聚丙烯卧式搅拌床反应釜工程放大研究
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摘要
SPG聚丙烯工艺是我国自行开发成功并具有自主知识产权的聚丙烯工艺,该工艺的产品质量优异,能耗、物耗低,在开发特殊牌号方面的潜力很大,但其核心设备气相卧式搅拌床反应釜的工程放大研究严重滞后,已制约了该工艺的规模化发展和推广应用。
本研究采用了流程模拟研究、实验室基础研究和工程设计研究等多种研发手段,对卧式釜的工程放大进行了系统的研究,主要过程和成果如下：
以Polymers Plus化工流程模拟软件为平台,选用PC-SAFT状态方程精确预测了反应体系热力学和动力学的物性,结合SPG工艺流程模拟结果和工程经验,确定了卧式气相搅拌床反应釜的停留时间和相关工艺设计参数。
在实验室冷模装置上进行了流动特性的研究,测定不同型式桨叶(叶片桨、T型桨、门桨)的停留时间分布特性,考察有／无挡板及挡板倾角对停留时间的影响,用多级全混釜串联模型和返混模型分析不同内件配置下卧式釜的返混和流型,实验及模型分析的结果为桨叶形式的选择和内件的设计提供了理论指导和依据；通过实验对三种桨叶进行了搅拌特性的研究：在吹气／不吹气条件下测定了三种桨叶搅拌的搅拌轴功率,考察了转速、加料系数及吹气流量对功率的影响,通过引入速度准数、加料准数、粉体性质等无因次变量对各搅拌桨的功率准数进行了经验回归,得到了搅拌功率的经验关联式,验证结果表明,精度可以满足工业放大的要求；对三种桨叶的料位分布特性进行了研究,考察了搅拌转速、加料系数、物料性质以及吹气对料位分布的影响,通过无因次关联得到了料面倾角的经验关联式,同时利用声发射装置采集固体颗粒撞击器壁而产生的声发射信号,分别在实验室冷模装置和工业热模装置上考察了声发射技术的准确性和可靠性,最后确定了适用于工业聚合反应器料位检测的新方法。
根据流程模拟确定的工艺参数、基础实验结果及功率准数经验回归公式,进行了卧式釜工程放大设计的研究,确定了反应釜的外形尺寸、搅拌的功率、反应釜的内部结构、搅拌型式和料位检测方法等。
通过以上研究工作不仅系统掌握了聚丙烯卧式釜工程放大的准则和关键技术,为大型卧式釜的工程设计提供了设计基础,而且还可为特殊牌号聚丙烯产品的开发提供可能及为新型催化剂的考评提供指导,大大加快了SPG工艺工业化应用的进程,对促进该技术的规模化发展和石化行业聚丙烯产业的发展,具有重大意义。
The SPG polypropylene process has been successfully developed by China and owns self-intellectual property rights. The excellence of this process is obvious, such as good quality of the product, low consumption of energy and raw material, and great potential in the development of special polypropylene grade. However, the scaled progress and application of the process has been limited due to the lack of engineering investigation on the core equipment of horizontal gas phase stirred reactor.
This study has made great effort to the engineering enlargement on horizontal reactor with systemic research, based on multi-methods of process simulation study, fundamental research in lab and engineering design investigation. The main progress and conclusions are as follows:
It has been pre-estimated exactly the thermodynamics and kinetics properties in reaction system via PC-SAFT equations of state on the platform of Polymers Plus process simulation software. While, it has also been specified the residence time and the relevant technological design parameters of the horizontal gas phase stirred reactor, due to the combination of SPG process simulation result and engineering experience.
The flow characteristic has been studied in the cold model experimental apparatus. The residence time distribution of different blades (leafe blade, T type blade and door type blade) has been measured, then the impact on residence time was studied under different situation such as with baffle, without baffle and changing incline angle of baffle. It has been analyzed the back mixing and flow pattern of horizontal reactor under different internals configuration by the method of CSTR in series model and back mixing model, which prodived theoretical instruction and the basis for the style selection of blade and the design of internals. The agitation characteristic of three kinds of blades has been researched via the experiment. The agitation shaft powers were measured with air blow and without air blow, therefore the impact on power of rotational speed, feeding coefficient and blow flow flux were discussed. The power number of the different blades has been empirical regressed by introducing nondimensional number such as velocity number, feeding nubmer and powder properties, thus the agitation shaft powers empirical correlation equation was obtained. The result showed that the accuracy can satisfy the need of engineering enlargement. The paper also studied the level distribution character. The acoustic emission signals coming from the solid particles striken on the wall was detected through the acoustic emission (AE) measuring device. The accuracy and reliability of acoustic emission (AE) technique has been testified based on the cold model in lab and hot model in industry. Thus, a new method to measure the level of industrial polymer reactor was proposed.
Accroding to process parameters achieved by process simulation, fundamental research result in lab and empirical regression formula of powers number, the reaearch on the engineering enlargement of horizontal reactors has been implemented and it was determined that the outside dimensions, agitation power, internals arrangement, agitator type and level detection method of the reactor.
The above reaseach not only systematically mastered the engineering enlargement criterion and key technology of polypropylene horizontal reactor, which provided the design basis for the engineering design of large-scale horizontal reactor, but also can provide the possibility of the developement of special polypropylene grade and the instruction to the new catalyst appraisal. Furthermore, the industrial applicaiton of the SPG process has been accelerated, and it is signaficant on scaled progress of this technology and the development of polypropylene production in petrochemical industry.
