模拟乙烷裂解炉管中流体返混对烧焦过程的影响

针对裂解炉管弯头处流体运动状态变化的特点,采用柱塞流反应器(PFR)与串联全混流反应器(CSTR)组合的反应器模型,耦合计算了炉膛传热和辐射段炉管内的烧焦过程.将烧焦时焦炭表面氧分压、烧焦速率、炉管出口气体温度和碳氧化物含量、焦炭层厚度等影响的模拟结果与无返混的PFR模型的模拟结果进行了比较.结果表明:两种模型模拟的炉管出口气体温度和碳氧化物含量均与生产实际基本相合,但有返混的模型能更准确地描述烧焦结束时残碳在管内的分布特点.     

Simulation of the decoking of an ethane cracker with a steam/air mixture

A combined furnace and reactor calculation is performed for the simulation of the decoking of an ethane cracker with a steam/air mixture. Different gas-solid reaction/diffusion models with a corresponding texture model describing the solid phase changes during the decoking operation are combined with kinetics for the decoking by combustion and gasification, determined based on experimental data [Heynderickx, G.J., Schools, E.M., Marin, G.B., 2005. Coke combustion and gasification kinetics in ethane steam crackers. A.I.Ch.E. Journal 51 (5), 1414-1428]. By comparing the calculated coil outlet temperatures and the calculated partial pressures of carbon dioxide at the coil outlet with the measured values in an industrial unit, the need for a general gas-solid reaction/diffusion model and the corresponding decoking kinetics is confirmed. The decoking time for an industrial unit is simulated adequately.     

Mass and heat transfer analysis of SAS: effects of thermodynamic states and flow rates on droplet size

The supercritical antisolvent (SAS) process entails attainment of extremely high supersaturation in an atomized solution droplet by a very rapid increase in the antisolvent CO₂ mole fraction in it during its flight through a CO₂ continuum. In this work the droplet dynamics has been studied for a single droplet of CO₂–acetone solution falling in a flowing CO₂ environment in terms of variations in its concentration, temperature and size due to the two-way mass transfer of CO₂ and solvent. A model based on the SAS mechanism of simultaneous mass and heat transfer has been simulated to study the effects of the thermodynamic states and the individual flow rates of CO₂ and solution. The hydrodynamics of the droplet and the convective mass and heat transfer have been combined in the model to ascertain the individual number of moles of CO₂ and solvent transferred and their directions at any instant of time during the flight. The effects of process parameters have been analyzed for the initial droplet size of the solution. The swelling or shrinking of the droplet has been analyzed with time till the solvent is completely evaporated, in the pressure range of 71–350 bar, temperature range of 313–333 K, SC CO₂ flow rate of 0.1136–1.136 mol/s and the ratio of the volumetric flow rates of CO₂-to-solution in the range of 100–1000. The mole fraction of CO₂ attained inside the non-isothermal droplet has been analyzed with time, which is needed in the design of supersaturaton and nucleation kinetics in the SAS process.     

Al_2O_3-H_2O两相流流体强化换热性能研究

将固体颗粒加入到传统换热介质中形成的固-液两相流流体是一种新型的强化换热介质。设计小型卧式直管加热炉试验装置,用粒径为60 nm,150 nm,55μm质量分数为1%的Al2O3-H2O两相流流体做换热试验,在流量为7,8,9 L/min和炉温为80,100,120,140℃情况下使用计算机对加热直管内、外壁温度和进、出口流体温度数据进行采集和分析。研究发现:固-液两相流流体强化对流传热的效果与颗粒的粒径、流体的流速和加热炉炉温有关。     

Modeling and experimental studies on absorption of CO2 by Benfield solution in rotating packed bed

This work presents the modeling and experimental investigation on absorption of CO₂ by Benfield solution in rotating packed bed (RPB). A model was established to illustrate the mechanism of gas–liquid mass transfer with reactions in RPB at higher gravity level. Experiments were carried out at various rotating speeds, liquid flow rates, gas flow rates and temperatures in RPB, with Benfield solution as the absorbent. The validity of this model was demonstrated by the fact that most of the predicted y_o (mole fraction of CO₂ in outlet gas) agreed well with the experimental data with a deviation within 10%. The presented profile of K_Ga (gas-phase volumetric mass transfer coefficient) along the radial direction of the packing could reasonably explain the end effect in RPB. As a result, this model is reliable in describing the removal of CO₂ by Benfield solution in RPB at higher gravity level.     

