基于遗传规划的生产混合物产品的分离过程综合研究
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摘要
对混合物原料经过多种操作以生产不同组成的多个混合物产品的分离过程称为非清晰分离过程,它广泛存在于化工及石油工业中。因此,非清晰分离过程综合问题一直是过程综合领域的热门课题,但由于可能的分离计划数量会因流程中分流器、混合器和精馏塔间的强相互交联而呈几何级数递增,使该类问题具有极度组合复杂性。因此,目前对该类问题的研究水平只是停留在简单分离计划的制定上,而该类问题的重要性使我们有必要从流程水平上对其综合方法和策略进行深入研究开发。本文旨在建立一套基于遗传规划-复合形法联合综合方法,以年度总费用最低为优化目标,求解热集成非清晰分离最优流程,给出重要设备的主要工艺参数,为实际生产提供准确的理论依据。本文主要内容概括如下:
1.为了探讨遗传规划求解非清晰分离综合问题的理论基础,本文首先提出了求解生产纯组份产品的清晰分离问题的遗传规划-复合形法联合算法。在化工分离专业要求指导下,算法利用遗传规划求解以复杂精馏塔结构并结合热集成技术表示的清晰分离过程结构变量,提出适用于该类问题的编码模型和进化方案,并建立了一个随机匹配系统冷凝器和再沸器的热集成策略,可以产生不同精馏结构间的复杂热匹配方案;同时,采用复合形法优化分离系统中的所有连续变量,明显提高了计算效率。
2.在对清晰分离过程研究基础上,提出了求解非清晰分离问题的遗传规划-复合形法联合算法。首先,提出了化工节点模型,将精馏分离、分流及混合任务分别用精馏塔节点、分流器节点及混合器节点三类节点表示。其中,精馏塔节点和分流器节点均产生左右分支以分别表示对物流的分离及分流操作,设置相应的节点属性以分别表示它们的操作特性;对于混合器节点,本文建立了独特的多层混合器网格结构,该结构由若干行列的混合器排列构成,可以灵活表示任意混合操作。为了清楚表示每个混合器在网格结构中所处位置,在混合器节点中设置一对属性参数分别记录该混合器在网格结构中所处行及列数。
3.为了准确利用上述三类节点生成表示非清晰分离流程的遗传规划代码,本文建立了多层交叉树状编码结构,以多层混合器网格为基本框架,以网格中每个混合器为子根节点而随机生长出一棵遗传规划子树,子树由精馏塔节点和分流器节点随机连接构成。由于本文设定每个子树中任何精馏塔节点或分流器节点的分支可以随机连接到位于该层下方混合器网格中任意层面的任意位置混合器上,所以不同层次的子树之间可能有物流交叉,物流也可以越过多层混合器网格而直达终端产品混合器,则最终整个遗传规划代码树是由层层子树叠加而构成复杂的多交叉树状结构,用以描述非清晰分离流程中分流器、混合器和精馏塔间可能出现的各类复杂交联流程,使算法能够发现很难为其它算法所知的更优流程结构。
同时,提出了适用于非清晰分离问题的改进遗传规划进化策略,尤其对于交换和变异操作,不同操作步骤中分别定义不同的可操作节点类,以充分保证新生代码的专业有效性,从而显著提高算法的进化效率。
4.采用了结构变量与连续变量同步优化的综合策略。在利用遗传规划搜索最优流程结构的同时,利用复合形法优化系统的连续变量。其中,对于分流器的分配比及非清晰精馏塔中轻、重关键组份回收率,利用复合形法将其彻底优化,保证产生符合指定混合物产品要求的有效代码;对于精馏塔的操作压力及回流比,利用复合形法进行有限次搜索寻优。上述对不同类型连续变量的分策略优化方法,不但有效促进了结构变量优化的进程,而且明显提高了计算效率。
5.利用本文建立的适用于非清晰分离问题的遗传规划-复合形法联合算法,针对不同目标函数,从不同层次研究了该类问题。首先,以简单非线性函数为目标,对该类问题进行物流决策流程水平的搜索寻优,发现了比文献值更优解,证明了算法的有效性。
在此基础上,首次以年度总费用为目标函数,给出了非清晰分离系统的设备设计和费用模型,同时,提出了热集成策略,可以产生一个精馏塔的冷凝器和再沸器同时与多个其它塔的再沸器及冷凝器热匹配的复杂热集成方案。本文利用以上策略,首次求解了包括酯、烃及醇三类物系的典型非清晰分离问题。同时,与文献报道的5组份算例相比,求解了更大规模算例(最多11组份)。计算结果表明:基于本文建立的综合算法,流程中采用非清晰精馏塔并配合热集成研究,可以求得非清晰分离问题的最优结构决策流程。算法具有简单易行、计算量小及快速准确的优点,求解过程不需给出任何提示信息及不必给出系统超结构,求解问题范围广,是非清晰分离系统综合的有效方法。
Separation process that deals with multicomponent products produced from mixture materials through various operations is called nonsharp separation and used widely in the chemical industry and the petroleum industry. Nonsharp separation process synthesis is always the focus in the process synthesis domain. The amount of the possible separation plans, however, will increase exponentially due to the strong interrelation between the splitter, mixer and the distillation column in the flowsheet which makes the problem being extremely combinatorial complex. The current research work for this kind of problem is to the decision of the simple separation plan, but the importance of this kind of problem lets us study the synthesis method and strategy in depth from the flowsheet level. This paper addresses a sort of united synthesis method that based on Genetic Programming(GP)and complex method. The proposed method regards minimizing the annually total cost as optimization objective and seeks the heat integration nonsharp separation optimal flowsheet to give the major technological parameters of the important equipments which provide the accurate theoretical basis for actual production. The main content of this paper is as follows:
1. The united synthesis method that based on GP and complex method to solve the sharp separation problem for pure component products is firstly proposed in order to probe into the theoretical basis solving the nonsharp separation synthesis problem using GP. The algorithm, under the guide of chemical engineering separation professional requirements, utilizes GP to solve the sharp separation process structural variables that expressed by the complex distillation column configurations combing with the heat integration method. The encoding model and evolutionary scheme that applicable to this problem are proposed and the heat integration strategy that matches system condenser and reboiler randomly is built to produce complex match scheme between various distillation structures. At the same time, the algorithm adopts complex method to optimize the entire continuous variable in the separation system which improves the computational efficiency obviously.
