UGPA3033: Process Optimization and Simulation

UGPA3033
PROCESS OPTIMIZATION
AND SIMULATION
TOPIC 3:
APPLICATIONS OF
OPTIMIZATION IN
ENGINEERING PROBLEMS
PART A
APPLICATION OF
OPTIMIZATION IN
ENGINEERING PROBLEMS
CONTENT
DEMONSTRATION 1 – OPTIMIZATION OF MANUFACTURING
COST
DEMONSTRATION 2 – MINIMIZATION OF CSTR OPERATING
COST
2
APPLICATION OF OPTIMIZATION
IN ENGINEERING PROBLEMS
• In this topic, we will be applying the techniques that you
have learned in previous topics to solve problems
encountered in operation and design of chemical engineering
processes.
DEMONSTRATION 1 – OPTIMIZATION OF
MANUFACTURING COST
• Your company must design a storage tank for isopropane.
• The customer’s specifications call for a cylindrical tank with
hemispherical ends, and the volume of the tank is 80 m3.
• The costs (per unit area) to machine the wall of the storage
tank are given by RM1000/m2 and RM500/m2 for
hemispherical ends and cylindrical part of the tank,
respectively.
3
• You are required to use Lagrange multiplier technique to

determine the minimum manufacturing cost of the storage
tank.
• Formulation of objective function:
Objective function = Manufacture cost C
= 4πr2(1000) + 2πrh(500)
= 4000 πr2 + 1000πrh
4
• Constraint is given by the total volume of the tank:
4 3 2
r + r h = 80
3
4 3
g r,h = πr + πr2 h – 80 = 0
3
• Write out Lagrangian function:
4
L(r, h, λ) = 4000 πr2 + 1000πrh + λ( πr3 + πr2 h – 80)
3
• Differentiate the Lagrangian function:
∂L
= 8000πr +1000πh + λ 4πr2 + 2πrh = 0 −−−−−− (1)
∂r
∂L 2
= 1000πr + λ πr = 0 −−−−−−−−−−−−−−−− (2)
∂h
∂L 4 3
= πr + πr2 h – 80 = 0 −−−−−−−−−−−−−−− (3)
∂r 3
5
1000
• From (2), λ = – −−−−−−−−−−−−−−−−−− (4)
r
• Substitute (4) into (1),
1000
8000πr + 1000πh – 4πr2 + 2πrh = 0
r
8r + h – 4r – 2h = 0
h = 4r −−−−−−−−−−−−−−−−−−−−−−−−− (5)
• Substitute (5) into (3),
4 3
πr + πr2 (4r) – 80 = 0
3
πr3 + 3πr3 – 60 = 0
4πr3 = 60
r3 = 15/π
3 15
𝑟= = 1.6839 m −−−−−−−−−− (6)
π
6
• Substitute (6) into (5):
h = 4(1.6839) = 6.7356 m
• Therefore, the radius r and height h are given by 1.6839 m
and 6.7356 m, respectively, to minimize the manufacturing
cost of the tank.
• Minimum cost of the tank is:
Minimum cost, Cmin = 4000 π(1.6839)2
+ 1000π(1.6839)(6.7356)
= RM 71264.37
7
DEMONSTRATION 2 – MINIMIZATION OF CSTR
OPERATING COST
• A feed stream carrying only reactant A with concentration
CA0 mol/m3 enters a CSTR with volumetric feed rate F m3/h
and undergoes a first order reaction A → B, as illustrated in
figure below:
8
• The rate of formation of B is given as rB = -rA = kCA where
k = 1.0 h-1 is the reaction rate constant.
• The cost of this operation per hour (CT , in RM/hr) can be
expressed as the sum of two cost components: cost of feed A
and cost of utility that depends on CSTR volume (V m3), as
follows:
CT = 5CA0 F + 0.3V
• The feed concentration of A is CA0 = 0.04 mol/m3 and it’s
required to produce 10 mol/h of B.
• Now, you are required to calculate the feed rate F and CSTR
volume V that would minimize the operating cost.
9
• By conducting material balance of component A on CSTR:
Rate of Rate of Rate of
mass – mass = mass
IN OUT ACCUMULATION
FCA0 – FCA = -VrA
• Since –rA = kCA:
FCA0 – FCA = VkCA −−−−−−−−−− (1)
• Rate of production of component B = VrB
= kCAV = 10
• Rearranging:
10
V= −−−−−−−−−−−−−−− (2)
kCA
10
• By substituting (2) into (1),
10
FCA0 – FCA = kCA
CA
FCA0 – FCA =10
10
F= −−−−−−−−−−−− (3)
CA0 – CA
• By substituting (2) and (3) into the operating cost formula,
CT = 5CA0 F + 0.3V
10 10
= 5CA0 + 0.3
CA0 – CA kCA
50CA0 3
= +
CA0 – CA kCA
11
• Since CA0 = 0.04 mol/m3 and k = 1.0 h-1,
50(0.04) 3
CT = +
0.04 – CA (1.0)CA
2 3
= +
0.04 – CA CA
• Differentiating:
dCT 2 3
= 2 – 2
dCA 0.04 – CA CA
• For minimum operating cost,
dCT
= 0 and CA = CA,opt
dCA
