炼油企业氢气系统优化研究及应用
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摘要
随着含硫原油和重质原油加工比例的增大,以及市场对油品质量的要求越来越高和环境保护法规的不断加强,加氢精制、加氢裂化等深加工技术在炼油企业得到了广泛的应用,以满足日益提高的产品质量和环保要求。随着氢气消耗量的日益增大,氢气成本已经是炼油企业原料成本中仅次于原油成本的第二位成本要素。对氢气系统进行优化将极大地挖掘炼油企业降本增效的潜力,同时为其节能降耗工作发挥重大作用。本文在综述了炼油企业氢气系统优化问题的国内外研究和应用现状后,对炼油企业氢气系统优化的相关问题进行了系统而深入的研究,并通过工业实际案例的应用研究证明了本文所提策略的可行性和有效性。本文的主要研究内容和创新点如下：
1)首先提出了两种改进的炼油企业氢气系统优化设计策略,将炼油企业氢气系统的优化设计分为提纯系统优化和供氢系统优化的分步优化设计策略,以及整个氢气系统的同步优化设计策略。为了使优化模型更切合炼油企业实际,将耗氢装置反应器入口的氢气流量、纯度和提纯装置的回收率视为变量,并增加了耗氢装置的最小纯氢量约束。以最小化年度成本为目标,综合考虑了氢源、氢阱、压缩机、提纯装置、逻辑变量等约束,建立了氢气系统优化设计的混合整数非线性规划(MINLP)模型。工业实际案例研究表明,相比以前的研究方法,提出的优化策略得到了更切合实际的氢气系统优化设计方案,并节省了大量的氢气成本,对实际炼油企业氢气系统的优化管理起到了重要指导作用。
2)针对氢气系统优化设计过程中需要同时实现操作成本和投资成本最小化的两个相互矛盾的目标函数,提出了炼油企业氢气系统的多目标优化设计策略。对氢气系统的驰放气资源进行了详细的分析和利用,建立了氢气系统多目标优化设计的MINLP模型。采用基于变化权系数的加权法处理该多目标优化问题,将多目标优化问题转化为单目标优化问题。通过不断改变权重系数求得多目标优化问题的Pareto最优前沿,根据Pareto最优前沿来权衡投资成本和操作成本的关系,以确定兼顾操作成本和投资成本的炼油企业氢气系统优化设计方案。案例研究表明,提出的多目标优化设计策略充分考虑了投资成本和操作成本的关系,确定了兼顾操作成本和投资成本的氢气系统优化设计方案。
3)针对氢气的产耗量、驰放气产量和其它价格要素受原油供应、产品需求、市场条件和操作条件的变化而随机波动的不确定问题,基于机会约束规划方法构建了一种新的炼油企业氢气系统优化设计策略。充分考虑了产氢量、耗氢量、驰放气供应量、电价、氢气价格、燃料气价格等不确定因素对氢气系统优化设计问题的影响,并引入置信度水平,将模型中的不确定性约束转化为确定性约束,使得不确定条件下的机会约束规划模型转变为可以求解的确定性混合整数非线性规划模型。案例研究表明,该方法能有效处理炼油企业氢气系统的参数波动问题,与传统的确定性方法相比更具有优越性。
4)针对炼油企业氢气系统不断变化的工况和氢气需求,提出了炼油企业氢气系统柔性优化设计策略,建立了多工况下氢气系统柔性优化设计的MINLP模型。提出了一种线性化策略对柔性优化设计模型进行了线性化处理,将难以求解的MINLP问题转化为易求解的混合整数线性规划(MILP)问题,并对线性化模型的特点进行了分析。采用提出的柔性优化策略对某炼油企业氢气系统进行了优化设计,柔性优化后的氢气系统可操作性强且具有较好的柔性调节能力,既节省了大量的运行成本,又为各工况下氢气系统的安全稳定运行提供了保障。
5)针对炼油企业工艺过程对氢气不断变化的需求,提出了炼油企业氢气系统调度优化策略。从炼油企业氢气系统的生产实际出发,详细分析了当前炼油企业氢气系统实际调度中的影响因素,建立了综合考虑多项影响因素的氢气系统多周期调度优化的MINLP模型。针对建立的多周期调度优化MINLP模型,提出了一种迭代求解策略,避免了对原始MINLP问题的直接求解,降低了问题的求解难度,取得了较好的求解效果。工业实例研究表明,该策略经一次迭代便可求得合乎要求的有效解,保证了产氢装置的平稳生产,避免了压缩机启停、氢源更换、氢气管网容量超限等非正常现象的发生,减少了氢气放空,取得了显著的节能减排效果,实现了有效的氢气系统调度优化,为企业带来了良好的经济效益。
During the past decade, crude oil has become heavier and contains more sulfur and nitrogen, while clean fuels specifications are progressively tightened via the market and legislation for environmental protection. Hydrocracking and hydrotreating, which consume the most part of hydrogen in refinery, are used more and more widely to upgrade heavy oils to obtain more valuable products. As the demand for hydrogen grows, hydrogen cost has become the second most important cost after the cost of crude oil. Optimization of hydrogen systems will play a great role in energy saving, and definitely will bring considerable profit to the refinery at the same time. In this thesis, after the summary of the recent research issues in refinery hydrogen system, challenging issues about the optimization of hydrogen system in refinery are investigated systematically. Finally, case studies based on the data from real refineries are presented to illustrate the effectiveness and feasibility of the proposed approaches. The main contributions of this thesis are as follows:
