/acidic conditions PH<7,
stress developed any where in a component should be less than
PEC the maximum allowable stress
Ahmed Mohamed Shafik Ali Attia
 Optimization Framework – Process Model

• A process model (HYSYS) is required to describe the manner in

which the design variables are related. The process model also
tells us how the objective function is affected by the design
variables.
• A model is a mathematical equation or is a collection of several
equations that define how the design variables are related and
the acceptable values these variables can take.

• Optimization studies are carried out using a simplified (but

reasonably accurate) model of a real system.

• Note:- working with real system (life) is time consuming,

expensive, risky & that’s why you need to work on a model
PEC rather than life case.
Ahmed Mohamed Shafik Ali Attia
 Classification of Optimization Methods
• Based on presence/absence of constraints:
1. Optimization problems which are subject to one or more
constraints.

2. Unconstrained optimization problem- No constraints exists

(Not Practical).

• Based on nature of equation involved:-

1. Linear Programming (LP)

2. Non – Linear Programming (NLP)

PEC 3. Sequential Quadratic Programming (SQP) Ahmed Mohamed Shafik Ali Attia
 Classification of Optimization Methods
• Based on nature of design variables:-
1. Continues optimization (Linear Programming )

2. Integer programming (IP) (integer values)

3. MILP mixed integer (Linear & Integer Programming)

4. MINLP (Non-Linear & Integer Programming)

• Based on local search methods or global search methods

• Based on number of object functions:

1. Single

2. Multi
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Ahmed Mohamed Shafik Ali Attia
 Examples of Optimization Application
Chemical reactor design:
Desired Product
D
FEED
REACTOR
A
Undesired Product
U

Target: Achieve design Conversion @ optimum cost

Possible Solutions:
• Increase Reactor Size at same separation capabilities
Cost Total Cost (energy) – (CAPEX).
Optimum Cost • Increase Separation requirements @ same reactor size
– (CAPEX).
Reactor Cost
• Optimize both, reactor size and the separation energy
requirements – (CAPEX / OPEX) - (Optimization
Separation Cost Path).

PEC Target Conversion Conversion

Ahmed Mohamed Shafik Ali Attia
  Design of Pipeline

1. Size

2. Price of material (CAPEX).

3. Cost of infrastructure (CAPEX).

4. Energy Cost (OPEX).

 Optimization of CDU

1. Feedstock cost (OPEX).

2. Refined product cost (OPEX).

3. Profit Margin (OPEX).

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Ahmed Mohamed Shafik Ali Attia
 Optimization Problem Formulation

• In order to be able to perform optimization on any process,

firstly you will need to formulate the optimization problem.

• In order to formulate a proper optimization problem, you will

need to digest the following expressions:

1. Process Models for optimization

2. Degrees of freedom analysis

3. Optimization problems in chemical engineering

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Ahmed Mohamed Shafik Ali Attia
 Process Models for Optimization

• Optimization requires use of mathematical techniques for

maximization or minimization of an objective function (Variable
required to be approached – Target).

Note: With advent of computers, optimization have become part

of computer-aided design

• In order to use optimization algorithms on computers, we must

have a quantitative model available to compute the responses
of objective function.

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Ahmed Mohamed Shafik Ali Attia
 1- Process Models for Optimization

A process model is a set of equations that imitates reality and

cannot incorporate all features the real process. However, a
reasonably accurate model saves us time and money as we can
avoid repetitive experience & measurements.

Classification of process models:-

1. Theoretical Models.
2. Database Models (Practical).

Other classifications:-
1. Linear vs non linear models
2. Steady state vs non steady state

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Ahmed Mohamed Shafik Ali Attia
 2- Degrees of Freedom Analysis

• The degrees of freedom analysis gives us the number of design

variables that can be changed during optimization process to obtain
the optimal solution

• Degrees of freedom, DOF = No. of variables – No. of linear

independent equations (As in Algebra)

1. If DOF = 0, unique solution exists – no optimization is possible

2. If DOF> 0, under determined system - Infinite solution exist &
optimization is possible
3. DOF< 0, over determined system - No solution exists

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Ahmed Mohamed Shafik Ali Attia
 Introduction to Linear Programing
• Is one of the most effective and widely used optimization
techniques

• A linear programming model seeks to Maximize or Minimize a

linear function, subject to a set of linear constraints

• The linear model consists of the following:

1. A set of design variables

2. An objective function which is a linear function of design

variables

3. A set of linear equality or inequality constraints

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Ahmed Mohamed Shafik Ali Attia
 How do the linear constraints arise?

1. Production limitation:- equipment limitation, storage limits, market

constant

2. Raw material limitation

3. Safety restriction:- allowable operating ranges for temp &

pressure

4. Physical property specification:- product quality constraints when

a blend property can be calculated as an average of pure
component .