Modelling and dynamic optimization of thermal cracking of propane for ethylene manufacturing

In tubular reactors inside a cracking furnace, heat transfer, thermal cracking reactions and coke buildup take place and closely interact with each other. It is important to understand the process and optimize its operation. A 1-dimensional (1D) pseudo-dynamic model was developed based on first principle and implemented in gPROMS^®. Coke buildup inside the tube wall was also accounted for. The model was validated dynamically. The impact of process gas temperature profile, and constant tube outer wall temperature profile on product yields and coking rate are assessed. Finally, dynamic optimization was applied to the operation of this tubular reactor. The effects of coking on reduction of production time and the decoking cost have been considered. The tube outer wall temperature profile and steam to propane ratio in the feed were used as optimization variables. Dynamic optimization investigation indicates that it can improve operating profit by 13.1%.     

二氯乙烷裂解管式反应器二维模拟

建立了二氯乙烷在管式反应器中进行气相热裂解的二维模型 ,模型考虑了二氯乙烷热解生成氯乙烯的主反应和生成焦前体的副反应以及气体密度变化对裂解反应的影响 .模拟计算表明 ,二氯乙烷和氯乙烯的浓度沿径向分布平坦 ;但是管内近壁面处由于存在边界层 ,始终存在着明显的径向温差 ;近管壁处始终是裂解的高速率区 ,副反应也主要发生在管壁区 .表明确定最优的炉管管径时必须考虑提高裂解速率与降低结焦速率之间的平衡 .在距进口量纲 1管程 0 .3左右的管壁处裂解速率达到最高 ;副反应速率的最大点位于出口管壁处 .与工业数据比较后发现 ,炉管出口的转化率、选择性、出口压力和温度等数据与模型预测值一致 ,表明模型具有较高的可信度     

Coupled simulation of an industrial naphtha cracking furnace equipped with long-flame and radiation burners

A coupled reactor/furnace simulation has been conducted for a 100 kt/a SL-II naphtha cracking furnace containing both long-flame and radiation burners. The computational fluid dynamics approach was used to simulate the flow, combustion and radiative heat transfer in the furnace. The software packages COILSIM1D and SimCO were used to account for the cracking process in the reactor coils. The simulation provides for the first time detailed information about concentration, velocity, and temperature fields for these types of furnaces. Comparison of the calculated product yields against measured industrial data validates the simulation and shows that the difference with using a predefined normalized heat flux profile is limited. The results show that the design of radiation section outlet leads to an asymmetric flue gas-temperature, concentration and velocity profile. Large recirculation zones exist near the reactor tubes, making the temperature in the middle of furnace more uniform.     

考虑切料过程的乙烯裂解炉炉群调度建模与优化

乙烯裂解炉炉群通常由多台裂解炉并行运行,将烃类原料裂解成小分子烃类化合物。由于随着裂解炉连续运行不可避免地在炉管内壁产生结焦,结焦导致裂解炉运行效率下降,所以需要对裂解炉进行周期性的停炉清焦。对于不同价格参数的多种原料不同清焦费用的多台裂解炉来说,整个乙烯裂解炉炉群系统的循环调度应是求得最优解使得收益最大化。本文对此类裂解炉炉群循环调度问题提出了一个新的混合整数非线性（MINLP）模型,相比较以前的研究该模型能够得到更好的求解多原料多裂解炉的问题,同时解决了裂解过程中切料时机选择的问题。最后,以某乙烯厂为研究实例进行切料时机的优化,优化后裂解炉全周期的运行效益显著提高,为操作人员选择最佳切炉时机提供了理论依据,说明了此模型的有效性。     

Computational fluid dynamics‐based steam cracking furnace optimization using feedstock flow distribution

