Fyp 2
Fyp 2
1. Introduction ..............................................................................................................................................3
1.1 Cement industry in Pakistan ............................................................................................................3
1.2 Energy Sector in Pakistan ................................................................................................................3
1.2.1 Energy generation source wise in Pakistan ..............................................................................4
1.2.2 Energy Consumption in Pakistan .............................................................................................4
1.2.3 Different Types of Load in Cement Industry ...........................................................................5
1.3 Energy Consumption in Pakistan .....................................................................................................5
1.4 Different Types of Load in Cement Industry ...................................................................................5
1.5 Organization of Thesis .....................................................................................................................5
2.1 Literature Review.................................................................................................................................6
2.2 Types Of Optimization...................................................................................................................... 18
2.2.1 Linear Programming ................................................................................................................. 19
2.2.2 Non Linear Programming ......................................................................................................... 20
2.2.3 Mix integer Linear programming .............................................................................................. 20
2.2.4 Mix integer Non-linear programming ....................................................................................... 20
2.3 Solution approaches .......................................................................................................................... 21
2.3.1 Fuzzy theory.............................................................................................................................. 21
2.3.1 Genetic algorithm...................................................................................................................... 21
2.3.2 Particle swarm approach ........................................................................................................... 21
2.3.2 Wind resource sharing algorithm .............................................................................................. 22
2.4 Tools ................................................................................................................................................. 22
2.4.1 MATLAB .................................................................................................................................. 22
2.5 Application areas .............................................................................................................................. 23
2.5.1 Smart Grid ................................................................................................................................. 23
2.5.1 Micro grids ................................................................................................................................ 24
2.5.2 Demand side management ........................................................................................................ 25
2.5.1 Distributed Grids ....................................................................................................................... 25
2.5.2 Smart energy management system ............................................................................................ 25
2.5.1 Electrical power and energy system .......................................................................................... 26
3.0 Energy Management System for Cement Industry ........................................................................... 28
3.1.1 History of Askari Cement Limited............................................................................................ 29
3.2 Cement Manufacturing Process ........................................................................................................ 29
3.2.1 Grid Station ........................................................................................................................... 30
3.3.1 Stage 1- Raw Material Extraction ............................................................................................. 30
3.3.1.1 Lime stone Crusher, Clay crasher and Storage ..................................................................... 30
3.3.2.1 Raw mill ................................................................................................................................ 32
3.3.4.1 Kiln: ...................................................................................................................................... 33
3.3.4.2 Cooler and Coal Mill .................................................................................................................... 33
3.3.6.1 Cement Mill: ......................................................................................................................... 36
3.3.7.1 Packing Plant ........................................................................................................................ 40
3.3 System Model of Askari Cement Limitted ....................................................................................... 43
3.4 Functions performed in block diagram ............................................................................................. 43
3.6 Objective Function and Constraints .................................................................................................. 44
Chapter 1
1. Introduction
Energy plays an important role in the economic of any country. The cement sector is the major
consumer of gas and electricity in Pakistan. Cement industry has different type of loads Crusher,
Cement mill, Raw mill, Kiln & Cooler, packing Plant, Compressor load, Chiller load, and Colony
load. Some of these load are shift able and some are non shift able. The Chiller load is a seasonal
load which is used only in summer season to maintain the temperature.
Energy Play an important role in the progress of any country. Pakistan is a 70 year old independent
country. Pakistan is still not been able to complete its demands in generation and power. Pakistan is
facing electrical power crises today. At present the electricity in Pakistan is generated by three
modes. Power generated by Thermal is 65%, Hydel is 33% and Nuclear is 2% . Two companies are
generating electricity in Pakistan WAPDA and KESC. Only 55% of the total population has access
to electricity. Thermal power stations contain 11 station of WAPDA operation, 4 station of KESE
operation and 14 stations independently of IPP’s operation. Hydel power generation has 1750 MW
at Tarbela Dam and 900 MW at Mangla Dam. There are also two nuclear reactor of 425 MW for
generation of electricity in Pakistan. The installed capacity of different power station in Pakistan is
given as, Tarbel 3478 MW, Mangla 1000 MW, Warsak 240 MW, Chashma 187 MW, Malakand
19.6 MW, Dargai 20 MW, Rasul 22 MW, Shadiwal 13.5 MW, Chickoki Malian 13.2 MW, Nandipur
13.8 MW, Kurram Garhi 4 MW, Renala 1.1 MW and Chitral power station has 1 MW installed
capacity. .
Figure 1.1: Energy Generation in Pakistan
1.2.1 Energy generation source wise in Pakistan
There are different energy sources to generate electricity in Pakistan. The energy generation by Gas
is 43.7%, Oil 29.0%, Coal 15.3%, electricity 15.3% and energy generation by LPG is 1.5%. Some
non conventional energy generation sources are also used in Pakistan like Solar energy, Wind
energy and Bio gas.
