5-1附录一 物料衡算计算书

扬子石化年产10万吨甲基丙烯酸甲酯项目 物料衡算计算书目录1.1概述11.2物料衡算目的11.3 物料衡算方法11.4总项目衡算21.4.1物料衡算任务21.4.2叔丁醇合成工段31.4.3甲基丙烯醛合成工段101.4.4甲基丙烯酸甲酯合成工段251.4.5总物料衡算421.5总结46 浙江工业大学A4团队 1/11.1概述本项目主要通过对C4抽余油中异丁烯的资源化利用，并以该异丁烯为主要原料，通过水合、氧化、氧化酯化等工艺合成纯度为99.95wt的甲基丙烯酸甲酯，年产量为10万吨，副产精制甲酸甲酯。在已确定化学生产工艺和流程后，由定性阶段转向定量阶段，通过对整个生产系统、生产车间，以及部分重要的生产单元进行物料衡算精算出主、副产品的产量，原材料的消耗定额、“三废”排放量及组成，以及产品收率等各项经济技术指标，从而定量地评述初步设计所选择的工艺路线、生产方法及工艺流程在经济上是否合理。1.2物料衡算目的工艺设计中，物料衡算是在工艺流程确定后进行的。目的是根据原料与产品之间的定量转化关系，计算原料的消耗量，各种中间产品、产品和副产品的产量，生产过程中各阶段的消耗量以及组成，进而为热量衡算、其他工艺计算及设备计算打下基础。对于已有装置，物料衡算可以弄清原料的来龙去脉，找出生产中的薄弱环节，为改进生产、完善管理提供可靠的依据和明确方向，并可作为检查原料利用率及三废处理完善程度的一种手段。1.3 物料衡算方法物料衡算是根据质量守恒定律，利用某进出化工过程中某些系统中的积累=输入-输出+生产-消耗式中，生成或消耗项是由于化学反应而生成或消耗的量；积累量可以是正值，也可以是负值，当系统中积累量不为零时称为非稳定状态过程；积累量为零时，称为稳定状态过程。稳定状态过程时，可以简化为：输入=输出-生成+消耗对无化学反应的稳定过程，又可表示为：输入=输出物料衡算包括总质量衡算、组分衡算和元素衡算。各种衡算方法的适用情况如表1-1所示：表1-1 各衡算方法适用情况类别物料衡算形式无化学反应有化学反应总衡算式总物流衡算式适用适用总物质的量衡算式适用不适用组分衡算式组分质量衡算式适用不适用组分物质的量衡算式适用不适用元素原子衡算式元素原子质量衡算式适用适用原始原子物质的量衡算式适用适用由于系统中存在化学反应，我们主要采用总质量衡算的衡算方法，同时列出每种物料组分的质量流量便于查找和计算。1.4总项目衡算从C4抽余油入厂到产品输出，其工艺路线可分为如下3个工段：异丁烯水合工段、甲基丙烯醛合成工段、甲基丙烯酸甲酯合成工段。1.4.1物料衡算任务对于本厂，工艺采取年开工350天（840小时）的连续操作，其中一年内的两周（约14天）用于固定的停车设备检修及紧急情况处理。物料衡算的主要任务在于：（1） 确定甲基丙烯酸甲酯以及副产品的实际产量以及质量指标；（2） 确定水、甲醇、环己酮的循环量及损失率等指标；（3） 确定工艺中的“三废”排放量等公共经济指标；（4） 各主要单元过程的物料衡算，并指导工艺设备的尺寸确定；（5） 汇总全流程物料衡算，数据用于完成物料流程图等后续设计任务。1.4.2叔丁醇合成工段图1-1 叔丁醇合成工段表1-2 叔丁醇合成工段总物料衡算表进出口进口出口流股编号01010103011701200121流股信息抽余C4工艺软水叔丁醇醇后C4脱附水Temperature 2520.6124.250.550.5Pressure bar51577Vapor Frac00000Mole Flow kmol/hr319.768569.516566.000175.4413.821Mass Flow kg/hr180001026018281.829909.33668.84374Volume Flow cum/hr30.60210.27824.55117.8530.071Enthalpy Gcal/hr-3.2134-38.9210-39.3806-1.7897-0.2591Mass Flow kg/hrH2O010259.9707596.4970.05068.821TBA0010645.29030.0650ISOBUTEN8418.60000.646337.2080IOSBUTAN522.00000.001521.9990N-BUT-011173.60000.2421173.35801-BUT-015513.40006.6595506.7410CIS-2-01725.400016.066709.3340TRANS-011641.600016.3461625.25401,3-B-015.40000.0725.3280O200.003000.003N200.002000.002MAL00.0030.00300MMA00000CH4O00000HQ00000CO00000CO200.017000.017C3H600000C6H10O00000MF00000Mass