并行原油蒸馏系统的工艺流程模拟及换热网络耦合与优化
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摘要
常减压装置是炼油加工的“龙头”,同时也是石油化工行业的耗能大户,其能耗约占炼油厂总能耗的20%左右。常减压装置换热网络的设计水平对其能量回收有着非常重要的意义。本论文以中海沥青股份有限公司的三套常减压装置为研究对象,并以这三套常减压装置的工艺流程模拟和三套装置换热网络优化及其耦合为研究内容。通过查阅文献发现,大多数研究者对换热网络的优化都是与流程模拟割裂开来的,而本文是在流程模拟的基础上,取得换热网络优化所需的基础数据,然后用夹点分析法对换热网络进行优化。主要研究工作如下：
第一,以PRO/Ⅱ作为流程模拟工作的工具,应用序贯模块法对三套常减压装置的闪蒸塔、初馏塔、常压塔与减压塔分别进行了稳态模拟。首先,PRO/Ⅱ利用实沸点蒸馏数据把原油切割为虚拟组分,并以此作为闪蒸塔或者初馏塔的进料物流。然后,选择合适的热力学模型、单元模块和模型求解方法,同时规定各单元模块的过程参数,对三套常减压装置分别进行模拟计算。工艺流程模拟的结果与现场数据吻合良好,证实模拟结果准确。可信的流程模拟结果为换热网络的优化奠定了坚实的基础。
第二,针对中海沥青换热网络比较落后的情况,以Hx-net为设计平台,应用夹点设计的方法对三套装置的换热网络分别进行了优化,结果表明节能效果显著。在进行网络优化的过程中,通过查阅文献发现当今国内外很少有研究者考虑到几套常减压装置换热网络的相互联系。为此,本论文在换热网络分别优化的基础上,通过寻求它们间的联系,对三套换热网络间进行热耦合,结果表明,大系统的优化将带来更大的经济效益。
Atmosphere-vacuum distillation unit (AVDU) is the first step of petroleum processing. These stage of process consumes a lot of energy in the petrochemical industry, which occupies about 20% of entire energy consumption in a crude oil refinery. The design level of the heat exchanger network (HEN) is very important to the energy recovery of AVDU. This dissertation probed China Offshore Bitumen CO.,LTD's three sets of AVDUs with process simulation.Optimization of the HENs and coupling of the HENs of 3 AVDUs were also included in the research.Published literatures generally tended to isolate the optimization of the HENs from the process simulation,while in this paper,the basic datas of HENs were acquired from the simulation of AVDU,and then, the HENs were optimized with pinch design method(PDM). The whole work is described as follow:
First, Pro/II with Provision was harnessed as the process simulation engine. Sequential modular was applied on flash column, prefractionator,atmospheric column and vacuum column for steady state simulation. According to the true boiling points(TBP) data, crude oil was divided into several pseudo components which were the input of flash column or the prefractionator. Suitable thermodynamics model, module unit and algorithm were selected, and process parameters were regulated simultaneously. At last, process simulation of three set of AVDU were done separately. The process simulation results showed good agreement with the on-site data. These results from process simulation provide firm foundation for the optimization of HEN.
Secondly, since the HENs in this refinery were relative backward, Hx-net was employed in this paper to separately optimize 3 HENs with PDM.The results showed that the effect of energy saving was remarkable. In the process of HEN's optimization, It is found that the interconnection among HENs of several different sets of AVDUs were scarcely reported by published literatures. Through this work of HEN Optimization, an attempt was made on dealing with paralleled AVDUs' integrated optimization of process and HENs.The results indicated that the least revamp under the direction of the optimization would bring greater economic benefits.
