通用炼油厂水系统优化模型开发与应用

传统水系统优化往往只考虑了新鲜水用量,而忽视了除盐水、除氧水、各等级蒸汽、蒸汽冷凝水、循环冷却水等类型的水,缺乏对各类型水量关联性的研究。针对这种局限性,提出了包含多种类型水的通用用水过程模型,以及通用炼油厂水系统优化的超结构和相应的数学模型,模型中集成了各装置及各种类型水之间关联的物料衡算方程。利用商业软件GAMS对某炼油厂的水系统进行建模求解,案例分析结果表明,除盐水用量有所下降,回用水用量增加,在优化前后雨水量保持469.36 t·h-1的情况下,系统的新鲜水用量从489.44 t·h~(-1)减小到283.94t·h~(-1),以系统新鲜水量和雨水量之和为基准,节水率达到21.4%。加工吨原油取水量从0.649 t减小至0.510 t,接近国内先进水平。案例研究表明,提出的优化模型能够有效地计算整个炼油厂水系统的新鲜水用量,验证了该模型的实用性。     

除盐水系统建模与物料衡算分析

新鲜水的工业除盐系统通常涉及膜分离(例如超滤、反渗透等),阴阳离子交换树脂床和储罐等。其中离子交换和膜分离单元可看作单入口双出口的半连续过程单元,具有间歇用水过程的特征。然而,尚未有关于除盐水系统的间歇水网络综合的研究报告。对除盐水系统中双出口半连续单元和水箱分别建立流量衡算、杂质质量衡算模型和储罐模型。根据不同工况下除盐水的需求量,利用GAMS软件平台对建立的数学模型进行求解,得出除盐水系统中每个储罐的容量和对应的新鲜水用量。进一步根据储罐最大容量需求,设计出满足不同工况条件下储罐容量。简化的工业案例研究验证了所提出模型的有效性。     

除盐水系统建模与物料衡算分析

新鲜水的工业除盐系统通常涉及膜分离（例如超滤、反渗透等），阴阳离子交换树脂床和储罐等。其中离子交换和膜分离单元可看作单入口双出口的半连续过程单元，具有间歇用水过程的特征。然而，尚未有关于除盐水系统的间歇水网络综合的研究报告。对除盐水系统中双出口半连续单元和水箱分别建立流量衡算、杂质质量衡算模型和储罐模型。根据不同工况下除盐水的需求量，利用GAMS软件平台对建立的数学模型进行求解，得出除盐水系统中每个储罐的容量和对应的新鲜水用量。进一步根据储罐最大容量需求，设计出满足不同工况条件下储罐容量。简化的工业案例研究验证了所提出模型的有效性。     

基于梯级用水的工业水系统节水优化研究

水系统节水优化是一种从系统层面分析水系统节水潜力的方法,借助数学模型可实现节水的量化研究。阐述了一种基于外排水再利用的水系统节水优化模型,并利用Vogel方法实现模型的求解。以火电企业为典型用水案例进行研究,将案例企业用水系统划分为6个子系统(循环冷却水系统、灰渣水系统、化学除盐水系统、脱硫用水系统、生活消防用水系统、其他杂用水系统),在污水排放改造的基础上构建了基于成本最优的节水优化模型并进行了求解。经案例研究发现,优化带来的经济效益最为明显,其次是节水、生态效益。案例企业优化后综合发电耗水、总用水成本、新鲜水取用量降幅分别为10.3%、13.6%、11.2%,对缓解当地水环境污染以及地下水开采压力具有积极意义。     

水系统逐层优化法在煤制甲醇中的应用

从工程实际出发,结合水夹点优化技术,应用水系统逐层优化法对某煤制甲醇工厂用水进行节水潜力分析.结果表明,在不添加设备的情况下,可节约新鲜水54t/h,降低废水排放54t/h.若增加浓水回收反渗透设备,则可减少新鲜水用量和降低废水排放各159t/h.水系统逐层优化法尤其适用于现有工艺用水网络改造优化.     