FracH2O01.0000.41601.000TBA000.5820.0030ISOBUTEN0.468000.0340IOSBUTAN0.029000.0530N-BUT-010.065000.11801-BUT-010.306000.5560CIS-2-010.04000.0010.0720TRANS-010.09100.0010.16401,3-B-010000.0010O200000N200000MAL00000MMA00000CH4O00000HQ00000CO00000CO200000C3H600000C6H10O00000MF00000总计28260.00028260.0001.4.2.1叔丁醇预反应器（R0101）图1-2 叔丁醇预反应器（R0101）表1-3叔丁醇预反应器物料衡算表进出口进口出口流股编号01070108流股信息抽余C4叔丁醇水溶液Temperature 8085Pressure bar2020Vapor Frac00Mole Flow kmol/hr889.284772.811Mass Flow kg/hr2826028260Volume Flow cum/hr42.74841.245Enthalpy Gcal/hr-40.659-41.576Mass Flow kg/hrH2O10259.9708161.674TBA08633.329ISOBUTEN8418.6001883.571IOSBUTAN522.000522.000N-BUT-011173.6001173.6001-BUT-015513.4005513.400CIS-2-01725.400725.400TRANS-011641.6001641.6001,3-B-015.4005.400O20.0030.003N20.0020.002MAL0.0030.003MMA00CH4O00HQ00CO00CO20.0170.017C3H600C6H10O00MF00Mass FracH2O0.3630.289TBA00.305ISOBUTEN0.2980.067IOSBUTAN0.0180.018N-BUT-010.0420.0421-BUT-010.1950.195CIS-2-010.0260.026TRANS-010.0580.0581,3-B-0100O200N200MAL00MMA00CH4O00HQ00CO00CO200C3H600C6H10O00MF00总计28260.00028260.0001.4.2.2叔丁醇反应精馏塔（T0101）图1-3 叔丁醇反应精馏塔（T0101） 表1-4叔丁醇反应精馏塔物料衡算表进出口进口出口流股编号010901100111流股信息异丁烯醇后C4叔丁醇Temperature 56.756.558.3Pressure bar777Vapor Frac0.20900Mole Flow kmol/hr772.81175.261670Mass Flow kg/hr282604189.08924070.910Volume Flow cum/hr572.1837.67431.475Enthalpy Gcal/hr-41.576-1.012-41.499Mass Flow kg/hrH2O8161.67433.6007631.769TBA8633.3298.18510667.160ISOBUTEN1883.571129.402208.455IOSBUTAN522.000429.49192.509N-BUT-011173.600593.922579.6781-BUT-015513.4002442.1473071.253CIS-2-01725.400139.171586.229TRANS-011641.600411.3941230.2061,3-B-015.4001.7553.645O20.0030.0030N20.0020.0020MAL0.00300.003MMA000CH4O000HQ000CO000CO20.0170.0150.001C3H6000C6H10O000MF000Mass FracH2O0.2890.0080.317TBA0.3050.0020.443ISOBUTEN0.0670.0310.009IOSBUTAN0.0180.1030.004N-BUT-010.0420.1420.0241-BUT-010.1950.5830.128CIS-2-010.0260.0330.024TRANS-010.0580.0980.0511,3-B-01000O2000N2000MAL000MMA000CH4O000HQ000CO000CO2000C3H6000C6H10O000MF000总计28260.00028260.0001.4.2.3脱碳塔（T0102）图1-4脱碳塔（T0102）表1-5脱碳塔物料衡算表进出口进口出口流股编号011201130117流股信息叔丁醇塔顶C4脱碳叔丁醇Temperature 