合成氨装置APC的开发和实施
摘要
增产降耗是合成氨工业永恒的主题，保证装置“安、稳、长、满、优”运行是合成氨人追求奋斗的目标。
为进一步使合成氨装置运行平稳、消耗降低、产量增加，云南云天化股份有限公司(以下简称云天化)合成氨装置APC(Advanced Process Control，简称APC)项目于2005年12月正式立项。云天化合成氨APC项目是由美国Honeywell公司和云天化共同开发实施的，是国内第一套真正意义上针对合成氨全装置的先进控制项目。
本文介绍了大型合成氨生产技术的现状和未来的发展方向，分析了云天化合成氨生产工艺和生产控制的技术关键，然后介绍了APC的基本概念和原理，接着阐述了云天化和Honeywell公司在云天化合成氨装置共同开发和实施APC的情况，研究并解决了APC的开发和实施中的关键技术问题：APC经济效益点的选取，APC系统设计方案的制定，如何做好阶跃测试工作等。
云天化合成氨APC项目融合了云天化多年来丰富的操作经验和Honeywell的过程控制技术，在国内同行业首次成功开发并实施了合成氨装置多变量模型预测控制，使云天化在过程控制水平上居同行业领先地位，对同行业装置的先进控制具有很好的借鉴作用和示范意义。
增产和节能降耗是合成氨生产的一个重要研究课题，云天化合成氨APC项目的成功实施和近一年来的稳定运行实践表明，云天化合成氨APC项目使合成氨能耗降低了0．5％左右，在外供天然气充足的情况下产量增加了2％左右，每年可带来500万元以上的直接经济效益。
Capacity up and energy down is a permanent topic for ammonia plant, to ensure a "safe, stable, long-term, fully, perfect" operation of the plant is target for person who is on the ammonia plant to pursue.
To ensure the ammonia plant a stable operation with energy decreasing while capacity increasing, Yunnan Yuntianhua Co, Ltd. (hereinafter called as Yuntianhua) set up the APC (Advanced Process Control) project in December of 2005. The project is jointly developed and implemented by both Honeywell Company and Yuntianhua Company, which is the first real advanced control project with respect to ammonia plant.
The article covers the present situation and development direction for the large scale ammonia plant, analyzes the technical critical point for ammonia process and control, integrates the basic concept of APC system, states the joint development of the APC system between Yuntianhua and Honeywell as well as the key point during the research and implementation, i.e. selection of APC economic points, establishment of APC system design, how to process the step test and so on.
The APC system integrated the workstaff 's long year operation experiences and Honeywell process control technology. It makes Yuntianhua as the first company in the similar industry to develop and implement successfully multi variables appraisement control in ammonia plant, and establish its leading postion in process control ammony the similar industry, which could be act as a reference and sample for other companies.
Capacity increasing and energy decreasing is an important research topic for ammonia plant. After more than one year operation, the APC system shows the energy is decreased by around 0.5% and the capacity is increased by 2% at a condition of shortage of natural gas, which can bring Yuntianhua 5 million profit.
为进一步使合成氨装置运行平稳、消耗降低、产量增加，云南云天化股份有限公司(以下简称云天化)合成氨装置APC(Advanced Process Control，简称APC)项目于2005年12月正式立项。云天化合成氨APC项目是由美国Honeywell公司和云天化共同开发实施的，是国内第一套真正意义上针对合成氨全装置的先进控制项目。
本文介绍了大型合成氨生产技术的现状和未来的发展方向，分析了云天化合成氨生产工艺和生产控制的技术关键，然后介绍了APC的基本概念和原理，接着阐述了云天化和Honeywell公司在云天化合成氨装置共同开发和实施APC的情况，研究并解决了APC的开发和实施中的关键技术问题：APC经济效益点的选取，APC系统设计方案的制定，如何做好阶跃测试工作等。
云天化合成氨APC项目融合了云天化多年来丰富的操作经验和Honeywell的过程控制技术，在国内同行业首次成功开发并实施了合成氨装置多变量模型预测控制，使云天化在过程控制水平上居同行业领先地位，对同行业装置的先进控制具有很好的借鉴作用和示范意义。
增产和节能降耗是合成氨生产的一个重要研究课题，云天化合成氨APC项目的成功实施和近一年来的稳定运行实践表明，云天化合成氨APC项目使合成氨能耗降低了0．5％左右，在外供天然气充足的情况下产量增加了2％左右，每年可带来500万元以上的直接经济效益。
Capacity up and energy down is a permanent topic for ammonia plant, to ensure a "safe, stable, long-term, fully, perfect" operation of the plant is target for person who is on the ammonia plant to pursue.
To ensure the ammonia plant a stable operation with energy decreasing while capacity increasing, Yunnan Yuntianhua Co, Ltd. (hereinafter called as Yuntianhua) set up the APC (Advanced Process Control) project in December of 2005. The project is jointly developed and implemented by both Honeywell Company and Yuntianhua Company, which is the first real advanced control project with respect to ammonia plant.