第一,以PRO/Ⅱ作为流程模拟工作的工具,应用序贯模块法对三套常减压装置的闪蒸塔、初馏塔、常压塔与减压塔分别进行了稳态模拟。首先,PRO/Ⅱ利用实沸点蒸馏数据把原油切割为虚拟组分,并以此作为闪蒸塔或者初馏塔的进料物流。然后,选择合适的热力学模型、单元模块和模型求解方法,同时规定各单元模块的过程参数,对三套常减压装置分别进行模拟计算。工艺流程模拟的结果与现场数据吻合良好,证实模拟结果准确。可信的流程模拟结果为换热网络的优化奠定了坚实的基础。
第二,针对中海沥青换热网络比较落后的情况,以Hx-net为设计平台,应用夹点设计的方法对三套装置的换热网络分别进行了优化,结果表明节能效果显著。在进行网络优化的过程中,通过查阅文献发现当今国内外很少有研究者考虑到几套常减压装置换热网络的相互联系。为此,本论文在换热网络分别优化的基础上,通过寻求它们间的联系,对三套换热网络间进行热耦合,结果表明,大系统的优化将带来更大的经济效益。
Atmosphere-vacuum distillation unit (AVDU) is the first step of petroleum processing. These stage of process consumes a lot of energy in the petrochemical industry, which occupies about 20% of entire energy consumption in a crude oil refinery. The design level of the heat exchanger network (HEN) is very important to the energy recovery of AVDU. This dissertation probed China Offshore Bitumen CO.,LTD's three sets of AVDUs with process simulation.Optimization of the HENs and coupling of the HENs of 3 AVDUs were also included in the research.Published literatures generally tended to isolate the optimization of the HENs from the process simulation,while in this paper,the basic datas of HENs were acquired from the simulation of AVDU,and then, the HENs were optimized with pinch design method(PDM). The whole work is described as follow:
First, Pro/II with Provision was harnessed as the process simulation engine. Sequential modular was applied on flash column, prefractionator,atmospheric column and vacuum column for steady state simulation. According to the true boiling points(TBP) data, crude oil was divided into several pseudo components which were the input of flash column or the prefractionator. Suitable thermodynamics model, module unit and algorithm were selected, and process parameters were regulated simultaneously. At last, process simulation of three set of AVDU were done separately. The process simulation results showed good agreement with the on-site data. These results from process simulation provide firm foundation for the optimization of HEN.
Secondly, since the HENs in this refinery were relative backward, Hx-net was employed in this paper to separately optimize 3 HENs with PDM.The results showed that the effect of energy saving was remarkable. In the process of HEN's optimization, It is found that the interconnection among HENs of several different sets of AVDUs were scarcely reported by published literatures. Through this work of HEN Optimization, an attempt was made on dealing with paralleled AVDUs' integrated optimization of process and HENs.The results indicated that the least revamp under the direction of the optimization would bring greater economic benefits.
引文
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[8]Shyamsundar,V.andG.Rangaiah,A method for simulation and optimization of multiphase distillation[J].Computers and Engineering and Processing,2004,43:483-493
[9]Mario Llano-Restrepo, Jaime Aguilar-Arias,Modeling and simulation of saline extractive distillation columns for the production of absolute ethanol[J].Computers and Chemical Engineering,2003,(27):527-549
[10]陆恩锡,化工过程模拟与相关高新杖术(Ⅱ)化工过程动态模拟[J].化工进展2000年1期：76-78
[11]F. BEZZO, R. BERNARDI,et al,Using process simulators for steady-state and dynamic plant analysis an Industrial case study [J]. Chemical Engineering Research and Design,2004,82(4):499-512
[12]Xiaole Yang, M. Sam Mannan,The development and application of dynamic operational risk assessment in oil/gas and chemical process industry[J].Reliability Engineering and System Safety,2010
[13]D. Pfleger,S. Becker,Modelling and simulation of the dynamic flow behaviour in a bubble column[J].Chemical Engineering Science,2001, (56):1737-1747
[14]S. Haugwitz I,et al,Dynamic start-up optimization of a plate reactor with uncertainties[J].2009,Journal of Process Control, (19):686-700
[15]D. LEE,Dynamic Simulation of the Sour Water Stripping Process and Modified Structure for Effective Pressure Control[J].Institution of Chemical Engineers,2002, (80): 167-178
[16]Tsung-Jen Ho et al,Dynamic simulation for internally heat-integrated distillation columns (HIDiC) for propylene-propane system[J].Computers and Chemical Engineering,2009,33:1187-1201
[17]Hwa C.S, Mathematical Formulation and Optimization of Heat Exchange network Using Separable Programming[J].AIChE-Intern Chem Eng Symp Series,1965,4:101
[18]韩文超,基于火用分析的低温甲醇洗过程工艺及换热网络优化[C].天津大学硕士学位论文,2009.06：7-8