58.345.8124.2Pressure bar755Vapor Frac000Mole Flow kmol/hr670104.000566.000Mass Flow kg/hr24070.9105789.09318281.820Volume Flow cum/hr31.47510.19924.551Enthalpy Gcal/hr-41.499-1.044-39.381Mass Flow kg/hrH2O7631.76935.2717596.498TBA10667.16021.88010645.280ISOBUTEN208.455207.8080.646IOSBUTAN92.50992.5080.001N-BUT-01579.678579.4360.2421-BUT-013071.2533064.5946.659CIS-2-01586.229570.16216.066TRANS-011230.2061213.86016.3461,3-B-013.6453.5730.072O2000N2000MAL0.00300.003MMA000CH4O000HQ000CO000CO20.0010.0010C3H6000C6H10O000MF000Mass FracH2O0.3170.0060.416TBA0.4430.0040.582ISOBUTEN0.0090.0360IOSBUTAN0.0040.0160N-BUT-010.0240.10001-BUT-010.1280.5290CIS-2-010.0240.0980.001TRANS-010.0510.2100.0011,3-B-0100.0010O2000N2000MAL000MMA000CH4O000HQ000CO000CO2000C3H6000C6H10O000MF000总计24070.90724070.9071.4.3甲基丙烯醛合成工段图1-5甲基丙烯醛合成工段表1-6 A甲基丙烯醛合成工段总物流衡算表进出口进口流股编号0202020302170223023203140319流股信息加热空气叔丁醇吸收甲醇甲醇工艺软水吸收尾气闪蒸尾气Temperature 33243025252533.635Pressure bar1.7511131Vapor Frac1100011Mole Flow kmol/hr1488.500566.00046.10075.000355.027282.6570.088Mass Flow kg/hr42943.82018281.8201484.9512403.1626395.9068067.1543.104Volume Flow cum/hr44054.4906569.6551.8663.0316.4352403.2852.260Enthalpy Gcal/hr3.2438 -31.3427 -2.6279 -4.2706 -24.2349 -1.2621-0.0023Mass Flow kg/hrH2O0 7596.497 0 0 6395.906 1.181 0.001 TBA0 10645.290 0 0 0 0 0 ISOBUTEN0 0.646 0 0 0 0.465 0.003 IOSBUTAN0 0.001 0 0 0 0 0 N-BUT-010 0.242 0 0 0 0.001 0 1-BUT-010 6.659 0 0 0 0.470 0.003 CIS-2-010 16.066 0 0 0 0.290 0.002 TRANS-010 16.346 0 0 0 0.295 0.002 1,3-B-010 0.072 0 0 0 0.004 0 O210002.340 0 0 0 0 133.722 0.362 N232941.470 0 0 0 0 7082.247 1.112 MAL0 0.003 0 0 0 0.000 0.000 MMA0 0 0 0 0 4.005 0.191 CH4O0 0 1473.939 2403.162 0 777.667 0.700 HQ0 0 11.011 0 0 0 0 CO0 0 0 0 0 0.062 0 CO20 0 0 0 0 22.366 0.164 C3H60 0 0 0 0 1.448 0.009 C6H10O0 0 0 0 0 0 0 MF0 0 0 0 0 42.931 0.554 Mass FracH2O0 0.416 0 0 1.000 0.000 0 TBA0 0.582 0 0 0 0 0 ISOBUTEN0 0 0 0 0 0 0.001 IOSBUTAN0 0 0 0 0 0 0 N-BUT-010 0 0 0 0 0 0 1-BUT-010 0 0 0 0 0 0.001 CIS-2-010 0.001 0 0 0 0 0.001 TRANS-010 0.001 0 0 0 0 0.001 1,3-B-010 0 0 