化工设计摘要.docx
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化工设计摘要
1.ProcessDesign
1.1RawMaterialandProducts
TherawmaterialofthisprojectisC4hydrocarbonmixture,whosecompositionasfollows:
Table1-1CompositionofRawMaterials
Composition
Fraction/wt%
i-butane
0.4
n-butane
5.8
1-butylene
37.27
Cis2-butene
4.0
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
0.1
Table1-2CompositionandSpecificationofProducts
Item
Testmethod
Nationalstandard/%
Companystandard/%
Quality
Production(kt/a)
1,3-butadiene
GB/T13291-2008
≥99.50(wt%)
99.7%(wt%)
excellentgrade
163
propylene
GB/T7716-2002
≥99.60(V/V)
99.7%(V/V)
excellentgrade
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.
Item
Unit
Amount
1
Productioncapacity
Kt/a
350
2
Plantarea
m2
102408
3
Architecturalarea
m2
23025.4
4
Operationdayinayear
Hours/year
8000
5
Theprojecttotalinvestment
TenthousandYuan
170568.6
6
Fixedassetinvestment(FAI)
TenthousandYuan
106797.7
7
Directmaterialcost
TenthousandYuan
287481.09
8
Totalstaffnumber
people
180
9
Annualtotalcost
TenthousandYuan/a
403071.4
10
Annualsalesproceeds
TenthousandYuan/a
487391.0
11
Annualtotalnetprofit
TenthousandYuan/a
59669.77
12
Investmentprofitratio
%
29.86
13
Staticrateofinvestmentreturns
%
43.44
14
Internalrateofreturns
%
18.96
15
Paybackperiod
Year
4.73
16
NPV
TenthousandYuan
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.