流化床气相聚合反应器中搅拌和颗粒外循环的作用机制研究
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摘要
流化床气相聚合反应器广泛应用于聚烯烃生产过程。颗粒发粘或静电引起的聚合物粘壁、团聚、结块使得流化床反应器内流化状况恶化,严重制约了流化床反应器的长周期稳定运行。传统的解决方案是使用机械搅拌,新的解决思路是使用颗粒外循环。掌握搅拌流化床和带颗粒外循环流化床的反应器特性,是实现过程调控和新产品开发的基础。本文围绕这一目标,开展了四方面的研究工作：(1)基于声发射技术的搅拌流化床中关键过程参数检测；(2)搅拌流化床的流体力学行为研究；(3)带颗粒外循环流化床的流体力学行为研究；(4)流化床中搅拌和颗粒外循环作用效果的对比研究。
本文的主要研究成果包括：
1.基于搅拌流化床中颗粒的发声特性,实现了起始流化速度、料位和扬析量的声发射检测。定义搅拌作用因子,根据搅拌作用因子-气速曲线得到了起始流化速度的声判据。提出了自校正料位检测法,提高了料位的测量精度。建立了声能量与扬析量的对应关系,实现了扬析量的声检测。
2.获得了搅拌对流化床流体力学行为的影响规律。阐明了流化床中搅拌的作用机制,发现搅拌通过抑制和破碎气泡,使得搅拌流化床与普通流化床相比具有较小的气泡尺寸和相对较低的压力脉动幅值,表现出类似湍动流化床的特征,在增强气固接触、强化颗粒混合、使得床内流动状况趋向于全混流的同时,减少夹带和减小静电势,改善流化质量,提高床层操作稳定性。最后,给出了搅拌转速的选取原则和建议。
3.获得了颗粒外循环对流化床流体力学行为的影响规律。基于二维CFD模拟发现带颗粒外循环流化床具有“环核结构”的流动模式,即核心区是向下运动的平推流,环形区是全混流,并得到实验验证。以此为基础阐明了流化床中颗粒外循环的作用机制,颗粒外循环通过破碎核心区气泡并促使其向壁面运动,使得气泡主要集中在环形区,可以增强气固接触,促进床内特别是壁面附近的颗粒混合,减少夹带和减小静电势,改善流化质量,提高床层操作稳定性。当外循环流量过大时,核心区的平推流效应过强,反而不利于颗粒混合。最后给出了外循环流量的选取原则和建议。
4.对比研究了流化床中搅拌和颗粒外循环的作用效果。提出以破碎气泡、减少夹带、强化颗粒混合、消除沟流和节涌、改善流化质量等作为关键指标,以降低床层压降和减小静电势作为参考指标,建立了搅拌和颗粒外循环的评价方法。分析发现颗粒外循环可以取代搅拌。
Gas phase fluidized bed polymerization reactor is widely used in polyolefin production process. Wall sheeting or agglomeration caused by sticky polymer particles or electrostatic effects in fluidized bed reactor, would make the fluidization deterioration. This problem seriously restricts the long term and stable operation of fluidized bed reactor. The traditional solution is using mechanical agitation, and the new solution is external particle circulation. Mastering the reactor characteristics of agitated fluidized bed and external particle circulation fluidized bed is the basis of process control and development for new products. To achieve this goal, four aspects of research works were carried out. Firstly, the key process parameters of agitated fluidized bed were measured by using acoustic emission technology. Secondly, hydrodynamic behavior of agitated fluidized bed was studied. Thirdly, hydrodynamic behavior of external particle circulation fluidized bed was also studied. Finally, effects of mechanical agitation on hydrodynamics were compared with those of external particle circulation.
The main research results are as follows:
1. Based on the particle acoustic characteristics in the agitated fluidized bed, the initial fluidization velocity, bed level and elutriation rate were measured by acoustic emission technology. By defining agitation effect factor (AEF), a criterion for initial fluidization velocity was proposed from the AEF-gas velocity figure. Subsequently, self-correction bed level measurement method was proposed. This method could improve the measurement accuracy. Finally, the measurement of elutriation rate was realized on the basis of corresponding relationship between AE energy and elutriation rate.
2. Effects of agitation on hydrodynamic behavior of fluidized bed were obtained. Based on the experimental results, effect mechanism of agitation in the fluidized bed was clarified. It was found that the agitated fluidized bed showed similar characteristics of turbulent fluidized bed, and there were much smaller size bubbles and lower pressure fluctuation amplitude in the agitated fluidized bed compared to general fluidized bed, due to the bubble repression and breakage caused by mechanical agitation. This could enhance gas-solid contact and intensify particle mixing in the bed. Meanwhile, reduction of entrainment and bed electrostatic potential, improvement of fluidization quality, increase of bed operating stability could also be realized. Finally, selection principles and recommendations for stirring speed were proposed.
3. Effects of external particle circulation on hydrodynamic behavior of fluidized bed were obtained. Based on two dimensional CFD simulations, the core-annulus structure flow pattern composed of plug flow in core zone and mixed flow in annulus was proposed and validated by experiments. Then effect mechanism of external particle circulation in the fluidized bed was clarified. External particle circulation broke the bubbles in the core zone and caused them move towards the wall, then concentrated in the annular zone. This could enhance gas-solid contact and intensify particle mixing in the bed, especially near the wall. Meanwhile, reduction of entrainment and bed electrostatic potential, improvement of fluidization quality, increase of bed operating stability could also be realized. However, excessive external particle circulation may adversely affect the particle mixing due to strong PFR effects in the core zone. Ultimately, selection principles and recommendations for external particle circulation flow rate were provided.