0 0 0 0 O20.233 0 0 0 0 0.017 0.117 N20.767 0 0 0 0 0.878 0.358 MAL0 0 0 0 0 0 0 MMA0 0 0 0 0 0 0.062 CH4O0 0 0.993 1.000 0 0.096 0.226 HQ0 0 0.007 0 0 0 0 CO0 0 0 0 0 0 0 CO20 0 0 0 0 0.003 0.053 C3H60 0 0 0 0 0 0.003 C6H10O0 0 0 0 0 0 0 MF0 0 0 0 0 0.005 0.178 总计79579.910表1-6 B甲基丙烯醛合成工段总物流衡算表进出口出口流股编号021302250231023402360238流股信息闪蒸水共沸塔顶液甲醇废水吸收尾气循环甲醇甲醇废水Temperature 44.868.5624697.4484522.6378558.3576799.52049Pressure bar111111Vapor Frac010100Mole Flow kmol/hr642.900216.065131.6341639.88149.270309.838Mass Flow kg/hr11582.03011539.3702403.26346896.7401573.6405584.831Volume Flow cum/hr11.8836013.1612.62540329.2302.0906.081Enthalpy Gcal/hr-43.9361 -7.6978 -8.7939 -9.3676 -2.7729 -20.7198 Mass Flow kg/hrH2O11582.000 2.635 2340.751 811.408 7.736 5577.944 TBA0 0 0 0 0 0 ISOBUTEN0 0.867 0 44.055 0.006 0 IOSBUTAN0 0 0 0.001 0 0 N-BUT-010 0.001 0 0.242 0 0 1-BUT-010 0.496 0 6.633 0.002 0 CIS-2-010 0.302 0 16.055 0.002 0 TRANS-010 0.307 0 16.334 0.002 0 1,3-B-010 0.005 0 0.072 0 0 O20.004 0.289 0 2458.055 0.029 0 N20.003 1.408 0 40023.270 0.150 0 MAL0.004 8496.012 0.279 0.005 0 0 MMA0 0 0 3.999 0.197 0 CH4O0 3016.608 51.222 17.406 1563.328 6.887 HQ0 0 11.011 0 0 0 CO0 0.056 0 615.222 0.006 0 CO20.019 20.387 0 2840.333 0.896 0 C3H60 0 0 1.456 0 0 C6H10O0 0 0 0 0 0 MF0 0 0 42.199 1.286 0 Mass FracH2O1.000 0 0.974 0.017 0.005 0.999 TBA0 0 0 0 0 0 ISOBUTEN0 0 0 0.001 0 0 IOSBUTAN0 0 0 0 0 0 N-BUT-010 0 0 0 0 0 1-BUT-010 0 0 0 0 0 CIS-2-010 0 0 0 0 0 TRANS-010 0 0 0 0 0 1,3-B-010 0 0 0 0 0 O20 0 0 0.052 0 0 N20 0 0 0.853 0 0 MAL0 0.736 0 0 0 0 MMA0 0 0 0 0 0 CH4O0 0.261 0.021 0 0.993 0.001 HQ0 0 0.005 0 0 0 CO0 0 0 0.013 0 0 CO20 0.002 0 0.061 0.001 0 C3H60 0 0 0 0 0 C6H10O0 0 0 0 0 0 MF0 0 0 0.001 0.001 0 总计79579.9101.4.3.1叔丁醇脱水反应器图1-6叔丁醇脱水反应器（R0201）表1-7叔丁醇脱水反应器物料衡算表进出口进口出口流股编号02030204流股信息叔丁醇水溶液异丁烯Temperature 430430Pressure bar51.7Vapor Frac11Mole Flow kmol/hr566.00709.618Mass Flow kg/hr18281.82018281.870Volume Flow cum/hr6569.65524349.050Enthalpy Gcal/hr-31.343-29.524Mass Flow