甲醇精馏系统模拟与优化
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摘要
甲醇是一种耗用量非常大的常见有机产品,它是合成多种有机产品的基本原料及重要的溶剂。同时,在当前世界石油资源日益减少的情况下,甲醇作为一种新的燃料已经成为趋势。在这个大背景下,国内的甲醇产能迅速扩张。合成的粗甲醇浓度一般不能达到使用要求,所以需要对粗甲醇进行精制。甲醇精馏过程占甲醇生产总能耗的20%左右。因此,研究甲醇精馏工艺系统,并通过对系统合理的设计和优化从而降低甲醇精馏过程的能耗、提高甲醇产品的收率和质量就更具有实际意义。
现有的甲醇四塔精馏工艺流程主要包括预精馏塔、加压精馏塔、常压精馏塔以及回收塔。此甲醇精馏系统为双效精馏：加压精馏塔塔顶的气相进入冷凝／蒸发器,有效地利用了加压精馏塔塔顶和常压精馏塔塔底的温度差,为常压精馏塔塔底提供热源的同时对加压精馏塔塔顶的气相进行冷凝。
本文应用ASPEN PLUS软件对甲醇四塔精馏系统的设计工况进行了严格的模拟分析。本文选用RadFrac单元操作模型作为精馏塔模型,并通过对比分析,选择改进的Wilson和改进的PSRK相结合的物性方法对系统进行模拟。在模拟结果与设计工况的数据吻合度较高的基础上,对现有的精馏系统进行模拟分析。通过分析发现,虽然现有加压塔与常压塔的双效精馏,但此精馏过程的能耗还是十分巨大的,同时整个精馏系统需要加入大量工艺水并且要排出大量废水。为实现能量和资源的合理利用,降低生产成本,本文应用ASPEN PLUS提供的灵敏度分析和参数优化等功能对现有流程存在的问题进行模拟分析,找出节能的关键并提出三个节能优化方案：(1)增加加压精馏塔侧线采出送常压精馏塔作为进料,(2)对常压精馏塔塔底和回收塔塔底部分废水进行循环,(3)采用加压精馏塔与预精馏塔双效精馏。经过模拟计算,改进后的新工艺流程在保证甲醇产品的产量与质量的前提下,共能节省24.57%的公用工程热量,节省26.84%公用工程冷量,节省工业用水55.55%,污水处理量减少54.89%。
本文所选用的单元操作模型及物性方法对于模拟甲醇精馏系统是准确可靠的,因此本文所提出的优化方案能为甲醇工业生产节能、节水以及减少废水排放的改造和新工艺流程的开发提供理论依据。
Methanol is a kind of common and large consumption organic product. It's not only the basic material and essential solvent to compose multiple organic products, but also becoming the trend to be a new kind of fuel in the world that the petroleum resource is decreasing day by day. In this background, the domestic methanol production capacity is expanding dramatically. Generally the crude methanol cannot meet the operation requirement so methanol distillation is needed. The energy consumption of methanol distillation process is 20% of the whole methanol producing energy consumption. So, it has more valuable significance to research the methanol distillation process system to reduce the energy consumption during the methanol distillation process by properly design and optimize the system and increase the yield and quality of the methanol products.
Existing methanol 4-tower distillation process mainly includes pre-distillation column, pressurize distillation column, normal pressure distillation column and recovery column. This methanol distillation system is called double effect distillation:the steam from top of pressurize column goes into condenser/vaporizer, effectively utilizes the temperature difference of the top of the pressurize distillation column and the bottom of the normal pressure distillation column, so as to provide heat source to the bottom of normal pressure distillation column while also condenses the steam on the top of the pressurize distillation column.
With utilizing of ASPEN PLUS, this paper strictly simulates and analyzes the methanol 4-column distillation system design condition. This paper chooses RadFrac unit operation model as distillation column model and improved Wilson and improved PSRK combined property method to simulate the system, through comparative analysis. Based on the high matching of the simulation result and design condition data, simulate and analyze the existing distillation system. The analyzing discoveries that the energy consumption is still huge with the existing double effect distillation by the pressurizer column and normal pressure column, meanwhile the whole distillation system requires large amount of water and discharges a lot of waste water. In order to use energy and resource reasonably and also reduce the cost of production, the paper utilize sensitivity analysis and parameter optimization, etc function of ASPEN PLUS to simulate and analyze the problem of the existing process, finds out the key to save energy and provide 3 energy saving optimizing solution:(1) Increase pressurize distillation column side stream to send to normal pressure distillation column as feed, (2) Circulate part of the waste water at bottom of the normal pressure distillation column and recovery column, (3) Utilize pressurize distillation column and pre-distillation column double effect rectification. Through simulating and calculating, the improved new process can save 24.57% public engineering amount of heat,26.84% public engineering cooling capacity,55.55% industrial water and decrease the waste water treatment by 54.89%, with the precondition to guarantee the methanol product quality and output.