清净下水回用技术及运行分析

介绍了某炼油厂300 t/h清净下水回用装置的运行情况。该装置由清净下水提升泵、微错流反应器、流砂过滤器、清水池、再生水外供泵、加药系统等部分组成。分析了清净下水水质对回用水装置的影响,以及回用水对循环水质量的影响。装置运行结果表明:回用水装置投用前后,循环水质量未发生较大变化,未出现超标数据。原水经过再生处理后,再生水水质达到生产给水水质控制指标,可替代部分新鲜水,回用至炼油厂作为循环冷却水系统、消防水系统的补充水。回用水装置投用后,循环水装置补水量大幅度降低,节水减排效果显著。     

延迟焦化装置降成本改造措施

延迟焦化装置能耗主要为燃料气、电能、蒸汽和水。以某设计能力100万t/a的延迟焦化装置为例,对其能耗结构及用能单耗进行了分析,指出降低装置综合能耗的关键是降低燃料气消耗、电消耗及蒸汽消耗。针对各用能单耗情况,采取了加热炉改造、采暖水换热系统优化、重油装置渣油直供焦化装置、冷焦过程配除盐水减少蒸汽、调整除焦时间等措施,每年可节省运行成本1800万元以上。     

毛细吸液芯冷却顶板流动阻力及制冷特性

基于现有空调系统耗能高,舒适性不够均匀,提出了多孔介质柠檬酸钾-石膏配制而成的毛细吸液芯辐射-冷却顶板,在用水作冷却介质时毛细吸液芯辐射-冷却顶板就成了一块内含多孔介质的均布流道。对以多孔介质孔隙率为55.3%的毛细吸液芯为例,水作为载冷剂流过毛细吸液芯冷却顶板进行了实验研究。介绍了毛细吸液芯冷却顶板的结构和内部配置,并通过搭建实验模型在维持室内温度（26±1）℃分布的情况下对其换热量进行了测试,分析了不同流量条件下流量与阻力的关系。结果表明,在冷水进口温度为10～16℃的条件下,相比常规蛇形辐射管,制冷量提高了36.6%～57.7%,当水流量从4 L·h^-1变化到28 L·h^-1时,黏性力减弱,摩擦因子逐渐减小,渗透率逐渐增大,但当流量从28 L·h^-1变化到40 L·h^-1时,渗透率开始减小。     

非洲干旱地区节水型炼油厂水系统设计的探讨

水资源是制约非洲干旱地区新建炼油厂的重要因素之一,因此,如何节水、用水,是炼油厂必须面对的问题。结合实际工程,通过对炼油厂取水、净化水、循环冷却水、除盐水、污水处理及污水回用水系统设计的分析,总结了炼油厂水系统的设计方法、节水思路和措施,对类似干旱地区炼油厂工程设计有一定的借鉴意义。     

粒焦处理尿素废碳铵液杂质

1　问题的提出山西焦化集团有限公司水处理站原设计为串联 H- Na离子交换软化系统 ,出力 1 2 0 t/h,供动力 3台 3 5 t/h锅炉及化肥系统废热锅炉用水。1 998年 1 0月 ,为提高蒸汽品质 ,解决锅炉炉水含盐量高、排污量大、供热管网积盐、化肥生产系统催化剂结块等问题 ,采用了徐州水处理研究所浅除盐水技术 ,对软化水系统实施了改造 ,其工艺为 :弱酸 强酸 弱碱 脱碳经两年多运行表明 ,效果良好 ,锅炉给水、炉水及蒸汽指标明显改善 ,达到了预期目的。该浅除盐水处理工艺采用尿素生产过程中产生的废碳铵液作为阴床再生液 ,既解决了废碳铵液出…     

Process optimization of an industrial acetic acid dehydration progress via heterogeneous azeotropic distillation