1) Two improved systematic mathematical approaches are developed based on a two-step approach and a simultaneous optimization approach respectively for the optimization design of hydrogen system in refinery. To make the approaches proposed more practical for the real system application, the flowrate and purity at the reactor inlet of hydrogen consumers and the recovery of purification units are considered as optimization variables, and at the same time the minimum pure hydrogen of hydrogen consumers will be satisfied. Mixed integer nonlinear programming (MINLP) models are formulated with the objective function of the minimization of total annual cost subject to constraints of sources, sinks, purifiers, logic variables, etc. As shown in the case study, optimized results are more practical and economical than those recently reported the literature. Therefore the proposed strategies play an important role in guiding the management of hydrogen system in refinery.
2) A novel multi-objective optimization approach is presented to balance the two conflicting objectives between operating cost and investment cost. Based on detailed analysis of off-gases of the hydrogen system, a MINLP model is formulated for the multi-objective optimization problem. This problem is transferred into the single objective optimization problem based on the weighted method with varying weight coefficients. By solving the problem, the Pareto front of the multi-objective optimization problem is obtained to balance the operating cost and investment cost leading to a suitable compromise between the two objectives. As shown in the case study, the relation of operating cost and investment cost indicates a deep insight in to the system operation,, and the optimized results based on the proposed multi-objective optimization strategy are practical and suitable for the real system.
3) The uncertainty of the crude oil supply, external product demand, market condition and operation condition will result in uncertainties in the hydrogen production and consumption, off-gases production and related prices in refinery. A novel chance constrained programming approach is adopted to address the hydrogen system optimization problem under various uncertainties such as hydrogen production and consumption, off-gases production and the price of electricity, hydrogen and fuel gas. In this way, important input and state constraints will be satisfied with predefined probability levels. The problem is then transformed to an equivalent deterministic MINLP problem so that it can be solved by a MINLP solver. The effectiveness of the proposed approach comparing with the traditional deterministic methods is demonstrated by a case study.
4) A novel approach for the design and optimization of flexible hydrogen systems is addressed based on the consideration of varying operation conditions and demand of hydrogen system in refinery, and a corresponding MINLP model is formulated to address the flexible optimization problem. Using a linearization method the MINLP formulation is approximated by a mixed-integer linear programming (MILP) problem, resulting in an acceptable quality and a high efficiency. An industrial hydrogen system is taken for a case study. As shown in the case study, the optimized hydrogen system based on the presented flexible optimization strategy has better flexibility, and significant savings and stable operation of hydrogen system is realized in comparison to the existing design.
