第40卷第2期化工設(shè)計(jì)通訊2014年4月Chemical engineering design communications200kt/a甲醇精餾系統(tǒng)的優(yōu)化設(shè)計(jì)姜濤!,金學(xué)坤,陳鳳娟(1.新疆化工設(shè)計(jì)研究院有限責(zé)任公司,新疆烏魯木齊830006;2.新疆大學(xué)物理科學(xué)與技術(shù)學(xué)院,新疆烏魯木齊830046)摘要:以粗甲醇為原料,采用四塔精餾工藝,基于 Aspen Plus工藝模擬軟件,對(duì)甲醇精餾系統(tǒng)進(jìn)行模擬優(yōu)化設(shè)計(jì)及塔器水力學(xué)計(jì)算;運(yùn)用DR換熱器設(shè)計(jì)軟件,對(duì)本裝置的換熱器進(jìn)行選型計(jì)算。模擬計(jì)算結(jié)果表明,精甲醇產(chǎn)品純度為99.99%(wt)、甲醇收率為99.67%、蒸汽單耗為1.09t、循環(huán)冷卻水單耗為83.24t,產(chǎn)品質(zhì)量符合GB338-2011國(guó)標(biāo)優(yōu)等品及美國(guó)聯(lián)邦A(yù)A級(jí)標(biāo)準(zhǔn)質(zhì)量要求,裝置能耗水平達(dá)到國(guó)內(nèi)先進(jìn)水平關(guān)鍵詞:甲醇精餾; AspenPLUS軟件;EDR軟件;模擬計(jì)算;設(shè)備選型中圖分類號(hào):TQ23.121文獻(xiàn)標(biāo)志碼:A文章編號(hào):1003-6490(2014)02-0057-04Design Optimization of 200 kt/a Methanol Distillation UnitJIANG Tao J /N Xue-hun CHEN Feng-juan(I. Xinjiang Chemical Engineering Design Research Institute Co. Ltd, Urumqi Xinjiang 830006China2. School of Physics Science and Technology, Xinjiang U niversity Urumqi Xinjiang 830046, China)Abstract Refine the crude methanol with the four-column distillation process. U sing the AspenPLUS Simulation softw are to simulate the design optimization and tower hy draulics calculation for themethanol distillation unit Use EDR heat exchanger design softw are to calculate the device option ofheat exchanger. The simulation results show that the refined methanol purity is 99. 99%(wt)ethanol yield is 99. 67%, steam consumption is 1. 09 t/t refined methanol, and circulating coolingwater consumption is 83. 24 t. The methanol quality meets GB 338-201l international superiorproduct and the U.S. Federal Grade AA standard. Also the unit energy consumption level reachesdomestic advanced levelKey words methanol distillation Aspen PLUS: EDR; simulation calculation equipment selection0前言塔溫、塔壓、塔頂回流比、進(jìn)料位置、進(jìn)料溫度進(jìn)行優(yōu)化分析以確定其最佳操作參數(shù);提出雙效甲醇是一種基礎(chǔ)化工原料,在夲研究中,作精餾模型,將加壓塔塔頂氣用作常壓塔再沸器熱為甲基化劑生產(chǎn)甲醛,以供應(yīng)下游BDO裝置。源,將各再沸器凝水用于塔進(jìn)料預(yù)熱,優(yōu)化其換在甲醛生產(chǎn)過程中,甲醇原料的質(zhì)量是其關(guān)鍵控?zé)峋W(wǎng)絡(luò);并運(yùn)用EDR軟件,對(duì)裝置中的換熱器制因素;鑒于此,本文探討200kt/a甲醇裝置精進(jìn)行選型計(jì)算。餾系統(tǒng)的優(yōu)化設(shè)計(jì),以期滿足甲醛生產(chǎn)對(duì)原料甲醇品質(zhì)的要求。