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[27]Papoulias S A,Grossmann I E. A Structural Optimization Approach in Process Synthesis Ⅲ:Total Processing Systems [J].Computers and Chemical Engineering,1983,7 (6): 723-734
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[32]Bagajewicz M J,Barbaro A F. On the Use of Heat Pumps in Total Site Heat Integration[J].Computers and Chemical Engineering,2003,27:1707-1719
[33]T.F. Yee, I.E. Grossmann, Simultaneous optimization models for heat integration-Ⅱ. Heat exchanger network synthesis[J].Computers and Chemical Engineering,1990, 14(10):1165-1184
[34]Papalexandri, Pistikopoulos, A multiperiod MINLP model for the synthesis of flexible heat and mass exchange networks[J]. Computers & Chemical Engineering,1994,18(11-12): 1125-1139
[35]原栋文,王瑶等,利用温焓图自动综合多流股换热器网络[J].计算机与应用化学2007年02期,24：235-238
[36]张俊峰,罗雄麟,换热网络设计方法的研究进展[J].化工进展2005年6期,(24)：625-628
[37]Jezowski J, Heat exchanger network synthesis algorithms of ordered search[J]. Inz. Chem. Proc,1981,2(1):45-58
[38]Androulakis, I. P.; Venkatasubramanian, V. A Genetic Algorithm Framework for Process Design and Optimization[J]. Comput. Chem. Eng.1991,15 (4):217-228
[39]Huang Y L, Fan L T, Distributed strategy for integration of process design and control Acknowledge engineering approach to the incorporation of controllability into exchanger network synthesis [J].Computers and Chemical Engineering,1992,16(5):497-522
[40]Islamoglu Y, A new approach for the prediction of the heat transfer rate of the wire-on-tube type heat exchanger-use of an artificial neural network model [J].Applied Thermal Engineering,2003, (23):243-249
[41]华贲.过程系统能量综合的研究和开发[C].中国系统工程学会过程系统专业委员会第一次学术交流会,1990
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[2]董文葆,化工过程模型化、优化管理及最优控制(Ⅰ)过程系统集成化及模型化[J].化工进展,1992年2期：31-36
[3]杨衡,锦西石化分公司Ⅱ套常减压装置扩能、降耗、改质改造[C].天津大学学位论文,2006
[4]杨友麒,化工过程模拟[J].化工进展,1996年3期：1-8
[5]姚平经,化工过程系统工程[M].大连：大连理工大学出版社,1996：2-3
[6]陆恩锡等,化二过程模拟及相关高新技术(Ⅰ)化工过程稳态模拟[J].化工进展,1999年4期：63-64
[7]Yang,L and K.T.chuang,A new approach to simulation of distillation in packed columns[J].Computers and Chemical Engineering,2000,24:1843-1849
[8]Shyamsundar,V.andG.Rangaiah,A method for simulation and optimization of multiphase distillation[J].Computers and Engineering and Processing,2004,43:483-493
[9]Mario Llano-Restrepo, Jaime Aguilar-Arias,Modeling and simulation of saline extractive distillation columns for the production of absolute ethanol[J].Computers and Chemical Engineering,2003,(27):527-549
[10]陆恩锡,化工过程模拟与相关高新杖术(Ⅱ)化工过程动态模拟[J].化工进展2000年1期：76-78
[11]F. BEZZO, R. BERNARDI,et al,Using process simulators for steady-state and dynamic plant analysis an Industrial case study [J]. Chemical Engineering Research and Design,2004,82(4):499-512
[12]Xiaole Yang, M. Sam Mannan,The development and application of dynamic operational risk assessment in oil/gas and chemical process industry[J].Reliability Engineering and System Safety,2010
[13]D. Pfleger,S. Becker,Modelling and simulation of the dynamic flow behaviour in a bubble column[J].Chemical Engineering Science,2001, (56):1737-1747
[14]S. Haugwitz I,et al,Dynamic start-up optimization of a plate reactor with uncertainties[J].2009,Journal of Process Control, (19):686-700
[15]D. LEE,Dynamic Simulation of the Sour Water Stripping Process and Modified Structure for Effective Pressure Control[J].Institution of Chemical Engineers,2002, (80): 167-178
[16]Tsung-Jen Ho et al,Dynamic simulation for internally heat-integrated distillation columns (HIDiC) for propylene-propane system[J].Computers and Chemical Engineering,2009,33:1187-1201
[17]Hwa C.S, Mathematical Formulation and Optimization of Heat Exchange network Using Separable Programming[J].AIChE-Intern Chem Eng Symp Series,1965,4:101
[18]韩文超,基于火用分析的低温甲醇洗过程工艺及换热网络优化[C].天津大学硕士学位论文,2009.06：7-8
[19]张俊峰,罗雄麟,换热网络合成问题的分析[C].第九届全国化学工艺年会论文集,2005
[20]张俊峰,罗雄麟,换热网络设计方法的研究进展[J].化工进展2005年6期,(24)：625-628
[21]Ravagnani, M. A. S. S., Silva, A. P., Arroyo, P. A., Constantino, A. A.,Heat exchanger network synthesis and optimisation using genetic algorithm[J]. Applied Thermal Engineering,2005,25:1003
[22]魏新利,潘惠华,刘宏,换热网络优化设计进展,郑州工业大学报[J].1998,19(增刊)：73-78
[23]Cerda, J.; Westerberg, A. W. Synthesizing Heat Exchanger Networks Having Restricted Stream/Stream Matches Using Transportation Problem Formulations [J]. Chem. Eng. Sci.1983,38(10),1723-1740.