The simulated process model of the HAc dehydration process under actual overloaded condition was conducted by amending the model of standard condition in our previous work using the process data collected from actual production. Based on the actual process model, the operation optimization analysis of each plant(HAc dehydration column, decanter and NPA recycle column) was conducted using Residue Curve Maps(RCMs),sensitivity analysis and software optimization module. Based on the optimized parameters, the influence of feed impurity MA and the temperature of decanter on the separating effect and energy consumption of the whole process were analyzed. Then the whole process operation optimizing strategy was proposed with the objective that the total reboiler duty Q Total of C-1 and C-3 reaches the minimum value, keeping C-1 and C-3 at their optimized separation parameters obtained above, connecting all the broken recycle and connection streams, and using the temperature of D-1 as operation variable. The optimization result shows that the total reboiler duty Q Total of the whole process can reach the minimum value of 128.32 × 10~6 k J·h~(-1) when the temperature of decanter is 352.35 K, and it can save 5.94 × 10~6 k J·h~(-1), about 2.56 t·h~(-1) low-pressure saturated vapor.     

干-湿冷却系统对空冷机组热经济性影响的分析

受环境温度影响, 空冷机组夏季工况的运行背压高, 严重限制了机组的带负荷能力, 并影响机组的热经济性和安全性。分析了一种干-湿混合冷却系统, 将汽轮机排汽分流出一部分通过循环水冷却, 以降低机组夏季工况背压。建立了干-湿混合冷却系统对机组热经济性影响的数学模型, 并以某330 MW直接空冷机组为例揭示了机组背压和净功率随主蒸汽流量、湿冷分流量以及环境温度的变化规律。结果表明:主蒸汽流量为1120 t·h^-1、湿冷分流量为175 t·h^-1时, 机组出力从326.266 MW达到330 MW满负荷运行, 提高了3.734 MW, 背压由46.8 kPa下降到31.9 kPa, 机组的热耗率降低了110.9 kJ·(kW·h)^-1, 发电标准煤耗率降低了4 g·(kW·h)^-1。     

基于可靠性分析的用水网络优化设计

由于水资源的有限性,用水网络的优化设计问题一直是研究热点。可靠性问题关系着安全生产并且和实际生产有着直接的经济联系,也越来越受到关注。这里提出基于可靠性分析的用水网络优化设计方法,应用多目标优化方法中的层次分析法,首先满足用水系统可靠性要求,在满足可靠性基础上优化用水网络,从而使最终的用水网络满足可靠性要求且新鲜水用量最小。计算实例表明了该方法的有效性。     

Coupling pinch analysis and rigorous process simulation for hydrogen networks with light hydrocarbon recovery

In refineries, some hydrogen-rich streams contain considerable light hydrocarbons that are important raw materials for the chemical industry. Integrating hydrogen networks with light hydrocarbon recovery can enhance the reuse of both hydrogen and light hydrocarbons. This work proposes an automated method for targeting hydrogen networks with light hydrocarbon recovery. A pinch-based algebraic method is improved to determine the minimum fresh hydrogen consumption and hydrogen sources fed into the light hydrocarbon recovery unit automatically. Rigorous process simulation is conducted to determine the mass and energy balances of the light hydrocarbon recovery process. The targeting procedures are developed through combination of the improved pinch method and rigorous process simulation. This hybrid method is realized by coupling the Matlab and Aspen HYSYS platforms. A refinery hydrogen network is analyzed to illustrate application of the proposed method. The integration of hydrogen network with light hydrocarbon recovery further reduces fresh hydrogen requirement by 463.0 m³·h^-1 and recovers liquefied petroleum gas and gasoline of 1711.5 kg·h^-1 and 643 kg·h^-1, respectively. A payback period of 9.2 months indicates that investment in light hydrocarbon recovery is economically attractive.     