5. Mass & energy balance

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Ahmed Mohamed Shafik Ali Attia
 How to formulate linear programming model:-

1. Determine design variables

2. Determine objective function/target

3. Determine constraints

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Ahmed Mohamed Shafik Ali Attia
Example for an Optimization Technique – MS Excel Solver

• Set variable cell process variable (put 1 as original value)

• Set objective cell target

• Select option don’t check assume linear or non linear

• Select method non linear, simplex LP, evolutionary

• Choose min value > 0 (non negative check box)

• Click solve you will get a dialog box stating that solver found a solution

• Check the Keep Solver Solution button & also select the Answer report

• If you have constraints then add then to solver & Click Solve

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Ahmed Mohamed Shafik Ali Attia
 Case Study 1 – Tank Area Optimization
Using MS. Excel Solver
• Objective

You have to design an open storage tank made of Stainless Steel with a square base.
The volume of the tank should be 50 m3.
Find the optimal dimensions of the tank that will require the least material and satisfy
minimum cost.

• Problem Formation:

Assume
X: Length of base
Y: Height of the tank

Quantity of material will depend on the total surface area of the tank

A = X^2 + 4XY -------------- This is the objective function

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Ahmed Mohamed Shafik Ali Attia
 Case Study 1 – Tank Area Optimization
Using MS. Excel Solver
A = X^2 + 4XY -------------- This is the objective function

Volume is give as a Constraint in the problem statement = 50 m3

Since volume = Area of base * Height

50 = X^2 * Y

Therefore,

Y=50 / X^2-------------------equation i

Since Total Surface Area of tank = Area of square + Area of base

Area = 4XY + X^2, substitute using equation i

Therefore, Area = X^2 + 4X (50/X^2) = X2 + 200/X Objective Function

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Ahmed Mohamed Shafik Ali Attia
 Case Study 1 – Tank Area Optimization
Using MS. Excel Solver
• There are two paths to proceed:
1. Short Path – Semi Quantitative Optimization.
2. Proper Engineered Path – Quantitative Optimization.

1. Semi-Quantitative Optimization
o Since the equation relating Area to Length is ready, then you can assume various values
for X, from 1 to 9, and then plot a curve for X versus Min Area.
o Trend will be as shown below:
X Area
1 201.00
2 104.00
3 75.67
4 66.00
5 65.00
6 69.33
7 77.57
8 89.00
9 103.22

o From the trend you can assume that the minimum area will be associated with a length
between 4 – 5 m.
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Ahmed Mohamed Shafik Ali Attia
 Case Study 1 – Tank Area Optimization
Using MS. Excel Solver
• There are two paths to proceed:
1. Short Path – Semi Quantitative Optimization.
2. Proper Engineered Path – Quantitative Optimization.

2. Proper Engineered Path – Quantitative Optimization:

o Use MS Excel Solver to get the accurate values of X & The associated Minimum Area.
o Following the steps of Solver discussed previously, you will get the below results:
Microsoft Excel 15.0 Answer Report
Worksheet: [Book1]Sheet1
Report Created: 7/9/2020 1:56:19 PM
Result: Solver found a solution. All Constraints and optimality conditions are satisfied.
Solver Engine
Engine: GRG Nonlinear
Solution Time: 0.047 Seconds.
Iterations: 4 Subproblems: 0
Solver Options
Max Time Unlimited, Iterations Unlimited, Precision 0.000001, Use Automatic Scaling
Convergence 0.0001, Population Size 100, Random Seed 0, Derivatives Forward, Require Bounds
Max Subproblems Unlimited, Max Integer Sols Unlimited, Integer Tolerance 1%, Assume NonNegative

Objective Cell (Min)

Cell Name Original Value Final Value
$C$5 Objective Function 201 64.6330407

PEC Variable Cells

Cell Name Original Value Final Value Integer
$C$4 Variable Function 1 4.641588834 Contin Ahmed Mohamed Shafik Ali Attia
 Case Study 2 - Hydrocarbon Pipeline Optimization
Using Simulation
• Objective

Optimally determine the best suited pipeline size considering the material cost of the
pipe, pump (CAPEX) and the associated running cost of pumping system (OPEX).