kg/hrH2O7596.49810183.810TBA10645.2800ISOBUTEN0.6468058.670IOSBUTAN0.0140.014N-BUT-010.2420.2421-BUT-016.6596.659CIS-2-0116.06616.066TRANS-0116.34616.3461,3-B-010.0720.072O200N200MAL0.0320.032MMA00CH4O00HQ00CO00CO200C3H600C6H10O00MF00Mass FracH2O0.4160.557TBA0.5820ISOBUTEN00.441IOSBUTAN00N-BUT-01001-BUT-010.0040.004CIS-2-010.0090.009TRANS-010.0090.0091,3-B-0100O200N200MAL00MMA00CH4O00HQ00CO00CO200C3H600C6H10O00MF00总计18281.8718281.871.4.3.2甲基丙烯醛合成反应器图1-7甲基丙烯醛合成反应器（R0202）表1-8甲基丙烯醛合成反应器物料衡算表进出口进口出口流股编号02050206流股信息反应原料气产品混合气Temperature 379.7380Pressure bar1.71.7Vapor Frac11Mole Flow kmol/hr2198.1182230.719Mass Flow kg/hr61225.68061225.680Volume Flow cum/hr70181.14071232.580Enthalpy Gcal/hr-26.280-47.575Mass Flow kg/hrH2O10183.81013925.450TBA00ISOBUTEN8058.67044.459IOSBUTAN0.0140.014N-BUT-010.2420.2421-BUT-016.6596.659CIS-2-0116.06616.066TRANS-0116.34616.3461,3-B-010.0720.072O21002.3402324.293N232941.47032941.470MAL0.0328496.296MMA00CH4O00HQ00CO0615.221CO202839.105C3H600C6H10O00MF00Mass FracH2O0.1660.227TBA00ISOBUTEN0.1320.001IOSBUTAN00N-BUT-01001-BUT-010.0010.001CIS-2-010.0030.003TRANS-010.0030.0031,3-B-0100O20.1630.038N20.5380.538MAL00.139MMA00CH4O00HQ00CO00.010CO200.046C3H600C6H10O00MF00总计61225.6861225.681.4.3.3甲基丙烯醛吸收塔（T0201）图1-8甲基丙烯醛吸收塔（T0201）表1-9甲基丙烯醛吸收塔物料衡算表进出口进口出口流股编号0216021802190220流股信息压缩气体甲醇吸收尾气吸收液Temperature 1025.5284612.3610610.81908Pressure bar4.54.54.54.5Vapor Frac0.8562269010Mole Flow kmol/hr1587.81946.1001361.216272.703Mass Flow kg/hr49643.6501484.95139589.05011539.560Volume Flow cum/hr7123.0691.8687180.66813.221Enthalpy Gcal/hr-19.6773 -2.6274 -7.9387 -14.3660 Mass Flow kg/hrH2O2343.450 0 0 2343.450 TBA0 0 0 0 ISOBUTEN44.459 0 43.592 0.867 IOSBUTAN0.001 0 0.001 0 N-BUT-010.242 0 0.241 0.001 1-BUT-016.659 0 6.162 0.496 CIS-2-0116.066 0 15.764 0.302 TRANS-0116.346 0 16.039 0.307 1,3-B-010.072 0 0.067 0.005 O22324.288 0 2323.999 0.289 N232941.470 0 32940.060 1.408 MAL8496.296 0 0.005 8496.291 MMA0 0 0 0 CH4O0 1473.939 809.254 664.685 HQ0 11.011 0.000 11.011 CO615.221 0 615.165 0.056 CO22839.086 0 2818.699 20.387 C3H60 0 0 0 C6H10O0 0 0 0 MF0 0 0 0 Mass FracH2O0.047 0 0 0.203 TBA0 0 0 0 ISOBUTEN0.001 0 0.001 0 IOSBUTAN0 0 