石化产业生态分析及水资源优化利用研究
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摘要
世界石化产业正经历着第三次产业结构调整，呈现出了产业集中化、科技化、生态化的特点。我国石化行业的资源利用和污染治理的整体水平与国际先进水平相比存在着相当大的差距，我国炼油行业的每吨原油加工耗水量平均2.37t／t，比国际先进水平的0.5t／t高5倍。目前某石化企业已经基本建成千万吨级炼油基地和石化产品出口基地，并形成较强的特色产品生产优势。但是，在产业结构方面，仍存在资源问题突出、环境污染严重、产业配置潜力巨大等问题。
本文作为上海市科委科研计划项目“上海石化行业产业生态试验与应用研究”(课题编号042312081)的主要组成部分，将产业生态理念运用于石化行业，进行石化产业生态分析，开展旨在提高资源生产率和污染排放最小化的生态链优化设计，研究开发石化行业生产过程中具有代表性的节能、节水、降低物料消耗和废物排放的共性关键技术。主要研究成果有：
(1)对某大型石化企业产业现状及其环境问题进行系统的分析。该企业内部已初步具有产业链的雏形，但存在产品物流简单粗放、资源浪费严重等问题。该企业废气方面应加强硫和有机物的回收利用以及低品味热能回收利用；废渣应加强资源化研究并进行优化管理；此外，企业内用水与废水网络系统优化的需求迫切，水资源节约和再利用潜力巨大。
(2)建立了环境管理数据库。利用Microsoft Visual Basic.net与Microsoft SQL Server 2000建立了包含石化行业各类环境管理相关信息的数据库，操作界面由主界面、查询窗口、信息窗口和提示对话框组成。
(3)对废气和废渣系统进行优化。典型石化企业废气可采用石灰石／石灰-石膏法、克劳斯工艺、吸附法和热力燃烧等工艺进行资源化处理，该企业高温废气采用间接换热方式回收余热，可回收热能8387.72 kw，产生效益折合人民币123，250元／天。该企业废渣可采用焚烧-热能回用的方法进行资源化处理，废碱可采用WAO+SBR组合工艺进行处理，催化剂宜采用化学方法再生。
(4)进行新型水系统优化方法的建立和应用。研究成果主要有以下两点：
1)提出了新型水系统优化方法的理论，并建立了一个或多个污染因子的水系统优化模型。新型水系统优化方法的基本假设为用水操作的传质动力模型，采用每个用水操作依次使用回用水源和新鲜水源配合的方式，水源采用顺序依次为浓度与用水操作入口极限浓度相等的回用水—其它回用水—新鲜水。水系统优化模型主要包括模型假设、目标函数、边界条件、模型函数、判断准则及其运算程序流程图。
2)编写了单污染因子和双污染因子新型水系统优化的计算机程序，并将其运用于实际计算。对实例中含硫水系统优化后的节水减排效率达到单污染因子38.31％和19.98％，多污染因子17.81％，含油水系统优化后的节水减排效率达到单污染因子33.30％和24.29％。此外，新型水系统优化方法适应性强，可以兼容流量改变，浓度改变、再生回用和再生循环等实际情况。
(5)运用新型水系统优化方法，对典型石化企业用水与废水网络系统进行优化并构建水系统产业链。研究成果主要有以下三点：
1)提出水系统回用的方法与原则。蒸汽凝结水回收、含硫含油污水串级回用、废水深度处理后回用等方法是水系统优化的有效途径。
2)工艺水及水回用系统优化。在工艺水系统回用水的等级划分与水质标准确定的基础上，运用新型水系统优化的理论和方法，对该企业工艺水系统进行优化。工艺水系统优化后，该企业电脱盐注水、水封用水和冷却用水三种工艺用水可采用回用水188.03t／h，新鲜水使用量由原来的199.62t／h降至11.59t／h。
3)通过对典型石化企业实际水系统的整体集成优化，构建水系统产业链。水系统整体优化后，该企业加工吨原油耗水量由原来的1.03t／t降至0.53t／t，加工吨原油排水量由原来的0.53t／t降至0.028t／t。
(6)进行石化行业产业生态系统保障体系的分析和构建，主要包括事故应急救援预案的构建以及环境组织管理体系的构建。
Now, the third structural readjustment has enabled the global petroleum and petrochemical industries that appear industry entralizing, scientific and ecological. The integral level of resource utilization and pollution control of China is lower than that of developed country. Water consumption to refine one ton petroleum in our country is 2.37t/t that is five times than 0.5t/t of developed country. The petrochemical enterprise's current nameplate capacity includes 1.13Mt/a of refinery throughput, more than 600 kt/a of petrochemical products output, but the enterprise has problems such as resource shortage, environment pollution, etc.
The dissertation supported by planned scientific programs of Shanghai Science and Technology Committee (Grant No.042312081) applied industrial ecology concept to petrochemical industry. Ecological analysis in petrochemical industry including ecological chain optimization to enhance productivity and reduce pollution and key technology exploration of energy saving, water saving, consumption and pollution reduction is showing in the dissertation. The main achievement is mentioned as below.
