Institute of Chemical engineering- Bulgarian academy of sciences Optimal loading the systems for resource consumption in case of multiproduct and multipurpose batch chemical plants (theoretical aspects and software realization) B.Ivanov, K.Mintchev Institute of Chemical engineering- Bulgarian academy of sciences ul. Acad. G.Bonchev, 103, Sofia 1113 Fax: +(359)(2) 8-70-75-23 e-mail: bivanov@bas.bg

1.Control problem - for a group of compatible batch products The offered software package is created on the base of original author’s methods published in international journals. Its present version uses MATLAB 6.5 and is adopted for WINDOWS-XP. The software package ECAM solves two main problems: 1.Control problem - for a group of compatible batch products 2.Simulation problem - for such of product group aiming to determine load parameters of resources supply systems. 1

ECAM could be used for investigation of different manufacturing states and as well as for evaluation the affect of energy integration processes on the resources supply systems. Thus, the technology changes could be properly assessed that provides opportunities for creation of proper production schedules ensuring optimal load of resources supply systems. 2

Main principles during the build up of ECAM The menus principle is used The principle of choices the data is used so that the human mistakes be reduced. Logical control about correctness the data The results are visualized All functions consist of subsidiary information ECAM working under Windows’XP area “Matlab 6.50” is used to build up the product 7

Help RUN PROGRAMME Exit programme Information About authors Information gives a detailing account about different task classes and objects in which ECAM can be used. Information about authors and description of the theoretical base in which ECAM is made of. After activating (push the button ) the necessary information (data base) is charged in the operative memory (RAM). ECAM is started. Help Information About authors 6

INPUT DATA BATCH PLANTS VIZUALIZATION OF SHEDULING INPUT DATA TECHNOLOGY INPUT DATA CAMPAIGN Module for creation a date base for a production system. It ensures a proper description of the existing plant units and connection between them OPTIMAL SHEDULING Module for creation a date base for technologies. It ensures description of different technologies available For processing in the plant. Module for formulation of different classes controlling problems. It involves definition of criteria for optimal control and set of constraints. VIZUALIZATION OF SHEDULING Module for automatically generation or customization of production campaign (group of compatible products) available to fulfill a given production demands. PRINT SHEDULING Module for formulation of different classes controlling problems. It involves definition of criteria for optimal control and set of constraints. Module for graphical interface for visualization the results obtained under optimal scheduling of campaign. 7

-delete the apparatus; -edit data base of current apparatus; Data for the apparatus and connection between each other in material flow. Charging the data base about existing apparatus and connection between them. Rule buttons: -add new apparatus; -delete the apparatus; -edit data base of current apparatus; -save data base of current apparatus; -exit form this module; -help. 1.Short name of plant. 2.Full name of plant. 3.Number of apparatus in Data Base. Visualization of apparatus which include: -short name of apparatus; -image of apparatus; -basic characterizations; -image of type apparatus; Creation the new connect or imaging of the existing connects between apparatus. 8

Information about resources: -quantity of each resource Data technology. Information about resources: -quantity of each resource required to one unit final product; -apportionment of resources in time; -consumption quantity for the stage. Rule buttons: -add new apparatus; -delete the apparatus; -edit data base ; -save data base ; -exit form this module; -help. Buttons which charge data base of chosen technology: -number of stages; -obtainable profit for unit product. Description the data for each stage of technology: -name of stages; -time of stage; -size factor; -type of apparatus. 9

Rule module for synthesis tasks of production variants and campaign. Manuel generation campaign; Design of manufacturing campaigns which a determinate group of manufacture. The program gives possibility to define the stages of each apparatus on given manufacture. After successful defining of all stages and manufactures the next step is to calculate evaluation of each variant which are included in given campaign. Automatically generation campaign maximum length Define the available manufacturing campaign , each one consist of : -maximal number manufactures which the manufacture program is made of. For obtainable manufacture campaign evaluate are given and also the variants of every manufacture which are included in relevant campaign. Automatically generation sets full campaign Define maximal number of campaign in case that the manufacture are given. For each variant of manufacture campaign variant which are consist of are given. Generation of given technology. Calculating available disposing in a given technology and parameters which are consist of: -Minimum batch size; -Maximum batch size; -Cycle time; -Minimum available manufacturing quantity; -Maximum available manufacturing quantity; 10

Define the variants of disposing of given technology List of apparatus which are disposing on every stage of technology of considering variant. That also include information about: -Maximum batch size; -Minimum batch size; -Cycle time; -Maximal and minimum product demand. Rule buttons: -delete the technology; -edit data technology ; -save technology to data base ; -exit form this module; -print variant; -help. Define the variants in case of given data base. Lead in the data base of technology: -Short name of technology; -Full name of technology; -Number of stages. Lead in the data base about planning horizon. Lead in the data base about production demand: -Minimum demand of product; -Normal demand of product; -Maximum demand of product; Lead in the data base about work regime: -Whit overlapping the cycle; -Without overlapping the cycle. 11