[24]Cerda, J.,Westerberg, A. W., Mason, D.,Linnhoff, B.,Minimum Utility Usage in Heat Exchanger Network Synthesis[J].Chem. Eng. Sci.1983,38 (3),373-387
[25]Soterios A. Papoulias, Ignacio E. Grossmann,A structural optimization approach in process synthesis-Ⅰ:Utility systems[J]. Computers & Chemical Engineering,1983,7(6): 695-706
[26]J Cerda, AW Westerberg, Minimum utility usage in heat exchanger network synthesis A transportation problem[J]. Chemical Engineering Science,1983,38(3):373-387
[27]Papoulias S A,Grossmann I E. A Structural Optimization Approach in Process Synthesis Ⅲ:Total Processing Systems [J].Computers and Chemical Engineering,1983,7 (6): 723-734
[28]Floudas, C.A., Ciric, A.R. and Grossmann, I.E., Automatic synthesis of optimum heat exchanger network generation[J]AICHE J,1986,32(2):276-290
[29]Ciric, A. R., and Floudas, C. A.,A mixed integer nonlinear programming model for retrofitting heat exchanger networks[J]. Industrial & Engineering Chemistry Research,1990, 29,239-251
[30]Yee, T. F., Grossmann, I. E, A screening Optimization approach for the retrofit of heat exchanger networks [J]. Industrial & Engineering Chemistry Research,1991,30,146-162
[31]Asante, N. D. K.; Zhu, X. X. An Automated and Interactive Approach for Heat Exchanger Network Retrofit[J].Chem.Eng. Res. Des.1997,75 (A),349-360
[32]Bagajewicz M J,Barbaro A F. On the Use of Heat Pumps in Total Site Heat Integration[J].Computers and Chemical Engineering,2003,27:1707-1719
[33]T.F. Yee, I.E. Grossmann, Simultaneous optimization models for heat integration-Ⅱ. Heat exchanger network synthesis[J].Computers and Chemical Engineering,1990, 14(10):1165-1184
[34]Papalexandri, Pistikopoulos, A multiperiod MINLP model for the synthesis of flexible heat and mass exchange networks[J]. Computers & Chemical Engineering,1994,18(11-12): 1125-1139
[35]原栋文,王瑶等,利用温焓图自动综合多流股换热器网络[J].计算机与应用化学2007年02期,24：235-238
[36]张俊峰,罗雄麟,换热网络设计方法的研究进展[J].化工进展2005年6期,(24)：625-628
[37]Jezowski J, Heat exchanger network synthesis algorithms of ordered search[J]. Inz. Chem. Proc,1981,2(1):45-58
[38]Androulakis, I. P.; Venkatasubramanian, V. A Genetic Algorithm Framework for Process Design and Optimization[J]. Comput. Chem. Eng.1991,15 (4):217-228
[39]Huang Y L, Fan L T, Distributed strategy for integration of process design and control Acknowledge engineering approach to the incorporation of controllability into exchanger network synthesis [J].Computers and Chemical Engineering,1992,16(5):497-522
[40]Islamoglu Y, A new approach for the prediction of the heat transfer rate of the wire-on-tube type heat exchanger-use of an artificial neural network model [J].Applied Thermal Engineering,2003, (23):243-249
[41]华贲.过程系统能量综合的研究和开发[C].中国系统工程学会过程系统专业委员会第一次学术交流会,1990
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