5) A multi-period optimization scheduling approach for hydrogen system is developed based on the consideration of the varying hydrogen demand. The impact factors of hydrogen system scheduling are elaborated, and a MINLP model is developed for the optimal scheduling of hydrogen system. The solution of the MINLP problem is obtained based on an MILP-NLP iterative algorithm, avoiding the solving of the MINLP problem directly and resulting in better quality and efficiency. A case study is presented to illustrate the effectiveness of the proposed methodology. Optimized results based on a complete iteration show that the optimized scheduling scheme is reliable and practical, the abnormal phenomena of the hydrogen imbalance, compressor start-stop, and hydrogen source change could be prevented, and the economic loss and unstable operation can also be avoided.
1)首先提出了两种改进的炼油企业氢气系统优化设计策略,将炼油企业氢气系统的优化设计分为提纯系统优化和供氢系统优化的分步优化设计策略,以及整个氢气系统的同步优化设计策略。为了使优化模型更切合炼油企业实际,将耗氢装置反应器入口的氢气流量、纯度和提纯装置的回收率视为变量,并增加了耗氢装置的最小纯氢量约束。以最小化年度成本为目标,综合考虑了氢源、氢阱、压缩机、提纯装置、逻辑变量等约束,建立了氢气系统优化设计的混合整数非线性规划(MINLP)模型。工业实际案例研究表明,相比以前的研究方法,提出的优化策略得到了更切合实际的氢气系统优化设计方案,并节省了大量的氢气成本,对实际炼油企业氢气系统的优化管理起到了重要指导作用。
2)针对氢气系统优化设计过程中需要同时实现操作成本和投资成本最小化的两个相互矛盾的目标函数,提出了炼油企业氢气系统的多目标优化设计策略。对氢气系统的驰放气资源进行了详细的分析和利用,建立了氢气系统多目标优化设计的MINLP模型。采用基于变化权系数的加权法处理该多目标优化问题,将多目标优化问题转化为单目标优化问题。通过不断改变权重系数求得多目标优化问题的Pareto最优前沿,根据Pareto最优前沿来权衡投资成本和操作成本的关系,以确定兼顾操作成本和投资成本的炼油企业氢气系统优化设计方案。案例研究表明,提出的多目标优化设计策略充分考虑了投资成本和操作成本的关系,确定了兼顾操作成本和投资成本的氢气系统优化设计方案。
3)针对氢气的产耗量、驰放气产量和其它价格要素受原油供应、产品需求、市场条件和操作条件的变化而随机波动的不确定问题,基于机会约束规划方法构建了一种新的炼油企业氢气系统优化设计策略。充分考虑了产氢量、耗氢量、驰放气供应量、电价、氢气价格、燃料气价格等不确定因素对氢气系统优化设计问题的影响,并引入置信度水平,将模型中的不确定性约束转化为确定性约束,使得不确定条件下的机会约束规划模型转变为可以求解的确定性混合整数非线性规划模型。案例研究表明,该方法能有效处理炼油企业氢气系统的参数波动问题,与传统的确定性方法相比更具有优越性。
4)针对炼油企业氢气系统不断变化的工况和氢气需求,提出了炼油企业氢气系统柔性优化设计策略,建立了多工况下氢气系统柔性优化设计的MINLP模型。提出了一种线性化策略对柔性优化设计模型进行了线性化处理,将难以求解的MINLP问题转化为易求解的混合整数线性规划(MILP)问题,并对线性化模型的特点进行了分析。采用提出的柔性优化策略对某炼油企业氢气系统进行了优化设计,柔性优化后的氢气系统可操作性强且具有较好的柔性调节能力,既节省了大量的运行成本,又为各工况下氢气系统的安全稳定运行提供了保障。
5)针对炼油企业工艺过程对氢气不断变化的需求,提出了炼油企业氢气系统调度优化策略。从炼油企业氢气系统的生产实际出发,详细分析了当前炼油企业氢气系统实际调度中的影响因素,建立了综合考虑多项影响因素的氢气系统多周期调度优化的MINLP模型。针对建立的多周期调度优化MINLP模型,提出了一种迭代求解策略,避免了对原始MINLP问题的直接求解,降低了问题的求解难度,取得了较好的求解效果。工业实例研究表明,该策略经一次迭代便可求得合乎要求的有效解,保证了产氢装置的平稳生产,避免了压缩机启停、氢源更换、氢气管网容量超限等非正常现象的发生,减少了氢气放空,取得了显著的节能减排效果,实现了有效的氢气系统调度优化,为企业带来了良好的经济效益。
During the past decade, crude oil has become heavier and contains more sulfur and nitrogen, while clean fuels specifications are progressively tightened via the market and legislation for environmental protection. Hydrocracking and hydrotreating, which consume the most part of hydrogen in refinery, are used more and more widely to upgrade heavy oils to obtain more valuable products. As the demand for hydrogen grows, hydrogen cost has become the second most important cost after the cost of crude oil. Optimization of hydrogen systems will play a great role in energy saving, and definitely will bring considerable profit to the refinery at the same time. In this thesis, after the summary of the recent research issues in refinery hydrogen system, challenging issues about the optimization of hydrogen system in refinery are investigated systematically. Finally, case studies based on the data from real refineries are presented to illustrate the effectiveness and feasibility of the proposed approaches. The main contributions of this thesis are as follows:
1) Two improved systematic mathematical approaches are developed based on a two-step approach and a simultaneous optimization approach respectively for the optimization design of hydrogen system in refinery. To make the approaches proposed more practical for the real system application, the flowrate and purity at the reactor inlet of hydrogen consumers and the recovery of purification units are considered as optimization variables, and at the same time the minimum pure hydrogen of hydrogen consumers will be satisfied. Mixed integer nonlinear programming (MINLP) models are formulated with the objective function of the minimization of total annual cost subject to constraints of sources, sinks, purifiers, logic variables, etc. As shown in the case study, optimized results are more practical and economical than those recently reported the literature. Therefore the proposed strategies play an important role in guiding the management of hydrogen system in refinery.