Design the manufacturing campaign from the customer. Rule buttons: -add new campaign; -delete campaign; -edit data base; -save to data base; -exit; -help. Read the campaigns data base Output information about the campaign: -Maximum batch size; -Minimum batch size; -Cycle time whitout overlapping; -Cycle time whit overlapping; Vizualization of apparatus in which the stage will carry out. Choise the existing campaign from data base or lead in the data for new one. Choise of relevant product who will be manufactured simultanuasly in campaign. Lead in the stage into relevant apparatus. Choise tha apparatus in which the stage will carry out. 12

-edit data base of given campaign; -save to data base; -exit; -help. Synthesis of variants of campaigns with relatable size to number of manufacture which are included in a plan. Output information about obtained variant of campaign: -list of apparatus which have to placed in relevant stage -basic characterization: -maximum batch size, minimum batch size; -cycle time; -maximum demand,minimum demand; -maximum number of variants. Rule buttons: -delete campaign; -edit data base of given campaign; -save to data base; -exit; -help. Lead in the data base of existing manufacture plan or including the new one. Choice the regime of manufacture: -With overlapping the cycle or without overlapping the cycle; -Production demand for the product: -minimum product quantity; -normal product quantity; -maximum product quantity; -Include the planning horizont. Calculating the all available campaigns which are consist of the maximum number manufacture working at the same time. 13

Synthesis of maximal number independent campaigns. Generalize information of found campaign, Gives the maximum number of in depended campaign. Rule buttons: -delete campaign; -edit data base of given campaign; -save to data base; -exit; -help. Lead in the data base of existing manufacture plan or including the new one. Choice the regime of manufacture: -With overlapping the cycles or without overlapping the cycles; -Production demand for the product: -minimum product quantity; -normal product quantity; -maximum product quantity; -Include the planning horizon. Calculating the all available campaigns which are consist of the maximum number manufacture working at the same time. 14

-edit data base of given campaign; -save to data base; -exit; -help. Output the result of procedure of synthesis of maximal number independent campaigns in given manufacture plan. Choice the manufacture variant included in given campaign which will be show on. Rule buttons: -delete campaign; -edit data base of given campaign; -save to data base; -exit; -help. List of apparatus in which have to placed the relevant stages. Output the obtained results for given variants of campaign. 15

Module explaining different optimizing tasks. Optimal scheduling. Optimal scheduling multicriteria formulation. 1.Minimum time production plane. 2.Maximum profit. Restriction: 1.Minimum demand; 2.Minimum resource. Optimal use of resource. Optimal sheduling for given variant of canpaign-one criteria formulation. Optimal use of resource. Optimal sheduling for full variant of canpaign. Multicriteria formulation. Optimal use of resource. Optimal sheduling for full variant of canpaign. One criteria formulation. Optimal scheduling. Optimal scheduling with possible one criteria. 1.Minimum time poduction plane. 2.Maximum profit. Restriction: 1.Minimum demand; 2.Minimum resource. Optimal use of resource. Optimal sheduling for given variant of canpaign. Multicriteria formulation. 16

Optimal loading the system. /formulation the task/ Define the optimization criteria for chosen campaign who consist of: -resource for optimization; -choice the regime: -variation -constant Output the results: -included technologies; -optimal start time; -optimal wait time; -optimal batch size. Of each manufacture Define the restrictions which are consist of: -restrictions about another resources; -minimum and maximum quantity in case of constant; -minimum and maximum quantity in case of variation. Choise the variant of campaign who will search optimal rule, in case of choosen criteria and defineded restrictions. Read the data base for existing plans and available campaign. Define the planning horizon in which a given campaign have to be done. Start the optimization procedure Define the quantity demand of each product. 17

Optimal loading the system in case of given manufacture program. Define the optimization criteria for chosen campaign who consist of: -resource for optimization; -choice the regime: -variation -constant Output the results: -included technologies; -optimal start time; -optimal wait time; -optimal batch size. Of each manufacture Define the restrictions which are consist of: -restrictions about another resources; -minimum and maximum quantity in case of constant; -minimum and maximum quantity in case of variation. Choise the variant of campaign who will search optimal rule, in case of choosen criteria and defineded restrictions. Read the data base for existing plans and available campaign. Define the planning horizon in which a given campaign have to be done. Define the quantity demand of each product. Start the optimization procedure 18

Optimal loading the system in case of given manufacture program. Lead in the nesesary information which are consist of: -DB for existing plants; -Planning horizon; -Production demands for each product; -Optimization criteria; -Restrictions. Output the optimal parameters of each campaign which are consist of: -Service time; -Time duration campaign; -List of manufacture included in campaign; -Start times; -Wait time; -Cycle time; -Optimal batch size; -Optimal batch number; -Quantity which are manufactured during campaign. 20

Visualization of obtainable scheduling. Summarize data : -Batch size; -Start time; -variation; -wait time; -constant production; -horizon Choice the resource for visualization Read data of manufacture plan. Input the number of campaign Choice the resource Choice the solution which have to be vizualizated Choice the production of given campaign Visualization the sum consumption curve of chosen resource in case of simultaneous working of all productions in given campaign. The average curve of loading The real curve of loading Summarize data : -variation; -max pic; -min pic Manual input the data : -Batch size; -Start time; -wait time; -horizon The average curve of loading The real curve of loading 19

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