在甲醇精餾工藝模擬過程中,1設(shè)計(jì)基礎(chǔ)資料品甲醇質(zhì)量參考取值范圍比較苛刻的GB338產(chǎn)品規(guī)模200kt/a精甲醇2011國(guó)標(biāo)優(yōu)等品及美國(guó)聯(lián)邦A(yù)A級(jí)標(biāo)準(zhǔn)中國(guó)煤化工0h本文針對(duì)裝置的實(shí)際要求,基于 AspenCNMHG產(chǎn)Ps軟件對(duì)四塔精餾過程進(jìn)行全流程模擬;對(duì)(4)操作彈性60%~110%(負(fù)荷)收稿日期:2014-03-15作者簡(jiǎn)介:姜濤(1964-),男,山東昌邑人,高級(jí)工程師,主要從事化工工程設(shè)計(jì)工作?；ぴO(shè)計(jì)通訊第40卷(5)原料粗甲醇成分(見表1)2甲醇精餾系統(tǒng)模擬計(jì)算表1原料粗甲醇成分表%(wt)組分2.1工藝流程(圖1)概述含量組分含量氧化碳0.0119正丁醇0.0119粗甲醇經(jīng)預(yù)熱器加熱后進(jìn)入預(yù)精餾塔,塔頂二氧化碳0.5327二甲基丙醇0,012不凝氣冷卻后送出裝置,塔底出料進(jìn)入加壓塔。乙酸甲酯加壓塔塔頂氣相溫度約127℃,去常壓塔再沸器水5.5373甲酸0.034作熱源,冷凝液部分回流,另一部分作為精甲醇0.012甲酸甲酯產(chǎn)品送出。加壓塔塔底岀料進(jìn)入常壓塔,常壓塔0.004丙酮o.0031塔底排岀廢水,塔頂精甲醇產(chǎn)品送岀。常壓塔側(cè)0.2388丁酮0.0014線采出液進(jìn)入回收塔,回收塔塔底廢水送出裝甲醇93.5398庚烷置,回收塔側(cè)線采岀雜醇油送岀裝置,塔頂甲醇二甲醚0.0006二甲基庚烷0.0007蒸氣冷卻后送回常壓塔。常壓塔塔底0.8MPa乙醇四甲基庚烷(G)蒸汽冷凝液作為預(yù)精餾塔和加壓塔預(yù)熱器熱正內(nèi)0.0154辛烷0.0004源,以回收能量。脫鹽水預(yù)塔一冷預(yù)塔二冷精甲醇冷卻器10%堿液2300kg/h冷凝器冷凝器(回流罐粗甲醇原料預(yù)加常粗甲醇預(yù)熱器4MPa蒸汽08MPa蒸汽雜醇油冷卻器雜醇油冷凝水再沸器再沸器再沸器,x◇g◇精甲醇冷卻器1圖1甲醇精餾四塔工藝流程簡(jiǎn)圖2.2模型建立及熱力學(xué)方法運(yùn)用 Aspen Plus軟件對(duì)甲醇精餾四塔工藝粗甲醇屬于非極性體系,可選的物性方法有過程進(jìn)行全流程模擬,結(jié)果見表2。WILSON、NRTL、 UNIQUAC等。據(jù)文獻(xiàn)及通過物料衡算,參照GB338-2011國(guó)標(biāo)優(yōu)現(xiàn)有裝置模擬分析,預(yù)精餾塔及加壓塔采用等品質(zhì)量要求,對(duì)本設(shè)計(jì)進(jìn)行對(duì)標(biāo)分析可以知UNIQUAC熱力學(xué)方法,常壓塔及回收塔選用道,產(chǎn)品指標(biāo)均達(dá)到要求;精甲醇產(chǎn)品純度為NRTL熱力學(xué)方法。精餾選用 Radfrac嚴(yán)格法精餾模型,換熱器選用HeaX模型,回流罐選用Flash模型,輸送泵選用Pump模型。dh醢收率為99.67%、蒸汽單耗中國(guó)煤化工毛為83.24t,裝置能耗CNMH標(biāo)結(jié)果詳見表3計(jì)算過程采用 Sensitivity及 Optimization優(yōu)化工具對(duì)各塔塔板數(shù)、進(jìn)料位置、溫度、壓力、3設(shè)備選型計(jì)算回流比等操作參數(shù)進(jìn)行優(yōu)化設(shè)計(jì)3.1精餾塔器2.3工藝過程模擬計(jì)算運(yùn)用 Aspen Plus軟件 Tray Sizing及Pack第2期姜濤等:200kt/a甲醇精餾系統(tǒng)的優(yōu)化設(shè)計(jì)·59表2甲醇精餾裝置工況及物料平衡表物流號(hào)(對(duì)應(yīng)圖1)40,0壓力/kPa501.3501,3125,0779,1819,1104.0129,3159.2體分率質(zhì)量流量/kg/h29647.531624.5323.047700.047700.01520.016424.512440.03804.5180體積流量/m3/h40,1177,1635171,922,216,1密度/kg/m742,7663,7774,8740,08978.3948.9組分(摩爾分率氧化碳0.000120.000000.010920.000000.00000000000,000000,000000,000000,00000氧化碳005330.000000.488900.000000.000000,000000,000000,000000,000000,000000.000020.000000.001930.000000.000000.000000.