Ferrer Nadal, Sergio
Total activity: 36
Research group
CEPIMA - Center for Process and Environment Engineering
Department
Department of Chemical Engineering
E-mail
sergio.ferrerestudiant.upc.edu
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Scientific and technological production
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1 to 36 of 36 results
  • An extended formulation for the flexible short-term scheduling of multiproduct semicontinuos plants

     Capon Garcia, Elisabet; Ferrer Nadal, Sergio; Graells Sobre, Moises; Puigjaner Corbella, Luis
    Industrial & engineering chemistry research
    Date of publication: 2009-01-05
    Journal article

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    Chemical plants are moving toward more-flexible environments, to adapt faster to market changes. For the sake of this flexibility, batch and continuous units might be integrated and operated along the same processing route in a semicontinuous mode, featured by production campaigns of finite duration. Constant production rates for the entire operation have been usually considered. Thus, production adjustments were achieved through storage resources, production line stops, and multiple product campaigns. The objective of this work is to improve the production schedules by developing a new concept for flexible manufacturing, which allows one to program production rate profiles within each semicontinuous operation campaign. Hence, the extended formulation presented allows to address the tradeoff between the opportunities that may arise when adjusting processing rates and the storage needs and opportunities. Finally, several case studies show that the proposed adjustment of the processing rates leads to less storage utilization and more-efficient production performance.

  • Managing risk through a flexible recipe framework

     Ferrer Nadal, Sergio; Puigjaner Corbella, Luis; Guillen Gosalbez, Gonzalo
    AICHE journal
    Date of publication: 2008-01-29
    Journal article

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  • Material transfer operations in batch scheduling. A critical modeling issue

     Ferrer Nadal, Sergio; Capon Garcia, Elisabet; Mendez, Carlos Alberto; Puigjaner Corbella, Luis
    Industrial & engineering chemistry research
    Date of publication: 2008-10-15
    Journal article

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  • Contribution to the Optimization and Flexible Management of Chemical Processes  Open access

     Ferrer Nadal, Sergio
    Defense's date: 2008-06-19
    Department of Chemical Engineering, Universitat Politècnica de Catalunya
    Theses

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    La industria química ha experimentado en las últimas décadas un aumento en la competencia por la cual las empresas se ven obligadas a adaptarse a un mercado cambiante y cada vez más exigente. Aunque la globalización ha abierto nuevos mercados, ha incrementado también el número de competidores, de tal manera que sólo las empresas que usen las plantas más integradas y eficientes podrán mantenerse en el negocio. En este contexto global, el principal propósito de esta tesis es desarrollar métodos que exploten la flexibilidad de los procesos, con el objetivo de aumentar la eficiencia de las plantas y asegurar los requerimientos de seguridad y calidad de los productos. Esta tesis contribuye a la optimización y a la gestión de la producción desde pequeñas plantas que usen procesos discontinuos hasta grandes plantas de procesado continuo.En primer lugar, esta tesis trata la gestión de los procesos continuos en los que suelen fabricar productos muy similares a gran escala. La gran ventaja de los procesos continuos es que pueden conseguir mayor consistencia en la calidad de los productos y que pueden aprovechar las economías de escala que reducen los costes y residuos. Sin embargo, la industria química para mantenerse competitiva necesita adaptar continuamente sus procesos a las condiciones del mercado y de operación. El sistema de control supervisor presentado en esta parte de la tesis disminuye el tiempo de reacción frente a incidentes en los procesos continuos y re-optimiza la producción en tiempo real, si existe posibilidad de mejora.A continuación, esta tesis trata la gestión de los procesos semicontinuos que permiten una operación más flexible y personalizada. Los procesos semicontinuos operan con puestas en marcha y paradas periódicas para acomodar las frecuentes transiciones entre diferentes productos. Esta tesis presenta un nuevo concepto de fabricación flexible que permite programar perfiles variables de velocidad de producción dentro de cada campaña de producción.La mayor parte del trabajo de investigación de esta tesis se dedica a la planificación de la producción en los procesos discontinuos por lotes, utilizados principalmente en la producción de productos químicos con alto valor añadido. Estos procesos ofrecen varias ventajas respecto a los procesos continuos y semicontinuos debido a la mayor flexibilidad para acomodar diversos productos, diferentes capacidades de producción, y la posibilidad de realizar operaciones completamente diferentes en los mismos equipos. Sin embargo, la obtención del plan de producción óptimo usando se complica al aumentar la complejidad de la planta y/o el número de lotes a planificar. La simplificación de considerar tiempos de transferencia despreciables es generalmente aceptada en la literatura para evitar la complejidad del manejo de las operaciones de transferencia. En cambio, esta tesis pretende resaltar el papel crítico que juegan las operaciones de transferencia en la sincronización de tareas, y en la consiguiente determinación de planes de producción factibles.Siguiendo con los procesos por lotes, esta tesis demuestra que el uso del concepto de recetas flexibles mejora la operación de los procesos en ambientes de producción con mucha incertidumbre. La flexibilidad de las receta se considera como una oportunidad adicional, tanto para la planificación de la producción reactiva como preactiva, reduciendo el riesgo de llegar a resultados económicamente desfavorables.Finalmente, esta tesis presenta las plantas discontinuas sin tuberías como una alternativas a las plantas por lotes clásicas. En la búsqueda de formas más competitivas y efectivas de producción, la flexibilidad para producir un elevado número de productos en plantas por lotes es limitada debido a la necesidad de equipos fijos conectados por tuberías y frecuentes tareas de limpieza. Las plantas sin tuberías presentan una mayor flexibilidad ya que el material se transfiere entre estaciones de procesamiento usando equipos que se mueven dentro de la planta. El trabajo presentado en esta parte de la tesis contribuye a la mejora en la gestión de este tipo de plantas proponiendo una formulación más eficiente a las encontradas en la literatura que resuelve el problema de la planificación de la producción.En resumen, esta tesis desarrolla nuevas estrategias de modelado y métodos de resolución encaminados al soporte de la toma de decisiones que explotan la flexibilidad intrínseca de los procesos químicos. Las principales ventajas de cada una de las contribuciones de esta tesis se demuestran mediante su aplicación a diferentes casos de estudio.

