Modeling and simulation of energy distribution systems in a petrochemical plant

A systematic method for analysis and design of plant-wide energy distribution systems is proposed to minimize the net cost of providing energy to the plant. The method is based on the steady-state modeling and simulation of steam generation process and steam distribution network. Modeling of steam generation process and steam distribution network were performed based on actual plant operation data. Heuristic operational knowledges are incorporated in the modeling of steam distribution network. Newton’s iteration method and a simple linear programming algorithm were employed in the simulation. The letdown amount from superheated high-pressure steam (SS) header and the amount of SS produced at the boiler showed good agreement with those of actual operational data.     

Optimization of the sulfolane extraction plant based on modeling and simulation

An optimization system, based on modeling and simulation, was developed for a sulfolane extraction plant. The primary objective of the operation of this plant is to increase benzene composition, which is mostly affected by the recycle streams in the plant. In this work the optimal recycle streams were identified and resulting product compositions were evaluated. In the optimization, suitable parametric models for each process unit were obtained first from the steady-state rigorous modeling and simulation of the sulfolane extraction plant. The parametric models were then employed to develop the optimization system based on the SQP scheme. Results of simulations show promise for further economic improvements over present operation states.     

合成氨装置蒸汽轮机结垢原因分析

通过对合成氨装置不同工艺部位蒸汽品质和水质的详细分析,初步确定蒸汽透平结垢的主要原因,并采取措施,通过控制透平用蒸汽、自产蒸汽、锅炉给水等各项指标,使四大机组运行情况较往年同比状况良好,达到了蒸汽管网稳定运行的目标。     

Convergence criterion in optimization of stochastic processes

A novel approach is developed and its applicability is demonstrated for defining convergence in optimization of stochastic processes for both design and control applications. The approach is computationally simple, does not require a priori knowledge, and does not get drawn into undesirable solutions from fortuitous good values.     

A systematic approach to the synthesis and design of flexible site utility systems

The paper presents a systematic approach for the synthesis of flexible utility systems satisfying varying energy demands. The approach combines benefits of total site analysis, thermodynamic analysis and mathematical optimisation. A thermodynamic efficiency curve (TEC) is developed, which gives an overview of the maximum thermodynamic efficiencies of all possible design alternatives. TEC and hardware composites guide the selection of candidate structures in the superstructure, excluding uneconomic options from the synthesis model. The integration of thermodynamics yields significant reduction in the synthesis model, addresses the impact of variable loads on the unit efficiencies, and enables a compact formulation of the design problem over long horizons of operation. The optimisation is formulated as a multi-period MILP problem that relies on new target models to describe the performance of steam turbines, condensing turbines, gas turbines and boilers. Target models account for the variation of efficiency with unit size, load and operating conditions in a simple, yet accurate way. As a result, these models are capable of accounting for the efficiency trends of realistic units.     

505E电子调速器透平控制系统的应用

介绍了505E电子调速器的控制原理、运行操作及其安装和调试的方法。通过其在中国石化扬子石化公司烯烃厂2#乙烯装置裂解气压缩机、丙烯压缩机、二元制冷压缩机透平控制系统中的成功应用，证明505E电子调速器透平控制系统操作简便、安稳可靠。     

Modeling and control of Wiener-type processes

We develop a simple relay feedback method to identify Wiener-type nonlinear processes. It separates the identification problem of the nonlinear static function from that of the linear dynamic subsystem to simplify the identification procedure significantly. Owing to the separation, the unmeasurable output of the linear dynamic subsystem can be obtained in a straightforward manner. Then, determining the model structure of the nonlinear static function becomes very simple and the estimates are robust to additive output noises. We can identify the whole activated region of the nonlinear static function as well as the ultimate information of the linear dynamic subsystem from only one relay feedback test. More information on the linear dynamic subsystem can be estimated by well-established linear system identification methods from additional tests. We use a nonlinear control strategy to compensate the nonlinear dynamics of the Wiener process so that the design parameters can be determined by usual tuning rules developed for linear processes and a high control performance can be achievable as in linear processes.     