The total power production of Pakistan is 19,500 MW. The short fall is about 45,00 MW. The
demand of electricity is increasing day by day at annual rate increase of 9%. While supply rate is
increasing very slow at annual rate of 7%. The power crimes are due to power line losses nearly
equal to 25%. According to survey the energy consumption is consumed as, Household sector
consume 44.2%, Industries consume 31.1%, Agriculture consume 14.3%, Govt. sector consume
7.4% and Commercial 5.5% consume electricity.
1.2.3 Different Types of Load in Cement Industry
There are different types of loads in Textile industry. Some of loads are shift able and some are non
shift able. The load like Raw Mill and Cement Mill sections load are shift able load. In this research
an energy management system is given for Cement industry which will help to schedule the different
loads on the basis of shift able or non shift able loads. It will help to minimize the cost and emission.
This cement industry has 21.4MW load. This industry has following energy resource
The total power production of Pakistan is 19,500 MW. The short fall is about 45,00 MW. The
demand of electricity is increasing day by day at annual rate increase of 9%. While supply rate is
increasing very slow at annual rate of 7%. The power crimes are due to power line losses nearly
equal to 25%. According to survey the energy consumption is consumed as, Household sector
consume 44.2%, Industries consume 31.1%, Agriculture consume 14.3%, Govt. sector consume
7.4% and Commercial 5.5% consume electricity.
There are different types of loads in Textile industry. Some of loads are shift able and some are non
shift able. The load like Raw Mill and Cement Mill sections load are shift able load. In this research
an energy management system is given for Cement industry which will help to schedule the different
loads on the basis of shift able or non shift able loads. It will help to minimize the cost and emission.
This cement industry has 21.4MW load. This industry has following energy resource.
This thesis is consist on different chapters. Chapter 1 is consist on the introduction which describes
the cement industry in Pakistan, the energy sector, energy generation and energy consumption in
Pakistan. Chapter 2 consist on brief literature review. In chapter 3 the proposed system model is
discussed. Chapter 4 consist simulation results and Chapter 5 describe the conclusion and future
work.
Chapter 2
This section consist of briefly review of different optimization techniques, objective functions,
solution approaches and tools related to solve energy management problem for textile industry. The
basic objective of demand side management is to minimize are cost, emission, energy losses, power,
peak load demand, power generation, energy loss and load, distributed generation cost, network
loss, phaser measurement unit, installed capacity, and fuel cost [1, 2]. There are some objective
function are calculated like multi objective hydrothermal scheduling, and to determine the suitable
PID controller [3]. The literature review consist of objective functions, optimization types, solution
types and tools like MATLAB, JAVA, SIMULINK, VISUAL C++, CPLEX and Monte Carlos
Simulation (MCS) [4]. The figure 2.1 shows the different objective function. The table 2.1 describe
the objective functions in detail.
the NG is number of
i, i, i, i and i
coefficients.
Table 2.1 – Minimization Objectives in DSM
z =X
the system s tT st et(2.2) mon coupling
stability (PCC),t T is the
min[zc(e); zS(v)]
given interval,
z
c is the cost
function and zs
is the stability
function, using
network stability
z
function s can
be rewrite as zS,
where st repre-
sents the penalty
associated with
forecasted volt-
age drop in the
interval t
Table 2.1 – Minimization Objectives in DSM
problem, B is
the number of
branches existing
in the network. P
Table 2.1 – Minimization Objectives in DSM
i=1
X port factor of load
i.
Table 2.1 – Minimization Objectives in DSM
rate ($/s), ex is
the energy flow
_
efficiency,Wn is
the net power
_
output (MW),EX
is the energy flow
rate (MW)
Table 2.1 – Minimization Objectives in DSM
n
consump- the r branches
tion multiplied by
t which in this
case is 1 hour.
Where in Objec-
tive function O2
where CPi(P )
is the unitary
fuel consumption
sources,pig;h;d the
power output of
generator.
Table 2.1 – Minimization Objectives in DSM
is the resistance
of ith branch,
Ii is current of
variables vector.
t
And C is the
CF
cost of electrical
energy generated
by FCPPs.
Table 2.1 – Minimization Objectives in DSM
t, When,W1 = 1
W
and 2 = 0,
utility objective
curve OCu(t)
is generated.
When,W1 = 0
and W2 = 1, con-
sumer objective
curve OCc(t) is
generated
Table 2.1 – Minimization Objectives in DSM
at time t, The
Connect(t) is
the energy which
is shifted from
the other time
to the time step
t, whereas the
Disconnect(t)
is the amount of
energy shifted to
the other time s
from the time step
t.
Table 2.1 – Minimization Objectives in DSM
a
the DG,bDG
and cDG are the
cost quadratic
coefficients of
respective DG.
The total active
power loss is
given in equation
3. Here Ii and
Ri are the value
of current and
resistance, i and n
are the number of
circuit branches.
Table 2.1 – Minimization Objectives in DSM
tions.Moreover,
, , , , a,
b, c and d are
the weight coeffi-
cients of objective
functions. The
best value of
F
obj1 and Fobj2
are zero. Op-
timization of
PID Controller
coefficients is the
minimization of
F
obj1 andFobj2.