    The chemical industry has become increasingly competitive over the past decades. Companies are required to adapt to changing market conditions and meet stricter product specifications. While globalization has opened new markets for the chemical industry, it has also increased the competitor pool, giving an advantage to companies with more efficient and highly integrated plants.In this context, the main aim of this thesis is to demonstrate new concepts and computational methods that exploit process flexibility to enhance plant profitability under transient operating conditions. These methods ensure that safety and product quality requirements are consistently met. This thesis makes contributions to the optimization and management of production in plants ranging from small batch plants to large capacity continuous processes.First, this thesis addresses the management of continuous processes, in which similar products are mass produced. Continuous processes can achieve the highest consistency and product quality by taking advantage of economies of scale and reduced manufacturing costs and waste. However, in order to remain competitive in the market, plants are required to dynamically adapt their processes to fit the continuously changing market and operating conditions. The supervisory control system presented in this part of the thesis decreases the system reaction time to incidences and re-optimizes the production in real time if the opportunity for improved performance exists.Next, this thesis addresses the management of semicontinuous processes, which allow more customized and flexible operation. Semicontinuous processes run with periodic start-ups and shutdowns to accommodate frequent product transitions. This thesis proposes an optimization model that creates improved production schedules by introducing a new concept of flexible manufacturing that allows production rate profiles to be programmed within each operation campaign.The major part of the research work of this thesis deals with the operational management of batch processes, which are mainly used for the production of high value-added chemicals. Batch processing offers the advantage of increased flexibility in product variety, production volume, and the assortment of operations that can be processed by a particular piece of equipment. However, the trade-off is that production scheduling is significantly complicated by the large number of batches involved with different production paths. In order to avoid the complexity of managing transfer operations, the assumption of negligible transfer times is generally accepted in batch scheduling. Conversely, this thesis highlights the critical role that transfer operations play in the synchronization of tasks and in determining the feasibility of production schedules.Continuing to focus on batch plant operation, this thesis demonstrates that the use of the concept of flexible recipes enhances the operation batch plants within an uncertain environment. Recipe flexibility is considered as an additional opportunity for reactive scheduling as well as a proactive way to reduce the risk of meeting unfavorable scenarios.Finally, this thesis examines pipeless plants as an alternative to batch plants. In the search for more competitive and effective ways of production, flexibility of batch plants for producing a large number of products is limited due to the need for equipment, piping and frequent cleaning tasks. Pipeless plants have enhanced flexibility over batch plants, because the material is moved along its production path through moveable vessels. This part of the thesis contributes to the optimization of the management of pipeless plants by proposing an alternative formulation for solving short-term scheduling problems.In summary, this thesis provides novel modeling approaches and solution methods aimed at supporting the decision-making process in plant production scheduling which exploit the existing flexibility in chemical processes. The main advantages of each contribution are highlighted through case studies.