Improvement in steam stripping of sour water through an industrial-scale simulation

Sour water containing hydrogen sulfide, carbon dioxide, hydrogen cyanide, and ammonia is mainly purified by steam stripping. Increased concern in recent times over effluent water quality and energy saving has caused sour water stripping to attract considerable attention. However, the development of the operation methodology and structure of this process has not been systemic, leading to inefficiencies in the systems commonly used. In this paper, the characteristics of a sour water stripping column are investigated by using an industrial-scale simulation. From these results, we propose several guidelines (high feed temperature, low composition of CO₂ in the feed, need of rectifying section, low mass flow rate of the second recycle stream, high reflux ratio, and modified structure using a pump-around side cooler) for improving stripper performance through changes in the operating condition and process structure. The proposed structure and guidelines can be applied not only to reduce steam consumption and lower the ammonia concentration in the effluent water but also to operate the system stably.     

Techno-economic optimization of IGCC integrated with utility system for CO2 emissions reduction—Maximum power production in IGCC

Environmental legislation, with its increasing pressure on the energy sector to control greenhouse gases, is a driving force to reduce CO₂ emissions. In this paper, pre-combustion CO₂ capture through integration of a site utility system with an integrated gasification combined cycle (IGCC) is investigated as an option to provide a compressed CO₂-rich stream from a process site for sequestration. This work presents a two-step procedure for integration and optimization of a site utility system with an IGCC plant: (i) screening and optimization of IGCC plant performance parameters; (ii) integration and optimization of the utility system of the site with the IGCC plant. In the first step, an optimization approach applies the results of screening studies based on rigorous simulation of the IGCC. Having fixed the inlet fuel flow rate, the IGCC design parameters (including oxygen consumption, diluent flow rate and turbine exit pressure) are optimized for maximum power generation. Energy flows between the IGCC and CO₂ compression train are considered. In the second step, the economic and operating performance of the utility system integrated with the IGCC plant are modeled and optimized for minimum operating cost to find the most appropriate level of integration. In a case study illustrating the approach, 94% of the fuel is gasified; additional power generation offsets the operating costs of pre-combustion CO₂ capture.     

Bi-objective minimization of environmental impact and cost in utility plants

A methodology to minimize potential environmental impact and operating cost in the selection of the operating conditions of a steam and power plant is presented. A bi-objective mixed integer nonlinear programming problem is formulated and solved in GAMS. Different strategies are implemented successfully to generate the Pareto curve such as: minimum distance to the utopia point, ?-constraint, weighted sum and global criterion. An analysis of the Pareto curve allows the identification of two regions where it is cheaper and more expensive respectively, to reduce the potential environmental impact, providing relevant information to support a decision making process. The economical valorisation of greenhouse gases emissions reduction was also carried out, showing the region of the Pareto curve in which the income would compensate the increment in operating cost, leading to a reduction of the potential environmental impact with no extra cost.     

透平积盐分析及清洗方案的选择

通过对乙烯压缩机透平积盐现象进行分析和研究，探讨在乙烯压缩机透平功率下降情况下应采取的措施，同时还对透平积盐的处理方法进行了对比分析，并选定了合适的处理方法，最后对乙烯压缩机透平清洗后的效果进行了总结?     

动静态汽封内部流场的数值模拟

将CFD软件作为计算平台,对汽轮机迷宫式隔板汽封内典型的三维紊流流场进行了数值模拟。应用结构化网格,采用有限体积法离散N-S方程和RNGk-ε双方程紊流模型封闭方程组。数值求解方法采用SIMPLE算法,迎风二阶格式求解对流项,迎风一阶格式求解扩散项。结果表明,转子的转动所带来的旋转效应对汽封内流体的轴向、径向、切向速度都产生影响,导致流体呈螺旋线流动,平均流速增大,湍动能耗散效应减弱,漏汽量比静止时有所增大。低压比时转速对漏汽量的影响较大,额定转速时的最大增幅达0.25%左右。     

Modeling and simulation of photofabrication processes using unsaturated polyester resins