000000.000000.000000.000000.055370.124640.000080.000000.000000.000000.239990.000000.994350.8815甲烷0.000120.000000.011010.000000.000000.000000.000000.000000.000000.00000氮?dú)?.000040.000000.003670.000000.000000.000000.000000.000000.000000.00000氬氣0.002390.000000.219160.000000.000000.000000.000000.000000.000000.000000.935400.874520.235150.999990.999990.999990.758410.999990.000010.09208二甲醚0.000010.000000.000550.000000.000000.000000.000000.000000.000000,000000.000140.000130.000000.000010.000010.000010.000250.000010.000070.02099正丙醇0.000150.000140.000000.000000.000000.000000.000280.000000.001110.001880.000120.000110.000000.000000.000000.000000.000210.000000.000920.0001二甲基丙醇0.000120.000110.000000.000000.000000.000000.000220.000000.000930,000乙酸甲酯0.000080.000000.007340.000000.000000.000000.000000.000000.000000.000甲酸0.000340.000320.000000.000000.000000.000000.000620.000000.002580.00167甲酸甲酯0.000180.000000.016520.000000.000000.000000.000000.000000.000000.000000.000030.000010.002320.000000.000000.000000.000010.000010.000000.00000丁酮0.000010.000010.000050.000000.000000.000000.000020.000000.000030.001440.000010.000000.000640.000000.000000.000000.000000.000000.000000.00000甲基庚烷0.000010.000000.000640.000000.000000.000000.000000.000000.000000.00000甲基庚烷0.000010.000000.000730.000000.000000.000000.000000.000000.000000.00000辛烷0.000000.000000.000370.000000.000000.000000.000000.000000000.00000Sizing模塊對(duì)精餾塔器進(jìn)行初步選型計(jì)算,結(jié)果表4甲醇精餾塔器選型計(jì)算表見表4項(xiàng)目數(shù)值/規(guī)格表3甲醇精餾裝置模擬計(jì)算值對(duì)標(biāo)表預(yù)精餾塔理論板數(shù)指標(biāo)模擬計(jì)算值精餾段規(guī)整填料350Y,總高度2.0m提餾段浮閥塔盤,共42塊(實(shí)際值);總高度約18m產(chǎn)品指標(biāo)塔高(切線)20m純度%(w1)≥99.8599,99乙醇/10-6(wt)里論板數(shù)丙酮和乙醛/106(wt)精餾段兩段規(guī)整填料350Y,總高度10.0提餾段浮閥塔盤,共32塊;總高度約15丙醛/10-6(wt)塔高游離酸(HAC計(jì))/10-6(wt)常壓堿度/10-6(wt)里論板數(shù)45水分%(wt≤0.10中國(guó)煤化工塊;板間距0.45m廢水中甲醇含量/106(wt)CNMHG甲醇收率醇產(chǎn)量/kg/h27640.0收理論板數(shù)進(jìn)裝置甲醇量/kg/h兩段規(guī)整填料350Y,總高度6.0m蒸汽單耗/提餾段兩段規(guī)整填料350Y,總高度6.0循環(huán)冷卻水單耗/t832460·化工設(shè)計(jì)通訊第40卷3.2換熱器(3)方案設(shè)計(jì)過程中,采用雙效精餾及換熱運(yùn)用EDR軟件,對(duì)換熱器進(jìn)行初步選型計(jì)網(wǎng)絡(luò)優(yōu)化,降低了再沸器蒸汽用量,保證了蒸汽算,結(jié)果見表5單耗低于1.2t的限額。表5換熱器選型計(jì)算表(4)精餾塔器及換熱器選型計(jì)算,提供了可序號(hào)設(shè)備名稱供參考的設(shè)備選型方案?？