教程化工-ce設計集

YongxinpetrochemicalindustryProjectoftreating100,000tonsofcarbon4ComprehensiveUtilizationPlantperCE-FLAMEteam,Shen Member:HanYingnanPatrick.ChowLiZhengyuZero.HouEdwardInstructor:LiuDongbinSunHuaiyuFanLihuiZhangLiShenYanmingProject ProcessSelectionand selectionofprocesstechnical AutomatedControl Siteselectionand site site Plant 6.Economic Table6.1maintechnicalandeconomic ThisprojectisdesignedforQing YongxinPetrochemicalCo.,.todealwith100,000tonsofcarbonf comprehensiveutilizationofthepreparationofp-tertDingJibenzoicacidandp-tertDingJibenzoatemethylesterdevice.Theplantcomprehensivelyusescarbon4fractionsandotherrawmaterialsinthemainplanttoprocesscarbon4resourcesthroughrecoveryofbutadiene,selectivehydrogenation.ProcessSelectionandselectionofprocesstechnicalButadieneisasyntheticrubber,themainrawmaterialofABSresin.SeparationandpurificationofbutadienefromcrackedcarbonFourhas ethemostimportantproductionmethodofbutadieneintheworldtoday.Thecarbonfourcomponentsobtainedbytheoilrefiningunitaredifferentfromeachother,sothelatetreatmentprocessisalsodifferent.Thecontentof1,3-butadieneproducedbypyrolysisCarbonFourcanbeashighas49.4%,theproductionofhighpurity1,3-butadieneisrealizedbysolventextractionandrecovery,thecontentofwhichisabout0.004%,tomeettherequirementsofdownstreamprocessMTBE.AndthecarbonffromtheFCC1,3-butadienecontentcanbeaslowas0.23%,becauseButadieneiseasilypolymerizedinthereactionofproducingMTBE,thepolymersformedareusuallythepoisonsoftheetherificationcatalysts,reducingthelifeofthecatalyst,andthepresenceof1,3-fortheseparationof1-butene,Theboilingpointofthetwoisonlydifference1.6c°,itisdifficulttoachieveseparationbyphysicalmethod,soitisveryimportanttodealwiththelowcontent1,3-butadiene. Thisprojectistreatedbyselectivehydrogenationtechnology.Therawmaterialcontainsonly1.9%butadiene0.02%acetyleneand0.2%butadiene.Butadienerecoveryisnotonlyhighcost,butalsolessbutadienecontent,sothehydrogenationprocessissuperior.Insaturatedhydrogenationandselectivehydrogenation,saturatedhydrogenationmeansthelossofvaluableolefinresources,whichisnotconducivetothedevelopmentofdownstreamproducts.Therefore,butadieneandbutadieneinfeedstockweretransformedinto-butenewithhighutilizationvaluebyselectivehydrogenationprocess,whileethylenewasremovedbyselectivehydrogenationofacetylene.Thedesiredreactionisdiolefin,hydrogenationofalkynes,asfollows:CH2=CH-CH=CH2+ CH≡CH+H2 CH3-CH2-C≡CH+ CH3-CH2-Intheprocessofselectivehydrogenation,butene1isomerizationintobutene2sidereaction,therateofthisreactionismuchlowerthanthatofbutadieneandalkyneshydrogenation,onlywhenthehydrogenationofbutadieneisnearcomplete,thesidereactionbeginstooccur.Thereactionisasfollows:CH2=CH-CH2- CH3-CH=CH-Theselectivehydrogenationcankeepthecontentof1butadieneatIsobutenepreparationofisobutenesectionbyMTBEcrackingisanimportantchemicalrawmaterial,mainlyfrom crackingandcarbonfourfractionincatalyticcrackingproducts.Inaddition,tertbutylalcoholdehydration,isobutanedehydrogenation,MTBEcrackingareoftenused.Whenusedaschemicalproductssuchassyntheticbutylrubber,polyisobutylene,andotherchemicalproducts,therequirementsforitspurityareequivalent.Itneedsalotofcomplicatedseparationprocess,acidextraction,adsorptionseparationandsoon.Amongthem,themethodofMTBEcrackingtoisobutenehasthecharacteristicsofsmallpollution,highpurity,highsinglepassconversionrateandstrongindependence.Upto2016,therewere24productionenterprisesinChina.HighpurityisobutenewasproducedbyMTBEAccordingtotheliteraturedata,theconversionrateofMTBEcanreach99.6241.6°~0.15bar,and99.9%forhighpurityisobuteneafterTable2.12016majorhighpurityisobuteneproduction產(chǎn)萬噸/采用的工藝 