Upgrading Siberian (Russia) crude oil by hydrodesulfurization: Kinetic parameter estimation in a trickle-bed reactor

Hydrodesulfurization(HDS) of sour crude oil is an effective way to address the corrosion problems in refineries and is an economic way to process sour crude oil in an existing refinery built for sweet oil.Siberian crude oil transported through the Russia-China pipeline could be greatly sweetened and could be refined directly in local refinery designed for Daqing crude oil after the effective HDS treatment.In this study,the HDS of Siberian crude oil was carried out in a continuous flow isothermal trickle-bed reactor over Ni-Mo/γ-Al_2 O_3.The effects of temperature,pressure and LHSV were investigated in the ranges of 320-360℃,3-5 MPa and 0.5-2 h~(-1),keeping constant hydrogen to oil ratio at 600 L·L~(-1).The HDS conversion could be up to 92.89% at the temperature of 360℃, pressure of 5 MPa,and LHSV of 0.5 h~(-1), which is sufficient for local refineries(84%).A three phase heterogeneous model was established to analyze the performance of the trickle-bed reactor based on the two-film theory using Langmuir-Hinshelwood mechanism.The order of sulfur component is estimated as 1.28,and the order of hydrogen is 0.39.By simulating the reactor using the established model,the concentration of H_2, H_2 S and sulfur along the catalyst bed is discussed.The model is significantly useful for industrial application with respect to reactor analysis,optimization and reactor design,and can provide further insight of the HDS of Siberian crude oil.     

Simultaneous recovery of phosphorus and nitrogen from liquid digestate by vacuum membrane distillation with permeate fractional condensation

A vacuum membrane distillation(VMD) process with permeate fractional condensation on membrane downstream has been developed for simultaneous recovery of phosphorus and nitrogen from liquid digestate. The polytetrafluoroethylene(PTFE) membrane flux could reach 6000 g·m~(-2)·h~(-1) with the rejection efficiency of total phosphorus(TP) over 0.99, under the condition of flowrate being 120 L·h~(-1) and temperature being 40°C. Membrane fouling occurred with a film of organics and microorganism deposited on the surface of the membrane. Membrane flux could be reversed after the membrane was rinsed by water. Higher feed temperature and flowrate could improve the membrane flux, while hardly affect the rejection efficiency of total phosphorus. The concentration of TP could reach 1600 mg·L~(-1) after membrane distillation, which is about 5 times of that in initial liquid digestate. On the downstream of the membrane, some of the permeate vapor was condensed under the vacuum condition and most of water was collected here. The remaining vapor enriched with total nitrogen(TN) was compressed and pumped to the atmospheric condition to condense. The TN concentration in atmospheric condensate was as high as 7000 mg·L~(-1) with the process separation factor for ammonia being enhanced to 114.     

Fuzzy optimization design of multicomponent refinery hydrogen network

Hydrogen and light hydrocarbon components are essential resources of the refinery. The optimization of the refinery hydrogen system and recovery of the light hydrocarbon components contained in the gas streams are key strategies to reduce the operating costs for sustainable development. Many research efforts have been focused on the optimization of single impurity hydrogen network, and the flowrates of the hydrogen sources and sinks are assumed to be constant. However, their flowrates vary along with the quality of crude oil and refinery processing plans. A general superstructure of multicomponent refinery hydrogen network is proposed, which considers four components, namely H₂, H₂S, CH₄ and , as well as the flowrate variations of hydrogen source and hydrogen sink. The mathematical model based on the superstructure is developed with objective functions, including the minimization of total annualized cost and the maximization of overall satisfaction of the hydrogen network. Moreover, the model considers the removal of hydrogen sulfide and the recovery of light hydrocarbon components (i.e.C₂₊, ) in the optimization. To verify the applicability of the proposed mathematical model, a simplified industrial case study with four scenarios is solved. The optimization results show that the economic benefit can be maximized by considering both the direct reuse of gas streams from high-pressure separator (HP gas stream) and from low-pressure separator (LP gas stream) and the recovery of the light hydrocarbon streams. The fuzzy optimization method can be used to guide the optimal design of the refinery hydrogen system with multi-period variable flowrates.     

