催化重整流程模拟与优化技术及其应用研究
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摘要
流程模拟与优化技术作为流程工业综合自动化技术的重要组成部分得到了广泛应用,带来了显著的经济效益。本论文以石化行业重要的石油二次加工过程——催化重整过程为研究对象,以该过程的模拟优化技术及其工业应用为研究主线,围绕催化重整集总反应动力学模型的建立、专用流程模拟优化软件的开发、基于ASPEN PLUS软件平台的全流程模拟与工业优化应用、机理模型的在线计算应用、遗传算法和混合遗传算法在约束优化和多目标优化中的应用等进行了深入研究。具体包括以下几个方面:
1) 在充分考虑反应机理和满足工业应用方便性的前提下,提出了一个新的催化重整20集总反应动力学模型。以此模型为基础,采用序贯模块法实现了由反应器、加热炉、换热器、分离罐等装置组成的催化重整循环流程的机理建模工作。为了方便工业应用,所有模型方程的求解和参数估计中的无约束优化方法均采用了成熟、快速而可靠的算法。以20集总反应动力学模型为核心的催化重整过程模型的成功建立,是本论文以下工业应用研究的基础。
2) 以C++为工具,开发了基于催化重整集总反应动力学模型的专用流程模拟优化软件ESP-Simpro。其清晰的功能模块设计、完整的模型库、快速可靠的算法、功能强大的输入/输出系统、友好的人机界面、标准化的接口和统一的权限管理等特点使得该软件具备了商业化应用的潜质和前景。该软件作为商业化软件产品在国内某工业级连续重整装置上得到了成功应用。其工业应用情况表明了机理模型和模拟软件在过程分析和操作指导上的重要意义。
3) 利用ASPEN PLUS用户模型技术,将催化重整过程机理模型开发成用户单元操作模块,从而在ASPEN PLUS平台实现了包含重整反应装置在内的催化重整全流程模拟。从实际的工业应用结果看,各主要操作点和操作指标的模拟计算值与实际操作值均吻合得较好。利用ASPEN PLUS内置的SQP优化算法,还对工业连续重整装置进行了操作参数优化研究,并将优化方案在该装置上进行了现场测试。测试结果表明芳烃收率的平均值实际提高0.49wt%,与优化计算结果相当吻合。该优化研究可为厂方带来每年600多万元的纯利润。
As the basic of integrated control technologies in modern petrochemical industrials, the technology of process simulation and optimization is widely applied and brings large profits for related plants or componies. This dissertation takes the importantsecondary process of refinery-----catalytic reforming as the research background, andfocuses on the simulation and optimization of this process and its typical industrial applications. The lumped kinetics model and corresponding process model of catalytic reforming is firstly developed in this dissertation. Based on this process model, the industrial applications comprise developing special simulation software, devolping secondary simulation software on ASPEN PLUS platform, on-line computation, constraint optimization and multi-objective optimization. The detailed content is arrangend as follows,1. A new kinetics model involving twenty lumped components and thirty-one reactions is developed for catalytic reforming. The deactivation of the catalyst in semiregenerative or continuous catalytic reforming process is modeled by two different methods. Sequential modular approach is then implemented for the process modeling of catalytic reforming, which is composed of reformers, heaters, heat exchanger and separator. Aiming at industrial application, the traditional and steady algorithms are selected to solve process model equations and unconstrained optimization problem deriving from parameter estimation. The process model is the foundation of all the following industrial applications.2. The special process simulation and optimization software for catalytic reforming is developed with C++ language based on the 20-lumped kinetics model. This software possesses good structure of functional modules, integrated model library, steady and fast algorithms and powerful input and output system. As commercial software, it has been applied upon one domestic industrial catalytic reforming unit successfully. The software is proved to be effective and convenient for application. In addition, the sensitivity analysis is also performed with this software to guide
process operations.3. By developing the process model as a user module, a whole industrial continuous catalytic reforming process is simulated on ASPEN PLUS platform. Fair agreement between the calculated and actual operating data is obtained. Based on the process model and the built-in SQP algorithm, process optimization is then studied and the calculated optimization results are also tested on the actual industrial unit about one month. The testing results show that the aromatics yield increases about 0.49 wt% averagely, which is close to the calculated result and makes a profit of about six million yuan annually.4. Based on the process mechanism model, linear PLS regression model and first-order TSK fuzzy neural network model, the on-line computation of production index for one industrial continuous catalytic reforming process is studied. The process model is proved to have such performances of stronger robustness and generalization, fewer samples for modeling needed and computing more than one index by using the same model and model parameters. By adopting an on-line prediction and correction strategy, the process model is used to on-line calculate aromatics yield, yield of each aromatics lump, and RON (Research Octane Number) of the process. The on-line prediction trend and precision are very good.5. A constrained optimization strategy of industrial catalytic reforming process is proposed based on the process model. A genetic algorithm based on infeasibility degree (IFDCOGA) is selected to compute this problem. This genetic algorithm is proved to have shortcomings of premature and dead state convergence during optimization computation. Aiming at overcoming its shortcomings, a new optimization method is proposed by integrating IFDCOGA with traditional algorithms. The feature of this method is its faster convergence speed and convenience because of not using the genetic algorithm each time in industrial applications.6. A new hybrid genetic algorithm, named as HNAGA, is proposed by integrating a genetic algorithm based on neighborhood and archived operation (NAGA) with traditional algorithm such as SQP or LM. Based on the process model, this hybrid
algorithm is then applied to compute a multi-objective optimization problem of industrial catalytic reforming process. The optimal objectives include maximizing the aromatics yield and minimizing the yield of heavy aromatics. Four reactor inlet temperatures, reaction pressure and hydrogen-to-oil molar ratio, are selected as decision variables. The hybrid algorithm HNAGA is proved to be more excellent than NAGA in obtaining Pareto optimal solutions.The dissertation is concluded with a summary and perspectives of some important problems to be solved in the future research and application.
