AVT Process Systems Engineering Prof. Alexander Mitsos, Ph.D.

DAAD Summer School 2017 Salvador de Bahia

Optimization Exercises 1 and 2

Exercise 1: Optimization of a vapour generator

The system shown in Fig. 1 is used for the production of vapor and electrical energy.
Two turbines are thereby employed with their relevant data as in Table 1. The first
turbine (Turbine 1) passes 2 intermediate flows (HE1 and LE1). The last stage produces
the condensate flow (C). The internal flow of Turbine 1 is given by I1-HE1. The second
turbine (Turbine 2) passes one intermediate flow (HE2) and one outflow (LE2). Three
vapour levels are denoted by HPS, MPS and LPS.
In order to always guarantee the requested electrical power, in case the produced
electrical power (PP) does not cover the demand, additional energy power (EP) is
purchased from another producer. The energy producer has been ensured that, the
purchased electrical power will not underlie the basic electrical power of 12 MW. In
the case the lower amount of the electrical power is requested from the producer, the
part of the electrical power, which is not purchased, is billed by the so-called demand
penalty. All required data for the solution of the exercise are given in the Tables 14.
Formulate the optimization problem to determine the optimal plant operating point
comprising the minimal operational costs in [/h]. You have to consider two cases:
one where the demand penalty is active; and one where it is not.

1. Identify the variables of the optimization problem.

2. Formulate the objective function for the described optimization problem.

3. Using the data from the Tables, try to develop an easy model of the plant.

4. Complete the problem formulation by considering all constraints.

5. Classify the obtained optimization problem.

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EP

Figure 1: Schematic representation of the system for vapour generation

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Table 1: Description of turbines

Parameters Turbine 1 Turbine 2
Max. power [kW] 6250 9000
Min. power [kW] 2500 3000
Max. inflow [kg/h] 87 000 110 000
Max. LPS-flow [kg/h] - 64 000
Max. condensate flow [kg/h] 28 000 -
Max. internal flow [kg/h] 60 000 -

Table 2: Vapour data

Vapour stage Enthalpy [kJ/kg]
HPS 3163
MPS 2949
LPS 2911
Condensate (Water) 449

Table 3: System requirements

Resource Demand
MPS 123 000 kg/h
LPS 45 000 kg/h
Electrical power 24.5 MW

Table 4: Energy data

Fuel cost [/106 kJ] 1.5
Evaporator efficiency 0.75
Condensate loss [/Kg] 0.008
Produced electrical power [/kWh] 0.02
Purchased electrical power [/kWh] 0.05
Demand penalty [/kWh] 0.001
Basic power [MW] 12
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Hints.

1. The selection of optimization variables is not unique. However, one possible

selection contains 18 variables, including P1 , P2 , P P , EP and others.

2. Due to the conditional demand penalty, the complete formulation of this opti-
mization problem comprises two cases, which have to formulated separately, i.e.,

(a) if 0 EP 12000[kW ]
(cost of) J = the produced vapour (HP S) + . . .
(b) if EP 12000[kW ]
(cost of) J = the produced vapour (HP S) + . . .

3. The model will comprise

(a) mass balances like HP S = I1 + I2 + BF1 (MB1);

(b) energy balances like 3163I1 = 2949HE1 + 2911LE1 + 449C + 3600P1 (EB1);
(c) and inequality constraints like 2500 P1 6250 (IC1).

4. A possible solution is shown in the introduction Exercise 2.

Exercise 2: Linear Programming with GAMS or Matlab

In Exercise 1 we have developed the following two models (one where the demand
penalty is active and one where it is not):

1. The collection of optimization variables to be considered is : xT = (P1 , P2 , P P ,

EP , P ower, F uel, C, I1 , I2 , HE1 , HE2 , LE1 , LE2 , BF1 , BF2 , HP S, M P S,
LP S), where x R18 .

2. The objective function comprises the sum of all operational costs. Still, we have
to take care of the demand penalty, namely, only in the case the additionally
purchased energy (EP) does not exceed the basic power (12 MW), the demand
penalty comes into play. Thus, the complete formulation of this optimization
problem comprises these two cases:

(a) J(x) = 1.5 106 F uel + 0.008 C + 0.02 P P + 0.05EP + 0, 001(12000 EP )

for 0 EP 12000 [kW ].
(b) J(x) = 1.5 106 F uel + 0.008 C + 0.02 P P + 0.05EP
for EP 12000 [kW ].
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3. Model:
Mass balances: HP S = I1 + I2 + BF1 (MB1)
I1 = HE1 + LE1 + C (MB2)
I2 = HE2 + LE2 (MB3)
HE1 + HE2 + BF1 = BF2 + M P S (MB4)
LP S = LE1 + LE2 + BF2 (MB5)

Energy balances: 3163I1 = 2949HE1 + 2911LE1 + 449C + 3600P1 (EB1)

3163I2 = 2949HE2 + 2911LE2 + 3600P2 (EB2)
P P = P1 + P2 (EB3)
P ower = P P + EP (EB4)
Enthalpy of HPS HP S = Evaporator Efficiency F uel (EB5)

P1 and P2 are in kW : 1kW = 1 kJ

s
= 3600 kJ
h

4. Inequality constraints:
2500 P1 6250 (IC1)
I1 87000 (IC2)
C 28000 (IC3)
I1 HE1 60000 (IC4)
3000 P2 9000 (IC5)
I2 110000 (IC6)
LE2 64000 (IC7)
MP S 123000 (IC8)
LP S 45000 (IC9)
P1 + P2 + EP 24500 (IC10)
all optimization variables shall be non-negative, i.e., 0 (IC11)
either case a) EP 12000 (IC12a)
or case b) EP 12000 (IC12b)

Complete optimization problem

case a) min J(x)
x
s.t. (MB1)-(MB5)
(EB1)-(EB5)
(IC1)- (IC11)
(IC12a)

case b) min J(x)

x
s.t. (MB1)-(MB5)
(EB1)-(EB5)
(IC1)- (IC11)
(IC12b)

Solve the evaporator optimization problem with the Matlab solver linprog,
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intlinprog or with GAMS. What are the optimal function value and the cor-
responding values of the optimization variables? Is the demand penalty
active or not?
Hint: The optimal function value is approximately 1944 [/hour].