Nonuniform temperature fields in steam cracking furnaces caused by geometry factors such as burner positions, shadow effects, and asymmetry of the reactor coil layout are detrimental for product yields and run lengths. The techniques of adjusting burner firing (zone firing) and feedstock mass flow rate (pass balancing) have been practiced industrially to mitigate these effects but could only reduce the nonuniformities between the so‐called modules (a group of many coils). An extension of the pass balancing methodology is presented to further minimize the intra‐module nonuniformities, that is, variation between the coils within a module, in floor fired furnaces. Coupled furnace‐reactor computational fluid dynamics‐based simulations of an industrial ultraselective conversion (USC) furnace were performed to evaluate four different feedstock flow distribution schemes, realizing equal values for coil outlet temperature, propene/ethene mass ratio, maximum coking rate and maximum tube metal temperature (TMT), respectively, over all the reactor coils. It is shown that feedstock flow distribution creates a larger operating window and extends the run length. Out of the four cases, the coking rate as criterion leads to the highest yearly production capacity for ethene and propene. Uniform maximum coking rates boost the annual production capacity of the USC furnace with a nameplate ethene capacity of 130 10³ metric tons per year with 1000 metric tons for ethene and 730 metric tons for propene. For industrial application, achieving uniform maximum TMT is more practical due to its measurability by advanced laser‐based techniques. Most steam cracking furnaces can be retrofitted by optimizing the dimensions of venturi nozzles that regulate the feedstock flow to the coils. © 2017 American Institute of Chemical Engineers AIChE J, 63: 3199–3213, 2017     

Mass transfer investigation and operational sensitivity analysis of amine-based industrial CO2 capture plant

In this article, the industrial process of CO₂ capture using monoethanolamine as an aqueous solvent was probed carefully from the mass transfer viewpoint. The simulation of this process was done using Rate-Base model, based on two-film theory. The results were validated against real plant data. Compared to the operational unit, the error of calculating absorption percentage and CO₂ loading was estimated around 2%. The liquid temperature profiles calculated by the model agree well with the real temperature along the absorption tower, emphasizing the accuracy of this model. Operational sensitivity analysis of absorption tower was also done with the aim of determining sensitive parameters for the optimized design of absorption tower and optimized operational conditions. Hence, the sensitivity analysis was done for the flow rate of gas, the flow rate of solvent, flue gas temperature, inlet solvent temperature, CO₂ concentration in the flue gas, loading of inlet solvent, and MEA concentration in the solvent. CO₂ absorption percentage, the profile of loading, liquid temperature profile and finally profile of CO₂ mole fraction in gas phase along the absorption tower were studied. To elaborate mass transfer phenomena, enhancement factor, interfacial area, molar flux and liquid hold up were probed. The results show that regarding the CO₂ absorption, the most important parameter was the gas flow rate. Comparing liquid temperature profiles showed that the most important parameter affecting the temperature of the rich solvent was MEA concentration.     

裂解炉蒸汽-空气烧焦过程计算及优化

通过对裂解炉烧焦过程的计算和分析,获得如下结果：当前裂解炉烧焦程序存在较大的改进空间,焦自身反应产生的热量带来的系统温升很小,不会产生局部过热。可通过及时提高烧焦温度、增加空气流量和降低稀释蒸汽流量来提高烧焦效率,烧焦时间可从原来的24h降低到15h。     

Form coke reaction processes in carbon dioxide

Uncertainty in metallurgical coke supplies has prompted development of form coke from low quality coals and fines. Reaction rates have been measured and mechanisms identified that control carbonaceous briquette reaction rate in CO₂. Three briquette formulations were prepared, characterized and coked in an inert atmosphere at high temperature. A given weight of each formulation was then reacted in a packed bed with CO₂ at 1373 K for 0.5–2 h. Partially reacted briquettes contained a solid core with some internal reaction surrounded by a loosely adhering layer of carbon-containing ash. The reaction rate of briquettes with CO₂ was affected by diffusion of CO₂ through the bulk gas and the ash-carbon layer to the core surface, as well as CO₂–carbon reaction. Key variables governing briquette reaction rate included CO₂ mole fraction and briquette void fraction.     