The article covers the present situation and development direction for the large scale ammonia plant, analyzes the technical critical point for ammonia process and control, integrates the basic concept of APC system, states the joint development of the APC system between Yuntianhua and Honeywell as well as the key point during the research and implementation, i.e. selection of APC economic points, establishment of APC system design, how to process the step test and so on.
The APC system integrated the workstaff 's long year operation experiences and Honeywell process control technology. It makes Yuntianhua as the first company in the similar industry to develop and implement successfully multi variables appraisement control in ammonia plant, and establish its leading postion in process control ammony the similar industry, which could be act as a reference and sample for other companies.
Capacity increasing and energy decreasing is an important research topic for ammonia plant. After more than one year operation, the APC system shows the energy is decreased by around 0.5% and the capacity is increased by 2% at a condition of shortage of natural gas, which can bring Yuntianhua 5 million profit.
引文
[1] 蒋德军．合成氨工艺技术的现状及其发展趋势．现代化工．2005．25(5)：9～14
[2] 袁一．大型合成氨生产工艺．北京：化学工业出版社．1984
[3] 日产1500吨合成氨工艺手册．云天化内部资料
[4] 日产千吨氨厂操作手册．云天化内部资料
[5] 美国M．W．凯洛格型日产千吨氨厂工艺手册．北京：化学工业出版社．1980
[6] 陈五平．无机化工工艺学．北京：化学工业出版社，1996
[7] 于遵宏 朱炳辰 沈才大等．大型合成氨厂工艺过程分析．北京：中国石化出版社，1993
[8] 先进控制项目介绍．Honeywell公司资料
[9] 先进控制(APC)讲座．Honeywell公司资料
[10] 先进控制简述，Honeywell公司资料
[11] 王树青．先进控制技术及应用．北京：化学工业出版社，2001
[12] 章卫国．先进控制理论与方法导论．西安：西北工业大学出版社．2000
[13] 黄德先．化工过程先进控制．北京：化学工业出版社．2006
[14] 席裕庚．预测控制．北京： 国防工业出版社．1993
[15] 王勇．王景芳．Honeywell先进控制在常减压装置上的控制策略．化工自动化及仪表．2003．01．17～19
[16] 陶兴文．先进控制成功应用的四大要素．世界仪表与自动化．2005．6．22～23
[17] 我国工业控制技术发展潮流及热点技术．http://www.cechinamag.com/article/html/2007-03/2007322104306.htm
[18] 王立国．先进控制及优化在海化纯碱生产工艺中的应用．http://www.cechinamag, com/Article/html/2007-O3/200733061845.htm
[19] 田涛．过程计算机控制及先进控制策略的实现．北京：机械工业出版社．2007
[20] 程代展．先进鲁棒控制与自适应控制理论及应用．北京：清华大学出版社．2005
[21] 高东杰．应用先进控制技术．北京：国防工业出版社．2003
[22] 诸静．智能预测控制及其应用．杭州：浙江大学出版社．2002
[23] 孙优贤．工业过程控制技术．北京：化学工业出版社．2006
[24] 程代展．第二十三届中国控制会议论文集(上下册)．上海：华东理工大学出版社．2004
[2] 袁一．大型合成氨生产工艺．北京：化学工业出版社．1984
[3] 日产1500吨合成氨工艺手册．云天化内部资料
[4] 日产千吨氨厂操作手册．云天化内部资料
[5] 美国M．W．凯洛格型日产千吨氨厂工艺手册．北京：化学工业出版社．1980
[6] 陈五平．无机化工工艺学．北京：化学工业出版社，1996
[7] 于遵宏 朱炳辰 沈才大等．大型合成氨厂工艺过程分析．北京：中国石化出版社，1993
[8] 先进控制项目介绍．Honeywell公司资料
[9] 先进控制(APC)讲座．Honeywell公司资料
[10] 先进控制简述，Honeywell公司资料
[11] 王树青．先进控制技术及应用．北京：化学工业出版社，2001
[12] 章卫国．先进控制理论与方法导论．西安：西北工业大学出版社．2000
[13] 黄德先．化工过程先进控制．北京：化学工业出版社．2006
[14] 席裕庚．预测控制．北京： 国防工业出版社．1993
[15] 王勇．王景芳．Honeywell先进控制在常减压装置上的控制策略．化工自动化及仪表．2003．01．17～19
[16] 陶兴文．先进控制成功应用的四大要素．世界仪表与自动化．2005．6．22～23
[17] 我国工业控制技术发展潮流及热点技术．http://www.cechinamag.com/article/html/2007-03/2007322104306.htm
[18] 王立国．先进控制及优化在海化纯碱生产工艺中的应用．http://www.cechinamag, com/Article/html/2007-O3/200733061845.htm
[19] 田涛．过程计算机控制及先进控制策略的实现．北京：机械工业出版社．2007
[20] 程代展．先进鲁棒控制与自适应控制理论及应用．北京：清华大学出版社．2005
[21] 高东杰．应用先进控制技术．北京：国防工业出版社．2003
[22] 诸静．智能预测控制及其应用．杭州：浙江大学出版社．2002
[23] 孙优贤．工业过程控制技术．北京：化学工业出版社．2006
[24] 程代展．第二十三届中国控制会议论文集(上下册)．上海：华东理工大学出版社．2004