2. The united synthesis method that based on GP and complex method to solve the nonsharp separation problem is proposed based on the sharp separation process research. The chemical engineering node model is proposed to denote distillation separation, splitting and mixing task as distillation column node, splitter node and mixer node separately. Both the distillation column node and splitter node generate left and right branch to denote separation and splitting operation for all streams and the corresponding node property is set to denote their operation specialty. As for mixer node, unique multilayer mixer grid structure that made up of many mixers is established to denote arbitrary mixing operation. To clearly denote the location of every mixer in the grid structure, a pair of property parameters is set in the mixer node to record the number of the row and column where the mixer located in separately.
3. Multilayer cross tree encoding structure is established in this paper to accurately express the GP code that produced from the above three kind of nodes to denote nonsharp separation flowsheet. A GP sub-tree is randomly produced from every mixer as sub-root node and it is made up of distillation column nodes and splitter nodes that randomly connected each other. The branch of distillation column node or splitter node of every sub-tree can joint to any mixer of the inferior mixer grid at random in this paper. Many GP sub-trees at different layer may have stream cross and the streams can pass through all layers of the mixer grid to arrive at terminal product mixer directly. So, the overall GP code tree is made up of layer upon layer sub-trees and forms complex multi-cross tree structure to describe all sorts of complex jointed flowsheet possibly produced between splitter, mixer and distillation column in nonsharp separation flowsheet. This enable the algorithm to discovery better flowsheet structure that is difficult found by other algorithms.
Besides, modified GP evolutionary strategy that is applicable for nonsharp separation problem is proposed in this paper. Different operable node classes are defined in various operation steps, especially for cross and mutation operation, to insure the professional validity of all GP codes, which improves the evolutionary efficiency evidently.
4. Synthesis strategy that adopts simultaneously optimization of structural variables and continuous variables is proposed in this paper. Complex method is used to optimize system continuous variables when using the GP to search the optimal flowsheet structure. As for the distribution ratio of the splitter, light and heavy key component recovery ratio of nonsharp distillation column, complex method is used to optimize them thoroughly to ensure generating valid codes that suitble to the required mixture products. As for the operation pressure and reflux ratio of the distillation column, complex method is used to search the optimum within the limited times. The above optimization method that using different strategy for various types of continuous variables not only accelerates the process of structural variable optimization effectively but also improves the computational efficiency.
5. To the various objective functions, the united synthesis method that based on GP and complex method to solve the nonsharp separation problem is used to study the problem from different level. A kind of simple linear function is used as the objective firstly and the better solutions are found through optimization of the problems at the stream decision flowsheet level which demonstrate the validity of the algorithm.
In this paper, annually total cost, for the first time, is used as optimization objective and the equipment design and cost model of nonsharp separation system is given. Heat integration is proposed simultaneously to generate complex heat exchange scheme that can express the condenser and reboiler of one distillation column matching with some condensers and reboilers of other distillation columns simultaneously. Typical nonsharp separation problems that include ester, hydrocarbon and alcohol mixtures, for the first time, are solved using above strategy. Bigger size of example, as much as 11 components, is solved comparing with the reported 5 components example. The computational results demonstrate that, based on the synthesis algorithm proposed in this paper, the optimal structural decision flowsheet can be obtained by using nonsharp distillation column and heat integration in the flowsheet. The proposed algorithm features simple to use, small amount of calculation and fast and accurate. The superstructure of separation system is not required in solving process and the solution bound is far and wide that shows the united synthesis algorithm proposed in this paper is an effective method for nonsharp separation system synthesis.