Table 2.1 – Minimization Objectives in DSM
PMUi denotes
the installation
of PMU at the
given bus i, PMU
is 1, if the PMU
is installed at the
bus i and zero
otherwise.And
N
unbs is number
of unobserved
buses in the
power systems.
Different objective functions based on the operation, planning and designing are formulated,
Figure shows the different optimization types to solve the problems. The detail of different
optimization types is given below.
Figure 2.2: Different types of Optimizations
Non Linear programming is a technique which is used to solve the optimization problem consist-
ing of system of equalities and inequalities are called constraints consist of unknown real variables
with an objective function which is to minimized or maximized, where some objective functions
and constraints are non linear. The minimization of cost and green house gas emission are the
objective function and cost, power, capacity and security are consider as the constraints in [22] To
determine the optimal operating strategy, cost and minimizing the emission of micro grids the
generalize formulation is presented [23]. Non linear programming is used to minimize generation
cost and emission of pollutants simultaneously, while Generator limits, Security limit and Power
transfer limit in both direction are constraints [24]. The proposed model help to tradeoff between
minimize the cost and emission of pollution present in electrical loads. The non linear
programming is used. Fuzzy theory approach is used considering DER operational capacity,
Distribution substation capacity, Thermal capacity of distribution feeder and Power balance limits
as a constraints to minimize the operation and investment cost and emission [25].
Mix integer Linear programming is a problem containing linear objective functions like f and x,
where f is a vector of constant and x is unknown vector. Designing of such systems that contain
conflicting objectives such as economical and friendly are much expensive. In [26] both economic
and environmental criteria is used in tri generation system. The Mix integer linear programming
is used to solve the objective functions of minimizing of cost and green house gas emission. Multi
objective dispatch of distributed generation problem can be solved by using smart energy
management system. The pare to-optimal solution is obtained by the optimization of operating
cost and emission [27]. Multi objective framework with integration of wind forms to distribution
networks upgrade on power system planning is proposed to minimize the operation and investment
cost [28]. In [29] the mathematical model is proposed for heat exchanger to minimizing the total
cost and environmental impact simultaneously by using mix integer non linear programming that
contain best allocation and use of hot and cold utilities.
An optimization problem consist of input variable, no. of constraints and objective functions,
which combine with each other and make difficult optimization problem. To solve this type of
difficult optimization problem single solution approach is not enough, So various solution
approaches are used by research community to solve the energy management problem. some are
explained here.
Power generation system consisting on hybrid renewable energy are best solution for future
distribution systems. Hybrid photovoltaic-wind turbine connected system are mostly used due to
their better performance. To get best solution of optimal balance between these two source is most
important aspect. A fuzzy logic algorithm is used to perform social criteria technique. Land, no.
of required WT, power generation system area are input variable. Social acceptance indicator is
an output [33].
Genetic algorithm mostly used in artificial intelligence that minimize the process of natural
selection. This technique is used to get best useful solutions. Genetic algorithm belongs to
evolutionary algorithm class. The connection of single phase solar generator also called micro
FITs (micro feed-in tariff) in distribution system may cause phase unbalance conditions. After
installation of micro FITs energy losses changes significantly. Non-dominated pare to-solution is
obtained to minimize the energy loss and current unbalance by using genetic algorithm [34].
Particle swarm optimization (PSO) technique was developed by Dr. Eberhart and Dr. Kennedy in
1995, which is population based optimization technique. Particle swarm optimization has
similarities with evolutionary techniques such as genetic algorithm. Particle swarm optimization
(PSO) is an efficient optimization algorithm. Multi objective optimization algorithm which is
based on PSO is used for design of photo voltaic grid system. To achieve the economic and
environmental benefits the methodology consist of optimal no. of system devices and PV module
installation is proposed [35] [36].
2.3.2 Wind resource sharing algorithm
Wind is an important source of electricity generation with no emission. Wind resource allocation
is important factor in different geographical locations. A wind resource sharing strategy is
proposed. Best wind resource allocation among different connected system to each other is
achieved by using Wind resource sharing strategy. To maximize the reliability and environmental
benefits with less system upgrade wind resource sharing algorithm is used. Wind capacity is taken
as constraint [37].
2.4 Tools
2.4.1 MATLAB
MATLAB is a high level language, which is used by engineers and scientist. It has many
applications in signal and image processing, communication, control system and computing
finance. In [38] To calculate the proposed control techniques a micro grid model consist of three
or four wire AC system. The proposed model are built on Matlab or Simulink environment. The
proposed approach is simulated in MATLAB to validate the effectiveness of proposed approach,
ensure to Reducing power losses and enhancing load ability [8,39]. Multi objective optimization
tool like MAT-LAB is used to solve the suggested model to get the desire results in [10]. Using
MATLAB script function the self developing code is built to maximize the DG benefits with
considering the volt-age rise issue [30,40]. MATLAB has following features like numerical
computation, visualization, problem solving, mathematical function of linear algebra, fourier
analysis, filtering, optimization, creating custom graphs and solving ordinary differential equations
[41]. Matlab/Simulink based simulation is used to test the large no. of scenarios and theoretical
analysis in [4, 42]. MATLAB has the features like multi-paradigm numerical computation
environment and fourth generation programming language [43]. The program was developed on
MATLAB to get the output of the generators and output of slack bus changed to set the constraints
[44]. The proposed control sys-tem is implemented on smart grid which is simulated under
MATLAB to minimize the operation cost and environment impact [20]. Mathematical model is
used in MATLAB to get pare to solution of energy circulation for the storage batteries and
electricity cost for energy purchasing [45]. Design variable are obtained by using genetic algorithm
in MATLAB. The objective functions to minimize the cost and maximize the availability of PV
and Wind are achieved [46]. Control sys-tem in greenhouse environment contain designing and
simulation of a certain control system. PID controller is design for electric lightning in greenhouse.