本研究采用了流程模拟研究、实验室基础研究和工程设计研究等多种研发手段,对卧式釜的工程放大进行了系统的研究,主要过程和成果如下：
以Polymers Plus化工流程模拟软件为平台,选用PC-SAFT状态方程精确预测了反应体系热力学和动力学的物性,结合SPG工艺流程模拟结果和工程经验,确定了卧式气相搅拌床反应釜的停留时间和相关工艺设计参数。
在实验室冷模装置上进行了流动特性的研究,测定不同型式桨叶(叶片桨、T型桨、门桨)的停留时间分布特性,考察有／无挡板及挡板倾角对停留时间的影响,用多级全混釜串联模型和返混模型分析不同内件配置下卧式釜的返混和流型,实验及模型分析的结果为桨叶形式的选择和内件的设计提供了理论指导和依据；通过实验对三种桨叶进行了搅拌特性的研究：在吹气／不吹气条件下测定了三种桨叶搅拌的搅拌轴功率,考察了转速、加料系数及吹气流量对功率的影响,通过引入速度准数、加料准数、粉体性质等无因次变量对各搅拌桨的功率准数进行了经验回归,得到了搅拌功率的经验关联式,验证结果表明,精度可以满足工业放大的要求；对三种桨叶的料位分布特性进行了研究,考察了搅拌转速、加料系数、物料性质以及吹气对料位分布的影响,通过无因次关联得到了料面倾角的经验关联式,同时利用声发射装置采集固体颗粒撞击器壁而产生的声发射信号,分别在实验室冷模装置和工业热模装置上考察了声发射技术的准确性和可靠性,最后确定了适用于工业聚合反应器料位检测的新方法。
根据流程模拟确定的工艺参数、基础实验结果及功率准数经验回归公式,进行了卧式釜工程放大设计的研究,确定了反应釜的外形尺寸、搅拌的功率、反应釜的内部结构、搅拌型式和料位检测方法等。
通过以上研究工作不仅系统掌握了聚丙烯卧式釜工程放大的准则和关键技术,为大型卧式釜的工程设计提供了设计基础,而且还可为特殊牌号聚丙烯产品的开发提供可能及为新型催化剂的考评提供指导,大大加快了SPG工艺工业化应用的进程,对促进该技术的规模化发展和石化行业聚丙烯产业的发展,具有重大意义。
The SPG polypropylene process has been successfully developed by China and owns self-intellectual property rights. The excellence of this process is obvious, such as good quality of the product, low consumption of energy and raw material, and great potential in the development of special polypropylene grade. However, the scaled progress and application of the process has been limited due to the lack of engineering investigation on the core equipment of horizontal gas phase stirred reactor.
This study has made great effort to the engineering enlargement on horizontal reactor with systemic research, based on multi-methods of process simulation study, fundamental research in lab and engineering design investigation. The main progress and conclusions are as follows:
It has been pre-estimated exactly the thermodynamics and kinetics properties in reaction system via PC-SAFT equations of state on the platform of Polymers Plus process simulation software. While, it has also been specified the residence time and the relevant technological design parameters of the horizontal gas phase stirred reactor, due to the combination of SPG process simulation result and engineering experience.
The flow characteristic has been studied in the cold model experimental apparatus. The residence time distribution of different blades (leafe blade, T type blade and door type blade) has been measured, then the impact on residence time was studied under different situation such as with baffle, without baffle and changing incline angle of baffle. It has been analyzed the back mixing and flow pattern of horizontal reactor under different internals configuration by the method of CSTR in series model and back mixing model, which prodived theoretical instruction and the basis for the style selection of blade and the design of internals. The agitation characteristic of three kinds of blades has been researched via the experiment. The agitation shaft powers were measured with air blow and without air blow, therefore the impact on power of rotational speed, feeding coefficient and blow flow flux were discussed. The power number of the different blades has been empirical regressed by introducing nondimensional number such as velocity number, feeding nubmer and powder properties, thus the agitation shaft powers empirical correlation equation was obtained. The result showed that the accuracy can satisfy the need of engineering enlargement. The paper also studied the level distribution character. The acoustic emission signals coming from the solid particles striken on the wall was detected through the acoustic emission (AE) measuring device. The accuracy and reliability of acoustic emission (AE) technique has been testified based on the cold model in lab and hot model in industry. Thus, a new method to measure the level of industrial polymer reactor was proposed.
Accroding to process parameters achieved by process simulation, fundamental research result in lab and empirical regression formula of powers number, the reaearch on the engineering enlargement of horizontal reactors has been implemented and it was determined that the outside dimensions, agitation power, internals arrangement, agitator type and level detection method of the reactor.
The above reaseach not only systematically mastered the engineering enlargement criterion and key technology of polypropylene horizontal reactor, which provided the design basis for the engineering design of large-scale horizontal reactor, but also can provide the possibility of the developement of special polypropylene grade and the instruction to the new catalyst appraisal. Furthermore, the industrial applicaiton of the SPG process has been accelerated, and it is signaficant on scaled progress of this technology and the development of polypropylene production in petrochemical industry.
引文
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