Mathematical analysis of nonisothermal mass transfer process-application to oxidation of carbon with CO2-CO mixtures

A mathematical analysis is made of the nonisothermal mass transfer occurring in reactions of gases with porous media involving appreciable enthalpy changes. The mathematical analysis of a nonisothermal reaction controlled by heat and mass transfer and by chemical reaction involves simultaneous solution of two second-order differential equations derived from the laws of conservation of mass and energy. For the purpose of demonstrating the mathematical solution, the oxidation of porous carbon in CO₂-CO mixtures is considered, on the assumption that no structural changes occur during oxidation, as would be the case in the early stages of oxidation. A similar mathematical treatment can be made for reactions of gases with other porous media. Although the thermal conductivity of coke is relatively low, it is found that the oxidation in CO₂ occurs under essentially isothermal conditions and the heat transfer to the sample is by radiation from the surface of the reaction tube. The results of the mathematical analysis were tested experimentally. During the early stages of burning in 1 atm CO₂ at 1200°C, the temperature at the center of a 22 mm dia. cylinder was found to be about 7°C below that at the surface, which was a few degrees below the furnace temperature. These findings are in accord with the results of the mathematical analysis.     

Simulation of natural gas steam reforming furnace

A mathematical model for natural gas reformer is established to draw up homogeneous phase one-dimensional reaction kinetics equation in the reforming tubes, and compute the tube external radiant heat transfer with zone method. Simulation result is compared with the operating data carried on Selas reformer used in Brown and Root Braun 1000 t NH₃/day production system in Urumqi Second Ammonia Plant, and they match well. This model has laid the foundation for the design variable optimization research, for example, the relations among specific heat transfer area of furnace tube, tube outlet temperature, tube pressure drop and maximum tube-wall temperature, as well as the effect of tube pitch, furnace chamber width, burner arrangement, furnace wall blackness, production load, water carbon ratio and fuel distribution on operation behaviors.     

丙烷脱氢Cr_2O_3/Al_2O_3催化剂烧焦再生过程的模型化与模拟(英文)

A heterogeneous model is developed for the regeneration of the Cr2O3/Al2O3 catalyst for the propane dehydrogenation process by considering the internal mass transfer and external mass/heat transfer during the coke combustion. Simulation shows that under practical operating conditions, multi-steady states exist for the catalyst pellets and the catalyst temperature is sensitive to gas temperature. However, at increased mass flow rate or lowered oxygen concentration, multi-steady states will not appear. Under the strong influences of film diffusion, the coke in the packed bed reactor will first be exhausted at the inlet, while if the film diffusion resistance is decreased, the position of first coke exhaustion moves toward the outlet of the reactor.     

管式加热炉节能的研究进展

以管式加热炉主要结构的节能为出发点,从改造燃烧器及辐射室结构、优化吹灰技术、研发新型清焦技术以及研制新型空气预热器和新型辐射炉管等方面,综述了目前管式加热炉燃烧器、辐射室、对流室及余热回收系统的节能效果的研究情况,其中增强辐射传热和余热回收能力可有效降低排烟温度,提高加热炉效率,因此其对于管式加热炉的节能更有效。最后对今后管式加热炉的节能研究提出展望。     

蛇管式换热器传热性能的数值模拟

利用Fluent对光滑蛇管换热器进行了模拟,将得出的结果与经典理论比较,发现数值模拟方法具有相当的可靠度,并在相同外部条件下对4种不同结构的波纹式蛇管进行模拟,得出湍流状态下管内流体的温度场和速度场,从微观上说明了波纹管强化传热机理。分析了波纹高度对波纹式蛇管传热效率的影响。     

炼磷高炉单元模拟

本文是高炉炼磷过程模拟工作的一部分,它着重讨论了高炉单元模块的各种操作参数,如:热风温度、富氧度、喷吹天然气量、水蒸汽量、煤粉量、火焰温度等相互之间的关系以及它们变化时引起的过程变化,可代替许多局部试验,为高炉炼磷的扩大试验带来效益。     

Parameters controlling supersaturation by DELOS using carbon dioxide

The present work pertains to estimation of the maximum degree of supersaturation that can be attained in an organic solution by the DELOS process using carbon dioxide (CO₂) as a cosolvent. The paper analyzes the effects of initial mole fraction of carbon dioxide, temperature and pressure on the degree of supersaturation of cholesterol in a CO₂—acetone—cholesterol solution. It has been observed that owing to liberation of large amounts of CO₂ very large temperature drops may be attained by depressurization, resulting in attainment of very high supersaturation. Within the ranges of the parameters studied in this work, the degree of supersaturation is higher with higher values of initial temperature and initial CO₂ mole fraction of the solution due to inverse interdependence of the final temperature and the residual CO₂ mole fraction in the depressurized solution. Copyright © 2006 Society of Chemical Industry