公司名稱產(chǎn)萬噸/采用的工藝1浙江新輝材料82盤錦和運7異丁烷脫3揚子-巴斯夫公64山東濱州裕華化工廠65寧波昊德化學工56中信國安化工（菏澤57山東玉皇化工48山東齊旺達49化工燕山山東東營仕通化工3蘇州宏偉實業(yè)3山東東營市齊發(fā)化工3淄博齊翔石油化工2山東濱州順東化工公2山東濱州利美化2山東成泰化工2湖南岳陽興2吉林錦江油化吉林精細化學品濰坊濱海石油化工洛陽煉化宏力化工杭州順1錦州精細化工公梅山化工廠（曙光控股子公司蘭州合syntheticprocessofp-tertDingJibenzoicSolvent-freeliquidphaseP-tertDingJibenzoicacid(PTBBA)wassynthesizedbysolvent-freeliquidphaseoxidationwithp-tertDingJitoluene(PTBT)asrawmaterialandaceticaciddrillascatalyst.Using40%acetaldehydeasinitiator,theinductionperiodcanbeshortenedobviously,theoptimumreactiontemperatureis170℃,theyieldof100minis50andtheselectivityis98.Theorderofreactionisorderat170℃,andtherateofoxidationisonlyrelatedtotheconcentrationof100min.solventliquidphaseWithp-tertDingJitolueneasrawmaterial,aceticaciddrillingascatalyst,aceticacidassolvent,250mLstainlesssteelautoclavewithmechanicalstirring,airinletandoutletforproducttestingarearrangedatthebottom.Thereactionisself-linked,andthereactionmechanismisasfollows:Comparedwithaceticacidsolvent,theliquidphaseaceticacidsolventoxidationmethodisusedtosynthesizePTBTs.Theadvantageofaceticacidisth eticacidcanimprovethesolubilityofthecatalystanddissolvethehighboilingpointPTBTproducts.Preventtheproductfromprecipitatingathighconcentration.Therefore,aceticacidwasselectedasthesolventforthesynthesisprocess.TheprocessflowchartisasFigure2.2fullprocesssimulationMixedC_4wasselectedtoremovebutadiene,alkynes,excesshydrogenanduncondensedgasasfuelgas,methanolandcarbon_4wereetherifiedtoprepareMTBEs,excessivemethanolwasrecovered,extractionwaterwasrecycled,andhighpurity1-butenewasproducedbyC_4afterether.ThepurityofMTBEwas98.9%toproducehighpurityisobutene,andhighpurityisobuteneandtoluenetoproducep-tertDingJitoluene,whichwasusedasrawmaterialforthesynthesisofp-tertDingJibenzoicacid.Methanolwasrecycledforesterificationofmethylp-tertDingJiEnergy-savingdesignandHeatpumpdistillationFigure3.1T-H(beforeFromthecombinationcurve,wecanseethatthereisa"thermalplatform"causedbylatentheatofvaporizationonbothsidesofthepinchpoint,whiakestheprocessrecoverableheatisverysmall.Ifthevaporizationtemperatureofthematerialischangedtochangethetemperaturepotentialofthethermalplatform,thetwoplatformscanbestaggeredtorecovermoreheat.Theheatpumpdistillationtechnologycanbeusedtorealizeeffectiveenergyrecoveryandenergysavingbychangingthecombinedcurvethermalplatform.Throughysis,itcanbeseenthatpartofthethermalplatformiscausedbythetopcondenserandbottomreboilerof1-butenedistillationcolumn(T-0202),andenergyconsumptionofthecolumnisThetemperatureof1-buteneconventionaldistillationtower(T-0202)is43.1°Catthetopand54.7°Catthebottom.Thetemperaturedifferencebetweenthetopandbottomofthecolumnissmall,whieetstherequirementofheatpumprectification.Soitissuggestedthattheheatpumprectificationtechnologyshouldbeinstalledtorecoverenergytosolvetheproblemoflargeenergyconsumption.Fig.3.2resultsofconventionaldistillationUsingthecompressortoraisethetemperatureofthetopgasofthetowerbyoneenergylevel,sothattheenergycanbedtothegasificationofthebottommaterialandthewholeprocesssimulationofAspenisshowninfigure(4-8).Fig.3.3HeatpumpdistillationInconventionaldistillationcolumn(T-0202),theheatloadoftopcondenserandbottomreboileris-6786.5KW,6666.46kW,486.2kW,336.85kWand887.941KWrespectively.Theenergyconsumptionoftopcompressorofheatpumpdistillationtoweris486.2kW,theheatloadofauxiliaryreboileris336.85kW,andtheheatloadofcondenseris-887.941KW.Themechanicalenergyandelectricenergyarethehighervalueenergyformofspecificheatenergy,theelectrothermalconversioncoefficientisabout3.2,sotheheatconsumptionofheatpumprectificationis888.01KW,andthecoolingconsumptionis-335.389KW.Saveheatengineering88.3,savecoldutilityTable3.4EnergySavingofHeatpumpalheatThermalColdOptimizationofHeattransferThisprojectusesthetechnologyofheatintegrationandenergysavingandthesoftwareofAspenEnergy