1.为了探讨遗传规划求解非清晰分离综合问题的理论基础,本文首先提出了求解生产纯组份产品的清晰分离问题的遗传规划-复合形法联合算法。在化工分离专业要求指导下,算法利用遗传规划求解以复杂精馏塔结构并结合热集成技术表示的清晰分离过程结构变量,提出适用于该类问题的编码模型和进化方案,并建立了一个随机匹配系统冷凝器和再沸器的热集成策略,可以产生不同精馏结构间的复杂热匹配方案;同时,采用复合形法优化分离系统中的所有连续变量,明显提高了计算效率。
2.在对清晰分离过程研究基础上,提出了求解非清晰分离问题的遗传规划-复合形法联合算法。首先,提出了化工节点模型,将精馏分离、分流及混合任务分别用精馏塔节点、分流器节点及混合器节点三类节点表示。其中,精馏塔节点和分流器节点均产生左右分支以分别表示对物流的分离及分流操作,设置相应的节点属性以分别表示它们的操作特性;对于混合器节点,本文建立了独特的多层混合器网格结构,该结构由若干行列的混合器排列构成,可以灵活表示任意混合操作。为了清楚表示每个混合器在网格结构中所处位置,在混合器节点中设置一对属性参数分别记录该混合器在网格结构中所处行及列数。
3.为了准确利用上述三类节点生成表示非清晰分离流程的遗传规划代码,本文建立了多层交叉树状编码结构,以多层混合器网格为基本框架,以网格中每个混合器为子根节点而随机生长出一棵遗传规划子树,子树由精馏塔节点和分流器节点随机连接构成。由于本文设定每个子树中任何精馏塔节点或分流器节点的分支可以随机连接到位于该层下方混合器网格中任意层面的任意位置混合器上,所以不同层次的子树之间可能有物流交叉,物流也可以越过多层混合器网格而直达终端产品混合器,则最终整个遗传规划代码树是由层层子树叠加而构成复杂的多交叉树状结构,用以描述非清晰分离流程中分流器、混合器和精馏塔间可能出现的各类复杂交联流程,使算法能够发现很难为其它算法所知的更优流程结构。
同时,提出了适用于非清晰分离问题的改进遗传规划进化策略,尤其对于交换和变异操作,不同操作步骤中分别定义不同的可操作节点类,以充分保证新生代码的专业有效性,从而显著提高算法的进化效率。
4.采用了结构变量与连续变量同步优化的综合策略。在利用遗传规划搜索最优流程结构的同时,利用复合形法优化系统的连续变量。其中,对于分流器的分配比及非清晰精馏塔中轻、重关键组份回收率,利用复合形法将其彻底优化,保证产生符合指定混合物产品要求的有效代码;对于精馏塔的操作压力及回流比,利用复合形法进行有限次搜索寻优。上述对不同类型连续变量的分策略优化方法,不但有效促进了结构变量优化的进程,而且明显提高了计算效率。
5.利用本文建立的适用于非清晰分离问题的遗传规划-复合形法联合算法,针对不同目标函数,从不同层次研究了该类问题。首先,以简单非线性函数为目标,对该类问题进行物流决策流程水平的搜索寻优,发现了比文献值更优解,证明了算法的有效性。
在此基础上,首次以年度总费用为目标函数,给出了非清晰分离系统的设备设计和费用模型,同时,提出了热集成策略,可以产生一个精馏塔的冷凝器和再沸器同时与多个其它塔的再沸器及冷凝器热匹配的复杂热集成方案。本文利用以上策略,首次求解了包括酯、烃及醇三类物系的典型非清晰分离问题。同时,与文献报道的5组份算例相比,求解了更大规模算例(最多11组份)。计算结果表明:基于本文建立的综合算法,流程中采用非清晰精馏塔并配合热集成研究,可以求得非清晰分离问题的最优结构决策流程。算法具有简单易行、计算量小及快速准确的优点,求解过程不需给出任何提示信息及不必给出系统超结构,求解问题范围广,是非清晰分离系统综合的有效方法。
Separation process that deals with multicomponent products produced from mixture materials through various operations is called nonsharp separation and used widely in the chemical industry and the petroleum industry. Nonsharp separation process synthesis is always the focus in the process synthesis domain. The amount of the possible separation plans, however, will increase exponentially due to the strong interrelation between the splitter, mixer and the distillation column in the flowsheet which makes the problem being extremely combinatorial complex. The current research work for this kind of problem is to the decision of the simple separation plan, but the importance of this kind of problem lets us study the synthesis method and strategy in depth from the flowsheet level. This paper addresses a sort of united synthesis method that based on Genetic Programming(GP)and complex method. The proposed method regards minimizing the annually total cost as optimization objective and seeks the heat integration nonsharp separation optimal flowsheet to give the major technological parameters of the important equipments which provide the accurate theoretical basis for actual production. The main content of this paper is as follows:
1. The united synthesis method that based on GP and complex method to solve the sharp separation problem for pure component products is firstly proposed in order to probe into the theoretical basis solving the nonsharp separation synthesis problem using GP. The algorithm, under the guide of chemical engineering separation professional requirements, utilizes GP to solve the sharp separation process structural variables that expressed by the complex distillation column configurations combing with the heat integration method. The encoding model and evolutionary scheme that applicable to this problem are proposed and the heat integration strategy that matches system condenser and reboiler randomly is built to produce complex match scheme between various distillation structures. At the same time, the algorithm adopts complex method to optimize the entire continuous variable in the separation system which improves the computational efficiency obviously.
