脂肪醇装置中酯分馏过程全流程模拟及优化
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摘要
本课题研究的主要内容是运用流程模拟技术进行脂肪醇装置中酯分馏过程的全流程模拟及应用。酯分馏装置流程主要包括两个精馏塔和其他一些简单单元设备,本文主要是研究精馏过程,故建立了精馏塔稳态模型,并将其应用于实际生产装置的全流程实时动态模拟。
该工艺过程的特点是流程结构复杂,组分繁多,体系非理想性强。甲酯分馏塔是本工艺过程中典型的重要分离设备,文中对其进行了深入的分析和论证,建立了严谨的数学模型,并采用适当的数学方法进行了求解。在此针对体系的非理想过程,采用改进UNIFAC(Dortmund)基团贡献法计算汽液平衡常数,解决了实验数据不足造成的局限。
稳态模型建立的基础是MESH方程,即物料平衡方程、相平衡方程、组分加和方程和焓平衡方程。其解算方法与传统的三对角矩阵方法类似。内层迭代是将物料平衡方程和相平衡方程联立,化为三对角矩阵形式,由之解出各板液相组成后,通过泡点计算法求定各板新的温度和相平衡常数。外层迭代以汽相流率V为切断变量,通过热量平衡方程进行计算。此法能够大大提高了计算效率和稳定性。
模型建立之后,对稳态模拟结果进行了讨论,其结果与生产实际相近似,从而验证了模型的正确性。在对主要生产设备进行机理分析的基础上,并根据模拟计算结果及结合实际生产数据,对该装置进行诊断分析,挖掘其中蕴涵的内在规律,在预测的基础上进行系统优
化分析,提出解决问题的具体方案,预测了应用前景及取得的经济效益,并进行科学、严谨的考核。
由于本软件的开发具有较强的机理性,从整体工艺的模拟情况看,整个模拟过程能够很好地反映出装置实际运行情况,它不仅可以作为操作人员分析生产过程的依据,而且也为技术人员进行优化生产、挖潜改造提供了一份参考资料。此研究成果成功地应用于大连华能化工厂一万五千吨/年脂肪醇装置的生产分析,并对生产装置的优化及控制有一定的指导意义。
This subject is mainly studying simulating the overall flowsheet of Ester Distillation process in the production of Aliphatic Alcohol and its application. The Ester Distillation process mainly consists of two distillation columns and some other simple units. Since the distillation process is focused on this study, the stable state model is established, which is also used to the real time simulation and practical process.
The characteristics of the technologic process are the complicated structure, numerous components and the highly non-ideal system. The two distillation towers are the typical separating equipments in this process. This paper deeply analyzed and demonstrated them, established a rigorous mathematical model and solves it with proper mathematical method. As to the non-linear process of the system, we calculate the constant of the vapor-liquid equilibrium by making use of the Modified UNIFAC Method(Dortmund) to solve the problem of the lack of experimental data.
The basis of stable model is MESH equation, or mass, vapor-liquid, component addition, and enthalpy equilibrium equations. Its computation method is similar to the traditional method of solving tridia-matrix. The internal iterative calculation is to correlate the equations of mass and phase equilibrium into a tridia-matrix from which the liquid compositions can be found out. And then temperatures and equilibrium coefficients in the trays along the column are solved through bubble point calculation. The external iteration regards flow rate of vapor as discontinuous variable and can be calculated by heat equation. This method increases greatly the computation efficiency and stability.
After establishment of the above-mentioned model, we have discussed the results of stable simulation. The result is so similar to industrial production that the accuracy of this model is verified. The technologic process was analyzed by the
comparison between the simulation results and the practical industrial data under the basis of the analysis of mechanism of the main equipments. After the comprehension of the inner law of the process, the system was optimized on the basis of forecasting. Thus the method to optimize the operation was proposed and the application future of solutions and their economic benefits were forecasted. The effects of these were assessed scientific religiously.