(1) Industry and environment problem was analysed systemically in a large petrochemical enterprise. Although primary industry ecological chain is forming, industry and environment problem such as rough production and large resource consumption is in existence. The enterprise should intensify the recovery of the sulfur, organic compound and low quality heat energy from the exhaust gas and optimize the management of the waste residue. Moreover, there is more space in the economy and reusing of the fresh water, and the optimization of the water supply and drainage pipe network is needed urgently.
(2) A database for environmental protection management was founded. The database containing almost all the information about the environmental management in petrochemical industry was built with Microsoft Visual Basic.net and Microsoft SQL Server 2000, and the operating interface included main interface, query window,
info window and prompt dialog-box.
(3) The exhaust gas and waste residue systems were optimized. The exhaust gas of the representative petrochemical enterprise could be reused by limestone/lime-gypsum method, Claus method, adsorption method and thermal combustion method. The remainder heat in the high temperature gas could be recovered with indirect heat exchange method, the waste residue could be recycled with burning-heat recovery method, the waste caustic could be treated with WAO+SBR, and the activator could be revivified with chemical method.
(4) A new water system optimization method was built and applied in the representative petrochemical enterprise. The following two research conclusions were obtained:
1) A new water system optimization method was advanced and a water system optimization model faced one or more pollution factors was built. The new water system optimization method was based on mass transfer model of water operation, evry operation used circle water and fresh water in turn, and the order is water with limit concentration- other circle water- fresh water. The water system optimization model included hypothesis, object function, terminal condition, pattern function, judgement guideline and operational sequence process chart.
2) An optimization programme for single pollution factor and two pollution factors water system was created and applied in practice. The result showed that in water system containing sulfur the fresh water reduction was 38.31% and 19.98% respectively on the conditions of single pollutant and 17.81% on the condition of two pollutants. In water system containing oil, the fresh water reduction was 33.30% and 24.29% respectively on the conditions of single pollutant. What is more, the optimization method had high applicability to conditions such as flowrate change, concentration change, water regeneration and water recycle.
(5) Water system was optimized and industry chain was built in the enterprise with new water system optimization method. The following three research conclusions were obtained:
1) The method and principle for water recycle were advanced. Effective pproach for water system optimization mainly included condensate recycle, series reuse of wastewater, recycle after deepness treatment, etc.
2) Process water system was optimized based on the establishment of water qulity standard and grade. After optimization, the fresh water consumption for desalter, water seal and cooling was reduced from 199.62t/h to11.59 t/h, and 188.03t/h recycle water became the substitute.
3) Water system industry chain was built by integrated optimization of the whole water system in the enterprise, the fresh water consumption refining one ton petroleum was reduced from 1.03t/t to 0.53 t/t and the water discharge from 0.53t/t to 0.028 t/t.
(6) The secure system for ecology industry was analysed and built. The system mainly consisted of emergency countermeasure for safe production and environment organization management system.
本文作为上海市科委科研计划项目“上海石化行业产业生态试验与应用研究”(课题编号042312081)的主要组成部分，将产业生态理念运用于石化行业，进行石化产业生态分析，开展旨在提高资源生产率和污染排放最小化的生态链优化设计，研究开发石化行业生产过程中具有代表性的节能、节水、降低物料消耗和废物排放的共性关键技术。主要研究成果有：
(1)对某大型石化企业产业现状及其环境问题进行系统的分析。该企业内部已初步具有产业链的雏形，但存在产品物流简单粗放、资源浪费严重等问题。该企业废气方面应加强硫和有机物的回收利用以及低品味热能回收利用；废渣应加强资源化研究并进行优化管理；此外，企业内用水与废水网络系统优化的需求迫切，水资源节约和再利用潜力巨大。
(2)建立了环境管理数据库。利用Microsoft Visual Basic.net与Microsoft SQL Server 2000建立了包含石化行业各类环境管理相关信息的数据库，操作界面由主界面、查询窗口、信息窗口和提示对话框组成。
(3)对废气和废渣系统进行优化。典型石化企业废气可采用石灰石／石灰-石膏法、克劳斯工艺、吸附法和热力燃烧等工艺进行资源化处理，该企业高温废气采用间接换热方式回收余热，可回收热能8387.72 kw，产生效益折合人民币123，250元／天。该企业废渣可采用焚烧-热能回用的方法进行资源化处理，废碱可采用WAO+SBR组合工艺进行处理，催化剂宜采用化学方法再生。
(4)进行新型水系统优化方法的建立和应用。研究成果主要有以下两点：
1)提出了新型水系统优化方法的理论，并建立了一个或多个污染因子的水系统优化模型。新型水系统优化方法的基本假设为用水操作的传质动力模型，采用每个用水操作依次使用回用水源和新鲜水源配合的方式，水源采用顺序依次为浓度与用水操作入口极限浓度相等的回用水—其它回用水—新鲜水。水系统优化模型主要包括模型假设、目标函数、边界条件、模型函数、判断准则及其运算程序流程图。
2)编写了单污染因子和双污染因子新型水系统优化的计算机程序，并将其运用于实际计算。对实例中含硫水系统优化后的节水减排效率达到单污染因子38.31％和19.98％，多污染因子17.81％，含油水系统优化后的节水减排效率达到单污染因子33.30％和24.29％。此外，新型水系统优化方法适应性强，可以兼容流量改变，浓度改变、再生回用和再生循环等实际情况。
(5)运用新型水系统优化方法，对典型石化企业用水与废水网络系统进行优化并构建水系统产业链。研究成果主要有以下三点：
1)提出水系统回用的方法与原则。蒸汽凝结水回收、含硫含油污水串级回用、废水深度处理后回用等方法是水系统优化的有效途径。
2)工艺水及水回用系统优化。在工艺水系统回用水的等级划分与水质标准确定的基础上，运用新型水系统优化的理论和方法，对该企业工艺水系统进行优化。工艺水系统优化后，该企业电脱盐注水、水封用水和冷却用水三种工艺用水可采用回用水188.03t／h，新鲜水使用量由原来的199.62t／h降至11.59t／h。
