Optimally Managing Chemical Plant Operations: An Example Oriented by Industry 4.0 Paradigms

Updating industrial facilities to increase the level of automation and digitalization to match Industry 4.0 paradigms has become essential for many companies. Following such a trend, this paper presents a real-time optimization algorithm that plays a central role in a larger project framework devoted to highly interconnecting different network components of an Italian chemical industrial site. The proposed methodology aims at best managing the production rates of various products to fulfill a sales plan organized to satisfy numerous client requests. The considered model takes into account both batch and continuous processes as well as salable and non-storable products. The algorithm structure relies on the use of a non-linear optimization scheme and on the concepts of batch scheduling. Different features of the proposed methodology have been tested on real plant data, showing how the predicted forecast always improved the initial operation plan by considering both aspects of feasibility and economic nature. The use of the proposed algorithm assures the basis for fully integrating the control systems and the selling department of the facility in a more interactive and responsive manner.