# RELOG: Reverse Logistics Optimization # Copyright (C) 2020, UChicago Argonne, LLC. All rights reserved. # Released under the modified BSD license. See COPYING.md for more details. using JuMP, LinearAlgebra, Geodesy, Cbc, Clp, ProgressBars, Printf, DataStructures function build_model(instance::Instance, graph::Graph, optimizer)::JuMP.Model model = Model(optimizer) model[:instance] = instance model[:graph] = graph create_vars!(model) create_objective_function!(model) create_shipping_node_constraints!(model) create_process_node_constraints!(model) return model end function create_vars!(model::JuMP.Model) graph, T = model[:graph], model[:instance].time model[:flow] = Dict((a, t) => @variable(model, lower_bound = 0) for a in graph.arcs, t = 1:T) model[:dispose] = Dict( (n, t) => @variable( model, lower_bound = 0, upper_bound = n.location.disposal_limit[n.product][t] ) for n in values(graph.plant_shipping_nodes), t = 1:T ) model[:store] = Dict( (n, t) => @variable(model, lower_bound = 0, upper_bound = n.location.storage_limit) for n in values(graph.process_nodes), t = 1:T ) model[:process] = Dict( (n, t) => @variable(model, lower_bound = 0) for n in values(graph.process_nodes), t = 1:T ) model[:open_plant] = Dict( (n, t) => @variable(model, binary = true) for n in values(graph.process_nodes), t = 1:T ) model[:is_open] = Dict( (n, t) => @variable(model, binary = true) for n in values(graph.process_nodes), t = 1:T ) model[:capacity] = Dict( (n, t) => @variable( model, lower_bound = 0, upper_bound = n.location.sizes[2].capacity ) for n in values(graph.process_nodes), t = 1:T ) model[:expansion] = Dict( (n, t) => @variable( model, lower_bound = 0, upper_bound = n.location.sizes[2].capacity - n.location.sizes[1].capacity ) for n in values(graph.process_nodes), t = 1:T ) end function slope_open(plant, t) if plant.sizes[2].capacity <= plant.sizes[1].capacity 0.0 else (plant.sizes[2].opening_cost[t] - plant.sizes[1].opening_cost[t]) / (plant.sizes[2].capacity - plant.sizes[1].capacity) end end function slope_fix_oper_cost(plant, t) if plant.sizes[2].capacity <= plant.sizes[1].capacity 0.0 else (plant.sizes[2].fixed_operating_cost[t] - plant.sizes[1].fixed_operating_cost[t]) / (plant.sizes[2].capacity - plant.sizes[1].capacity) end end function create_objective_function!(model::JuMP.Model) graph, T = model[:graph], model[:instance].time obj = AffExpr(0.0) # Process node costs for n in values(graph.process_nodes), t = 1:T # Transportation and variable operating costs for a in n.incoming_arcs c = n.location.input.transportation_cost[t] * a.values["distance"] add_to_expression!(obj, c, model[:flow][a, t]) end # Opening costs add_to_expression!( obj, n.location.sizes[1].opening_cost[t], model[:open_plant][n, t], ) # Fixed operating costs (base) add_to_expression!( obj, n.location.sizes[1].fixed_operating_cost[t], model[:is_open][n, t], ) # Fixed operating costs (expansion) add_to_expression!(obj, slope_fix_oper_cost(n.location, t), model[:expansion][n, t]) # Processing costs add_to_expression!( obj, n.location.sizes[1].variable_operating_cost[t], model[:process][n, t], ) # Storage costs add_to_expression!(obj, n.location.storage_cost[t], model[:store][n, t]) # Expansion costs if t < T add_to_expression!( obj, slope_open(n.location, t) - slope_open(n.location, t + 1), model[:expansion][n, t], ) else add_to_expression!(obj, slope_open(n.location, t), model[:expansion][n, t]) end end # Shipping node costs for n in values(graph.plant_shipping_nodes), t = 1:T # Disposal costs add_to_expression!( obj, n.location.disposal_cost[n.product][t], model[:dispose][n, t], ) end @objective(model, Min, obj) end function create_shipping_node_constraints!