0 0 N-BUT-010 0 0 0 1-BUT-010 0 0 0 CIS-2-010 0 0 0 TRANS-010 0 0 0 1,3-B-010 0 0 0 O20.047 0 0.059 0 N20.664 0 0.832 0 MAL0.171 0 0 0.736 MMA0 0 0 0 CH4O0 0.993 0.020 0.058 HQ0 0.007 0 0.001 CO0.012 0 0.016 0 CO20.057 0 0.071 0.002 C3H60 0 0 0 C6H10O0 0 0 0 MF0 0 0 0 总计51128.606251128.60621.4.3.4共沸精馏塔（T0202）图1-9共沸精馏塔（T0202）表1-10共沸精馏塔物料衡算表进出口进口出口流股编号02210224022202250228流股信息MAL吸收液甲醇再沸液甲醇-MAL釜液Temperature 10.524052599.2468.5624697.44838Pressure bar4.51111Vapor Frac000.598380410Mole Flow kmol/hr272.70375.0001072.820216.0651204.454Mass Flow kg/hr11539.5602403.16219586.64011539.37021989.910Volume Flow cum/hr13.2163.03119742.8806013.16124.014Enthalpy Gcal/hr-14.3660 -4.2706 -65.4102 -7.6978 -80.4641 Mass Flow kg/hrH2O2343.450 0 19077.170 2.635 21417.920 TBA0 0 0 0 0 ISOBUTEN0.867 0 0 0.867 0 IOSBUTAN0 0 0 0 0 N-BUT-010.001 0 0 0.001 0 1-BUT-010.496 0 0 0.496 0 CIS-2-010.302 0 0 0.302 0 TRANS-010.307 0 0 0.307 0 1,3-B-010.005 0 0 0.005 0 O20.289 0 0 0.289 0 N21.408 0 0 1.408 0 MAL8496.291 0 2.276 8496.012 2.555 MMA0 0 0 0 0 CH4O664.685 2403.162 417.459 3016.608 468.681 HQ11.011 0 89.740 0 100.750 CO0.056 0 0 0.056 0 CO220.387 0 0 20.387 0 C3H60 0 0 0 0 C6H10O0 0 0 0 0 MF0 0 0 0 0 Mass FracH2O0.203 0 0.974 0 0.974 TBA0 0 0 0 0 ISOBUTEN0 0 0 0 0 IOSBUTAN0 0 0 0 0 N-BUT-010 0 0 0 0 1-BUT-010 0 0 0 0 CIS-2-010 0 0 0 0 TRANS-010 0 0 0 0 1,3-B-010 0 0 0 0 O20 0 0 0 0 N20 0 0 0 0 MAL0.736 0 0 0.736 0 MMA0 0 0 0 0 CH4O0.058 1.000 0.021 0.261 0.021 HQ0.001 0 0.005 0 0.005 CO0 0 0 0 0 CO20.002 0 0 0.002 0 C3H60 0 0 0 0 C6H10O0 0 0 0 0 MF0 0 0 0 0 总计33530.00033530.0001.4.3.5甲醇吸收塔（T0203）图1-10甲醇吸收塔（T0203）表1-11甲醇吸收塔物料衡算表进出口进口出口流股编号0232023302340235流股信息工艺水吸收尾气废气甲醇吸收液Temperature 2516.0946322.6378513.96155Pressure bar1111Vapor Frac0110Mole Flow kmol/hr355.0271643.9621639.881359.107Mass Flow kg/hr6395.90647659.31046896.7407158.471Volume Flow cum/hr6.43539535.23040329.2307.545Enthalpy Gcal/hr-24.2349 -9.2031 -9.3676 -24.0704 Mass Flow kg/hrH2O6395.906 1.182 811.408 5585.680 TBA0 0 0 0 ISOBUTEN0 44.060 44.055 0.006 IOSBUTAN0 0.001 0.001 0 N-BUT-010 0.242 0.242 0 1-BUT-010 6.