Conceptual design of an extractive distillation process for the separation of azeotropic mixture of n-butanol-isobutanol-water

In many chemical processes, large amounts of wastewater containing butanol and isobutanol are produced. Given that n-butanol-isobutanol-water can form triple azeotrope, high-purity butanol cannot be recovered from the wastewater by ordinary distillation. To economically and effectively recover butanol from this kind of wastewater, 1,4-butanediol is selected as an extractant to break the formation of the azeotropes, and a doubleeffect extractive distillation process is proposed. The conceptual design of the proposed process is accomplished based on process simulation. With the proposed process, the purity of recovered butanol and water is greater than 99.99 wt%. In comparison with the conventional azeotropic distillation process, economic analysis shows that the operating cost of the proposed process is lower:when the capacity of wastewater treatment is 100 t·h^-1, the total operating cost decreases by 5.385×10⁶ USD per year, and the total annual cost of the new process decreases by 5.249×10⁶ USD per year. In addition, in the extractive distillation system, variable effects on separation purities and cost are more complex than those in the ordinary distillation system. The method and steps to optimize the key variables of the extractive distillation system are also discussed in this paper and can provide reference for similar studies.     

冷却水流量对ORC系统性能影响的实验研究

采用自主研发的单螺杆膨胀机作为机械动力,实验研究了冷却水流量对ORC余热发电测试系统及单螺杆膨胀机性能的影响。实验结果表明：当冷却水流量从8 m³·h^-1升至19 m³·h^-1时,单螺杆膨胀机输出功和轴效率分别从4.31 kW、36.38%增至5.15 kW、41.1%,分别增加了19.5%、13%。针对本实验系统,在考虑润滑油泵、工质泵、冷却水泵和冷却塔风扇等所有系统辅机功耗之后,当冷却水流量为12 m³·h^-1时,系统净输出功和系统净效率达到最大值,分别为2.44 kW和2.47%。通过研究冷却水流量对ORC系统性能的影响,为ORC冷却系统的设计和优化系统性能提供重要的实验依据。     

基于空冷的疏水陶瓷膜冷凝器用于烟气脱湿过程强化的实验研究

以环境空气为冷源,采用硅烷接枝的疏水Al₂O₃陶瓷膜构建膜冷凝器开展烟气脱湿实验。对比了疏水陶瓷膜与传统疏水钢管的冷凝性能;系统考察了烟气流量、烟气温度、吹扫因子、吹扫气温度、跨膜压差等过程参数对疏水陶瓷膜水回收性能的影响;比较了疏水陶瓷膜冷凝器(空冷)与亲水陶瓷膜冷凝器(水冷)的冷凝性能。结果表明,相同水接触角下(120°),多孔陶瓷膜的烟气温降是致密304钢管的1.3~2.5倍,疏水陶瓷膜能有效强化冷凝传热。疏水陶瓷膜的过程水通量随烟气流量、烟气温度、吹扫因子的增加而上升,随跨膜压差、吹扫气温度的增加而降低。过程水回收率随烟气流量、跨膜压差、吹扫气温度的增加而降低,随吹扫因子的增加而增加,随烟气温度的增加先上升,然后趋于稳定,而后下降。实验工况下,疏水陶瓷膜实现了0.6~5.2 kg·m^-2·h^-1的水通量和7.6%~57.4%的水回收率。低冷却介质流量下,基于水冷的亲水陶瓷膜的烟气冷凝性能更优异;随着冷却介质流量的上升,疏水陶瓷膜的冷凝性能迅速提升,并达到亲水陶瓷膜的性能。疏水陶瓷膜冷凝器在气体脱湿和水分回收领域有广阔的应用前景,将为改善工业过程的“能源-水资源-环境”关系助力。