对二甲苯（PX）氧化反应器的流体动力学研究
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摘要
本文以探讨大型工业PX氧化反应器设计中的关键技术和开发新型PX氧化反应器为目标,对比分析了两种现有PX氧化反应器的流体力学性能与几何结构部件之间的相互关系,从而为反应器结构改进、强化和新结构反应器探索提供一定依据。相关工作成果现已在某厂PTA装置实际改造工作中得到应用,取得了良好的经济价值。主要工作概括起来主要分以下三个方面：
1)现有PX氧化反应器工程化分析和结构优化
系统研究了已工业化的两种PX氧化反应器的流体力学性能,并对气体分布器设计、桨叶液泛等关键问题进行了分析和优化。
对浅层鼓泡塔PX氧化反应器,其设计考虑的不仅是气体分散,同时还应兼顾液体混合和固体悬浮。文中考察了高径比、管式气体分布器、底部形状、短尺寸导流筒等结构对反应器性能的影响,并对其进行结构优化,以便指导反应器的放大设计。
对翼型／涡轮组合桨PX氧化反应器,桨叶液泛特性决定反应器的最大操作能力。文中研究了工况高气速、高固含率下翼型桨液泛规律,探讨了通气管设计与桨叶液泛的关系,优化了通气管与桨叶之间的位置,以降低甚至消除液泛发生的可能
2)相关基础问题研究
针对工业PX氧化反应器高通气量的工况,在研究大孔径单孔气体射流及其流型转变过程中作出了新的尝试,建立了一种客观的电容层析成像(ECT)测试技术,揭示了气体鼓泡过程中管径大小与流型转变之间的关系,提出了区分大小孔径的临界孔径,为气体分布器的设计提供了一定指导。
利用粒子图像测速(PIV)技术和大涡(LES)模拟计算得到了翼型桨反应器内的详细流场结构信息,系统阐述了翼型桨叶片尾涡的结构特征,揭示了其与透平桨等径向流桨流型差异的原因所在,从而进一步解释翼型桨液泛规律。
3)工程应用
在比较分析国内外氧化反应器现有结构,和对所涉基本物理现象进一步理解的基础上,应用开发了一种新型PX氧化反应器,在一个反应器内实现全混流与活塞流的合理组合,与PX氧化反应特性更加匹配。将其与现有两种PX氧化反应器进行比较,具有明显的结构和性能优势,进一步优化开发有工业应用前景。
This research investigated the key technologies for designing large-scale industrial PX oxidation reactor and the development of a new style PX oxidation reactor. A serious of technical suggestions have been proposed for the structure intensification of existed reactor and the design of a new reactor after the investigation on the relationships between hydrodynamics and geometrical structures of two existed representative PX oxidation reactors. Some proposals have already been applied for the modification of a PTA process in a company and created economic value.
This research consisted of three parts which were shown as follows:
1) Structure Optimization of Existed PX Oxidation Reactor
Based on the systematical investigation on the hydrodynamics of two existed industrial-scale PX oxidation reactors, the gas sparger design and impeller flooding etc. were optimized.
The design of shallow bubble column PX oxidation reactor is usually controlled by gas dispersion, liquid mixing and solid suspension. This research investigated the influences of aspect ratio, gas sparger, bottom shape and short size draft tube on the reactor performance. The optimized structure design was accordingly proposed.
The maximum capability of hydrofoil/turbine mixed impellers stirred vessel PX oxidation reactor is generally controlled by the impeller flooding. This research investigated the hydrofoil impeller flooding characters of the reactor with high gas velocity and high solid concentration. The relationship between the position of gas inlet and flooding impeller was also investigated and the optimized position of gas inlet was found.
2) Foundamental Research
An electrical capacitance tomography (ECT) method corresponding to the high gas flow rate in the industrial PX oxidation reactor has been developed to identify bubbling/jetting regimes transition from large submerged orifices. The influences of the nozzle diameter on the flow regime transition were investigated during the gas bubbling process. The critical nozzle diameter for distinguishing small nozzles from large nozzles was proposed.
With the particle image velocimetry technique (PIV) and the large eddy simulation (LES), the flow pattern and the trailing vortex structure of a hydrofoil impeller stirred reactor were investigated. The difference between flow patterns induced by axial flow impeller and those induced by radial flow impeller was understood and the occurrence of the impeller flooding was accordingly explained.
