A Structural Decomposition-Based Optimization Approach for the Integrated Scheduling of Blending Processes in Raw Material Yards

The blending process in raw material yards is essential for maintaining precise material proportions in downstream production, directly influencing product quality and energy efficiency in industries such as steel and coal processing. However, stringent operational constraints, including silo capacity limits, discharge rates, equipment movement delays, and a strict no-empty-silo requirement, result in a strongly coupled, high-dimensional combinatorial scheduling problem. In this paper, we develop a mixed-integer nonlinear programming (MINLP) model to capture the complex dynamics of silo weight and equipment operations. The primary scientific contribution of this work lies in the theoretical discovery of a structural decoupling property within the complex MINLP. We analytically prove that by fixing the replenishment sequence, the intractable global problem can be rigorously decomposed into two subproblems: a linear programming (LP) problem for silo-filling cart scheduling and a shortest-path problem solvable via dynamic programming (DP) for reclaimer scheduling. Leveraging this decomposition, a two-stage metaheuristic algorithm is proposed, combining greedy initialization with multi-round simulated annealing enhanced by local search. Experimental validation using real industrial data demonstrates that the proposed method consistently outperforms the greedy algorithm. Crucially, while the commercial solver Gurobi struggles to converge within a practical 1800 s time limit, our approach yields comparable solution quality in mere seconds. Furthermore, robustness analysis under a 20% demand surge confirms the algorithm’s adaptive capability, maintaining the silo weight stability through re-optimization. This research provides a robust, computationally efficient solution for the blending process in raw material yards.