  • Uncovering the relevance of modeling transfer times in the short-term scheduling of multipurpose batch plants

     Capon Garcia, Elisabet; Ferrer Nadal, Sergio; Mendez, Carlos Alberto; Puigjaner Corbella, Luis
    Foundation of Computer-Aided Process Operations (FOCAPO 2008)
    Presentation of work at congresses

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  • Conceptual model and evaluation of generated power and emissions from an integrated gasification combined cycle power plant

     Pérez-Fortes, M; Pérez Fortes, Maria del Mar; Bojarski, Aaron David; Ferrer-Nadal, S; Ferrer Nadal, Sergio; Álvarez, C R; Kopanos, Georgios; Nougues, Jose Maria; Velo Garcia, Enrique; Puigjaner Corbella, Luis
    CHISA 2008 - 18th International congress of chemical and process engineering
    Presentation of work at congresses

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  • Enhanced modeling and integrated simulation of gasification and purification gas units targeted to clean power production

     Pérez Fortes, Maria del Mar; Bojarski, Aaron David; Ferrer Nadal, Sergio; Kopanos, Georgios; Nougues, Jose Maria; Velo Garcia, Enrique; Puigjaner Corbella, Luis
    European Symposium on Computer Aided Process Engineering
    Presentation of work at congresses

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  • Chisa 2008

     Ferrer Nadal, Sergio; Capon Garcia, Elisabet; Graells Sobre, Moises; Puigjaner Corbella, Luis
    CHISA 2008 - 18th International congress of chemical and process engineering
    Presentation of work at congresses

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  • An integrated framework for on-line supervised optimization

     Ferrer Nadal, Sergio; Yélamos Ruiz, Ignacio; Graells Sobre, Moises; Puigjaner Corbella, Luis
    Computers & chemical engineering
    Date of publication: 2007-06
    Journal article

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  • Sistema de Optimización en línea y diagnosis de Fallos para Procesos Químcos

     Yélamos Ruiz, Ignacio; Ferrer Nadal, Sergio; Graells Sobre, Moises; Puigjaner Corbella, Luis
    Información tecnológica (Online)
    Date of publication: 2007-05
    Journal article

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  • Optimal reactive scheduling of manufacturing plants with flexible batch recipes

     Ferrer Nadal, Sergio; Méndez, Carlos A.; Graells Sobre, Moises; Puigjaner Corbella, Luis
    Industrial & engineering chemistry research
    Date of publication: 2007-09
    Journal article

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  • Enhanced Model for Integrated Simulation of an Entrained Bed Gasifier Implemented as Aspen Hysys Extension

     Pérez-Fortes, M; Pérez Fortes, Maria del Mar; Bojarski, Aaron David; Ferrer-Nadal, S; Ferrer Nadal, Sergio; Kopanos, Georgios; Mitta, Narendar Reddy; Pinilla Rodriguez, Carlos Andres; Nougues, Jose Maria; Velo Garcia, Enrique; Puigjaner Corbella, Luis
    2007 International Conference on Coal Science and Technology
    Presentation of work at congresses

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  • CAPE_OPEN- Aspen based mathematical modelling for integrated simulation of an entrained bed gasifier

     Pérez Fortes, Maria del Mar; Bojarski, Aaron David; Kopanos, Georgios; Ferrer Nadal, Sergio; Mitta, Narendar Reddy; Pinilla Rodriguez, Carlos Andres; Nougues, Jose Maria; Velo Garcia, Enrique; Puigjaner Corbella, Luis
    European Congress of Chemical Engineering
    Presentation of work at congresses

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  • Conceptual Modeling and Simulation of an entrained bed gasifier reactor

     Pérez Fortes, Maria del Mar; Ferrer Nadal, Sergio; Bojarski, Aaron David; Kopanos, Georgios; Nougues, Jose Maria; Velo Garcia, Enrique; Puigjaner Corbella, Luis
    AIChE Annual Meeting
    Presentation of work at congresses

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  • A MILP Decomposition Approach for the risk management within a flexible recipe framework

     Ferrer Nadal, Sergio; Graells Sobre, Moises; Puigjaner Corbella, Luis
    European Congress of Chemical Engineering
    Presentation of work at congresses

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  • Exploiting the use of a flexible recipe framework to manage financial risk

     Ferrer Nadal, Sergio; Puigjaner Corbella, Luis
    European Symposium on Computer-Aided Process Engineering-17
    Presentation of work at congresses

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  • A novel continuous-time MILP approach for short term scheduling of multipurpose pipeless batch plants

     Ferrer Nadal, Sergio; Mendez, Carlos Alberto; Graells Sobre, Moises; Puigjaner Corbella, Luis
    European Symposium on Computer-Aided Process Engineering-17
    Presentation of work at congresses

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  • A novel continuous-time MILP approach for short term scheduling of multipurpose pipeless batch plants

     Ferrer Nadal, Sergio; Graells Sobre, Moises; Puigjaner Corbella, Luis
    Date of publication: 2007-06
    Book chapter

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  • Exploiting the use of a flexible recipe framework to manage financial risk

     Ferrer Nadal, Sergio; Puigjaner Corbella, Luis
    Date of publication: 2007-06-30
    Book chapter

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  • Hedging Risk through the Flexible Recipe Framework