The proposed control system is complete with MATLAB simulation [17]. To calculate the
proposed control techniques a micro grid model consist of three or four wire AC system. The
proposed model are built on Matlab or Simulink environment. MATLAB genetic algorithm
toolbox is used to solve the multi objective optimization problem [47]. PID controller gain is
optimize by using multi objective Artificial Bee Colony(ABC) algorithm MATLAB is used to
carry out the simulation and modeling [48]. To setup the parallel environment MATLAB parallel
computing and distributed computing is used. Minimize the cost and maximize the vehicle to grid
income are the objective function. power and voltage are constraints [49]. To minimize the total
generation cost and emission while demand, transmission losses, power balance and generating
capacity are the constraints. MATLAB environment (Math Works) is used for simulations [50].
MATLAB is used to solve the multi objective problem using enhanced multi objective algorithm
to achieve the objective function like minimize the cost and load shedding and Transmission
expansion planning [51]. The software used for simulation and graphical representation is
developed in MATLAB environment. Multi strategy is used for substation placement and feeder
routing [52]. Dispersed storage system (DSSs) are very important solution for supporting the
control and operation of active distributed networks. Simulations are carried out on MATLAB to
evaluate the investment, maintenance costs and minimize the voltage deviation and flow [31]. The
dispatching model of smart home energy management system is a mix integer non linear
optimization problem. So mix integer non linear programming is used to solve the problem with
MTLAB [32].
The applications related to demand side management are briefly discussed such as smart grid,
micro grids, demand side management, distributed grids, smart energy management system,
combined heat and power system, electrical power and energy system, and combined cool and
power system.
Smart grid is a system which contain different operational and energy measurement like smart
meters, smart appliances and renewable energy resources. The main aspects of the smart grid are
electrical power conditioning, control of the power generation and distribution. Virtual power plant
is the basic part of smart grid. An attempt is made to reveal the performance analysis of the virtual
power plant by taking two conflicting objectives such as maximization of profit and minimization
of risk [10]. In [41] the author proposed the multi objective ant colony optimization for the fast
charging station to minimize the both total cost of line installation and also line losses. To get the
optimal solution of smart grid A new multi objective optimization model is proposed. Two
different approaches are used one is objective sum criterion and weighted sum criterion. The power
losses minimization, voltage profile optimization, security margin maximization and smart
charging are the main objectives while voltage, transformer size and current are the constraints
[56]. The objective of moving towards the smart grid is to make power system more reliable and
economical. A pare to front approach is used to obtain the objective like Maximize the reliability
and reduce the energy purchasing cost taking energy storage technology as a constraint [19].The
major problem in inefficiency in the power grid is the under utilization of energy. This is due to
the maximum load demand during the peak hours as compared to off peak hours. Keeping in view
the load demand is increasing, the two way communication system is proposed to installing new
power plants on smart grids to minimize the load shedding. The two way communication is enable
by smart meters and demand response [21]. The solar and wind power sources are becoming more
popular now a days. In [46] the author used a multi objective genetic algorithm to design the
proposed model to determine the system design by taking multiple criteria such as size, cost and
availability of PV panels and wind. Performance and efficiency of the industrial system is depends
on development and improvement in the industrial control system. The main target of the multi
objective optimization is to determine suitable amount of PID controller in green house electrical
lightening system [17]. The proposed model is used for multi objective energy resources
scheduling of smart grid taking in view the use of distributed generation and vehicles to grid.
Particle swarm approach is used to achieve the objective functions such as Minimize the total
operation cost and Maximize the V2G income [49]. Smart grid maturity model has been improved
by analyzing the characteristics of each stage of smart grid. The reliability and clean economic
objective function are achieved [57]. To improve the security and reduce the power shortage
different computer aided tools are used like supervisory control and data acquisition (SCADA),
wide area monitoring system (WAMS) and global positioning system(GPS) are used. The phaser
measurement unit is measured [18]. Smart grid is an infrastructure in which two way
communication exist. The WiMax technology plays an important role in smart grid. The placement
of WiMax is achieved in this paper [58].
Micro grids are small scale and modern grids instead of traditional centralized grid. Micro grids
can work separately by disconnecting from the centralize grid. They are low voltage AC grid.