As a whole process of technology simulation, The whole simulation process is good to reflect the running conditions of equipment due to its great mechanism. The simulation results not only provide foundation for operators to analyse production process, but also provide technic workers with referential materials to develop potential and to make further improvement. This research has successfully applied in the systemic analysis on the production of Aliphatic Alcohol whose capacity is 5 million tons per year went into operation in Dalian Huaneng Chemical Factory. The result shows that this model has guide significantly to optimization and control of production units.
该工艺过程的特点是流程结构复杂,组分繁多,体系非理想性强。甲酯分馏塔是本工艺过程中典型的重要分离设备,文中对其进行了深入的分析和论证,建立了严谨的数学模型,并采用适当的数学方法进行了求解。在此针对体系的非理想过程,采用改进UNIFAC(Dortmund)基团贡献法计算汽液平衡常数,解决了实验数据不足造成的局限。
稳态模型建立的基础是MESH方程,即物料平衡方程、相平衡方程、组分加和方程和焓平衡方程。其解算方法与传统的三对角矩阵方法类似。内层迭代是将物料平衡方程和相平衡方程联立,化为三对角矩阵形式,由之解出各板液相组成后,通过泡点计算法求定各板新的温度和相平衡常数。外层迭代以汽相流率V为切断变量,通过热量平衡方程进行计算。此法能够大大提高了计算效率和稳定性。
模型建立之后,对稳态模拟结果进行了讨论,其结果与生产实际相近似,从而验证了模型的正确性。在对主要生产设备进行机理分析的基础上,并根据模拟计算结果及结合实际生产数据,对该装置进行诊断分析,挖掘其中蕴涵的内在规律,在预测的基础上进行系统优
化分析,提出解决问题的具体方案,预测了应用前景及取得的经济效益,并进行科学、严谨的考核。
由于本软件的开发具有较强的机理性,从整体工艺的模拟情况看,整个模拟过程能够很好地反映出装置实际运行情况,它不仅可以作为操作人员分析生产过程的依据,而且也为技术人员进行优化生产、挖潜改造提供了一份参考资料。此研究成果成功地应用于大连华能化工厂一万五千吨/年脂肪醇装置的生产分析,并对生产装置的优化及控制有一定的指导意义。
This subject is mainly studying simulating the overall flowsheet of Ester Distillation process in the production of Aliphatic Alcohol and its application. The Ester Distillation process mainly consists of two distillation columns and some other simple units. Since the distillation process is focused on this study, the stable state model is established, which is also used to the real time simulation and practical process.
The characteristics of the technologic process are the complicated structure, numerous components and the highly non-ideal system. The two distillation towers are the typical separating equipments in this process. This paper deeply analyzed and demonstrated them, established a rigorous mathematical model and solves it with proper mathematical method. As to the non-linear process of the system, we calculate the constant of the vapor-liquid equilibrium by making use of the Modified UNIFAC Method(Dortmund) to solve the problem of the lack of experimental data.
The basis of stable model is MESH equation, or mass, vapor-liquid, component addition, and enthalpy equilibrium equations. Its computation method is similar to the traditional method of solving tridia-matrix. The internal iterative calculation is to correlate the equations of mass and phase equilibrium into a tridia-matrix from which the liquid compositions can be found out. And then temperatures and equilibrium coefficients in the trays along the column are solved through bubble point calculation. The external iteration regards flow rate of vapor as discontinuous variable and can be calculated by heat equation. This method increases greatly the computation efficiency and stability.
After establishment of the above-mentioned model, we have discussed the results of stable simulation. The result is so similar to industrial production that the accuracy of this model is verified. The technologic process was analyzed by the
comparison between the simulation results and the practical industrial data under the basis of the analysis of mechanism of the main equipments. After the comprehension of the inner law of the process, the system was optimized on the basis of forecasting. Thus the method to optimize the operation was proposed and the application future of solutions and their economic benefits were forecasted. The effects of these were assessed scientific religiously.