• Thus,
2 3
2 – 2 =0
0.04 – CA,opt CA,opt
12
• By solving the quadratic equation above,
CA,opt = 0.02202 mol/m3
• By substituting CA,opt = 0.02202 mol/m3 into (2) and (3),
10
Vopt =
kCA,opt
10
=
(1.0)(0.02202)
= 454.13 m3
10
Fopt =
CA0 – CA,opt
10
=
0.04 – 0.02202
= 556.18 m3/hr
13
• Hence,
2 3
Minimum operating cost, CT,min = +
0.04 – CA,opt CA,opt
2 3
= +
0.04 – 0.02202 0.02202
= RM 247.47/hr
14
Example 3.1
Design the optimal cylindrical container (figure below) that is
open at one end and has walls of negligible thickness. The
container is to hold 0.2 m3. Design it so that the areas of its
bottom and sides are minimized.
15
Example 3.2
An industrious farmer is designing a silo to hold her
900π m3 supply of grain. The silo is to be cylindrical
in shape with a hemispherical roof. (See Figure in next slide.)
Suppose that it costs five times as much (per square meter of
sheet metal used) to fashion the roof of the silo as it does to
make the circular floor and twice as much to make the
cylindrical walls as the floor. If you were to act as consultant
for this project, what dimensions would you recommend so
that the total cost would be a minimum? (Assume that the
entire silo can be filled with grain.)
16
Example 3.2 (cont'd)
17
Example 3.3
Consider TWO (2) continuous stirred tank reactors (CSTRs)
which are connected in series, as shown in the figure below:
F0, CA0 F0, CA1 F0, CA2
Reactor 1 Reactor 2
V1 V2
18
Example 3.3 (cont’d)
In these reactors, a reaction that consumes component A takes
place:
A→B
in which the volumetric reaction rate is first order with respect
to component A:
r = kCA
where r = volumetric reaction rate (mol/s.m3)
k = reaction rate constant (1/s)
CA = concentration of component A (mol/m3)
The volumetric flow rate of the inlet stream to each CSTR is

fixed at F0 (m3/s), as illustrated in the figure in previous slide.
19
Given that:
k = 1 s-1
F0 = 0.02 m3/s
CA0 = 1 mol/m3
Due to the space limitation, the total volume of both CSTR is
equal to 5 m3.
Determine the volumes of Reactors 1 and 2 that minimize the

concentration of reactant (A) at the outlet of the second reactor
(CA2).
20
Example 3.4
Consider there are few units of continuous stirred tank reactors
(CSTRs) which are connected in series, as shown in the figure
below:
F0, CA0 F0, CA1 F0, CA2 F0, CA(n–1) F0, CAn
Reactor 1 Reactor 2 Reactor n
V V V
21
The reactant A is converted into product B in the CSTR and
the reaction rate is obeying first order kinetics:
r = kCA
where r = volumetric reaction rate
k = rate constant
CA = concentration of reactant A
The cost of a reactor is the function of its volume (V m3) and is
expressed as:
RM 25000(V0.5)
22
Additional information:
• Volumetric flow rate of liquid F0 is fixed at 0.9 m3/hr
• The first order kinetics rate constant k = 12 hr-1
• The desired concentration change ratio (for component A
at the inlet and outlet of the last reactor is 10000.
• The volume of all reactors are the same at V
Determine the optimum number of reactors so that the cost is
minimum:
a) Express the objective function to be optimized in term of n
only.
b) Solve the objective function by using finite difference of
Newton’s method, by taking the initial guess n0 = 5 and
step size h = 0.01.
23
Example 3.5
As a petrochemical engineer, you are asked to determine the
dimensions of a small cylindrical tank to transport toxic waste
that is to be mounted on the back of a pickup truck. Your
overall objective will be to minimize the cost of the tank. A
schematic diagram of the tank is shown in the next slide, in
which the tank consists of a cylinder with two plates welded
on each end. The tank must has volume of 0.8 m3 and
thickness of 3 cm.
24
The cost of the tank involves two components: (1) material