3)通过对典型石化企业实际水系统的整体集成优化，构建水系统产业链。水系统整体优化后，该企业加工吨原油耗水量由原来的1.03t／t降至0.53t／t，加工吨原油排水量由原来的0.53t／t降至0.028t／t。
(6)进行石化行业产业生态系统保障体系的分析和构建，主要包括事故应急救援预案的构建以及环境组织管理体系的构建。
Now, the third structural readjustment has enabled the global petroleum and petrochemical industries that appear industry entralizing, scientific and ecological. The integral level of resource utilization and pollution control of China is lower than that of developed country. Water consumption to refine one ton petroleum in our country is 2.37t/t that is five times than 0.5t/t of developed country. The petrochemical enterprise's current nameplate capacity includes 1.13Mt/a of refinery throughput, more than 600 kt/a of petrochemical products output, but the enterprise has problems such as resource shortage, environment pollution, etc.
The dissertation supported by planned scientific programs of Shanghai Science and Technology Committee (Grant No.042312081) applied industrial ecology concept to petrochemical industry. Ecological analysis in petrochemical industry including ecological chain optimization to enhance productivity and reduce pollution and key technology exploration of energy saving, water saving, consumption and pollution reduction is showing in the dissertation. The main achievement is mentioned as below.
(1) Industry and environment problem was analysed systemically in a large petrochemical enterprise. Although primary industry ecological chain is forming, industry and environment problem such as rough production and large resource consumption is in existence. The enterprise should intensify the recovery of the sulfur, organic compound and low quality heat energy from the exhaust gas and optimize the management of the waste residue. Moreover, there is more space in the economy and reusing of the fresh water, and the optimization of the water supply and drainage pipe network is needed urgently.
(2) A database for environmental protection management was founded. The database containing almost all the information about the environmental management in petrochemical industry was built with Microsoft Visual Basic.net and Microsoft SQL Server 2000, and the operating interface included main interface, query window,
info window and prompt dialog-box.
(3) The exhaust gas and waste residue systems were optimized. The exhaust gas of the representative petrochemical enterprise could be reused by limestone/lime-gypsum method, Claus method, adsorption method and thermal combustion method. The remainder heat in the high temperature gas could be recovered with indirect heat exchange method, the waste residue could be recycled with burning-heat recovery method, the waste caustic could be treated with WAO+SBR, and the activator could be revivified with chemical method.
(4) A new water system optimization method was built and applied in the representative petrochemical enterprise. The following two research conclusions were obtained:
1) A new water system optimization method was advanced and a water system optimization model faced one or more pollution factors was built. The new water system optimization method was based on mass transfer model of water operation, evry operation used circle water and fresh water in turn, and the order is water with limit concentration- other circle water- fresh water. The water system optimization model included hypothesis, object function, terminal condition, pattern function, judgement guideline and operational sequence process chart.
2) An optimization programme for single pollution factor and two pollution factors water system was created and applied in practice. The result showed that in water system containing sulfur the fresh water reduction was 38.31% and 19.98% respectively on the conditions of single pollutant and 17.81% on the condition of two pollutants. In water system containing oil, the fresh water reduction was 33.30% and 24.29% respectively on the conditions of single pollutant. What is more, the optimization method had high applicability to conditions such as flowrate change, concentration change, water regeneration and water recycle.
(5) Water system was optimized and industry chain was built in the enterprise with new water system optimization method. The following three research conclusions were obtained:
1) The method and principle for water recycle were advanced. Effective pproach for water system optimization mainly included condensate recycle, series reuse of wastewater, recycle after deepness treatment, etc.
2) Process water system was optimized based on the establishment of water qulity standard and grade. After optimization, the fresh water consumption for desalter, water seal and cooling was reduced from 199.62t/h to11.59 t/h, and 188.03t/h recycle water became the substitute.
3) Water system industry chain was built by integrated optimization of the whole water system in the enterprise, the fresh water consumption refining one ton petroleum was reduced from 1.03t/t to 0.53 t/t and the water discharge from 0.53t/t to 0.028 t/t.
(6) The secure system for ecology industry was analysed and built. The system mainly consisted of emergency countermeasure for safe production and environment organization management system.
引文
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