     Ferrer Nadal, Sergio; Guillén, G; Puigjaner Corbella, Luis
    AIChE Annual Meeting
    Presentation of work at congresses

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  • A mathematical programming approach including flexible recipes to batch operation rescheduling

     Ferrer Nadal, Sergio; Méndez, Carlos A.; Graells Sobre, Moises; Puigjaner Corbella, Lluis
    European Symposium on Computer Aided Process Engineering
    Presentation of work at congresses

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  • A new strategy for exploiting recipe flexibility in batch processes with decaying performance

     Ferrer Nadal, Sergio; Méndez, Carlos A.; Graells Sobre, Moises; Puigjaner Corbella, Luis; Angelini, Raffaele
    17th International Congress of Chemical and Process Engineering
    Presentation of work at congresses

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  • A mathematical programming approach including flexible recipes to batch operation rescheduling

     Ferrer Nadal, Sergio; Graells Sobre, Moises
    European Symposium on Computer Aided Process Engineering
    Presentation of work at congresses

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  • Modelling and Simulation of a Tyre Gasification Plant for Synthesis Gas Production

     Ferrer Nadal, Sergio; Perales Lorente, Jose Francisco; Velo Garcia, Enrique
    European Symposium on Computer Aided Process Engineering
    Presentation of work at congresses

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  • Conceptual Design and Modeling of Entrained Bed Gasifier

     Mitta, N R; Ferrer Nadal, Sergio; Perales Lorente, Jose Francisco; Velo Garcia, Enrique; Puigjaner Corbella, Luis
    AIChE Annual Meeting
    Presentation of work at congresses

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  • A mathematical programming approach including flexible recipes to batch operation rescheduling

     Ferrer-Nadal, S; Ferrer Nadal, Sergio; Mendez, Carlos Alberto; Graells Sobre, Moises; Puigjaner Corbella, Luis
    European Symposium on Computer Aided Process Engineering
    Presentation of work at congresses

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  • Rigorous scheduling resolution of complex multipurpose batch plants: S-Graph vs. MILP

     Ferrer Nadal, Sergio
    European Symposium on Computer Aided Process Engineering
    Presentation of work at congresses

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  • On-line Fault Diagnosis Support for Real Time Evolution applied to Multi-Component Distillation

     Ferrer-Nadal, S; Ferrer Nadal, Sergio; Yélamos-Ruiz, I; Yélamos Ruiz, Ignacio; Graells Sobre, Moises; Puigjaner Corbella, Luis
    European Symposium on Computer Aided Process Engineering
    Presentation of work at congresses

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  • An MILP-based framework for reactive scheduling of batch processes with flexible recipes

     Ferrer Nadal, Sergio; Mendez, Carlos Alberto; Graells Sobre, Moises; Puigjaner Corbella, Luis
    Mediterranean Congress of Chemical Engineering
    Presentation's date: 2005
    Presentation of work at congresses

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  • On-line Fault Diagnosis Support for Real Time Evolution applied to Multi-Component Distillation

     Ferrer-Nadal, S; Ferrer Nadal, Sergio; Yélamos-Ruiz, I; Yélamos Ruiz, Ignacio; Graells Sobre, Moises; Puigjaner Corbella, Luis
    European Symposium on Computer Aided Process Engineering
    Presentation of work at congresses

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  • Clean fuel gas production using tyre gasification plant

     Ferrer Nadal, Sergio; Lozevic, A.M.; Mitta, Narendar Reddy; Perales Lorente, Jose Francisco; Velo Garcia, Enrique; Puigjaner Corbella, Luis
    Mediterranean Congress of Chemical Engineering
    Presentation's date: 2005
    Presentation of work at congresses

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  • An on-line approach for optimal maintenance of multistage continuous plants

     Ferrer Nadal, Sergio; López-Castro, J; Graells Sobre, Moises; Puigjaner Corbella, Luis
    Mediterranean Congress of Chemical Engineering
    Presentation's date: 2005
    Presentation of work at congresses

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  • Scheduling of Multipurpose Batch Plants with Different Storage Policies: a Comparative Study Between S-Graph and MILP Methods

     Ferrer Nadal, Sergio; Puigjaner Corbella, Luis
    Mediterranean Congress of Chemical Engineering
    Presentation of work at congresses

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  • On-line Fault Diagnosis Support for Real Time Evolution applied to Multi-Component Distillation

     Puigjaner Corbella, Luis; Graells Sobre, Moises; Yélamos Ruiz, Ignacio; Ferrer Nadal, Sergio
    Date of publication: 2005-01
    Book chapter

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  • Application of Real Time Evolution to continuous multi-component distillation column

     Ferrer Nadal, Sergio; Yélamos Ruiz, Ignacio; Graells Sobre, Moises; Puigjaner Corbella, Luis
    AIChE Annual Meeting
    Presentation of work at congresses

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