flexible manufacturing and demand response for smart grid...

Flexible Manufacturing and Demand Response for Smart Grid Coordination

David Mendoza-Serrano and Donald J. Chmielewski

Department of Chemical and Biological EngineeringIllinois Institute of Technology

Chicago, IL

P1

P2

P3

P4

Utility Plant

S1

S2

S3

S4S5

Department of Chemical and Biological Engineering

Illinois Institute of Technology

Outline

• Introduction to Smart Grid

• Modeling of a Flexible Chemical Plant

- Material Flow Manipulations

- Flexible Utilities (Steam and Electricity)

- Material Storage

• Smart Grid Operation and Revenue



DispatchableGeneration

Consumer DemandTransmission

Energy Storage

Renewable Generation Smart Homes

SmartBuildings Smart

Manufacturing

Overview of the Smart Grid



Real-time Pricing for Electricity

Historic data from the PJM Western Hub, Day-Ahead prices: June 1, 2001 through June 20, 2001, http://www.pjm.com/markets-and-operations/energy/day-ahead/day-ahead-historical.aspx





Energy Storage



Manufacturing

Overview of the Smart Grid



IGCC

Gasification Unit

PGPower Block

vH2,G

vcoal

vH2



IGCC with Dispatch Capability

Gasification Unit

PG

Storage Tank

Power Block

vH2,S

vH2,G

vcoal

vH2



Economic MPC for IGCC Dispatch



Smart Buildings and Thermal Energy Storage



Economic MPC for TEC Coordination





Energy Storage



Manufacturing

Objective



Outline

• Introduction to Smart Grid

• Modeling of a Flexible Chemical Plant

- Material Flow Manipulations

- Flexible Utilities (Steam and Electricity)

- Material Storage

• Smart Grid Operation and Revenue



P1

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Toy Example



Material Balances at Process Units

1214

1213

9811

9810

57

56

214

213

9.01.0

2.07.08.03.0

417.0583.0

1.075.09.025.0

νννν

νννννν

νννν

νννννν

==

+=+=

==

+=+=

P1

P2

P3

P4



Material Flow Manipulations

⎥⎥⎥⎥⎥⎥⎥⎥⎥⎥⎥

⎦

⎤

⎢⎢⎢⎢⎢⎢⎢⎢⎢⎢⎢

⎣

⎡

=

16

15

12

9

8

5

2

1

νννννννν

mP1

P2

P3

P4

mΔ=ν⇒



Material Balances at Streams

P1

P2

P3

P4

214

151211

1697

84

53

00000

νννννννν

νννν

−=−−=−−=

−=−=




P1

P2

P3

P4

214

151211

1697

84

53

00000

νννννννν

νννν

−=−−=−−=

−=−=

mΔ=ν+ mΛΔ=0⇒



Material Flow Constraints

P1

P2

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P4

max412

max398

max25

max121

uu

uu

≤≤+

≤≤+

ννν

ννν0≥ν

,

,



P1

P2

P3

P4

Utility Plant

Process Utilities



P1

P2

P3

P4

Utility Plant

Energy Requirements of Process Units

124

983

52

211

45.05.0

5.05.05.0

ννν

ννν

=+=

=+=

eeee



P1

P2

P3

P4

Utility Plant

Energy Requirements of Process Units

124

983

52

211

45.05.0

5.05.05.0

ννν

ννν

=+=

=+=

eeee

⇒ νΓ=e



P1

P2

P3

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Utility Plant

Steam Utilities



Possible Electric Utilities



If energy is steam, conversion efficiency assumed ηs = 0.75

If energy is electric, conversion efficiency assume ηe = 0.95

In vector form,

where

Energy Conversion Efficiency

eess eee Θ+Θ=

Iss η=Θ Iee η=Θ

,



Energy Balance at Utilities

Steam Plant Steam Bank

Electric Node

sps1

s2s3

s4

e1e2e3

e4

g



Possible Co-Generation Plant


Electric Node

Co-Generation Plant

sp

cog

s1s2s3

s4

e1e2e3

e4

g



Energy Balance at Steam Bank


Electric Node

Co-Generation Plant

fsp

fcog

es1es2es3

es4

ee1ee2ee3

ee4

eg

scogcogsspsp eff 1=+ηη 75.0=spη

50.0=cogsη

T

⎥⎥⎥⎥

⎦

⎤

⎢⎢⎢⎢

⎣

⎡

=

1111

1



Energy Balance at Electric Node


Electric Node

Co-Generation Plant

fsp

fcog

es1es2es3

es4

ee1ee2ee3

ee4

eg

ecogcogeg efe 1=+η

50.0=cogsη

T

⎥⎥⎥⎥

⎦

⎤

⎢⎢⎢⎢

⎣

⎡

=

1111

1

15.0=cogeη



Process Economics

P1

P2

P3

P4

,

,


Electric Node

Co-Generation Plant

fsp

fcog

es1es2es3

es4

ee1ee2ee3

ee4

eg

[ν1 ν6 ν10 ν13 ν15 ν16] [-100 200 120 35 50 100]($/bbl)

