The scheduling of the converter aisle of a nickel smelting plant is a non-trivial task with significant consequences to plant profitability and production. An optimization-based scheduling formulation is developed using a continuous-time paradigm to accurately represent event timings. The formulation accounts for environmental restrictions on sulfur dioxide emissions using event timing constraints. The formulation includes novel semi-continuous modeling to represent flash furnaces which operate with a continuous inlet flow and intermittent discrete material removal, as well as, a novel sequencing and symmetry-breaking scheme to account for identical units operating in parallel. A rolling horizon feature is included in the formulation to accommodate multi-period optimization. Tightening constraints are developed and used to improve the computational performance of the optimization and demonstrate the capacity of the proposed methodology to function as a real-time decision-support tool. A solution procedure is presented where an aggregate model is used to bound the objective function of the master problem in a two layer optimization scheme. Finally, a novel multi-tiered procedure is presented to enhance the optimization solution by re-optimizing for objectives of decreasing priority in order to minimize task start times and penalize deviations in the furnace flow rate.
To address the closed-loop properties of scheduling, a reactive scheduling mechanism is included to allow for rescheduling to account the impact of process disturbances on the operating schedule. A methodology for reducing radical scheduling changes due to the optimization during reactive scheduling is presented. The reactive scheduling algorithm utilizes a tiered optimization approach that progressively increases the degrees of freedom available, as required, in order to achieve a feasible production schedule. The use of the reactive scheduling algorithm demonstrates the ability to reject disturbances and transition plant operation in an agile manner. / Thesis / Master of Applied Science (MASc)
| Identifer | oai:union.ndltd.org:mcmaster.ca/oai:macsphere.mcmaster.ca:11375/16095 |
| Date | January 2014 |
| Creators | Ewaschuk, Christopher |
| Contributors | Swartz, Christopher, Chemical Engineering |
| Source Sets | McMaster University |
| Language | English |
| Detected Language | English |
| Type | Thesis |
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