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Bayer digestion maintenance optimisation with lazy constraints and Benders decomposition

Author

Listed:
  • Sandy Spiers

    (ARC Centre for Transforming Maintenance through Data Science
    Curtin University)

  • Hoa T. Bui

    (ARC Centre for Transforming Maintenance through Data Science
    Curtin University)

  • Ryan Loxton

    (ARC Centre for Transforming Maintenance through Data Science
    Curtin University)

  • Moussa Reda Mansour

    (Alcoa of Australia Limited)

  • Kylie Hollins

    (Alcoa of Australia Limited)

  • Richard Francis

    (Alcoa of Australia Limited)

  • Christopher Martindale

    (Alcoa of Australia Limited)

  • Yogesh Pimpale

    (Alcoa of Australia Limited)

Abstract

This paper describes a maintenance scheduling model for digester banks. Digester banks are network-connected assets that lie on the critical path of the Bayer process, a chemical refinement process that converts bauxite ore into alumina. The banks require different maintenance activities at different due times. Furthermore, the maintenance schedule is subject to production-related constraints and resource limitations. Given the complexity of scheduling maintenance for large fleets of digester banks, a continuous-time, mixed-integer linear program is formulated to find the cost-minimising maintenance schedule that satisfies all required constraints. A solution approach that employs lazy constraints and Benders decomposition is proposed to solve the model. Unlike generic implementations of Benders decomposition, we show that the subproblems can be solved explicitly using a specialist algorithm. We solve the scheduling model for realistic scenarios involving two Bayer refineries based in Western Australia.

Suggested Citation

  • Sandy Spiers & Hoa T. Bui & Ryan Loxton & Moussa Reda Mansour & Kylie Hollins & Richard Francis & Christopher Martindale & Yogesh Pimpale, 2024. "Bayer digestion maintenance optimisation with lazy constraints and Benders decomposition," Annals of Operations Research, Springer, vol. 338(1), pages 269-302, July.
    • Handle: RePEc:spr:annopr:v:338:y:2024:i:1:d:10.1007_s10479-023-05561-6
    DOI: 10.1007/s10479-023-05561-6
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    References listed on IDEAS

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    1. Rahmaniani, Ragheb & Crainic, Teodor Gabriel & Gendreau, Michel & Rei, Walter, 2017. "The Benders decomposition algorithm: A literature review," European Journal of Operational Research, Elsevier, vol. 259(3), pages 801-817.
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    3. Joe Naoum-Sawaya & Christoph Buchheim, 2016. "Robust Critical Node Selection by Benders Decomposition," INFORMS Journal on Computing, INFORMS, vol. 28(1), pages 162-174, February.
    4. J. N. Hooker, 2007. "Planning and Scheduling by Logic-Based Benders Decomposition," Operations Research, INFORMS, vol. 55(3), pages 588-602, June.
    5. Ivan Contreras & Jean-François Cordeau & Gilbert Laporte, 2011. "Benders Decomposition for Large-Scale Uncapacitated Hub Location," Operations Research, INFORMS, vol. 59(6), pages 1477-1490, December.
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