丙烯精馏塔塔釜丙烯含量高的原因分析与优化.pdf

工业技术乙烯工业2 0 2 4,3 6(1)1 8 2 0ETHYLENE INDUSTRY丙烯精馏塔塔釜丙烯含量高的原因分析与优化赖喜江，王俊斌，张磊，黄超波，张杨龙（中国石油天然气股份有限公司独山子石化分公司，新疆独山子8 3 3 6 9 9）摘要：2 2 0 kt/a乙烯装置丙烯精馏馅塔随着装置负荷的提高，造成塔釜循环丙烷中丙烯损失达到10%。为减少丙烯精馅塔釜丙烯损失，利用AspenPlus采用丙烯精馏塔运行数据建立丙烯精馏塔模型，对丙烯精馏塔运行进行模拟分析研究，通过查找模拟数据和实际运行参数偏差点，对丙烯精馏塔进行调整优化，减少了塔釜丙烯损失，实现了丙烯产量增加，达到了提质增效的目的。关键词：丙烯精馅塔模拟优化乙烯装置裂解炉出口物流经急冷、压缩、干燥、预分馏等过程分离出C2、C 3 等组分,C3组分经加氢大部分丙炔和丙二烯转化成丙烯和丙烷，加氢后流出物进人丙烯精馏塔，在丙烯精馏塔侧线得到丙烯产品，塔釜获得丙烷。为保证丙烯精馏塔侧线丙烯产品质量合格，且避免塔釜丙烯出现损失过大，本文利用AspenPlus化工流程模拟软件对中石油独山子石化分公司2 2 0 kt/a乙烯装置的丙烯精馏塔进行流程模拟，并进行操作运行分析研究。通过对主要参数模拟精度分析，查找模拟数据和实际运行参数偏差点，对偏差较大的丙烯精馏塔塔底温度和再沸器急冷水流量进行调整优化，以减少塔釜丙烯损失，在确保塔顶丙烯质量要求的前提下，实现丙烯产量最大化。1丙烯精馏塔流程丙烯精馏由1 号丙烯精馏塔（C40 7）和2 号丙烯精馏塔（C40 8）串联实现丙烯和丙烷的分离,来自碳二加氢反应器加氢后物料进入安装有95块双溢流DJ-5型高效筛板的1 号丙烯精馏塔第一块板，其组分（摩尔分数）为9 0.6 9%的丙烯和8.1 4%的丙烷以及少量碳三以上重组分,塔底抽出丙烷经汽化后送入裂解炉作为裂解原料，要求抽出釜液中丙烯含量（摩尔分数）不高于5%，塔顶气相进人安装有1 1 5块双溢流DJ-5型高效筛板的2 号丙烯精馏塔第1 1 5块板下部。2 号丙烯精馏塔塔顶冷凝器冷凝的液相全部回流，丙烯产品从第1 1 层塔盘抽出，要求采出产品丙烯摩尔分数不低于9 9.6%，生产操作通过对回流量、加热量的控制生产出合格产品。丙烯精馏塔流程示意见图1。2丙烯精馏塔流程模拟2.1丙烯精馏塔模型建立以丙烯精馏塔实际工况的标定运行数据作为模型的输入参数,利用Aspen Plus 流程模拟软件建立丙烯精馏塔的静态模拟模型，代入标定数据，模拟丙烯精馏塔稳态操作工况，研究提高塔侧线采出对产品质量的影响，以期达到确保丙烯产品质量合格的前提下，提高侧线丙烯产品的产量，减少塔釜丙烯损失的目的。采用AspenPlus软件中的PR-BM物料属性包和精馏RadFrac模块建立丙烯精馏塔的模拟模型 1-2 ,见图2。输人操作和进料分析数据进行模拟核算 2-3 ,丙烯精馏塔操作参数见表1,进出料组成分析数据见表2,物料平衡数据见表3。对当前操收稿日期：2 0 2 2-1 2-1 6；修改稿收到日期：2 0 2 3-1 1-2 2。作者简介：赖喜江，男，2 0 0 9 年毕业于中国石油大学（华东）机械设计制造及自动化专业，主要从事工艺管理工作，注册安全工程师，工程师。第3 6 卷作数据的物料平衡分析后，进出口误差约为1 0%，由于C-407塔进料流量表波动和误差较大,因此碳二加氢反应器出料罐E-415A/B丙烯精馏塔再沸器选项卡1名称进科流搭顶温度回流流量搭顶压力回流流量cale塔顶冷超温度便线产品流量健线菜出温度塔庭温度塔鹿循环内烧流量ko/hr便线丙爆分率酒鹿采出丙烧分室513BOTSDETOPOAS表1 丙烯精馏塔操作参数项目进料流量/(kg h-1)塔顶温度/回流流量/(kg h-l)塔顶压力(G)/MPa塔顶冷凝温度/侧线产品流量/(kgh-l)侧线采出温度/塔底灵敏板温度/塔底循环丙烷流量/(kgh-l）赖喜江等.丙烯精馏塔塔釜丙烯含量高的原因分析与优化C-407一号丙烯精馏塔21528595循环丙烷图1丙烯精馏塔流程示意单位值kg/hr15482C42.4519kg/hr.186000MPag7.71045kg/hr168045C26kg/hr14086.943.4511C52.42871291.750.9960.803631137EEE-O11352.50E415ABFOUTH-11352.50图2丙烯精馏塔模拟模型示意表2 市丙烯精馏塔进出料组成分析数据操作参数进料16 458甲烷(),%43.7乙烷(),%乙烯(),%186 080丙烷（）,%1710环丙烷(),%42.2丙烯（）,%14046乙炔(),%44.4乙烯基乙炔（$）,%50.4乙基乙炔(),%1 299.1MA+PD(o),%19.进料数据采用丙烯精馏塔塔顶、塔底和侧线采出加和后的值。C-408二号丙烯精馏塔11V-406丙烯精馏塔回流罐丙炔气至V-205115P-410A/B/CC-408回流泵丙烯产品P-411A/B/CC-407塔回流泵丙烯精馏塔C-407886-128E-417A/B/C丙烯精馏塔冷凝器E-435丙烯尾气冷却器OP538E417-66.59526FUFO2717.60E4FHOTIN负荷/kWQ负荷/kW527丙烯PUSF2E416HOTEHOTOUT-2917.54循环丙烷535分析值1.540.096.670.0490.980.010.010.060.160220.