(model::JuMP.Model) graph, T = model[:graph], model[:instance].time model[:eq_balance] = OrderedDict() for t = 1:T # Collection centers for n in graph.collection_shipping_nodes model[:eq_balance][n, t] = @constraint( model, sum(model[:flow][a, t] for a in n.outgoing_arcs) == n.location.amount[t] ) end # Plants for n in graph.plant_shipping_nodes @constraint( model, sum(model[:flow][a, t] for a in n.incoming_arcs) == sum(model[:flow][a, t] for a in n.outgoing_arcs) + model[:dispose][n, t] ) end end end function create_process_node_constraints!(model::JuMP.Model) graph, T = model[:graph], model[:instance].time for t = 1:T, n in graph.process_nodes input_sum = AffExpr(0.0) for a in n.incoming_arcs add_to_expression!(input_sum, 1.0, model[:flow][a, t]) end # Output amount is implied by amount processed for a in n.outgoing_arcs @constraint( model, model[:flow][a, t] == a.values["weight"] * model[:process][n, t] ) end # If plant is closed, capacity is zero @constraint( model, model[:capacity][n, t] <= n.location.sizes[2].capacity * model[:is_open][n, t] ) # If plant is open, capacity is greater than base @constraint( model, model[:capacity][n, t] >= n.location.sizes[1].capacity * model[:is_open][n, t] ) # Capacity is linked to expansion @constraint( model, model[:capacity][n, t] <= n.location.sizes[1].capacity + model[:expansion][n, t] ) # Can only process up to capacity @constraint(model, model[:process][n, t] <= model[:capacity][n, t]) if t > 1 # Plant capacity can only increase over time @constraint(model, model[:capacity][n, t] >= model[:capacity][n, t-1]) @constraint(model, model[:expansion][n, t] >= model[:expansion][n, t-1]) end # Amount received equals amount processed plus stored store_in = 0 if t > 1 store_in = model[:store][n, t-1] end if t == T @constraint(model, model[:store][n, t] == 0) end @constraint( model, input_sum + store_in == model[:store][n, t] + model[:process][n, t] ) # Plant is currently open if it was already open in the previous time period or # if it was built just now if t > 1 @constraint( model, model[:is_open][n, t] == model[:is_open][n, t-1] + model[:open_plant][n, t] ) else @constraint(model, model[:is_open][n, t] == model[:open_plant][n, t]) end # Plant can only be opened during building period if t ∉ model[:instance].building_period @constraint(model, model[:open_plant][n, t] == 0) end end end default_milp_optimizer = optimizer_with_attributes(Cbc.Optimizer, "logLevel" => 0) default_lp_optimizer = optimizer_with_attributes(Clp.Optimizer, "LogLevel" => 0) function solve( instance::Instance; optimizer = nothing, output = nothing, marginal_costs = true, ) milp_optimizer = lp_optimizer = optimizer if optimizer == nothing milp_optimizer = default_milp_optimizer lp_optimizer = default_lp_optimizer end @info "Building graph..." graph = RELOG.build_graph(instance) @info @sprintf(" %12d time periods", instance.time) @info @sprintf(" %12d process nodes", length(graph.process_nodes)) @info @sprintf(" %12d shipping nodes (plant)", length(graph.plant_shipping_nodes)) @info @sprintf( " %12d shipping nodes (collection)", length(graph.collection_shipping_nodes) ) @info @sprintf(" %12d arcs", length(graph.arcs)) @info "Building optimization model..." model = RELOG.build_model(instance, graph, milp_optimizer) @info "Optimizing MILP..." JuMP.optimize!(model) if !has_values(model) @warn "No solution available" return OrderedDict() end if marginal_costs @info "Re-optimizing with integer variables fixed..." all_vars = JuMP.all_variables(model) vals = OrderedDict(var => JuMP.value(var) for var in all_vars) JuMP.set_optimizer(model, lp_optimizer) for var in all_vars if JuMP.is_binary(var) JuMP.unset_binary(var) JuMP.fix(var, vals[var]) end end JuMP.optimize!