Micro grids uses distributed energy resources such as solar and wind. The proposed model allows
the bidirectional AC/DC conversion and integrate the small DC micro grids to the main grid [38].
The multi objective approach is used for the control of load and bi directional energy storage in
micro grids. The two conflicting objectives are consider like Minimization of the cost and
maximization of the system stability [6]. In [11] application area is taken for new approach for
optimal dispatch of energy sources in smart grid. Glow-worm swarm optimization is used to
achieve Minimize the power loss, overall production cost, and CO2 emission. The proposed multi
objective energy management model is used to minimize the operation cost and environmental
effect of micro grid [20]. To determine the optimal operating strategy, cost and minimizing the
emission of micro grids the generalize formulation is presented [23]. Future power grids are
expected to consist of micro grids, solar, wind and plug in electric vehicles. The potential game
theory is used to accurate method for interconnected micro grids [59]. A multi objective stochastic
planning approach is used for stand-alone micro grid consisting of diesel generators, wind solar
and batteries to obtain economic and environmental benefits [36]. The purpose of micro grids is
to use more renewable energy and reduce carbon emission. Several challenges are faced like trade
off between renewable and non renewable energy resources. An evolutionary approach is used to
obtain the objective of maximize the profit and minimize the emission [60]. Solving power supply
problem in islands for stand-alone micro grids containing renewable energy and battery storage
plays important role. The life time of batteries should be investigate to achieve reliable and
economic operation of micro grids [61].
Demand side management is a technique which plays very important role to reduce the energy
price at both ends user like domestic, commercial and industrial as well as energy supplier. Energy
supplier offer multi benefits to the user to use less energy. The reliability and sustain ability in the
smart grid is achieved by demand side management. The objective functions Minimization of the
Electricity Bill and fill the objective load curve are achieved by using genetic algorithm [15].
Distributed generation is an approach that contain small scale technologies to generate electricity
near to end user of power. Distribution generation is a new challenge for traditional distribution.
The multi objective index based analytical approach is used to determine optimal size and power
factor of DG [39]. Renewable energies such as solar wind are the solution of sustain ability,
environment friendly and making cost decisions for the distributed grids [62]. Designing of such
systems that contain conflicting objectives such as economical and friendly are much expensive.
In [26] both economic and environmental criteria is used in tri generation system. The total annual
cost and emission are the objective functions to be minimized. The distributed generation is
becoming popular to use in traditional distribution system. DGs are cost effective, reliable and
environment friendly
Economic load dispatch is a process to determine the low cost, efficient and reliable operation of
power system. Environmental issues are arises due to operation of fossil fuel. The pare to-optimal
approach is used to minimizing the quadratic cost function and minimize emission [5].
Environmental issues are arises due to operation of fossil fuel. Economic dispatch is a problem to
distribute load demand to respective generators in power system. The bacteria foraging algorithm
and evolutionary algorithm are used to achieve the objectives to minimize the fuel cost and
minimum emission dispatch [12]. Demand response has take more attention in reduction of cost,
improvement in security and improvement in performance. A method is developed for optimal
choosing the locations of Demand Response program to obtained maximum benefits obtained from
the program. The Non-Sorting-Genetic Algorithm II (NSGA-II) algorithm is used to Maximize the
availability transmission capacity, minimize active power loss and DR capacity [63]. Demand side
management is widely used to reduce the cost. By scheduling the appliances with respect to time
of use tariff the cost can be minimized. An evolutionary algorithm is used to minimize the actual
power consumption, Reduce the peak load demand and reshape the load curve [4]. Multi objective
dispatch of distributed generation problem can be solved by using smart energy management
system. The pare to optimal solution is obtained by the optimization of operating cost and net
emission in micro grid [27]. Due global warming and generators environmental issues are arises
due to operation of fossil fuel. The proposed algorithm is used to solve the multi objective
economic load dispatch problems. Foraging meta-heuristic algorithm is use to minimize the fuel
cost and emission dispatch [44]. Multi objective optimization library is developed to solve the
different type of problems arising due to cogeneration. Temperature, pressure, and no. of heat
exchanger are the constraints. Genetic algorithm is used to minimize the energy loss and Lifetime
cost [64]. Utilization of renewable energy at the spot is possible by integrating PV system and EV
charging stations. DC micro grid consisting of PV system and EV charging stations is pro-posed.
Non-Sorting-Genetic Algorithm II (NSGA-II) is used to minimize the cost of electricity
purchasing and energy circulation while EV charging time and storage batteries charging power
are constraints [45]. Smart home energy management system with distributed energy resources
and intelligent home appliances is proposed. Math model is developed which helps to live
comfortable and saving money. This model is applied to one house consisting of wind turbine,
solar panels, storage batteries and time of use tariff to minimize the operation cost [32]. The
proposed model help to tradeoff between minimize the cost and emission of pollution present in
electrical loads. Fuzzy theory approach is used considering DER operational capacity, Distribution
substation capacity, Thermal capacity of distribution feeder and Power balance limits as a
constraints to minimize the operation and investment cost and emission [25].