1) 在充分考虑反应机理和满足工业应用方便性的前提下,提出了一个新的催化重整20集总反应动力学模型。以此模型为基础,采用序贯模块法实现了由反应器、加热炉、换热器、分离罐等装置组成的催化重整循环流程的机理建模工作。为了方便工业应用,所有模型方程的求解和参数估计中的无约束优化方法均采用了成熟、快速而可靠的算法。以20集总反应动力学模型为核心的催化重整过程模型的成功建立,是本论文以下工业应用研究的基础。
2) 以C++为工具,开发了基于催化重整集总反应动力学模型的专用流程模拟优化软件ESP-Simpro。其清晰的功能模块设计、完整的模型库、快速可靠的算法、功能强大的输入/输出系统、友好的人机界面、标准化的接口和统一的权限管理等特点使得该软件具备了商业化应用的潜质和前景。该软件作为商业化软件产品在国内某工业级连续重整装置上得到了成功应用。其工业应用情况表明了机理模型和模拟软件在过程分析和操作指导上的重要意义。
3) 利用ASPEN PLUS用户模型技术,将催化重整过程机理模型开发成用户单元操作模块,从而在ASPEN PLUS平台实现了包含重整反应装置在内的催化重整全流程模拟。从实际的工业应用结果看,各主要操作点和操作指标的模拟计算值与实际操作值均吻合得较好。利用ASPEN PLUS内置的SQP优化算法,还对工业连续重整装置进行了操作参数优化研究,并将优化方案在该装置上进行了现场测试。测试结果表明芳烃收率的平均值实际提高0.49wt%,与优化计算结果相当吻合。该优化研究可为厂方带来每年600多万元的纯利润。
As the basic of integrated control technologies in modern petrochemical industrials, the technology of process simulation and optimization is widely applied and brings large profits for related plants or componies. This dissertation takes the importantsecondary process of refinery-----catalytic reforming as the research background, andfocuses on the simulation and optimization of this process and its typical industrial applications. The lumped kinetics model and corresponding process model of catalytic reforming is firstly developed in this dissertation. Based on this process model, the industrial applications comprise developing special simulation software, devolping secondary simulation software on ASPEN PLUS platform, on-line computation, constraint optimization and multi-objective optimization. The detailed content is arrangend as follows,1. A new kinetics model involving twenty lumped components and thirty-one reactions is developed for catalytic reforming. The deactivation of the catalyst in semiregenerative or continuous catalytic reforming process is modeled by two different methods. Sequential modular approach is then implemented for the process modeling of catalytic reforming, which is composed of reformers, heaters, heat exchanger and separator. Aiming at industrial application, the traditional and steady algorithms are selected to solve process model equations and unconstrained optimization problem deriving from parameter estimation. The process model is the foundation of all the following industrial applications.2. The special process simulation and optimization software for catalytic reforming is developed with C++ language based on the 20-lumped kinetics model. This software possesses good structure of functional modules, integrated model library, steady and fast algorithms and powerful input and output system. As commercial software, it has been applied upon one domestic industrial catalytic reforming unit successfully. The software is proved to be effective and convenient for application. In addition, the sensitivity analysis is also performed with this software to guide
process operations.3. By developing the process model as a user module, a whole industrial continuous catalytic reforming process is simulated on ASPEN PLUS platform. Fair agreement between the calculated and actual operating data is obtained. Based on the process model and the built-in SQP algorithm, process optimization is then studied and the calculated optimization results are also tested on the actual industrial unit about one month. The testing results show that the aromatics yield increases about 0.49 wt% averagely, which is close to the calculated result and makes a profit of about six million yuan annually.4. Based on the process mechanism model, linear PLS regression model and first-order TSK fuzzy neural network model, the on-line computation of production index for one industrial continuous catalytic reforming process is studied. The process model is proved to have such performances of stronger robustness and generalization, fewer samples for modeling needed and computing more than one index by using the same model and model parameters. By adopting an on-line prediction and correction strategy, the process model is used to on-line calculate aromatics yield, yield of each aromatics lump, and RON (Research Octane Number) of the process. The on-line prediction trend and precision are very good.5. A constrained optimization strategy of industrial catalytic reforming process is proposed based on the process model. A genetic algorithm based on infeasibility degree (IFDCOGA) is selected to compute this problem. This genetic algorithm is proved to have shortcomings of premature and dead state convergence during optimization computation. Aiming at overcoming its shortcomings, a new optimization method is proposed by integrating IFDCOGA with traditional algorithms. The feature of this method is its faster convergence speed and convenience because of not using the genetic algorithm each time in industrial applications.6. A new hybrid genetic algorithm, named as HNAGA, is proposed by integrating a genetic algorithm based on neighborhood and archived operation (NAGA) with traditional algorithm such as SQP or LM. Based on the process model, this hybrid
algorithm is then applied to compute a multi-objective optimization problem of industrial catalytic reforming process. The optimal objectives include maximizing the aromatics yield and minimizing the yield of heavy aromatics. Four reactor inlet temperatures, reaction pressure and hydrogen-to-oil molar ratio, are selected as decision variables. The hybrid algorithm HNAGA is proved to be more excellent than NAGA in obtaining Pareto optimal solutions.The dissertation is concluded with a summary and perspectives of some important problems to be solved in the future research and application.
引文
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