expense, which based on weight of material, and (2) welding
expense based on length of weld. Note that the latter involves
welding both interior and exterior seams where the plates
connect with the cylinder.
25
Determine the dimension of the tank (diameter D and length L)
that minimizes the construction cost of the tank. What is the
minimum construction cost of the tank? (The information
below might be required in your calculation)
Parameter Symbol Value
Density of material (kg/m3) ρ 8000
Material cost (RM/kg) cm 4.5
Welding cost (RM/m) cw 20
26
Example 3.6
Ammonia is usually produced from an artificial nitrogen
fixation process with hydrogen called Haber process. The
process will react atmospheric nitrogen (N2) with hydrogen
gas (H2) in the presence of metal catalyst (usually iron) under
high temperature (450 °C) ant pressure (200 atm) conditions.
Its batch operation requires a minimum operating reaction time
to achieve equilibrium reaction completion. After ammonia
has been produced, additional time for reactor cleaning and
maintenance will need to be performed to prepare for the next
month operation.
27
The operating time for each cycle can be expressed as 4P0.5
(h), where P is the amount of ammonia (ton) produced per
batch. Meanwhile, the reactor cleaning and maintenance
demands additional time of 2.8P0.5 + 5 (h) for every hour of
operating time taking place. After considering the cost of labor
and utilities, the operating and cleaning cost are calculated to
be RM12 and RM6 per hour respectively. The annual fixed
cost, CF for the reactor is also proportional to the production
amount per batch which can be represented by 450P2.5
(RM/year). The production plant will only operate for 3600
h/year. The annual demand of ammonia is 100 ton.
Calculate the optimum production amount of ammonia, P*
(ton/cycle) that minimize the total annual cost.
28
PART B
INDUSTRIAL REVOLUTION
4.0 AND INTERNET OF
THING (IoT)
CONTENT
1. WHAT IS INDUSTRIAL 4.0?
2. HISTORICAL INDUSTRIAL REVOLUTIONS
3. INTERNET OF THINGS (IoT)
4. ROLE OF PROCESS OPTIMIZATION IN INDUSTRY 4.0
4.1 Digitalization
4.2 Sensorization
4.3 Optimization
29
INDUSTRIAL REVOLUTION 4.0
AND INTERNET OF THING (IoT)
1. WHAT IS INDUSTRIAL 4.0?
• The concept of “Industrial 4.0” appeared first and was
published in an article by the German government in
November 2011.
• In April 2013, the term “Industry 4.0” appeared again at an
industrial fair in Hannover Germany, and quickly rose as the
German national strategy.
• This concept has being discussed vastly in recent years,
emerging as the connecting access for most information
industry and other industries globally therefore making
“Industry 4.0” a new industrial revolution which will have a
tremendous impact on international industry.
30
• Industry 4.0 which is led by intelligent manufacturing is
considered to be the fourth industry which was created from
the industrial revolution.
• Industry 4.0 is aimed at connecting systems and equipments
to facilitate high product customization and automation,
making mass production more flexible, effective and
efficient.
• The industry 4.0 target is to develop a highly supple model
for the production of personalized digital products and
services in the production phase to enable interaction
between people, product and devices in the real-time.
31
2. HISTORICAL INDUSTRIAL REVOLUTIONS
• The levels of industrial revolution are illustrated in figure
below:
32
• Brief description on 4 industrial revolutions:
 Industry 1.0: The use of water and steam power engine
for mechanization of production.
 Industry 2.0: Mass production with the help of Electric
Power.
 Industry 3.0: The Digital Revolution from analog to
digital devices and signals. Use of Electronics and IT to
further Automate Production.
 Industry 4.0: The combination of industry, automation,
digitalization and the current Internet of Things (IoT)
technology. It is also termed as the fourth industrial
revolution.
33
• The efficiency through the use of hydropower, increased use
of steam power and development of machine tools was
achieved by the first industrial revolution.
• The second industrial revolution brought electricity and
mass production of assembly lines.
• The automation using electronics and information
technology was furthered accelerated by the third industrial
revolution.
• Recently the fourth industrial revolution (Industry 4.0) is
emerging which is led by Cyber-Physical System (CPS)
technology to integrate the real world with the information
era for future industrial advancement.
34
• Cyber-physical systems (CPSs):
 An emerging discipline that involves engineered
computing and communicating systems interfacing the
physical world.
 Integrate computation with physical processes, provide
abstractions, modeling, design, and analysis techniques
for the integrated whole.
 Require computing and networking technologies to
embrace not merely information, but also physical
dynamics.
35
3. INTERNET OF THINGS (IoT)
• The concept of Internet of Things (IoT) dates back to the
1999 and was originated by Kelvin Ashton a British
technology pioneer.
• Most physical objects were made “SMART” by connecting
them to the internet and also utilizing ubiquitous sensors;
this became one of the factors leading to the gradual
substitution of conventional computers and major changes in
every aspects of our daily life today.
• In the United States, the concept of SMART is adopted by
the non-profit Industrial Internet Consortium (IIC) which is
presently working on the future of manufacturing.
36
• Several technological concepts operates on Industry 4.0,
including the fore mentioned cyber-physical systems and the
already popular IoT.
• This concept termed IoT facilitates the communication and
cooperation processes of CPSs. Common IoT technologies
such the wireless networks, intelligent or smart objects,
sensory technology and the actuating element are used in
Industry 4.0 by most Smart factories.
• Definition of IoT:
 the use of intelligently connected devices and systems to
leverage data gathered by embedded sensors and actuators
in machines and other physical objects (GSMA).
37
 the networking of physical objects accessed via the
internet, as defined by technology analyst and visionaries
(CISCO).
 a global infrastructure for the information society, which
enables advanced services by physical and virtually
interconnecting things based on existing and evolving
interoperable information and communication
technologies ICT (ITU-T).
4. ROLE OF PROCESS OPTIMIZATION IN INDUSTRY