An electrical power system is used to supply or transmit the power. To design the multi-machine
power system stabilizer the chaotic algorithm is used. Power system stabilizer parameters are
consider as constraints [40]. Genetic algorithm is used to evaluate multi objective optimization
problem for load-frequency control to design PI controller in power system [43]. Network
reconfiguration in distribution system for service restoration is difficult optimization problem.
Evolutionary algorithm is used to improve the capacity of MEAN [65]. Multi objective framework
with integration of wind forms to distribution networks upgrade on power system planning is
proposed to minimize the operation and investment cost [28]. The given model solve
simultaneously three objectives like minimize the cost, environmental impact and maximize the
reliability. The optimization problem helps to decide the size, time and technology type of
generating units. [3]. Integration of renewable energy resources become sustainable energy source
for users against rising cost and pollutant nature. Non-Sorting-Genetic Algorithm II (NSGA-II) is
used to minimization renewable energy cost the system reliability [66]. Artificial Bee Colony
(ABC) algorithm is used for load frequency control implemented on two ares connected to each
other reheat thermal power system. Artificial bee colony algorithm is used to optimize the PID
controller gain evaluate the frequency respond settling time and maximum overshoot [48]. The
model is proposed for solving the trans-mission expansion problem while multi generation is
involved. Evolutionary algorithm is used to minimize the cost level, load shedding and
Transmission expansion planning [51]. Multiple generation scenario is used to solve the
transmission expansion planning. MGS are the result of multiple flow load pattern. Which are
caused by operation of network, like energy market rules, generators availability and fuel prices.
Multi objective optimization algorithm is use to minimize the investment cost and emission [67].
To calculate the growth of system load a large number of constraints is a difficult multi objective
optimization problem. For optimal expansion planning of distribution network the imperialist
competitive algorithm is used to minimize the investment cost, operation cost and emission.
Chapter 03
3.1 Introduction
Cement industry is the largest production industry in Pakistan. C industry is playing an important
role in employment of Pakistan. The Warping machine can be taken as shift able load. The
manufactured cloth is combination of Warp and Weft. Sizing is a process of applying the material.
The sizing machine is used to increase the strength of the Warp. The sizing machine is also shift
able load. In this research, we have proposed an energy management system for Cement industry.
We have energy sources like wapda, solar, diesel generators and gas turbine. Some loads are
seasonal like chiller. Some are shift able like Cement Mill, Raw Mill and Packing Plant. But some
loads are non-shift able load. We can shift the Cement Mill, Raw Mill and Packing Plant load to
manage our load but other loads Kiln, Cooler and compressor load can not be shifted. The diagram
of cement industry consisting on different loads is shown below.
Askari cement limited is the part of Fauji Foundation, one is the largest business conglomerate in
Pakistan. With its two plants at Wah and Nizampur, have a total production capacity 825 tons per
day and only Asakri Cement Wah capacity is 3750 tons per day. Besides having major share in
Pakistan market, Asakri Cement is being export to Afghanistan, Central Asian Republics, India
and South Africa.
Askari Cement Limited has a credit of being first in cement industry to acquire ISO 9001
certification. It also now stands as the first to acquire the ISO 14001 Environment friendly
standards certification in Pakistan.
Its established in 1921, is the successor of Associated Cement Company, the first cement plant the
territory now constituting Pakistan. The plant the famous Bombay based Indian company in 1921,
with a rate capacity of 120 tons per day. The plant acquire by Army Welfare Trust in 1996.
After acquisition AWT changed the name of brand to Askari Cement. The plant installed 1994
was 3000 tons per day single production line design by FL Smidth of Denmark. The capacity of
plant enhance 750 tons per day in 2006.
On 30yh July 2013, shares a Askari Cement Limited were purchased by Faufi Foundation.
Production of cement complete after passing of raw materials from the flowing seven stages. There
is;
Raw material extraction / Quarry
Grinding, proportioning and blending
Pre-heater phase
Kiln phase
Cooling of Clinker
Final grinding at Cement Mill
Packing and Loading
Load of all areas
Table 3.1 – Areas load of Askari Cement
SR. Unit Name Load
NO.
1 Cement Mill 5.5MW
2 Raw Mill 5 MW
3 Kiln 3.8 MW
4 Coal Mill & Cooler 2 MW
5 Crusher 1.15 MW
6 Packing Plant 0.4 MW
7 Grid 0.05 MW
8 Admin 0.15 MW
9 Colony 0.4 MW
Table 3.2 – Load distribution on both Transformers in Askari Cement
SR. Load Capacity
NO.
1 Transformer 1 11.2 MW 20 MW
2 Transformer 2 7.6 MW 20 MW
Grid station is uninterrupted load. Its maximum load is 20 kwh and range is 10- 20 kwh.
Cement users raw materials that cover calcium, silicon, iron and aluminum. Such raw material are
limestone, clay and sand. Limestone is for calcium, it is combined with much smaller proportions
of sand and clay. Sand and clay fulfill the need of silicon, iron and aluminum. Generally cement
plants are fixed where the quarry of limestone is nearby. This save the extra fuel cost and makes
cement somehow economical. Raw materials are extracted from the quarry and by means of
conveyor belt material is transported to the cement plant.