(续表2)丁烷(),%丁烯(),%丁二烯(）,%Cs(0),%Cs(),%样品取回时间不凝气排放（暂无分析数据，根据2 0 2 1 年9 月3 0 日数据）甲烷(),%乙烷(）,%乙烯(）,%丙烷($),%环丙烷(),%丙烯（）,%乙炔(s),%乙烯基乙炔($）,%乙基乙炔(),%MA+PD(),%丁烷(),%丁烯（）,%丁二烯(),%Cs(),%样品取回时间丙烷(）,%丙烯($),%MA+PD(),%丁烷(),%丁烯（）,%丁二烯(),%Cs(0),%氢气/(mLm-3)甲醇/(mL m3)一氧化碳/(mL m-3)二氧化碳/（mLm3)(H2+Nz+CH4)/(mLm-3)丙烯（）,%甲烷/(mL m-3)乙烷/(mLm-3)乙烯C;烷烃(),%乙炔/(mLm-3)MA+PD/(mL m-3)丁烯+丁二烯/(mLm=3)C4及以上/(mLm-3)氧气/(mLm-3)样品取回时间乙烯工业进料分析值0.020.040.020.060.0920:0017.061.180.010.140.0176.550.010.020.20.020.020.040.021.9920:00丙烯精馏塔塔底79.4818.031.490.20.130.020.26丙烯精馏塔采出3999.59322220.4011142201.020:00第3 6 卷表3 丙烯精馏塔物料平衡数据项目流量/(kgh-)C-407 塔进料16 458塔顶采出87.3塔底采出1 299.1侧线采出14046进出误差%10.2562.2模型模拟及结果分析利用以上数据代入已搭建丙烯精馏塔的模型运行 2-3 ,模拟结果与现场数据对比见表4。表4丙烯精馏塔模拟结果与现场数据对比项目工厂值进料流量/(kg h-l)15 432(修正后）塔顶温度/43.70塔顶压力/kPa1710回流量/(kgh-1)186080.0塔顶冷凝温度/42.20侧线产品流量/（kgh-l）14046.00侧线采出温度/44.40塔底温度/56.50塔底灵敏板温度/50.40塔底循环丙烷流量/（kgh-）1299.10侧线丙烯(mol),%99.59塔底采出丙烷（mol）,%78.48表4的模拟结果表明：模型模拟结果大部分和现场数据吻合良好，模型能够用于预测实际生产过程、研究相关操作变量对产品质量指标和热量消耗影响，指导调整优化实际生产操作运行参数，最大限度调高侧线丙烯产量，减少塔釜丙烯损失量。2.3丙烯精馏塔模拟结果的优化应用按照模型模拟结果，并结合现场丙烯精馏塔实际运行，对丙烯精馏塔采取了优化调整措施。1)2022年8 月结合现场检测换热器（E415A/B)急冷水流速情况，判断E-415B急冷水存在偏流，根据急冷水泵出口流量及各用户急冷水用量,关小B台急冷水进水流量阀门,调整B台急冷水流速至0.9 m/s,提高A台急冷水的流速，提升A台的换热效果。(下转第2 3 页）模拟值误差，%15 4320.0042.452.861 7100.00168044.99.6939.965.3114086.860.2943.452.1452.427.2150.130.531291.750.5799.600.0180.361.8815第3 6 卷4管道系统改造效果此次出口消音器及管道改造项目于2 0 2 2 年9月2 0 日实施，9 月2 4日改造完成投人运行。通过监测,消音器的振动值最大为3 2 mm/s,降低了3倍；出口管道小接管连接法兰振动值最大为100(,-s.wu)/806040200出口短节茶消音器本体出口弯头出口法兰改造前；改造后图6 出口管道改造前、后振动分析数据对比5结语2019一2 0 2 2 年丁二烯装置循环气压缩机出口消音器及管道每年会发生因振动导致的泄漏事件发生,若发现不及时将导致恶性的着火爆炸事故发生,给安全生产带来极大的隐患。同时每次泄张小伟等.丁二烯装置循环气压缩机出口消音器及管道振动原因分析及改造23，15mm/s,降低了2 倍；出口管道的振动值最大为10mm/s,降低了8 倍，管道主频率为2 0 0 Hz,降低了1 倍,属于美国普渡压缩机技术协会关于振幅的要求中的设计界限（安全界限)内，具体振动数值对比如图6 所示。管道管道弯头小接管漏必然会导致一次装置非计划循环或停工事件发生，造成大量的经济损失。消音器每个大修周期更换1 次，每次更换原进口消音器的费用为58 万元，现国产消音器的价格为2 1 万元，每个大修周期可节省3 7 万元。(上接第2 0 页)2)优化塔压工艺参数，C40 7 塔顶压力由1710kPa调整到1 6 50 kPa。调整优化后，丙烷中的丙烯在线含量A-14010由1 0%降至5%以下。调整前、后丙烯精馏塔塔底出口分析结果见表5。表5丙烯精馏塔塔底出口物流分析数据，%数值项目2022-08-03T11:00丙烧84.43丙烯12.02MA+PD1.17丁烧0.18丁烯0.08丁二烯0.02Cs1.483结语丙烯精馏塔在进料量和组分保持不变，且在保证丙烯精馏塔侧线丙烯质量的前提下，通过降低C40 7 塔操作压力优化措施，C-407塔釜丙烷中的丙烯含量（体积分数）由1 2%降至4%，丙烯侧线产量平均增加50 0 kg/h，丙烯损失由优化前的1 56.1 5kg/h降低至优化后的48 kg/h，减少损失量1 0 8.1 5kg/h，按照年运行8 0 0 0 h计算，可2022-09-012022-011-22T21:00T20:0085.5292.793.624.021.180.800.130.050.060.040.020.028.281.78减少丙烯损失8 6 5.2 t/a，增加效益1 0 0 余万元。参考文献：1威廉L鲁平.如何使用ASPENTM软件模拟完成精馏的设计和控制（原著第二版）M.马后炮化工网，译.上海：华东理工大学出版社,2 0 1 5.2孙兰义.化工过程模拟实训-Aspen Plus教程 M.2版.北京：化学工业出版社，2 0 1 9.3熊杰明，李江保.化工流程模拟AspenPlus实例教程M.