yzerV8.8torealizethedesignofheattransfernetworkwithlargeenergyreuse.Theoptimizedheattransfernetworkdiagramwedesignedisasfollows:Fig.6.1finalheattransferscheme(noheatpumprectification)Bydesigningtheprocessheattransfernetworkafterpyrolysisandcombiningwiththeformerheattransfernetwork,thetotalrequiredthermalengineeringare13802kW,thecoldutilityis16169.7KW,thethermalutilityenergyrecovery25.5andthecoldutilityenergyrecoveryisFigure3.4optimalheattransfertemperatureHeatpumpdistillationwasdesignedforconventionaldistillation(T-0202),andmostoftheenergywasrecovered.ThefullflowheattransfernetworkdiagramforaddingheatpumpsisshownFigure3.5Finalheattransferscheme(withheatpumpThecoldutilityusedinthisprojectis:circulatingcoolingwater.Thethermalutilityusedislowpressure at1:170℃andhighpressure 310℃.Publicworkscanbeprovidedbytheplantpublicworksstation.Table6.1detailsofpublicworksforthisProcessschemetechnology1technologyIndustrialproductionofMTBEismainlycausedbymethanolandisobuteneinthecatalysisofacidiccatalystsaftertheetherificationreaction,thereactionequationisasfollows:ThecatalystmodelselectedinthisprojectistheD-006typecatalystwhichiswidelyusedinindustry,thecatalystisthelargeporestrongacidiccationexchangeresinofthepolystyrenestructureofsulfonatedethylene-biphenyl,anditisknownfromtheliteraturethatthecatalystissusceptibletothefollowingexternalconditions:1.catalystholesIftheparentchannelofthecatalystisblocked,thereactionmaterialwillnotbeabletoenterthechannelandcontactwithitsactivecenterforchemicalreaction.Thissituationismainlyduetothehighcontentofbutadieneintherawmaterials.whenthetemperatureistoohigh,butadienewillundergoself-polymerizationreactionandblockthecatalystchannels. 2.cationexceedsAccordingtotheresearchand ysisofdeactivatedcatalystbycatalystmanufacturers,thedeactivationofcationiccatalystaccountsfor60%ofthetotal,whichisoneofthemainreasonsforcatalystdeactivation.Becausecationsdisplacehydrogenionsinthecatalyst,theacidityoftheresincannotbereleasedandthusitscatalyticeffectcannotbeexerted. 3.RawmaterialsC4andmethanolbothcontaintraceamountsofsaturatedwater,whichoftencontainsmoremetalcations.watercangeneratetertiarybutanolbysidereactionwithisobutylene,andcanhydrolyzeanddesulfurizewithcatalyticresin,thusinactivatingtheresin.4.influenceofDuetodifferencesinthemanufacturingprocessandvariousrawmaterials,someproductsareacidicandsomeareweaklyalkaline.Ifitisweaklyacidic,ithasnoeffectonetherificationreactionandcatalyst.Ifitisalkalescent,itwillcausepoisoningofacidiccatalyst4.1.2ThetechnologicalinnovationthesourceofthisprocessisthesameastheFCCdevice,butthe1,3-butadieneisreducedtothefollowingstandardbyselectivehydrogenation.Therefore,thecauseofdeactivationofcatalystismainlytheaminecontentmentionedintheliteratureandtheexcessivemetalcation.Combinedwiththeprocessandcharacteristicsoftheprocess,carbonfourrawmaterialsbeforeenteringtheetherChemicalsectionisaselectivehydrogenationprocess,intheselectionofhydrogenationreactorusedinthehydrogenationcatalystforthePd/al2o3series,thecatalystisalsosusceptibletoalkalinesubstancesandmetalionslossofactivity.Consideringthecharacteristicsofthesetwocatalysts,thecatalystpoisonshouldhavebeenremovedpriortocontactwiththecatalyst,sofortheselectionofhydrogenationreactortomakethefollowingimprovements,carbonfourrawmaterialsfromthebottomintothereactor