ννc⇓

gecogfspf ecfcfc −−−

[fsp fcog eg] [ 3 3 5.5]($/MMBTU)

⇓



Process Optimization (RTO)

{ }

max412

max398

max25

max121

,0,0,0,0

,0,0

0 s.t.

max

uu

uu

efeeffeemm

ecfcfcc

ecogcogegscogcogsspsp

eess

gecogfspf

eff

eem

g

cogspes

≤≤+

≤≤+

=+=+Θ+Θ=ΓΔΛ=Δ=

−−−

≥≥≥≥≥≥

ννν

ννν

ηηηνν

ννν

11



Baseline Solution

then5.5 If =ec

****sec/3.26$ gecogfspf ecfcfcc −−−= νν

fsp* = 7.21 GJ/sec, fcog

* = 0 eg

* = 0



Baseline Solution

then5.5 If =ec

****sec/3.26$ gecogfspf ecfcfcc −−−= νν

sec/48$* =ννc

fsp* = 7.21 GJ/sec, fcog

* = 0 eg

* = 0



Real-time Pricing for Electricity



Operation with Real-time Pricing



Revenue with Real-time Pricing

Average profit found to be

$32.3/sec

22.8% increase wrt baseline

$26.3/sec



P1

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P4

Utility Plant

S1

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S3

S4S5

Impact of Material Storage




214

151211

1697

84

53

00000

νννννννν

νννν

−=−−=−−=

−=−=

mΛΔ=0mΔ=ν+ ⇒



Material Balances with Storage

2145

1512114

16973

842

531

νν

ννν

ννν

νν

νν

−=

−−=

−−=

−=

−=

M

M

M

M

M

&

&

&

&

&

mΔ=ν+ mM ΛΔ=&⇒

P1

P2

P3

P4

S1

S2

S3

S4S5

max)(0 MtM ≤≤



Process Optimization (RTO)

{ }

max412

max398

max25

max121

,0,0,0,0

,0,0

0 s.t.

max

uu

uu

efeeffeemm

ecfcfcc


eess

gecogfspf

eff

eem

g

cogspes

≤≤+

≤≤+


−−−

≥≥≥≥≥≥

ννν

ννν

ηηηνν

ννν

11



Process Optimization with Storage

{ }

max

max412

max398

max25

max121

,0,0,0,0

,0,0

0

s.t.

max

MM

uu

uu

efeeffeemMm

ecfcfcc


eess

gecogfspf

eff

eem

g

cogspes

≤≤

≤≤+

≤≤+


−−−

≥≥≥≥≥≥

ννν

ννν

ηηηνν

ννν

11

&



Economic MPC

max

max412

max398

max25

max121

0,,0,0

,0,0,0,0

0

s.t.

)]()()()()([1max

MM

uu

uu

efeeffeemMm

dttetctfctfctcT


eess

Tt

tgecogfspf

Meff

eem

g

cogspes

≤≤

≤≤+

≤≤+


⎪⎭

⎪⎬⎫

⎪⎩

⎪⎨⎧

−−−∫+

≥≥≥

≥≥≥≥

ννν

ννν

ηηηνν

ννν

11

&



Literature on EMPC

• Conceptual Development and Stability Issues: Rawlings and Amrit (2009); Diehl, et al. (2011); Huang and Biegler (2011); Heidarinejad, et al. (2012)

• Process Scheduling: Karwana and Keblisb (2007); Baumrucker and Biegler (2010); Lima et al. (2011); Kostina et al. (2011)

• Power Systems: Zavala et al. (2009); Xie and Ilić (2009), Hovgaard, et al. (2011), Omell and Chmielewski (2011)

• HVAC Systems: Braun (1992); Morris et al. (1994); Kintner-Meyer and Emery (1995); Henze et al. (2003); Braun (2007); Oldewurtel et al. (2010), Ma et al. (2012); Mendoza and Chmielewski (2012)



Revisit Example with 2 Storage Units

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S4S5



Operation with Real-time Pricingand Storage

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S4S5



Operation with Real-time Pricingand Storage



Revenue with Real-time Pricingand Storage

EMPC average profit $34.2/sec

A 30% increase wrt baseline$26/sec

A 7.2% increase wrt RTO$32.3/sec



Conclusions

• Numerous Options for Smart Grid Flexibility in Chemical Plants

• For the given example profit increased by - 22.6 % with electric utilities and co-generation - 30.0 % if storage also included

• Operation Can Get Complicated Very Fast!!!!

• Next Question is Capital Cost of Equipment Upgrades



Acknowledgements

• Current and Former Students:Ben OmellDavid Mendoza-Serrano Ming-Wei Yang (Taiwan Electric)

• Personal Communications Don BartusiakJeff Siirola

• Funding:National Science Foundation (CBET – 0967906)

flexible manufacturing and demand response for smart grid...

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