北京：化学工业出版社,2 0 1 6.ABSTRACTSREVIEW OF SINOPECS ETHYLENE PRODUCTION IN20231Zeng Miaoyang,Zhang Xiaoming,Ma Guofeng,Zhang Wei.Chemical Department of SINOPEC,Beijing,P.C.100728Abstract:The achievement and performance of SINOPEC s ethyleneproduction in 2023 are introduced and analyzed briefly from theaspects of safety and environmental protection,feedstock andoperation optimization,energy saving and consumption reduction,technology research,long-term operation and maintenance,and theobjectives and focus of SINOPECs ethylene production in 2024 areput forward.Key words:SINOPEC;ethylene operation;reviewOVERVIEW OF PETROCHINAS ETHYLENE BUSINESS IN20237Shen Yang,Jiao Lifei,Liu Zhaohui,Liu Xiaozhou.PetroChinaRefining,Chemicals&New materials Company,Beijing,P.C.100007Abstract:This paper summarizes the development of PetroChinasethylene business in 2023,including the ethylene production,ethylene yield,yields of ethylene and propylene,processing lossratio and energy consumption _of its subordinate petrochemicalenterprises,as well as the feedstock optimization,long-termoperation,maintenance,technical modification and technicalmeasures.The_focus of work,concerning long-term optimumoperation of ethylene plants in 2024 is put forward.Key words:PetroChina;ethylene;overviewAPPLICATIONOFDEMULSIFIERAND SCALEINHIBITORINETHYLENEPLANT13Huang Zikun,Wang Zhicheng.SINOPEC-SK(Wuhan)Petrochemi-cal Company Limited,Wuhan,Hubei,P.C.430000Abstract:In recent years,affected by the diversification of rawmaterial to ethylene plant,the emulsification of quench wateroccurred.More and more benzene series remain in the system,leading to serious polymerization in process water system.Thepolymerization of process water not only leads to the blockage ofmultiple heat exchangers in the quench unit,but also may lead tothe shutdown of the quench unit in severe cases,which becomes one.of the main botlenecks for the long-term operation of ethylene plant.A new reagent is used in the quench water system to improve thewater quality and alleviate the emulsification and fouling problems ofthe water system,thus effectively prolonging the operation period ofthe ethylene plant.,Key words:quench water;emulsification;fouling;demulsifer andscale inhibitorCAUSE ANALYSIS AND OPTIMIZATION OF HIGH PRO-PYLENE CONTENTAT BOTTOM OFPROPYLENE RECTI-FICATIONTOWER18Lai Xijiang,Wang Junbin,Zhang Lei,Huang Chaobo,ZhangYanglong.PetroChina Dushanzi Petrochemical Company,Dushanzi,Xinjiang,P.C.833699Abstract:With the increase in the load of propylene rectificationtower in a 220 kt/a ethylene plant,the propylene loss in thecirculating propane