(model) end @info "Extracting solution..." solution = get_solution(model, marginal_costs = marginal_costs) if output != nothing write(solution, output) end return solution end function solve(filename::AbstractString; heuristic = false, kwargs...) @info "Reading $filename..." instance = RELOG.parsefile(filename) if heuristic && instance.time > 1 @info "Solving single-period version..." compressed = _compress(instance) csol = solve(compressed; output = nothing, marginal_costs = false, kwargs...) @info "Filtering candidate locations..." selected_pairs = [] for (plant_name, plant_dict) in csol["Plants"] for (location_name, location_dict) in plant_dict push!(selected_pairs, (plant_name, location_name)) end end filtered_plants = [] for p in instance.plants if (p.plant_name, p.location_name) in selected_pairs push!(filtered_plants, p) end end instance.plants = filtered_plants @info "Solving original version..." end sol = solve(instance; kwargs...) return sol end function get_solution(model::JuMP.Model; marginal_costs = true) graph, instance = model[:graph], model[:instance] T = instance.time output = OrderedDict( "Plants" => OrderedDict(), "Products" => OrderedDict(), "Costs" => OrderedDict( "Fixed operating (\$)" => zeros(T), "Variable operating (\$)" => zeros(T), "Opening (\$)" => zeros(T), "Transportation (\$)" => zeros(T), "Disposal (\$)" => zeros(T), "Expansion (\$)" => zeros(T), "Storage (\$)" => zeros(T), "Total (\$)" => zeros(T), ), "Energy" => OrderedDict("Plants (GJ)" => zeros(T), "Transportation (GJ)" => zeros(T)), "Emissions" => OrderedDict( "Plants (tonne)" => OrderedDict(), "Transportation (tonne)" => OrderedDict(), ), ) plant_to_process_node = OrderedDict(n.location => n for n in graph.process_nodes) plant_to_shipping_nodes = OrderedDict() for p in instance.plants plant_to_shipping_nodes[p] = [] for a in plant_to_process_node[p].outgoing_arcs push!(plant_to_shipping_nodes[p], a.dest) end end # Products if marginal_costs for n in graph.collection_shipping_nodes location_dict = OrderedDict{Any,Any}( "Marginal cost (\$/tonne)" => [ round(abs(JuMP.shadow_price(model[:eq_balance][n, t])), digits = 2) for t = 1:T ], ) if n.product.name ∉ keys(output["Products"]) output["Products"][n.product.name] = OrderedDict() end output["Products"][n.product.name][n.location.name] = location_dict end end # Plants for plant in instance.plants skip_plant = true process_node = plant_to_process_node[plant] plant_dict = OrderedDict{Any,Any}( "Input" => OrderedDict(), "Output" => OrderedDict("Send" => OrderedDict(), "Dispose" => OrderedDict()), "Input product" => plant.input.name, "Total input (tonne)" => [0.0 for t = 1:T], "Total output" => OrderedDict(), "Latitude (deg)" => plant.latitude, "Longitude (deg)" => plant.longitude, "Capacity (tonne)" => [JuMP.value(model[:capacity][process_node, t]) for t = 1:T], "Opening cost (\$)" => [ JuMP.value(model[:open_plant][process_node, t]) * plant.sizes[1].opening_cost[t] for t = 1:T ], "Fixed operating cost (\$)" => [ JuMP.value(model[:is_open][process_node, t]) * plant.sizes[1].fixed_operating_cost[t] + JuMP.value(model[:expansion][process_node, t]) * slope_fix_oper_cost(plant, t) for t = 1:T ], "Expansion cost (\$)" => [ ( if t == 1 slope_open(plant, t) * JuMP.value(model[:expansion][process_node, t]) else slope_open(plant, t) * ( JuMP.value(model[:expansion][process_node, t]) - JuMP.value(model[:expansion][process_node, t-1]) ) end ) for t = 1:T ], "Process (tonne)" => [JuMP.value(model[:process][process_node, t]) for t = 1:T], "Variable operating cost (\$)" => [ JuMP.value(model[:process][process_node, t]) * plant.sizes[1].variable_operating_cost[t] for t = 1:T ], "Storage (tonne)" => [JuMP.value(model[:store][process_node, t]) for t = 1:T], "Storage cost (\$)" => [ JuMP.value(model[:store][process_node, t]) * plant.storage_cost[t] for t = 1:T ], ) output["Costs"]["Fixed operating (\$)"] += plant_dict["Fixed operating cost (\$)"] output["Costs"]["Variable operating (\$)"] += plant_dict["Variable operating cost (\$)"] output["Costs"]["Opening (\$)"] += plant_dict["Opening cost (\$)"] output["Costs"]["Expansion (\$)"] += plant_dict["Expansion cost (\$)"] output["Costs"]["Storage (\$)"] += plant_dict["Storage cost (\$)"] # Inputs for a in process_node.incoming_arcs vals = [JuMP.value(model[:flow][a, t]) for t = 1:T] if sum(vals) <= 1e-3 continue end skip_plant = false dict = OrderedDict{Any,Any}( "Amount (tonne)" => vals, "Distance (km)" => a.values["distance"], "Latitude (deg)" => a.source.location.latitude, "Longitude (deg)" => a.source.location.longitude, "Transportation cost (\$)" => a.source.product.transportation_cost .* vals .* a.values["distance"], "Transportation energy (J)" => vals .* a.values["distance"] .* a.source.product.transportation_energy, "Emissions (tonne)" => OrderedDict(), ) emissions_dict = output["Emissions"]["Transportation (tonne)"] for (em_name, em_values) in a.source.product.transportation_emissions dict["Emissions (tonne)"][em_name] = em_values .* dict["Amount (tonne)"] .* a.values["distance"] if em_name ∉ keys(emissions_dict) emissions_dict[em_name] = zeros(T) end emissions_dict[em_name] += dict["Emissions (tonne)"][em_name] end if a.source.location isa CollectionCenter plant_name = "Origin" location_name = a.source.location.name else plant_name = a.source.location.plant_name location_name = a.source.location.location_name end if plant_name ∉ keys(plant_dict["Input"]) plant_dict["Input"][plant_name] = OrderedDict() end plant_dict["Input"][plant_name][location_name] = dict plant_dict["Total input (tonne)"] += vals output["Costs"]["Transportation (\$)"] += dict["Transportation cost (\$)"] output["Energy"]["Transportation (GJ)"] += dict["Transportation energy (J)"] / 1e9 end plant_dict["Energy (GJ)"] = plant_dict["Total input (tonne)"] .* plant.energy output["Energy"]["Plants (GJ)"] += plant_dict["Energy (GJ)"] plant_dict["Emissions (tonne)"] = OrderedDict() emissions_dict = output["Emissions"]["Plants (tonne)"] for (em_name, em_values) in plant.emissions plant_dict["Emissions (tonne)"][em_name] = em_values .* plant_dict["Total input (tonne)"] if em_name ∉ keys(emissions_dict) emissions_dict[em_name] = zeros(T) end emissions_dict[em_name] += plant_dict["Emissions (tonne)"][em_name] end # Outputs for shipping_node in plant_to_shipping_nodes[plant] product_name = shipping_node.product.name plant_dict["Total output"][product_name] = zeros(T) plant_dict["Output"]["Send"][product_name] = product_dict = OrderedDict() disposal_amount = [JuMP.value(model[:dispose][shipping_node, t]) for t = 1:T] if sum(disposal_amount) > 1e-5 skip_plant = false plant_dict["Output"]["Dispose"][product_name] = disposal_dict = OrderedDict() disposal_dict["Amount (tonne)"] = [JuMP.value(model[:dispose][shipping_node, t]) for t = 1:T] disposal_dict["Cost (\$)"] = [ disposal_dict["Amount (tonne)"][t] * plant.disposal_cost[shipping_node.product][t] for t = 1:T ] plant_dict["Total output"][product_name] += disposal_amount output["Costs"]["Disposal (\$)"] += disposal_dict["Cost (\$)"] end for a in shipping_node.outgoing_arcs vals = [JuMP.value(model[:flow][a, t]) for t = 1:T] if sum(vals) <= 1e-3 continue end skip_plant = false dict = OrderedDict( "Amount (tonne)" => vals, "Distance (km)" => a.values["distance"], "Latitude (deg)" => a.dest.location.latitude, "Longitude (deg)" => a.dest.location.longitude, ) if a.dest.location.plant_name ∉ keys(product_dict) product_dict[a.dest.location.plant_name] = OrderedDict() end product_dict[a.dest.location.plant_name][a.dest.location.location_name] = dict plant_dict["Total output"][product_name] += vals end end if !skip_plant if plant.plant_name ∉ keys(output["Plants"]) output["Plants"][plant.plant_name] = OrderedDict() end output["Plants"][plant.plant_name][plant.location_name] = plant_dict end end output["Costs"]["Total (\$)"] = sum(values(output["Costs"])) return output end