4.0
• Manufacturers are able to make strides toward Industry 4.0
through three pillars of thought: digitization, sensorization
and optimization.
38
4.1 Digitalization
• Before sensorization and optimization can occur, existing
operations must be digitized to provide visibility over
everything as it happens in real time.
• This allows faults and detection of issues in real time.
• Digitizing workflows allows labor and products to be
monitored and actioned on immediately.
4.2 Sensorization
• The first step towards machine inter-connectivity, is
sensorization. IoT is leading this charge.
• This eliminates human monitoring and frees up resources for
more critical areas.
39
• Sensors are cost-effective ways to measure variables such as
temperature, moisture, air quality, motion and vibration,
among others.
• This enables equipment to auto-detect issues, which leads to
auto-triggers and auto-configurations from a software and
hardware perspective.
• For example, the implementation of non-contact temperature
sensors allows for the auto-adjustment of roller speeds when
gluing two pieces of cardboard together at a cardboard
manufacturing facility. This data can then be utilized to
improve the bonding conditions and durability of the final
product.
40
4.3 Optimization
• Amidst all the data collected from digitization, sensorization
and integration, transitioning this data into finding the
hidden gems is the next priority.
• Optimization of manufacturing data comes through
analytics, simulation, predictive and preventative
maintenance, etc.
• Ultimately, the goal is to reduce costs and improve quality.
41

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UGPA3033

• You are required to use Lagrange multiplier technique to

The volumetric flow rate of the inlet stream to each CSTR is

Determine the volumes of Reactors 1 and 2 that minimize the

Reactor 1 Reactor 2 Reactor n

The cost of the tank involves two components: (1) material

4. ROLE OF PROCESS OPTIMIZATION IN INDUSTRY

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