3) Industrial Application
Based on the structure optimization and basic research results, a new PX oxidation reactor has been designed. And the reasonable combination of mixed flow and plug flow in the new reactor was carried out to match with the PX oxidation character. The new reactor has apparent advantages in structure and performance compared with the two existed PX oxidation reactors. With further optimized structure, bright industrial prospects can be foreseen
1)现有PX氧化反应器工程化分析和结构优化
系统研究了已工业化的两种PX氧化反应器的流体力学性能,并对气体分布器设计、桨叶液泛等关键问题进行了分析和优化。
对浅层鼓泡塔PX氧化反应器,其设计考虑的不仅是气体分散,同时还应兼顾液体混合和固体悬浮。文中考察了高径比、管式气体分布器、底部形状、短尺寸导流筒等结构对反应器性能的影响,并对其进行结构优化,以便指导反应器的放大设计。
对翼型／涡轮组合桨PX氧化反应器,桨叶液泛特性决定反应器的最大操作能力。文中研究了工况高气速、高固含率下翼型桨液泛规律,探讨了通气管设计与桨叶液泛的关系,优化了通气管与桨叶之间的位置,以降低甚至消除液泛发生的可能
2)相关基础问题研究
针对工业PX氧化反应器高通气量的工况,在研究大孔径单孔气体射流及其流型转变过程中作出了新的尝试,建立了一种客观的电容层析成像(ECT)测试技术,揭示了气体鼓泡过程中管径大小与流型转变之间的关系,提出了区分大小孔径的临界孔径,为气体分布器的设计提供了一定指导。
利用粒子图像测速(PIV)技术和大涡(LES)模拟计算得到了翼型桨反应器内的详细流场结构信息,系统阐述了翼型桨叶片尾涡的结构特征,揭示了其与透平桨等径向流桨流型差异的原因所在,从而进一步解释翼型桨液泛规律。
3)工程应用
在比较分析国内外氧化反应器现有结构,和对所涉基本物理现象进一步理解的基础上,应用开发了一种新型PX氧化反应器,在一个反应器内实现全混流与活塞流的合理组合,与PX氧化反应特性更加匹配。将其与现有两种PX氧化反应器进行比较,具有明显的结构和性能优势,进一步优化开发有工业应用前景。
This research investigated the key technologies for designing large-scale industrial PX oxidation reactor and the development of a new style PX oxidation reactor. A serious of technical suggestions have been proposed for the structure intensification of existed reactor and the design of a new reactor after the investigation on the relationships between hydrodynamics and geometrical structures of two existed representative PX oxidation reactors. Some proposals have already been applied for the modification of a PTA process in a company and created economic value.
This research consisted of three parts which were shown as follows:
1) Structure Optimization of Existed PX Oxidation Reactor
Based on the systematical investigation on the hydrodynamics of two existed industrial-scale PX oxidation reactors, the gas sparger design and impeller flooding etc. were optimized.
The design of shallow bubble column PX oxidation reactor is usually controlled by gas dispersion, liquid mixing and solid suspension. This research investigated the influences of aspect ratio, gas sparger, bottom shape and short size draft tube on the reactor performance. The optimized structure design was accordingly proposed.
The maximum capability of hydrofoil/turbine mixed impellers stirred vessel PX oxidation reactor is generally controlled by the impeller flooding. This research investigated the hydrofoil impeller flooding characters of the reactor with high gas velocity and high solid concentration. The relationship between the position of gas inlet and flooding impeller was also investigated and the optimized position of gas inlet was found.
2) Foundamental Research
An electrical capacitance tomography (ECT) method corresponding to the high gas flow rate in the industrial PX oxidation reactor has been developed to identify bubbling/jetting regimes transition from large submerged orifices. The influences of the nozzle diameter on the flow regime transition were investigated during the gas bubbling process. The critical nozzle diameter for distinguishing small nozzles from large nozzles was proposed.
With the particle image velocimetry technique (PIV) and the large eddy simulation (LES), the flow pattern and the trailing vortex structure of a hydrofoil impeller stirred reactor were investigated. The difference between flow patterns induced by axial flow impeller and those induced by radial flow impeller was understood and the occurrence of the impeller flooding was accordingly explained.
3) Industrial Application
Based on the structure optimization and basic research results, a new PX oxidation reactor has been designed. And the reasonable combination of mixed flow and plug flow in the new reactor was carried out to match with the PX oxidation character. The new reactor has apparent advantages in structure and performance compared with the two existed PX oxidation reactors. With further optimized structure, bright industrial prospects can be foreseen
引文
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