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工业水网络分析与合成方法的研究
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摘要
工业水网络的过程集成技术是节能减排的重要手段。以水夹点技术和数学规划法为代表的过程集成技术已于过去二十年间在工业水网络中得到了广泛的研究和应用。
     随着水网络集成技术的不断深入发展,一些存在于实际用水网络中的复杂问题开始逐渐受到人们的关注。比如,传统单输入、单输出的再生装置模型已不能描述膜分离等新型废水再生装置,构建基于新的再生装置模型的再生用水网络优化方法成为当前亟待解决的问题;再比如,对于大型工业企业(如石化总厂)的水网络集成,其内部众多装置的操作独立性和空间距离使得柔性设计成为新的关注对象。此外,水在流程工业中不仅是杂质传输的载体,同时也承担着热量传递的任务。考虑热集成的用水网络综合和优化已逐步成为研究的热点。
     本论文针对以上不同特征的水网络展开了4个方面的研究工作:(1)水分配网络新鲜水与废水量最小化;(2)基于膜分离类再生装置的水分配网络新鲜水量最小化;(3)多装置用水网络柔性设计;(4)热集成用水网络的优化。具体工作如下:
     1.常规水分配网络中不同用水操作、不同目标参数的统一化图形方法的建立。定义夹点浓度,并推导出最小新鲜水量及废水量与夹点浓度的关系。以此为基础合成了反映用水网络水源盈亏情况的总组合曲线,并由此得到最小废水量和新鲜水量。为考虑废水再生情况,提出通过用再生水线和废水线合成废水排放线的方法求解再生情况下的最小新鲜水量。同时,根据总组合曲线得到了废水组合曲线,求得最小废水处理量。从而使得水分配网络中用水、再生和废水处理三个子系统的目标参数能够同时得到。
     2.含膜分离类再生装置的再生用水网络最优解求取算法的提出。分别以再生装置入口浓度和再生处理量为自变量,并结合夹点分析,建立了再生用水网络新鲜水量最小化的非线性规划(NLP)数学模型。发现并严格证明了该NLP数学模型最优解的充分和必要条件:(1)再生入口浓度大于或等于所有水源的最大混合浓度;(2)再生处理量达到其对应再生入口浓度下的最大值;(3)系统的夹点出现在某些指定区域。提出了依据最优性充分和必要条件的求解最小新鲜水量的分步算法,与以往的方法相比,能够保证得到最优解。
     3.多装置、多周期用水网络优化设计方法的研究。提出一种新的结合夹点原理的数学规划法。首先通过一种新的转运模型来确定单一装置的最小新鲜水用量,再将该转运模型扩展到多装置的情况。此后,通过建立混合整数非线性规划(MINLP)模型来求解l个CPI情况下的最小总操作费用,并用序贯比较的方法来获得最优的CPI值。最后,通过求解混合整数线性规划(MILP)模型来得到各装置的柔性用水网络。
     4.区分混合传热与间接传热的热集成用水网络综合方法的建立。提出新的同时考虑间接传热和混合传热的热集成转运模型,并与用水网络超结构NLP模型结合以求取△T_(min)=0℃时用水网络的公用工程目标。新转运模型与以往的模型相比变量数和约束方程数都大大减少。进一步,针对现有综合方法△T_(min)不可调的局限性,采用改进的换热网络转运模型,提出了区分处理混合传热和间接传热的综合方法。该方法不仅可以得到优化的公用工程费用和换热匹配数,而且与传统的方法相比可以调整△T_(min),得到更合理的换热网络结构。算例表明,结合新转运模型的NLP模型与结合改进转运模型的综合方法都要优于以往的模型和方法。
     5.操作可分解情况下热集成用水网络的优化。发现在操作允许分解情况下,系统的总费用具有进一步降低的潜力。将操作不分解情况下的热集成用水网络模型推广到操作分解情况,仍采用目标-设计两步法来求解。提出在第1步的目标函数中包含公用工程的费用和分解的子操作数目,而第2步用水网络的设计则通过求解MINLP数学模型实现。
Water network integration is one of the most efficient technologies for energy saving and pollution reduction.During the past two decades,both the water pinch technology and the mathematical programming method have been frequently discussed and widely applied in the industry.
     With the rapid development of water network integration technology,some practical problems are becoming more and more popular.These problems include the optimization of regeneration reuse water networks with membrane units,the flexible design of multiple plant water networks and the optimal design of energy efficient water networks.
     This thesis focuses on the optimal solution of the single contaminant water allocation networks with the above mentioned characteristics,the main contents are as follows:
     1.A new approach for targeting minimum freshwater and minimum effluent treatment flow rate of a water allocation network is presented.By defining pinch point,the relationship between freshwater consumption and pinch concentration is established first.Then,a grand composite curve based on the concept of Wang and Smith's limiting composite curve is constructed firstly to determine the wastewater line with minimum flow rate.Subsequently,the wastewater line is modified for the case of regeneration-reuse.The minimum treatment target is obtained through a wastewater composite curve,which is generated from the grand composite curve.The proposed approach can be applied to the fixed flow rate as well as the fixed contaminant load problems with a single contaminant.Finally,the reuse,regeneration-reuse and wastewater treatment problems can be solved in a single concentration versus contaminant load diagram.
     2.A NLP model for the optimization of regeneration reuse water networks with membrane units is established.The necessary and sufficient conditions for the optimal solution of this problem are proved:(1) the regeneration concentration should be larger than the concentration of maximum mixing;(2) the regeneration inlet flow rate should be set at its maximum value corresponding to the concentration;(3) the pinch points of the system are set at particular regions.According to these necessary and sufficient conditions,a step-by-step algorithm to achieve the minimum freshwater usage is also proposed.
     3.A design methodology for flexible multiple plant water networks is introduced.By combining pinch insight with mathematical programming,target freshwater usage and cross plant interconnections(CPIs) conditions are obtained firstly without considering the detailed network design.Subsequently,an MILP model is established for the design of flexible water networks of individual plants.The proposed systematic approach can be applied for both fixed contaminant(FC) operations and fixed flowrate (FF) operations,limited to a single contaminant.Example from literature and a practical example of chlor-alkali complex are used to illustrate the applicability of the approach.
     4.An optimal design approach for energy efficient water networks is developed.A new kind of NLP model for utility targeting under△T_(min)=0℃is presented which can reduce the number of variables greatly.Moreover,an improved design approach considering the specified△T_(min) is generated.This approach,which treats the direct and indirect heat transfer separately,provides the information to construct the water utilization system as well as the corresponding heat exchanger network without any△T_(min) violation.
     5.The design of energy efficient water utilization systems allowing operation split is explored.Practical features such as operating flexibility and capital cost have made the number of sub operations an important parameter of the problem.By treating the direct and indirect heat transfers separately,target freshwater and energy consumption as well as the operation split conditions are first obtained.Subsequently,a mixed integer non-linear programming(MINLP) model is established for the design of water network and the heat exchanger network(HEN).The proposed systematic approach is limited to a single contaminant.Example from literature is used to illustrate the applicability of the approach.
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