• Constraints:

1. Pipeline ANSI rating 300# and 600#.

2. Pipeline Length 125 km.
3. Diesel design flow of 725 m³/hr.
4. Operational hours of 16 hrs.
5. Potential pipe sizes (X), of 16”, 18” and 20”.
6. ACCE (Aspen Capital Cost Estimator) for pipeline cost estimate.
PEC 7. APEA (Aspen Process Economic Evaluation) for pump fixed and running cost.
Ahmed Mohamed Shafik Ali Attia
 Case Study 2 - Hydrocarbon Pipeline Optimization
Using Simulation

• Case 1- Base Case:

1. Design Flow 725 m³/hr.

2. ANSI rating 600#.
3. Operational hours: 16 hrs.
4. Pipe ID: 16”.

Variable ID 16”
Pump Discharge Pressure @ 725m³/hr. 74.7 barg
Pipeline CAPEX ($) 25,581,335
PEC Pump OPEX ($/year) 679,345 Ahmed Mohamed Shafik Ali Attia
 Case Study 2 - Hydrocarbon Pipeline Optimization
Using Simulation

• Case 2:

1. Design Flow 725 m³/hr.

2. ANSI rating 300#.
3. Operational hours: 16 hrs.
4. Pipe ID: 18’’.

Variable ID 18”
Pump Discharge Pressure @725m³/hr. 42.7 barg
Pipeline CAPEX ($) 25,286,779
PEC Pump OPEX ($/year) 386,270 Ahmed Mohamed Shafik Ali Attia
 Case Study 2 - Hydrocarbon Pipeline Optimization
Using Simulation
• Case 3:

1. Design Flow 725 m³/hr.

2. ANSI rating 300#.
3. Operational hours: 16 hrs.
4. Pipe ID: 20”.

Variable ID 20”
Pump Discharge Pressure@ 725m³/hr. 27.6 barg
Pipeline CAPEX ($) 29,643,110
PEC Pump OPEX ($/year) 248,313 Ahmed Mohamed Shafik Ali Attia
 Case Study 2 - Hydrocarbon Pipeline Optimization
Using Simulation
Key Results
Variable Case 2 Case 3 Case 1

Pipe ID. 18” 20” 16”

ANSI rating. 300# 300# 600#

Pump Discharge Pressure @ 725m³/hr. 42.7 barg 27.6 barg 74.7 barg

Pipeline CAPEX ($) 25,286,779 29,643,110 25,581,335

Design Pressure Exceedance Pump Shut-in Exceeds 47.7 Pump Shut-in within 47.7 Pump Shut-in within 94
barg barg barg

Pump CAPEX ($) 349,200 292,600 445,600

Pump OPEX ($/year) considering 16hrs 386,270 248,313 679,345

Ahmed Mohamed Shafik Ali Attia

 Case Study 2 - Hydrocarbon Pipeline Optimization
Using Simulation
Conclusions
CASE 2 CAN BE DISQUALIFIED WHERE THE SHUT OFF PRESSURE OF THE
EXPORT PUMP WILL EXCEED THE DESIGN PRESSURE OF 47.7 BARG.
• CASE 1 AND CASE 3 ARE TECHNICALLY VIABLE WHERE THEM MEET THE
FLOW REQUIREMENTS AND THE DESIGN PRESSURE OF 300# AND 600#
RESPECTIVELY.
• CASE 1 (16” PIPELINE - ANSI 600#) HAS REPORTED A LOWER CAPEX TO CASE
3 (20” - ANSI 300#), HOWEVER THE PUMP COST AND ELECTRICITY COST OF
CASE 1 IS HIGHER.
• ALTHOUGH CASE 1 HAS REPORTED LOWER PIPELINE CAPEX, HOWEVER, IT
CAN BE DISMISSED FOR THE FOLLOWING REASONS:
• PUMP OPEX IS NEARLY THREE TIMES THE VALUE OF CASE 3.
• MAXIMUM OPERATING PRESSURE UNDER CASE 1 IS 2.8 TIMES OF CASE 3. AS A
RESULT, THE EXPECTED PEAK SURGE AND RELIEVING VOLUME WOULD RESULTS IN A
BIGGER SRV SIZE AND MORE RELIEVING VOLUME.

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Ahmed Mohamed Shafik Ali Attia
 Case Study 2 - Hydrocarbon Pipeline Optimization
Using Simulation
Recommendation
CONSIDERING PREVIOUS TECHNICAL DISCUSSION AND OUTCOMES
FROM TECHNO-ECONOMIC ANALYSIS, IT IS RECOMMENDED TO:
• CASE 3 IS DEEMED MORE FAVORABLE AND TECHNICALLY VIABLE
TO CATER FOR THE OPERATIONAL REQUIREMENTS (DESIGN FLOW
RATE AND LESS SURGE DEMAND) AND MORE ECONOMIC
COMPARED TO CASE 1 AND CASE 2.

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Ahmed Mohamed Shafik Ali Attia
NOW YOU KNOW
IT’S ALL ABOUT
CAPEX VS OPEX

THANK YOU

Ahmed Mohamed Shafik Ali Attia