contactwiththeadsorbent,thatis,underthecatalystBedSetprotectiveagentbedlayer,asshowninthefigure.Themaincomponentsoftheaddedprotectiveagentaresilica-aluminumcompounds,highporosity,Gongjon,suitablespecificsurfacearea,effectiveadsorptionofamineandalkalinesubstancesinrawmaterials.Thiscannotonlyprotectthehydrogenationcatalyst,butalsoprolongtheusetimeoftheetherificationcatalyst,andreducethetwoamineremovalequipment,whichhastheadvantagesofsimpleflow.Onthebasisofthisimprovement,theMTBEsynthesisreactorstillusesthecontrollableproductionprocessasshowninthefigurebelow.ProductstructureLog-Butylbenzoicacidistheoutputproductincrystalform,andthedownstreamproductionisalsoincrystalsolidform,sowecancontrolthestart-uptimeofp-tert-butylbenzoicacidesterificationreactor,therebycontrollingtheproductionofmethyltert-butylbenzoate,productstructurediversification,to izeprofits,toobtainmore.Goodeconomicbenefits.equipmentcolumnThetraditionalpackingtoweradopt ichring,Bauerringandsoon.ThestructureoftheRasichringisrelativelysimple,whichwillleadtoseriouswallflowandditchflowinthetower,andthendecreasethemasstransferefficiency.TheBauerringisanimprovementontheLaceyring,butthemechanicalstrengthisslightlylower.Forthisprocess,theseparationof1-butenerequireshighefficiency,resultinginthehighheightofthepackedtower,thereisacertainsafetyrisk,soourteamuseourschoolZhangLiteachertoleadthedevelopmentanddesignofthefour-leaffiller,Thisnewtypeofswirlpackingcaneffectivelyremovethewallflowanddrainretentionoffluidinthetower,improvetheeffectofmasstransferbetweenphases,andreducethepressuredropmoreeffectively.Fig.4.2comparisonofmasstransfercoefficient fig.4.3comparisonofpressuredropbetweenbetweenfourleafpackingandLaceyring; fourleafpackingandLaceyringFig.4.4ComparativediagramofHETPchangesbetweenfour-leafpackingandLaceyringpackingwithfixedliquidflowrateItcanbeseenfromtheexperimentaldatathatthepressuredropandmasstransfercoefficientratioofthefour-leafregularpackingarehigherthanthatoftheLaceyringpacking,andtheHETPisalsoobviouslydecreased.Onthebasisoftheexperimentaldata,theFluentsoftwareisusedtosimulatetheflowfield. ly,themodelisbuiltandmeshedbyGambit,andintroducedintoFluent.Thek-wmodel,theEulertwo-phaseflowmodelandtheporousmediamodelareusedtosimulatetheflowfield.Thesimulationresultsareasfollows Fig.4.5pressureclouddiagramofgas- Fig.4.6Four-leafpackinggas-two-phaseflowwithfour-leafpackino-phaseliquidphasevelocityclouddiagramAftercalculatingbyFluent,thepressuredropdataareprocessed,andtheresultsobtainedbyOriginarecomparedwiththoseobtainedbyTheexperimentalresultsarecomparedwitheachother,asshownintheFig.4.7comparisonofexperimentalandsimulateddataofgas-liquidtwo-phaseflowthroughfour-leafpackingItcanbeseenfromthediagramthattheerrorbetweenthesimulatedvalueandtheexperimentalvalueissmaller,whichprovestheaccuracyandreliabilityofthesimulationprocessandverifiesthecorrectnessofsolvingthecoefficient.Thesimulationmethodcanbeusedasatheoreticalbasisforindustrialamplificationinthefuture.Four-leafstructuredpackinghasthecharacteristicsofhighmasstransferefficiency,smallpressuredropandsmallequivalentplatespacing,andeffectivelysolvestheproblemofexcessive1-butenedistillationcolumninthisprocess.Theheightofpackingcanbereducedandthedesiredseparationeffectcanbeachievedbyusingfour-leafregularity.HeatExchangerInnovationSKstaticmixingdeviceTheproblemofheattransferdeteriorationcausedbylowheattransferefficiencyandfoulingofheattransfersurfaceareaisadifficultproblemintheprocessofheattransferwhichhasbeenwaitingtobesolvedallovertheworldformanyyears,anditisalsoabottleneckproblemthatrestrictsthedevelopmentofchemicalindustrytoimproveenergyconsumptionutilizationratio.Consideringtheabovefactors,theexistingequipmentsusuallyuseemptytubeasheattransferpipe,whichiseasytoformfoulingandscalingandreduceheattransferefficiency.Therefore,thisprojectusesthe-"SK"staticmixingdevicedevelopedbyWuJianhuainourschool.WeuseSolidworkssoftwaretobuild3Dmodelof"SK"staticmixerandairpipe.WeuseGambitsoftwaretomeshthecalculationarea,importitintoFluent,andselectK-εmodelforhydrodynamicsimulation.Theresultisasfollows: Fig.4.8cloudchartofATCtemperature Fig.4.9Cloudimageoftemperature distributionafteraddingSKstaticmixingdeviceItcanbeclearlyseenfromthediagramthattheheattransferprocessofthepipelineisstrengthenedafteraddingSK,andtheeffectofheattransferisbetterthanthatoftheemptytube.Theheattransfercoefficientofactualproductionisincreased,theheattransferareaisreduced,andthesizeoftheheatexchangerisalsoreduced.Itsavesspaceandreducesproductioncost.AutomatedControlESDcontrolESD(Emergencyparkingsystem)isalinkofSIS(secureinterlockingsystem)andthemostimportantlinkinphysicalhardware.Itisdesignedforsafetyinproduction.Itisusedincontinuousoperationfieldssuchashightemperature,highpressure,flammableandexplosive.Itistorespondtoandprotectthepossibledangeroftheproductionplantortotakenomeasurestokeepitdeteriorating,sothattheproductionplantcanquicklyenterasafeshutdowncondition,sothattheriskcanbeminimizedinordertoensurenel,equipment,Safetyoftheproductionandinstallationorsurroundingcommunitiesoftheplant.TraditionalchemicalplantsmostlyuseDCSdistributedcontrolsystem,andthisprocessWehaveadoptedamorerapidandsensitiveESDemergencyparkingsystem.CALCULATORcomputerAsshowninthefigure,inthehydrogenationreaction,themassratioofdiolefins,alkynesandhydrogenwasstrictlycontrolledbymeansofacalculator.Inconventionalcontrol,toomuchhydrogenwillleadtothedeephydrogenationofalkanes,toolittlehydrogenwillleadtopletehydrogenationofalkyne,andtoomuchalkynesinthefeedstockwilldeactivatePDinthecatalyst.Inordertosolvethisproblem,weadoptinligentcomputercontrol,bymeasuringthepipelineflowrateofalkynesanddiolefinsincarbonfourfeed,theratioofcarbon4tohydrogeniscontrolledinastablestate,sothatthereactioncanbecarriedoutefficiently.Theyieldofmonoolefinswasincreased.Siteselectionand sitesite PetrochemicalCo.,.islocatedinQing ShixifengIndustrialPark,GansuProvince,isaproduction,sales,warehousingandlogisticsasoneofthecomprehensivechemicalenterprises.Thecompanyhasobviousregionaladvantages,locatedbetweenLanzhouEconomicCircleandXi'anEconomicCircle,locatedontheLonghaiEconomicZone.ItsdevelopmentissimultaneouslyaffectedbytheradiationofthesetwoeconomiccirclesandtheeconomicdevelopmentaxisofLonghai.Inaddition,theXifengDistrictHighway,Therailwayiswelldevelopedandconvenientfortransportation.WeselectedthesitefortheexpansionsiteofQing YongxinPetrochemicalCo.,inXinfengDistrict,Qing City,GansuProvince.ThelocationofthesiteisshowninthefollowingFig.5.1Salitemapof Fig5.2sitePlantFig.5.3GenerallayoutThereareatotaloffourdoorsinthefactoryarea:oneontheeastsideandoneonthenorthside,oneonthewestsideandoneonthesouthside.Fivemainroadswithawidthof12mconstitutethemainlogisticschannels.Itisfavorableforthelargecartoenterandexit,andthevehicledoesnothavetoreverse,canleavefactorydirectly,thelogisticslineoffactoryareaisclearandcontrollable.Thetwosidesofthechannelaredividedintoproductionarea,loadingandunloadingarea,storageareaandsoon,whichfacilitatetheloadingandunloadingandtransportationofauxiliarymaterialsandproducts.Thischannelconcentratesthelogisticslineinthelogisticsconcentrationareaofthefactoryarea.Themainentrancetotheeastandnorthisthemainpassagewayofpeople.Onbothsidesofthepassagearetheofficebuildings,thecentralcontrolroom,andthelaboratorycenterMoreconcentratedandquietenvironmentarea,thepassagewillbeconcentratedinthenortheastcornerofthefactory.A12mwidefiretunnelissetasideforemergencyevacuationandfireSuchadesignmakesthedrivingareaofthetransportvehiclemainlyloca