Several kinetic models have been proposed to simulate thermosetting cure reactions. The most complex models, based on a mechanistic approach of cure reactions, are developed based on the concepts of free radical polymerization and the mechanism of reactions with diffusion. However, mechanistic models are usually quite impractical for engineering purposes because of the difficulty in obtaining the model parameters. An alternative to these mechanistic models are the phenomenological models, formulated in terms of the degree of cure and much easier to apply. Phenomenological models have been largely used to study thermal‐initiated cure reactions, although only few works used them to model the kinetics of ultraviolet‐initiated cure reaction. This work proposes a photo‐thermal‐kinetic model to study the behavior of unsaturated polyester resins during ultraviolet‐initiated cure reactions. The model considers samples with different amounts of initiator concentration and cure reactions performed under different ultraviolet light intensities. The model has been numerically solved using the finite element technique. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2009     

Marine macrofouling: a review of control technology in the context of an on-line experiment in the turbine condenser water box of Al-Jubail Phase-1 power/MSF plants

The problem of macrofouling has serious implications in the performance of desalination and power plants. Intake structures, screens, seawater piping systems and heat-exchanger tubes are the sites worst affected in the plants, causing an overall decline in plant efficiency at great economic cost. The last half century has witnessed significant advancements in the development ofmacrofouling control technologies. Materials of inherent antifouling properties are widely used in the construction sector. Control technologies available include antifouling paints and coatings, injection of biocides, marine bio-active compounds, materials of inherent antifouling properties, heat treatment, pulse-power devices, UV and nuclear radiation, scrubbing devices, biological control, etc. A literature search carried out during the last few years has yielded about 450 references. This paper presents, in a very concise manner, state-of-the- art macrofouling control technologies pertinent to desalination and power plants in the Kingdom. The paper also discusses the issues of biofouling control in the Al-Jubail plants based on the results of an on-line macrofouling experiment conducted in one of the turbine condensers of Al-Jubail phase-I MSF/power plants.     

微加压与升压氨合成回路的模拟及优化

根据过程系统工程原理 ,对大型氨合成装置的微加压氨合成 (合成压力 10MPa)回路和升压氨合成 (合成压力 15MPa)回路进行结构分析 ,建立了单元模型。以序贯模块法作为流程模拟方法 ,采用可行路径法对两种流程进行了优化。并根据模拟与优化的结果对两种流程进行了比较 ,结果表明 ,微加压氨合成流程具有良好的经济技术指标。     

Conceptual design and optimization of chemical processes under uncertainty by two-stage programming

This contribution presents a method and a tool for modelling and optimizing process superstructures in the early phase of process design where the models of the processing units and other data are inaccurate. To adequately deal with this uncertainty, we employ a two-stage formulation where the operational parameters can be adapted to the realization of the uncertainty while the design parameters are the first-stage decisions. The uncertainty is represented by a set of discrete scenarios and the optimization problem is solved by stage decomposition. The approach is implemented in the computer tool FSOpt (Flow sheet Superstructure Optimization) FSOpt provides a flexible environment for the modelling of the unit operations and the generation of superstructures and algorithms for the translation of the superstructure into non-linear programming models.The approach is applied to two case studies, the hydroformylation of dodec-1-ene and the separation of an azeotropic mixture of water and formic acid.     

乙烯装置急冷系统流程模拟计算方法的探讨

目前国内乙烯装置急冷系统操作大部分不理想，尤其是急冷油系统的操作参数与设计值偏离很大。为了解决该实际问题，笔者摸索出一套急冷系统的正确模拟计算方法，为将来乙烯装置的改造和国产化技术的应用打下基础。     

苯-环己烷萃取精馏过程模拟和优化研究

以UNIFAC方程为物性计算方法,使用化工过程模拟系统PRO/对苯-环己烷萃取精馏分离过程进行模拟和优化研究。采用双塔联用工艺,对萃取剂种类、萃取剂用量、温度、加入位置,原料液进料温度、进料位置,两塔的总理论板数分别进行了优化。结果表明:以糠醛为萃取剂,糠醛用量与原料液用量摩尔比为2.2、加入温度为298.15℃、在塔1的第7块板加入,原料液进料温度为353.85℃、在塔1的第25块板进料,塔1的总理论板数为35块,塔2总理论板数为10块时,分离过程达到最优。此时,塔1的环己烷产品纯度为0.9953,塔2的苯产品纯度为0.9890,循环糠醛纯度为0.9985。