As a whole process of technology simulation, The whole simulation process is good to reflect the running conditions of equipment due to its great mechanism. The simulation results not only provide foundation for operators to analyse production process, but also provide technic workers with referential materials to develop potential and to make further improvement. This research has successfully applied in the systemic analysis on the production of Aliphatic Alcohol whose capacity is 5 million tons per year went into operation in Dalian Huaneng Chemical Factory. The result shows that this model has guide significantly to optimization and control of production units.
引文
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周章玉、杨少华、成思危、华贲,发展过程工业CIPS的策略探讨,现代化工1999年增刊,99过程系统工程年会论文集,北京,1999,pp202-208;
杨友麒,从CIMS走向供应链的动态优化,化工进展1999年增刊,第七届计算机化工应用学术年会论文集,北京,1999.10,pp24-34;
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彭秉璞,化工系统分析与模拟,北京,化学工业出版社,1990;
杨冀宏、麻德贤,过程系统工程导论,北京,烃加工出版社,989;
杨友麒,实用化工系统工程,北京,化学工业出版社,1989;
朱开宏, 化工流程模拟, 北京,中国石化出版社,1993;
高松武一郎,,沈静珠译,化工过程系统工程,北京,化学工业出版社,1978;
房德中、朱建业,化工过程分析与模拟,北京,化学工业出版社,1991;
姚平经,化工过程系统工程,大连,大连理工大学出版社,1991;
王健红,化工系统工程基本原理与技术,北京化工大学研究生教材,待发表;
时钧、汪甲鼎、余国琮、陈敏恒,化学工程手册(第二版),北京,化学工业出版社,1996;
杨少华、周章玉、华贲、成思危,过程系统技术与管理的综合集成,现代化工1999年增刊,99过程系统工程年会论文集,北京,1999,pp209-214;
周章玉、杨少华、成思危、华贲,发展过程工业CIPS的策略探讨,现代化工1999年增刊,99过程系统工程年会论文集,北京,1999,pp202-208;
杨友麒,从CIMS走向供应链的动态优化,化工进展1999年增刊,第七届计算机化工应用学术年会论文集,北京,1999.10,pp24-34;
张跃敏、王红、周家驹、许志宏,论集成性化工过程模拟系统的建立和应用,中国化工学会计算机应用学会化工过程的数学模拟分析会议第三届年会论文集,北京,1990.10;
成思危,综合集成整体优化—论我国过程系统工程的发展方向,现代化工1999年增刊,99过程系统工程年会论文集,北京,1999,pp1-3;
Roger,G.E.Franks, Modeling and Simulation in Chemical Engineering , 1971;
W.L.Luyben, Process Modeling, Simulation, and Control for Chemical Engineers, McGraw-Hill, 1973;
Williams, T.J., Systems Engineering for the Process Industries, McGraw-Hill, 1961;
E.M.Rosen, Steady State Chemical Process Simulation: A State-of-the-Art Review,
Computer Applications to Chemical Engineering, ACS Symposium Series 124, 1980, pp3-36;
Arthur W.Westerberg, A Review of Process Synthesis, Computer Applications to Chemical Engineering, ACS Symposium Series 124, 1980, pp53-88;
Heinz A. Preisig, Mark Kimmich, David W.T.Rippin, A Study of Dynamic System Modeling, Comput. Chem. Engng, Vol. 12, No.5, 1988, pp455-460,;
John E Pace,Use of Speed Up Modeling in the Commercialization of a New Polymerization Reator Design, GE Plastics;
C Ganna Varapu, et al. Simulation,Optimization and Control System Design for An Industrial Process, Chem Eng Symposium Series,No.114;
P.W.Galier, L.B.Evan, H.I.Britt, J.F.Boston, and P.K.Gupta, “ASPEN: Advanced Capabilities for Modeling and Simulation of Industrial Process”, Computer Applications to Chemical Engineering, ACS Symposium Series 124, 1980, pp293-308;
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