连续重整装置流程模拟技术与应用
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摘要
连续重整是重要的石油化工二次加工过程之一,是芳烃原料和高辛烷值汽油调和组分的重要来源。随着经济的高速发展,装置挖潜增效的要求日益凸显。将流程模拟技术应用于重整装置,实现操作优化,是提高经济效益的有效可行的方法,装置模拟软件日益受到炼油与石化企业的青睐。本文针对连续重整装置,围绕重整反应机理、动力学模型的建立、模型参数估计等问题展开研究,以此为基础将流程模拟技术应用于连续重整装置,对重整过程进行了分析与优化,并开发了连续重整装置模拟平台软件。具体包括以下几个方面：
1)根据集总理论和连续重整的反应机理,基于工业连续重整装置,提出了一个包含38个集总组分、86个反应的重整反应动力学模型,建立了相应的反应网络。该模型集总组分划分较详细,覆盖了反应物料绝大部分信息,更加接近实际反应,保证了模拟精度。确立了86个待估模型参数,给出了分层策略和BFGS算法相结合的参数估计方法,并基于大量工业现场数据,对模型参数进行了估计。
2)在所建立的38集总重整动力学模型基础上,构建了连续重整装置的流程模拟框架。对某炼油厂连续重整装置进行了模拟计算,模拟结果与实际值吻合较好,验证了38集总重整动力学模型的可靠性与准确性。将模型用于芳烃收率的预测,在两个多月的时间内收率预测精度与趋势均令人满意。以芳烃收率最大化为目标,对操作参数进行了优化计算,结果表明,通过对各反应器入口温度的轻微调整,芳烃收率提高了0.17%。
3)以MATLAB为工具,开发了基于图形用户界面(GUI)的连续重整装置模拟平台软件CataRefsim,人机界面友好,操作简单。软件具有装置模拟、灵敏度分析以及操作参数优化等功能,它的开发为研究连续重整装置的流程模拟、系统分析、先进控制与优化等提供了一条有效途径。
Continuous catalytic reforming(CCR) is one of the most important secondary processes for producing aromatic feedstock and high octane gasoline in petroleum-refining and petrochemical industries. The requirement of potentiality-tapping and profit-increasing of the CCR unit is highlighted progressively with the rapid development of the economy. The application of process simulation technology to the reforming unit, which could optimize the operating conditions, is a effective and feasible way to improve the economic efficiency. The process simulation software is becoming more and more popular in refining and petrochemical enterprises. This thesis takes the CCR unit as the research background, and the reforming kinetic, the modeling of the process and the parameter estimation are studied. Based on those work, the process simulation technology is applied to the CCR unit, and the reforming process is analyzed and optimized. A simulation platform software for CCR unit is developed. In this thesis, the main contributions are as follows.
1) Based on the lumping theory and catalytic reforming reaction mechanisms, a new kinetic model involving 38 lumped components and 86 reactions is developed for the industrial CCR unit. The reaction network of the model is established according to the reaction mechanism of bi-functional catalyst and related kinetic theory. As the detailed division of the lumped components, most of the reactants' information is covered, consequently the model could be more realistic.86 model parameters are identified and a parameter estimation method, which combines the hierarchical strategy and BFGS algorithm, is given.
2) On the basis of the 38-lumped kinetic model, the process simulation framework of CCR unit is built. Simulation of a refinery reformer is carried out, and fair agreement between the calculated results and the actual operating data is obtained. The result could demonstrate the reliability and accuracy of the developed model. The model is applied to predict the aromatics yield, and the result showed that (?) of the trend and precision of the aromatics yield prediction are satisfied in more than two months time. The process optimization is implemented, and an (?)rease of 0.17% on aromatics yield is obtained by a slight tuning of each inlet temperature.
(?)simulation platform software for CCR unit, CataRefsim, with a friendly (?)face and simple operation features is developed based on MATLAB/GUI. The (?)ware could be used in performing steady-state simulation of the basic process (?)CCR unit, as well as sensitivity analysis and process optimization. The development of the software could provide an effective way for the research of the (?)unit's process simulation, system analysis, advanced control and (?)mization.
1)根据集总理论和连续重整的反应机理,基于工业连续重整装置,提出了一个包含38个集总组分、86个反应的重整反应动力学模型,建立了相应的反应网络。该模型集总组分划分较详细,覆盖了反应物料绝大部分信息,更加接近实际反应,保证了模拟精度。确立了86个待估模型参数,给出了分层策略和BFGS算法相结合的参数估计方法,并基于大量工业现场数据,对模型参数进行了估计。
2)在所建立的38集总重整动力学模型基础上,构建了连续重整装置的流程模拟框架。对某炼油厂连续重整装置进行了模拟计算,模拟结果与实际值吻合较好,验证了38集总重整动力学模型的可靠性与准确性。将模型用于芳烃收率的预测,在两个多月的时间内收率预测精度与趋势均令人满意。以芳烃收率最大化为目标,对操作参数进行了优化计算,结果表明,通过对各反应器入口温度的轻微调整,芳烃收率提高了0.17%。
3)以MATLAB为工具,开发了基于图形用户界面(GUI)的连续重整装置模拟平台软件CataRefsim,人机界面友好,操作简单。软件具有装置模拟、灵敏度分析以及操作参数优化等功能,它的开发为研究连续重整装置的流程模拟、系统分析、先进控制与优化等提供了一条有效途径。
Continuous catalytic reforming(CCR) is one of the most important secondary processes for producing aromatic feedstock and high octane gasoline in petroleum-refining and petrochemical industries. The requirement of potentiality-tapping and profit-increasing of the CCR unit is highlighted progressively with the rapid development of the economy. The application of process simulation technology to the reforming unit, which could optimize the operating conditions, is a effective and feasible way to improve the economic efficiency. The process simulation software is becoming more and more popular in refining and petrochemical enterprises. This thesis takes the CCR unit as the research background, and the reforming kinetic, the modeling of the process and the parameter estimation are studied. Based on those work, the process simulation technology is applied to the CCR unit, and the reforming process is analyzed and optimized. A simulation platform software for CCR unit is developed. In this thesis, the main contributions are as follows.
1) Based on the lumping theory and catalytic reforming reaction mechanisms, a new kinetic model involving 38 lumped components and 86 reactions is developed for the industrial CCR unit. The reaction network of the model is established according to the reaction mechanism of bi-functional catalyst and related kinetic theory. As the detailed division of the lumped components, most of the reactants' information is covered, consequently the model could be more realistic.86 model parameters are identified and a parameter estimation method, which combines the hierarchical strategy and BFGS algorithm, is given.
2) On the basis of the 38-lumped kinetic model, the process simulation framework of CCR unit is built. Simulation of a refinery reformer is carried out, and fair agreement between the calculated results and the actual operating data is obtained. The result could demonstrate the reliability and accuracy of the developed model. The model is applied to predict the aromatics yield, and the result showed that (?) of the trend and precision of the aromatics yield prediction are satisfied in more than two months time. The process optimization is implemented, and an (?)rease of 0.17% on aromatics yield is obtained by a slight tuning of each inlet temperature.
(?)simulation platform software for CCR unit, CataRefsim, with a friendly (?)face and simple operation features is developed based on MATLAB/GUI. The (?)ware could be used in performing steady-state simulation of the basic process (?)CCR unit, as well as sensitivity analysis and process optimization. The development of the software could provide an effective way for the research of the (?)unit's process simulation, system analysis, advanced control and (?)mization.
引文
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