The unit operation model and property method selected in the paper is accurate and reliable to simulate the methanol distillation system, so the optimizing solution in this paper can contribute theory evidence for improving and new process development in terms of energy, water saving and decrease waste water discharge for methanol commercial production.
现有的甲醇四塔精馏工艺流程主要包括预精馏塔、加压精馏塔、常压精馏塔以及回收塔。此甲醇精馏系统为双效精馏：加压精馏塔塔顶的气相进入冷凝／蒸发器,有效地利用了加压精馏塔塔顶和常压精馏塔塔底的温度差,为常压精馏塔塔底提供热源的同时对加压精馏塔塔顶的气相进行冷凝。
本文应用ASPEN PLUS软件对甲醇四塔精馏系统的设计工况进行了严格的模拟分析。本文选用RadFrac单元操作模型作为精馏塔模型,并通过对比分析,选择改进的Wilson和改进的PSRK相结合的物性方法对系统进行模拟。在模拟结果与设计工况的数据吻合度较高的基础上,对现有的精馏系统进行模拟分析。通过分析发现,虽然现有加压塔与常压塔的双效精馏,但此精馏过程的能耗还是十分巨大的,同时整个精馏系统需要加入大量工艺水并且要排出大量废水。为实现能量和资源的合理利用,降低生产成本,本文应用ASPEN PLUS提供的灵敏度分析和参数优化等功能对现有流程存在的问题进行模拟分析,找出节能的关键并提出三个节能优化方案：(1)增加加压精馏塔侧线采出送常压精馏塔作为进料,(2)对常压精馏塔塔底和回收塔塔底部分废水进行循环,(3)采用加压精馏塔与预精馏塔双效精馏。经过模拟计算,改进后的新工艺流程在保证甲醇产品的产量与质量的前提下,共能节省24.57%的公用工程热量,节省26.84%公用工程冷量,节省工业用水55.55%,污水处理量减少54.89%。
本文所选用的单元操作模型及物性方法对于模拟甲醇精馏系统是准确可靠的,因此本文所提出的优化方案能为甲醇工业生产节能、节水以及减少废水排放的改造和新工艺流程的开发提供理论依据。
Methanol is a kind of common and large consumption organic product. It's not only the basic material and essential solvent to compose multiple organic products, but also becoming the trend to be a new kind of fuel in the world that the petroleum resource is decreasing day by day. In this background, the domestic methanol production capacity is expanding dramatically. Generally the crude methanol cannot meet the operation requirement so methanol distillation is needed. The energy consumption of methanol distillation process is 20% of the whole methanol producing energy consumption. So, it has more valuable significance to research the methanol distillation process system to reduce the energy consumption during the methanol distillation process by properly design and optimize the system and increase the yield and quality of the methanol products.
Existing methanol 4-tower distillation process mainly includes pre-distillation column, pressurize distillation column, normal pressure distillation column and recovery column. This methanol distillation system is called double effect distillation:the steam from top of pressurize column goes into condenser/vaporizer, effectively utilizes the temperature difference of the top of the pressurize distillation column and the bottom of the normal pressure distillation column, so as to provide heat source to the bottom of normal pressure distillation column while also condenses the steam on the top of the pressurize distillation column.
With utilizing of ASPEN PLUS, this paper strictly simulates and analyzes the methanol 4-column distillation system design condition. This paper chooses RadFrac unit operation model as distillation column model and improved Wilson and improved PSRK combined property method to simulate the system, through comparative analysis. Based on the high matching of the simulation result and design condition data, simulate and analyze the existing distillation system. The analyzing discoveries that the energy consumption is still huge with the existing double effect distillation by the pressurizer column and normal pressure column, meanwhile the whole distillation system requires large amount of water and discharges a lot of waste water. In order to use energy and resource reasonably and also reduce the cost of production, the paper utilize sensitivity analysis and parameter optimization, etc function of ASPEN PLUS to simulate and analyze the problem of the existing process, finds out the key to save energy and provide 3 energy saving optimizing solution:(1) Increase pressurize distillation column side stream to send to normal pressure distillation column as feed, (2) Circulate part of the waste water at bottom of the normal pressure distillation column and recovery column, (3) Utilize pressurize distillation column and pre-distillation column double effect rectification. Through simulating and calculating, the improved new process can save 24.57% public engineering amount of heat,26.84% public engineering cooling capacity,55.55% industrial water and decrease the waste water treatment by 54.89%, with the precondition to guarantee the methanol product quality and output.
The unit operation model and property method selected in the paper is accurate and reliable to simulate the methanol distillation system, so the optimizing solution in this paper can contribute theory evidence for improving and new process development in terms of energy, water saving and decrease waste water discharge for methanol commercial production.
引文
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