2. The united synthesis method that based on GP and complex method to solve the nonsharp separation problem is proposed based on the sharp separation process research. The chemical engineering node model is proposed to denote distillation separation, splitting and mixing task as distillation column node, splitter node and mixer node separately. Both the distillation column node and splitter node generate left and right branch to denote separation and splitting operation for all streams and the corresponding node property is set to denote their operation specialty. As for mixer node, unique multilayer mixer grid structure that made up of many mixers is established to denote arbitrary mixing operation. To clearly denote the location of every mixer in the grid structure, a pair of property parameters is set in the mixer node to record the number of the row and column where the mixer located in separately.
3. Multilayer cross tree encoding structure is established in this paper to accurately express the GP code that produced from the above three kind of nodes to denote nonsharp separation flowsheet. A GP sub-tree is randomly produced from every mixer as sub-root node and it is made up of distillation column nodes and splitter nodes that randomly connected each other. The branch of distillation column node or splitter node of every sub-tree can joint to any mixer of the inferior mixer grid at random in this paper. Many GP sub-trees at different layer may have stream cross and the streams can pass through all layers of the mixer grid to arrive at terminal product mixer directly. So, the overall GP code tree is made up of layer upon layer sub-trees and forms complex multi-cross tree structure to describe all sorts of complex jointed flowsheet possibly produced between splitter, mixer and distillation column in nonsharp separation flowsheet. This enable the algorithm to discovery better flowsheet structure that is difficult found by other algorithms.
Besides, modified GP evolutionary strategy that is applicable for nonsharp separation problem is proposed in this paper. Different operable node classes are defined in various operation steps, especially for cross and mutation operation, to insure the professional validity of all GP codes, which improves the evolutionary efficiency evidently.
4. Synthesis strategy that adopts simultaneously optimization of structural variables and continuous variables is proposed in this paper. Complex method is used to optimize system continuous variables when using the GP to search the optimal flowsheet structure. As for the distribution ratio of the splitter, light and heavy key component recovery ratio of nonsharp distillation column, complex method is used to optimize them thoroughly to ensure generating valid codes that suitble to the required mixture products. As for the operation pressure and reflux ratio of the distillation column, complex method is used to search the optimum within the limited times. The above optimization method that using different strategy for various types of continuous variables not only accelerates the process of structural variable optimization effectively but also improves the computational efficiency.
5. To the various objective functions, the united synthesis method that based on GP and complex method to solve the nonsharp separation problem is used to study the problem from different level. A kind of simple linear function is used as the objective firstly and the better solutions are found through optimization of the problems at the stream decision flowsheet level which demonstrate the validity of the algorithm.
In this paper, annually total cost, for the first time, is used as optimization objective and the equipment design and cost model of nonsharp separation system is given. Heat integration is proposed simultaneously to generate complex heat exchange scheme that can express the condenser and reboiler of one distillation column matching with some condensers and reboilers of other distillation columns simultaneously. Typical nonsharp separation problems that include ester, hydrocarbon and alcohol mixtures, for the first time, are solved using above strategy. Bigger size of example, as much as 11 components, is solved comparing with the reported 5 components example. The computational results demonstrate that, based on the synthesis algorithm proposed in this paper, the optimal structural decision flowsheet can be obtained by using nonsharp distillation column and heat integration in the flowsheet. The proposed algorithm features simple to use, small amount of calculation and fast and accurate. The superstructure of separation system is not required in solving process and the solution bound is far and wide that shows the united synthesis algorithm proposed in this paper is an effective method for nonsharp separation system synthesis.
引文
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