4. Effects of mechanical agitation and external particle circulation on hydrodynamics behavior in fluidized bed were compared. To establish the evaluation method for mechanical agitation and external particle circulation, five key evaluation indexs and two reference evaluation indexs were put forward. Key evaluation indexes included entrainment reduction, bubble breakage, particle mixing, gas channeling and slugging elimination, fluidization quality improvement. Reference evaluation indexes included electrostatic charge reduction and pressure drop reduction. The analysis results showed that external particle circulation could replace the traditional mechanical agitation.
本文的主要研究成果包括：
1.基于搅拌流化床中颗粒的发声特性,实现了起始流化速度、料位和扬析量的声发射检测。定义搅拌作用因子,根据搅拌作用因子-气速曲线得到了起始流化速度的声判据。提出了自校正料位检测法,提高了料位的测量精度。建立了声能量与扬析量的对应关系,实现了扬析量的声检测。
2.获得了搅拌对流化床流体力学行为的影响规律。阐明了流化床中搅拌的作用机制,发现搅拌通过抑制和破碎气泡,使得搅拌流化床与普通流化床相比具有较小的气泡尺寸和相对较低的压力脉动幅值,表现出类似湍动流化床的特征,在增强气固接触、强化颗粒混合、使得床内流动状况趋向于全混流的同时,减少夹带和减小静电势,改善流化质量,提高床层操作稳定性。最后,给出了搅拌转速的选取原则和建议。
3.获得了颗粒外循环对流化床流体力学行为的影响规律。基于二维CFD模拟发现带颗粒外循环流化床具有“环核结构”的流动模式,即核心区是向下运动的平推流,环形区是全混流,并得到实验验证。以此为基础阐明了流化床中颗粒外循环的作用机制,颗粒外循环通过破碎核心区气泡并促使其向壁面运动,使得气泡主要集中在环形区,可以增强气固接触,促进床内特别是壁面附近的颗粒混合,减少夹带和减小静电势,改善流化质量,提高床层操作稳定性。当外循环流量过大时,核心区的平推流效应过强,反而不利于颗粒混合。最后给出了外循环流量的选取原则和建议。
4.对比研究了流化床中搅拌和颗粒外循环的作用效果。提出以破碎气泡、减少夹带、强化颗粒混合、消除沟流和节涌、改善流化质量等作为关键指标,以降低床层压降和减小静电势作为参考指标,建立了搅拌和颗粒外循环的评价方法。分析发现颗粒外循环可以取代搅拌。
Gas phase fluidized bed polymerization reactor is widely used in polyolefin production process. Wall sheeting or agglomeration caused by sticky polymer particles or electrostatic effects in fluidized bed reactor, would make the fluidization deterioration. This problem seriously restricts the long term and stable operation of fluidized bed reactor. The traditional solution is using mechanical agitation, and the new solution is external particle circulation. Mastering the reactor characteristics of agitated fluidized bed and external particle circulation fluidized bed is the basis of process control and development for new products. To achieve this goal, four aspects of research works were carried out. Firstly, the key process parameters of agitated fluidized bed were measured by using acoustic emission technology. Secondly, hydrodynamic behavior of agitated fluidized bed was studied. Thirdly, hydrodynamic behavior of external particle circulation fluidized bed was also studied. Finally, effects of mechanical agitation on hydrodynamics were compared with those of external particle circulation.
The main research results are as follows:
1. Based on the particle acoustic characteristics in the agitated fluidized bed, the initial fluidization velocity, bed level and elutriation rate were measured by acoustic emission technology. By defining agitation effect factor (AEF), a criterion for initial fluidization velocity was proposed from the AEF-gas velocity figure. Subsequently, self-correction bed level measurement method was proposed. This method could improve the measurement accuracy. Finally, the measurement of elutriation rate was realized on the basis of corresponding relationship between AE energy and elutriation rate.
2. Effects of agitation on hydrodynamic behavior of fluidized bed were obtained. Based on the experimental results, effect mechanism of agitation in the fluidized bed was clarified. It was found that the agitated fluidized bed showed similar characteristics of turbulent fluidized bed, and there were much smaller size bubbles and lower pressure fluctuation amplitude in the agitated fluidized bed compared to general fluidized bed, due to the bubble repression and breakage caused by mechanical agitation. This could enhance gas-solid contact and intensify particle mixing in the bed. Meanwhile, reduction of entrainment and bed electrostatic potential, improvement of fluidization quality, increase of bed operating stability could also be realized. Finally, selection principles and recommendations for stirring speed were proposed.
3. Effects of external particle circulation on hydrodynamic behavior of fluidized bed were obtained. Based on two dimensional CFD simulations, the core-annulus structure flow pattern composed of plug flow in core zone and mixed flow in annulus was proposed and validated by experiments. Then effect mechanism of external particle circulation in the fluidized bed was clarified. External particle circulation broke the bubbles in the core zone and caused them move towards the wall, then concentrated in the annular zone. This could enhance gas-solid contact and intensify particle mixing in the bed, especially near the wall. Meanwhile, reduction of entrainment and bed electrostatic potential, improvement of fluidization quality, increase of bed operating stability could also be realized. However, excessive external particle circulation may adversely affect the particle mixing due to strong PFR effects in the core zone. Ultimately, selection principles and recommendations for external particle circulation flow rate were provided.
4. Effects of mechanical agitation and external particle circulation on hydrodynamics behavior in fluidized bed were compared. To establish the evaluation method for mechanical agitation and external particle circulation, five key evaluation indexs and two reference evaluation indexs were put forward. Key evaluation indexes included entrainment reduction, bubble breakage, particle mixing, gas channeling and slugging elimination, fluidization quality improvement. Reference evaluation indexes included electrostatic charge reduction and pressure drop reduction. The analysis results showed that external particle circulation could replace the traditional mechanical agitation.
引文
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