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大型精对苯二甲酸装置优化运行方法及其应用研究
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摘要
精对苯二甲酸(purified terephthalic acid,简称PTA)作为聚酯的原料,化纤行业的“龙头”,是重要的化工大宗产品。我国早已成为世界第一大PTA生产国和消费国,并且我国PTA装备国产化已取得了突破,但由于缺乏对机理的深入了解与优化运行技术软体的支撑,我国PTA装置的整体运行技术与国外先进技术相比还存在一定的差距。本文融合实验机理分析结果和工业装置运行信息,对大型PTA装置对二甲苯(p-Xylene,简称PX)氧化反应过程、共沸精馏溶剂脱水过程和粗对苯二甲酸(crude terephthalic acid,简称CTA或TA)加氢反应过程的建模与优化运行技术进行了较为系统的分析和研究。本文主要研究成果如下:
     (1)由于复杂化工工业操作条件的优化极其困难,传统的优化算法极易陷入局部最优,或需要对象的梯度信息。粒子群优化(particle swarm optimization,简称PSO)算法是一种有效、简单的群体智能优化算法,吸引了越来越多研究者的关注。本文首先对相位角粒子群优化(phase angle based particle swarm optimization,简称θ-PSO)算法进行了改进,提出了基于交叉变异的改进θ-PSO算法。在此基础上,又进一步研究了动态环境下θ-PSO算法跟踪极值的性能,提出了一种结合记忆追溯与变尺度随机初始化策略的改进θ-PSO算法。通过标准测试函数MPB的仿真,表明在一定的动态环境下,引入记忆追溯,有利于提高算法的寻优性能。
     (2)本文在分析PX氧化主、副反应机理的基础上,建立了PX氧化反应宏观动力学模型以及反应器中醋酸、PX燃烧损失模型。通过ASPEN PLUS建立了INVISTA工艺的PX氧化反应过程集成模型并实现了流程模拟。采用改进的交叉变异θ-PSO算法对PX氧化反应过程反应器和第一结晶器的工艺操作参数进行了寻优,并以此调整了PX氧化反应过程的操作条件,取得了显著的降耗效果。
     (3)针对PX氧化反应过程非线性、耦合难控制的特点,采用FRONT-Suite先进控制软件实施了INVISTA工艺PX氧化反应过程的多变量预测控制,实现了反应器尾气O2浓度、氧化产品CTA中对羧基苯甲醛(4-carboxybenzaldehyde,简称4-CBA)浓度和第一结晶器尾气O2浓度的优化控制,稳定了PX氧化反应过程的运行。
     (4)选用合适的共沸精馏多元组分物性方法,研究了以醋酸正丙酯为共沸剂的共沸精馏溶剂脱水过程机理,建立了INVISTA工艺共沸精馏溶剂脱水过程的模型,并实现了流程模拟。根据模型分析与装置操作经验,进行了有效的节能优化操作,包括溶剂脱水塔回流量优化调整、溶剂脱水塔顶部汽相冷凝温度优化调整和釜水含量优化调整,稳定优化了共沸精馏溶剂脱水过程的运行,降低了再沸器蒸汽的消耗。
     (5)本文在实验室动力学模型和反应器模型研究的基础上,研究了工业装置Pd/C催化剂的失活动力学,表明在正常工业加氢生产过程中,催化剂失活是缓慢均匀的。同时,基于ASPEN PLUS平台建立了AMOCO工艺CTA加氢反应过程的流程模拟,模型预测结果表明该模型能较好地表征实际工业生产的特征。基于模型,本文采用交叉变异θ-PSO算法进行了工业加氢生产过程操作条件的优化分析,指导了实际工业生产的优化调整,取得了很好的应用效果。
Purified terephthalic acid (PTA) which is the raw material of polyester is one of the most important chemical products. China has already become the world's largest PTA producer and consumer. Though the domestic PTA equipment has made a breakthrough, there is still a big gap in operation between the domestic and abroad plants due to the lack of in-depth understanding of mechanism and optimization technology. Based on the experimental mechanism analysis and plant operation data, the modeling and optimization study of the p-Xylene oxidation process, the azeotropic distillation solvent dehydration process, and the crude terephthalic acid hydrogenation process of PTA plant is carried out. The main contributions of this dissertation are described as follows:
     (1) Because of the complexity of chemical process, traditional optimization methods may easily fall into the local minimum. Particle swarm optimization (PSO) is a simple but effective swarm intelligence optimization, which has attracted more and more researchers' attention. An improved phase angle based PSO (θ-PSO) algorithm using crossover and mutation is put forward. Then another improved θ-PSO with memory recall and varying scale randomization strategy is studied. The eligible memory particles are recalled when the landscape changes. And the vary scale randomization is introduced through the evolution to maintain the swarm diversity. The offline error in the non-trivial multimodal dynamic functions MPB indicates that this improved θ-PSO deals well with the complex dynamic tracking and optimization.
     (2) Based on the analysis of main and side reaction mechanism of p-Xylene oxidation, industrial macro reaction kinetics and the combustion loss models of acetate and p-Xylene are established. Then an integrated process model of p-Xylene oxidation is achieved. The operating conditions are adjusted according to the optimization results of the improved crossover and mutation θ-PSO algorithm, which obtains a significant effect.
     (3) In order to overcome the control difficulties, such as nonlinear and coupling characteristics, a multivariable predictive control strategy of p-Xylene oxidation process is put forward using the advanced control software FRONT-Suite. The4-carboxybenzaldehyde (4-CBA) concentration in the product of p-Xylene oxidation process together with the oxygen concentration in the reactor and first crystallizer is much more stable than before.
     (4) After the selection of the proper property method of the azeotropic distillation, the mechanism and a process model of an azeotropic distillation solvent dehydration process of INVISTA technology is studied. According to the model analysis and device operational experience, the energy-saving orientated optimization is carried out. including the adjustment of the solvent dehvdration column's hack flow and the condensing temperature. After the application, the azeotropic distillation solvent dehydration process runs more economically.
     (5) A generalized dynamic kinetics of the catalytic hydrogenation reaction is studied, which has an engineering kinetics with a time-dependent deactivation function. It suggests that in the actual industrial hydrogenation process, the catalyst deactivation is slow and even. Then the process model of an AMOCO patented industrial terephthalic acid hydrogenation purification process is established using the actual industry data in ASPEN PLUS platform. The model predictive performance of the product quality4-CBA is good. The operating conditions are adjusted according to the optimization results of the improved crossover and mutation θ-PSO algorithm, which achieves a remarkable effect.
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