There are also various other materials used for cement manufacturing. For example shale, fly ash,
mill scale and bauxite. These raw materials are directly brought from other sources because of
small requirements.
Before transportation of raw materials to the cement plant, large size rocks are crushed into smaller
size rocks with he help of crusher at quarry. Crusher reduced the size of large rocks to the size of
gravels.
We have to run the clay crusher for 6 hours and lime stone crusher for 8 hours and storage running
time is correspond with raw mill. When clay and lime stone crusher are under running form so
load is 1100-1200 kwh. If lime stone crusher and storage both are under running form then load
will be 700-800 kwh. If only storage area is under running form then load will be 300-400 kwh.
Table 3.3 – Motors Data of Lime stone, Clay Crusher and storage Areas
Power Current Rated Types Remarks
SR# Motor Code (KW) (Amp) Current
1 211-BC3 55 105 74.1
2 211-BC4 21.8 42.9 30.2
3 211-BC5 87.64 157 115
4 211-FN2 10.2 20.8 15 3 MOTORS
5 211-ST 30 58 31.5 2
6 OTHER MOTORS 7.24
7
8 Clay
9 211-CR1 177 322 -
10 221-AC1 22 53.1 17.8
11 221-CP1 18 33.8 --
12 221-FN1 34.8 65.3 45.7
13 221-BC2 43.8 81.8 53 2
14 221-BC3 48.3 77.2 40.3
15 221-BC4 27.66 52.2 39.8
16 221-ST1 22 43 20.9
17 OTHER MOTORS 30.24
18
19
20 LIMESTONE
21 211-CR1 1060 115 60 INPUT 6.3 KV
22 211-CR1-MO2 45 84 45.2
23 211-AC1 20.9 50.7 40.6 2 MOTORS
24 211-BC2 74.33 136 69.1
25 211-BC2-MO1 15 28.5 17.4
25 211-FN1 51 98 64.7
26 OTHER MOTORS 22.74
27
The raw materials from quarry are now routed in plant laboratory where, they are analyze and
proper proportioning of limestone and clay are making possible before beginning of grinding.
Generally limestone is 80% and remaining 20% is the clay.
Now cement plant grinding the raw mix with the help of heavy wheel types other rollers and
rotating table at raw mill. Rotating table rotates continuously under the roller bringing the raw mix
in contact with the roller. Roller crushes the material to a fine powder and finishes the job. Raw
mix the stored in a silo ready to be fed to pre heater cyclones.
3.3.2.1 Raw mill
The capacity of RAW MILL is 300-310 tons per hour. Its maximum load is 5100 kwh and
average is 5000 kwh. We can store the material of RAW MILL in silo and silo capacity is 15000
tons and also we can stop the RAW MILL for 3 hours in a day.
After grinding of raw mix by raw mill, the material is ready to face the pre-heating chamber. Pre-
heating chamber consists of series of vertical cyclone from where the raw material passes before
entering the kiln. Pre-heater utilized the emitting hot gases from kiln. Pre-heater of the material
save the energy and make plant environment friendly.
Kiln is huge rotating furnace also called as the heart of cement making process. Here, raw
material is heated up to 1250 c. in this process, carbon dioxide released the material. Kiln is
heated up from the exit side by the use of Furnace oil, natural gas and coal.
3.3.4.1 Kiln:
The capacity of kiln is 160 tons per hour. Its input is 240 – 260 tons per hour and output is 155 –
160 tons per hour. Its multiplying factor is 0.6 and 0.4 is wastages (gases etc). If the feed of kiln
is 260 tons per hour so the output will be 160 tons per hour. The maximum load of kiln is 3660
kwh and average is 3310 kwh.
Its attached with Kiln and not a independent area. Its maximum load is 2000 kwh and average is
1900 kwh. Coal mill provide fuel (coal) to Kiln and Cooler function is cooling of clinker which a
output of kiln.
Kiln feed to cooler and cooler after cooling process store the material and its storage is 1 lac tons
capacity. We can’t interrupt the Kiln, Cooler and Coal Mill areas.
After passing out from the kiln, clinker are cooled by mean of forced air, Clinker release the absorb
heat and cool down at lower temperature. After cooling the clinker ready for fed in cement mill
for final grinding.
3.3.6 Stage 6: Final Grinding at Cement Mill
Final grinding of clinker takes place in cement mill. A typical cement mill consists of Ball mill. A
horizontal ball mill is filled by steel balls i.e grinding media. Here, the steel balls crush the clinker
into very final powder. During grinding gypsum is also added at 5%.
After grinding at cement mill, the cement transported to cement storage silos at packing plant.
The capacity of CEMENT MILL is 200-210 tons per hour. The maximum load is 5300 kwh and
average load is 5100 kwh. The function of cement mill is grinding and we can store its output (fine
material) therefore its storage capacity is 20000 tons so we can stop that area for 4 hour in a day.
