化工设计摘要Word文件下载.docx

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Trans-2-butene

5.16

i-butene

1.17

1,2-butadiene

-

1,3-butadiene

45.3

1-butyne

2-butyne

Vinylacetylene

0.7

C5

0.1

C3

Table1-2CompositionandSpecificationofProducts

Item

Testmethod

Nationalstandard/%

Companystandard/%

Quality

Production（kt/a）

GB/T13291-2008

≥99.50（wt%）

99.7%（wt%）

excellentgrade

163

propylene

GB/T7716-2002

≥99.60（V/V）

99.7%（V/V）

145

ethylene

GB/T7715-2003

≥99.90（V/V）

99.9%（V/V）

first-class

32

1.2ProcessScheme

Thisprojectconsistsoftwosections:

butadieneextractionandraffinateC4catalyticcracking.ThesectionofbutadieneextractionistoextractthebutadienefromtheC4hydrocarbonmixturerawmaterial,whichconsistsofdoubleextracting,doublestrippingandbutadienepurification.Thesectionofcatalyticcrackingconsistsofcatalyticcrackingandseparating,whichproducedpolymergradepropyleneandethylene.

Figure1-1ButadieneExtractionProducePFD

Figure1-2RaffinateC4CrackingProducePFD

1.3MainInnovationofProcess

（1）.C4~C8olefinscanbereactedintheZSM-5catalyst.SotheC4~C5olefinscanberecycledtotherawmaterial,whichimprovestheyieldcoefficientofpropylene.

（2）Wefoundthebestconditionsofcatalyticcrackingreactionfromrelatedpatent.Butthebestdimensionofthereactorisunknown.Forthat,wesimulatedthreedifferentaspectratiosofreactorbyusingComsolMultiphysics.Fromtheresultofsimulation,wegotthebestdimensionofreactor.

Figure1-3TheResultofSimulationbyComsolMultiphysics

（3）.ThecontrolparametercanbeoptimizedbyAspenDynamics,whichhasguidingsignificanceforthepracticaloperation.

Figure1-2TheSimulationofPropyleneCouplingTower

2.Energy-savingDesign

2.1SimulationofHeatExchangerNetwork

Accordingtopinchpointtheory,weanalyzedtheheatexchangernetworkoftheproductionofbutadiene,propyleneandethylenebyAspenEnergyAnalyzer,researchingthebottleneckoftheusingofheatexchangernetwork,soastofindouttheirrationalpartsandreasons.Withthatwecanmeettheminimumcostofutilitysystemandequipment.

Figure2-1ButadieneExtractionSectionEnergyMatching

Figure2-2RaffinateC4CrackingSectionEnergyMatching

Figure2-3PartofHeatExchangeMethodSimulation

2.2TertiaryRefrigerationTechnology

Thetraditionalrefrigerantmethane,ethyleneandpropylenearemixedproportionatelyinarefrigerationcompressortoofferkindsofrefrigerantofdifferenttemperatureleveltothecoolingutilitysystem.Withthistechnology,weturnedthreeindependentrefrigeratingsystemintoone,whichreducedthecostofequipment.

3.SecurityScheme

3.1SecurityRiskAnalysis

Thetanksofbutadiene,propyleneandethylenearethemajorhazardinstallations,whichisanalyzedbyRisksystem.Bysimulatingpoolfireaccident,vaporexplosionaccidentandvaporcloudexplosionmodel,wecanforecastthedamagerangeandtakethesafetymeasures.

3.2EventTreeAnalysis

Byusingeventtreetoanalyzethegas-liquidseparator,weobtaintheimprovementmethod.

4.EquipmentDesign

AccordingtotheprocesssimulationresultsfromAspenplus,wedesignthereactorR0201,de-ethanetowerT0202andheatexchangerE0103indetail.WiththehelpofKG-towerandSW6-98,wecheckedalltowersinthisproject.Also,alltheheatexchangerischeckedbySW6-98andAspenHTFS.Besides,weaccomplishedthemodelselectionofallthestandardequipmentsuchaspump,compressor,tower,storagetank,buffertank,refluxtanketc.

5.ControlScheme

Takingthe“safetyfirst”asourdesignprinciple,HAZOPisusedtoanalyzethebutadieneextractiontower,catalyticcrackingreactor,compressorandpropylenetanks.Then,weutilizeAspenDynamicstosimulatethecontrolconditionsofpropylenecouplingtower.

6.LayoutScheme

FromthecomparisonoftheXinjiangKelamayiMunicipalityDushanziDistrict,FujianProvinceQuanzhouMunicipalityQuangangDistrictandTianjinMunicipalityBinhaiDistrict,wefinallyselectedXinjiangKelamayiMunicipalityDushanziDistrictasthesiteofourplantforitssuperiorgeographiclocation,abundantrawmaterialsourceandprivilegenationalpolicy.

Thelayoutschemefollowedthepolicyof“Taketheadvantageofeveryinchofland,preserveeveryinchoffarmland”.Adjustmeasurestolocalconditions,landconservation,andimprovelanduse.Ourplantlayoutschemeasfollows:

Figure6-1PlantLayout

7.EconomyAssessment

Throughtheinvestmentestimateandfinancialevaluation,weobtainedthecomprehensivetechnicalandeconomicindexshownastable7-1.

Table7-1ComprehensiveTechnicalandEconomicIndex

No.

Unit

Amount

1

Productioncapacity

Kt/a

350

2

Plantarea

m2

102408

3

Architecturalarea

23025.4

4

Operationdayinayear

Hours/year

8000

5

Theprojecttotalinvestment

TenthousandYuan

170568.6

6

Fixedassetinvestment（FAI）

106797.7

7

Directmaterialcost

287481.09

8

Totalstaffnumber

people

180

9

Annualtotalcost

TenthousandYuan/a

403071.4

10

Annualsalesproceeds

487391.0

11

Annualtotalnetprofit

59669.77

12

Investmentprofitratio

%

29.86

13

Staticrateofinvestmentreturns

43.44

14

Internalrateofreturns

18.96

15

Paybackperiod

Year

4.73

16

NPV

89256.54

8.Summary

Takingthe“safetyandsteady,energy-savingandenvironmentalprotection,harmoniousdevelopment”asourdesignprinciple,weaccomplishthewholepreliminarydesignof350kt/aC4comprehensiveutilizationproject.

Therawmaterialsourceandproductschemearemadebyresearchingrelatedpatentandmarketanalysis.Then,Aspenplusisusedtocompletethecalculationofthisprocess.Accordingtothesimulationresult,AspenEnergyAnalyzerisusedtooptimizetheprocessofenergyintegration.Also,withthehelpofAspenplus,weaccomplishedthesimulationcalculationoftheutility.Inaspectofsecurity,weciteDow’sFire&

ExplosionindexmethodtoassessthetanksandforecastthedamagerangebyRisksystem.Inaspectofcontrol,weutilizeHAZOP、eventtreeanalysistoanalyzepartofequipments,andAspenDynamicsisusedtooptimizethecontrolparametersofpropylenecouplingtower.Atlast,thecatalyticcrackingreactorisoptimizedbyComsolMultiphysics.