at the bottom of tower reached 10%.In order toreduce the propylene loss at the bottom of propylene rectificationtower,Aspen Plus was used to establish a propylene rectificationtower model with the operation data of propylene rectification tower,and the current operation of the propylene rectification tower wasanalyzed and studied.By identifying the deviation points betweenthe simulation data and the actual operating parameters,theoperation of propylene rectification tower was adjusted andoptimized,so as to reduce propylene loss at the bottom of tower,increase propylene production and achieve the purpose of improvingquality and efficiency.Key words:propylene rectification tower;simulation;optimizationCAUSE ANALYSIS OF VIBRATION OF SILENCER ANDPIPELINEAT OUTLET OF RECYCLEGAS COMPRESSORINBUTADIENEUNITAND THE MODIFICATION21Zhang Xiaowei,Feng Min,Sheng Nan,Ju Tao,Jiang Feng.PetroChina Dushanzi Petrochemical Company,Dushanzi,Xinjiang,P.C.833699Abstract:To solve the vibration problem of the silencer and pipelineat the outlet of screw compressor in a chemical company,the gasETHYLENEINDUSTRYStarted Publication in 1989,Quarterly.Mar:2024 Vol.36 No.1 Total 137thpulsation and pipeline vibration of the existing exhaust pipe wasanalyzed,the main causes of the pipeline vibration were identifiedcombined with the measured data of pipeline vibration on site,andsome corresponding modification measures were put forward.Somereasonable vibration elimination measures were taken such asreplacing the silencer with three-chamber impedance compoundsilencer,revamping the exhaust pipe,installing pipe supports andreinforcing the thermocouple branches.After modification,thepressure unevenness at each point inside the exhaust pipe can meetthe requirements of API 619,and the gas pulsation decreased by72%on average.The first-order natural frequency of the exhaustpipe system increased from 4.572 Hz to 8.862 Hz,and the high-order natural frequency was 10%away from the compressorexcitation frequency.The maximum vibration of the silencerdecreased by 64%to 32 mm/s and the maximum vibration of theoutlet pipe decreased by 87.5%to 10 mm/s compared with thosebefore the modification,proving the effectiveness of the modificationmeasures.Key words:screw compressor;silencer;pipeline vibration;mea-sureCAUSE ANALYSIS AND PREVENTIVE MEASURES FORLEAKAGE OF TUBE BUNDLESOF STEAM-WATER HEATEXCHANGERS24Zhang Changsong,Huang Chaobo,Li Wenting,Du Zhiqi,LeiQian.PetroChina Dushanzi Petrochemical