2) A novel multi-objective optimization approach is presented to balance the two conflicting objectives between operating cost and investment cost. Based on detailed analysis of off-gases of the hydrogen system, a MINLP model is formulated for the multi-objective optimization problem. This problem is transferred into the single objective optimization problem based on the weighted method with varying weight coefficients. By solving the problem, the Pareto front of the multi-objective optimization problem is obtained to balance the operating cost and investment cost leading to a suitable compromise between the two objectives. As shown in the case study, the relation of operating cost and investment cost indicates a deep insight in to the system operation,, and the optimized results based on the proposed multi-objective optimization strategy are practical and suitable for the real system.
3) The uncertainty of the crude oil supply, external product demand, market condition and operation condition will result in uncertainties in the hydrogen production and consumption, off-gases production and related prices in refinery. A novel chance constrained programming approach is adopted to address the hydrogen system optimization problem under various uncertainties such as hydrogen production and consumption, off-gases production and the price of electricity, hydrogen and fuel gas. In this way, important input and state constraints will be satisfied with predefined probability levels. The problem is then transformed to an equivalent deterministic MINLP problem so that it can be solved by a MINLP solver. The effectiveness of the proposed approach comparing with the traditional deterministic methods is demonstrated by a case study.
4) A novel approach for the design and optimization of flexible hydrogen systems is addressed based on the consideration of varying operation conditions and demand of hydrogen system in refinery, and a corresponding MINLP model is formulated to address the flexible optimization problem. Using a linearization method the MINLP formulation is approximated by a mixed-integer linear programming (MILP) problem, resulting in an acceptable quality and a high efficiency. An industrial hydrogen system is taken for a case study. As shown in the case study, the optimized hydrogen system based on the presented flexible optimization strategy has better flexibility, and significant savings and stable operation of hydrogen system is realized in comparison to the existing design.
5) A multi-period optimization scheduling approach for hydrogen system is developed based on the consideration of the varying hydrogen demand. The impact factors of hydrogen system scheduling are elaborated, and a MINLP model is developed for the optimal scheduling of hydrogen system. The solution of the MINLP problem is obtained based on an MILP-NLP iterative algorithm, avoiding the solving of the MINLP problem directly and resulting in better quality and efficiency. A case study is presented to illustrate the effectiveness of the proposed methodology. Optimized results based on a complete iteration show that the optimized scheduling scheme is reliable and practical, the abnormal phenomena of the hydrogen imbalance, compressor start-stop, and hydrogen source change could be prevented, and the economic loss and unstable operation can also be avoided.
引文
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