Using extraction gates fed to packing plant for package of cement bags usually 50 kg or 1 ton or
in bulk. Cement are loaded to transportation vehicles ready for transportation to the market.
We have 4 lines in Packing Plant therefore its capacity is 400 tons per hour. The maximum load
is 120 kwh, average is 100 kwh and minimum load is 40 kwh when it is in stop position. It
haveto run only 10- 12 hour a day.
641-BN1-BN4- 4 OFF
26. 1500 4.0 7.0 8
MO4,MO5 4 ON
1420/18
27. 641-BN1-BN4-MO6 1.1 2.8 4
.5
1420/17
28. 641-BC1-4-MO1 0.75 2.15 4
2
1420/16
29. 641-BW1-4-MO1 0.75 2.15 4
5
1420/17
30. 641-BC1-4-MO2 0.75 2.15 4
2
Speed Power Current Remarks
QNT
SR# Motor Code (RPM) (KW) (Amp)
651-BDA-BDY-MO2 OFF
35. 1500/80 0.7 1.73 20
661-BDA-BDD-M02
4 ON 4
36. 651-BCA-BCH-MO1 1420/83 1.5 3.75 8
OFF
There are different kinds of loads in cement industry. Each types of load has different type of
appliances. These load types are Shift able load, Non shift able load, auxiliary load and seasonal
load etc.
Interruptible Load, Uninterruptible Load, Sequential operation, Size of Batch cycles, Number of
batch cycles, Material flow, Material balance, Final products, By products
Figure 3.3 Block Diagram
Shiftable Load: Cement Mill, Packing Plant, Crusher, Workshop and and Water Turbine.
Non Shift-able: Raw Mill, Stock, Kiln, Cooler, Compressor.
Seasonal Load: Chiller is the seasonal load.
Auxiliary Load: Colony.
In this research we proposed a model which is used to minimize the cost by scheduling the different
textile industry loads related to electricity cost and energy sources. There are different tariff rates
like TOU tariff, Peak pricing, IBR tariff, CPP and DAP.
The primary goal of any industry is to maximize its profit, and minimize its cost
i.e, revenue minus cost. On one hand, revenue depends on the amount and price of each final
product and by product. On the other hand, cost depends on the amount and purchase price of raw
materials, storage of raw materials, labor cost and also the operational cost of industrial units,
including their cost of electricity. Therefore, we have
Profit= revenue-cost
Revenue= ∑f∈F mf [T]pf
The first term in (3) is the total cost of raw materials consumed during the scheduling horizon and
the second term is the total cost of storing materials of any type and the third term is any fixed cost
that does not depend on our decision variables, e.g., cost of labor, facility, etc. Finally, and most
importantly, the fourth term is the cost of electricity, which we explain next.
The cost of electricity depends on both the electric load profile and the pricing method used by the
utility company.
This pricing method is used, e.g., by Ameren Inc., in Illinois . In DAP, the utility releases the
hourly prices for the next day on a daily basis. Let p[t] $/kWh denote the day-ahead price of
electricity at time slot t. Also, let L[t] denote the total power consumption at the industrial complex
of interest at time slot t. We have
This pricing method is used, e.g., by Riverside Public Utilities in California . It usually has two
components
1) usage charge and 2) peak demand charge. Usage charge is based on flat or time-of-use rates.
It can be modeled as in . Peak demand charge is rather based on the consumer’s daily or
monthly peak load. It is calculated by measuring electricity usage at the hour of the day or
month during which the consumer’s load is at its highest amount. The peak price, denoted by
ppd $/kWh, is usually much higher than the prices that are used to calculate the usage charge.
That is, ppd _ p[t] for all t ∈T . As a result, PP can encourage users to consume electricity
more uniformly during the day in order to improve the load factor. The cost of electricity when
PP method is used can be calculated as
Otherwise if L[t] > L0 [t] then the cost of electricity at time t becomes
𝐶𝑒𝑙𝑒𝑐 [𝑡] = pbl [t]L[t] + (L[t]-L0 [t]) phl [t]
This pricing method is used, e.g., by Fort Collins Utilities in Fort Collins, CO, USA . In CPP, there
is an additional charge during the hours where the utility experiences spikes in the total load
demand in its service territory. Since CPP depends on the combined behavior of all consumers,
individual customers are unaware of its happening time. Therefore, utilities send warnings from 5
min to 24 h in advance to inform users about the occurrence of an upcoming
critical peak hour. The exact setup of CPP may vary in different places. In this paper, we assume
that the CPP price pcp $/kWh and the start and duration of each critical peak hour are announced
as part of the warning signal sent by the utility.
Following the analysis of historical CPP warnings in , we assume that warnings accurately identify
the critical peak hour, i.e., no CPP false alarm may be sent to consumers. Similar to PP, CPP is
usually combined with usage charges. The cost of electricity under CPP pricing methods becomes
where tbeg and tend denote the beginning and the end of the critical peak time frame, where tbeg
< tend. The CPP price is usually much higher than the regular usage price and even peak price. As
reported in , when CPP is used, at least 23% of the cost of electricity comes from the CPP charges.
tbeg −1 tend T
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