偠灾?本研究可為1粗甲醇預(yù)熱器1BEM400-4/4-30.5-4.5/25-41甲醇精餾系統(tǒng)的設(shè)計(jì)提供較為完備的工藝包。2預(yù)塔再沸器1BEM1200-44-179.2-2.5/32-113預(yù)塔主冷凝器1BEM800-44-194.2-6/25-21參考文獻(xiàn)預(yù)塔次冷凝器1BEM550-4/4-70.3-4.5/251]董華,高硫煤綜合利用甲醇生產(chǎn)危險(xiǎn)有害性分析評(píng)價(jià)及預(yù)5加壓塔第一預(yù)熱器1BEM800-44-234.5-6/25-11控[D].天津:天津大學(xué)學(xué)生論文,20126加壓塔第二預(yù)熱器1AEM300-4/4-13.7-3/25-21[2]褚立志,甲醇三塔精餾工藝[J].河北化工,2010,37加壓塔再沸器2BEM1400-4/4(6):50~528加壓塔頂后冷器1BEM500-4/4-37.5-3/253]黃風(fēng)林,向小鳳,甲醇精餾過程四塔流程模擬分析匚J]9常壓塔再沸器2BEM1800-44-491.3-3/32-11石油與天然氣化工,2007,36(1):18~2110常壓塔冷凝器1BEM1200-44-509.5-6/25-114]牛寶玉,吳紅超,王玉斌,甲醇裝置三塔精餾運(yùn)行總結(jié)11回收塔再沸器BEM400-44-16.9J].化工設(shè)計(jì)通訊,2012,38(4):80~822回收塔冷凝器1BEM400-4/4-21.9-3/25-41[5]劉源貴,馬希凱,蘭文禮,三塔精餾技術(shù)在甲醇工業(yè)精餾3廢水冷卻器1BEM500-4/4-41.2-3/25-21中的應(yīng)用[J].石油化工應(yīng)用,2009,29(2):113~11414雜醇油冷卻器AEM300-44-12.16]葛方晉,三塔流程甲醇精餾技術(shù)的應(yīng)用[J].小氮肥5精甲醇冷卻器IBEM500-44-67.8-6/25-212007,35(12):12-146精甲醇冷卻器ⅡBEM600-4/4-129.5-6/25-117]臧楠.甲醇精餾工藝模擬計(jì)算與優(yōu)化及新工藝研究[D注:換熱器主要材質(zhì)均為CS(碳鋼)西安:西安石油大學(xué)碩士論文,2011[8]薛長(zhǎng)征,精甲醇中水含量的優(yōu)化控制[J].中國(guó)化工貿(mào)易4總結(jié)9]陳金,焦?fàn)t摻燒甲醇弛放氣提高甲醇產(chǎn)量的工藝及裝備研(1)通過模擬優(yōu)化設(shè)計(jì),本四塔甲醇精餾裝究[D].天津:河北工業(yè)大學(xué)碩士論文,2011置生產(chǎn)的精甲醇純度高、收率高;裝置能耗低,[10]田旭,劉小英,秦麗萍,等.甲醇精餾工藝流程分析蒸汽單耗僅為1.09t,循環(huán)冷卻水單耗為83.24「J].小氮肥,2011,39(11):1~5t;環(huán)保水平高,廢水中甲醇含量?jī)H為12×1面粗光,張?jiān)屏?王劍鋒,甲醉精過程節(jié)能降耗初探10-6,遠(yuǎn)低于30×10°的限額[J].化學(xué)工業(yè)與工程技術(shù),2013,34(1):36~3912]張銳.年產(chǎn)50萬噸甲醇精餾裝置的數(shù)值模擬計(jì)算及優(yōu)化(2)全流程模擬中,選擇了合適的熱力學(xué)模D].天津:天津大學(xué)研究生論文,2012型及設(shè)備模型,采用優(yōu)化工具對(duì)操作參數(shù)進(jìn)行處13]王宗濤,楊龍慧.甲醇精餾操作優(yōu)化[].化工設(shè)計(jì)通理,以降低能耗,并得出了優(yōu)化的設(shè)計(jì)方案。訊,2013,39(2):70~71(上接第47頁(yè))液,具有一定的利用價(jià)值高洗器3結(jié)語調(diào)溫?zé)崴畖循環(huán)加熱器在CO2汽提法尿素裝置中,各冷卻設(shè)備均通過循環(huán)水換熱,某些物料工藝上要求換熱后溫?zé)崮芑厥斩勿s塔度較高,汶將會(huì)伂拖執(zhí)后循環(huán)水溫度較高,導(dǎo)致中國(guó)煤化工丸效果,進(jìn)而影響到系CNMHG中,據(jù)具體情況,對(duì)圖2增加熱能回收段后高壓調(diào)溫水流程換熱后工藝上要求溫度較高的物料,應(yīng)對(duì)該部分中H2含量較高,在爆炸限以內(nèi),為了裝置的安熱量予以回收,以達(dá)到節(jié)能降耗的目的。以上是全運(yùn)行,高壓調(diào)溫水溫度控制在110~120℃之筆者對(duì)實(shí)際生產(chǎn)中裝置熱能回收的一些認(rèn)識(shí),期間,此時(shí)回水溫度在135℃以上,利用它加熱尿待與同行們進(jìn)行交流,如有不足之處,請(qǐng)指正。