Company,Dushanzi,Xin-jiang,P.C.833699Abstract:To solve the leakage of steam-water corrugated-tube heatexchanger in hydrogen plant,the causes of the leakage of heatexchanger tube bundle were analyzed combined with the specificoperating conditions,the analysis results were obtained combinedwith the actual inspection report based on the corrosion mechanismof corrugated tubes in the environment of chlorine-containingmedium,and some specific preventive measures were developedcorrespondingly based on the cause analysis.The corrosion hazardswerecompletely eliminated throughheat exchange tubemodification,the operating cycle of the heat exchanger wasextended,and the long-term operation of the heat exchanger wasensured.Key words:steam-water heat exchanger;corrosion;leakage;improvementCAPACITY EXPANSION SCHEMES OF QUENCH SYSTEMINETHYLENEPLANT28Song Zhiqi,Ma Guomin,Ding Shaohui,Wu Liaosha,Xu Wenming.PetroChina Dushanzi Petrochemical Company,Dushanzi,Xinjiang,P.C.833699Abstract:In 2019,the capacity of a megaton ethylene plant wasexpanded in the overhaul window period,including the installationof an ethane cracking furnace,a viscosity reducing tower system anda toluene extraction system as well as the transformation of relatedsupporting equipment and facilities,so that the capacity reached1.15 million tons per year.This paper analyzes and summarizes theoperation of the ethylene plant after two overhauls in 2015 and 2019respectively,in order to find out the operation bottleneck of quenchsystem and formulate targeted optimization plans.Key words:ethylene plant;quench system;capacity expansion;long period operationAPPLICATION OF CFD TECHNOLOGY IN THE RE-SEARCH ON PIPING LAYOUT FOR RECYCLING DECOK-ING EFFLUENT TO FIREBOX OF LARGE-SCALE CRACK-INGFURNACE33Lin Jiangfeng,Xiao Jia.SINOPEC Engineering Incorporation,Bei-jing,P.C.100101Abstract:Recycling decoking effluent to firebox of cracking furnaceis one of the effective measures to reduce pollutant emissions fromthe cracking furnace,and the piping layout for recycling decokingeffluent to firebox has a significant impact on the decoking effect.This article uses CFD technology to numerically simulate the pipinglayout for recycling decoking effluent to firebox.RNG k-8turbulence model is used for the simulation,and the wall functionStandard Wall Fn is used to correct the near wall flow.Thecalculation results indicate that a reasonable piping layout canensure the even entry of decoking effluent into the firebox without