5-2附录二 能量衡算

中海壳牌年产11.7wt聚甲基丙烯酸甲酯项目能量衡算中山大学Triumph团队15目录1 概述12 能量衡算原理23 能量衡算任务34 能量衡算表34.1 异丁烯水合制叔丁醇工段34.1.1 异丁烯热泵提浓塔(T0101-T0102)34.1.2 连续搅拌釜反应器(R0101-R0103)44.1.3 叔丁醇三级串联提浓塔(T0103-T0105)54.2 叔丁醇氧化制MAL工段74.2.1 叔丁醇氧化鼓泡反应器(R0201)74.2.2 空气压缩机（C0201）74.2.3 换热器(E0201E0202)74.2.4 中空纤维膜分离器（V0201）84.2.5 精馏塔（T0201）94.2.6 三元共沸热泵精馏塔（T0202）94.3 MAL直接氧化酯化工段94.3.1 甲基丙烯醛一步氧化酯化反应器(R0301)94.3.2 甲醇膜分离器(V0302V0103)104.3.3 中空纤维膜分离器（V0301）114.3.4 间接式热泵精馏塔（T0301）114.3.5 换热器（E0304E0305）114.4 MMA聚合工段124.4.1 树脂纯化塔(T0401)124.4.2 间歇式釜反应器(R0401-R0402)134.4.3 闪蒸罐(V0401)134.4.4 混合器（M0401M0402）145 附录：物质说明151 概述本项目拟建一套年产13.8万吨聚甲基丙烯酸甲酯的装置，在全工艺段中伴随着物料从一个体系或单元进入另一个体系或单元，在发生质量传递的同时也伴随着热量的消耗、释放和转化。其中的热量变换数量关系可以从能量衡算求得，对于新设计的车间，可以由此确定设备的热负荷。再根据设备的热负荷大小、所处理物料的性质及工艺要求选择恰当的设备。总而言之，通过下述能量衡算，可以为后续设计工作中提高能量的利用率，降低能耗提供主要依据。设计过程中利用Aspen Plus对全流程进行模拟，并在此基础上完成物料衡算、能量衡算。Aspen plus全模拟流程如图1-11-4所示：图1-1 异丁烯水合制叔丁醇工段图1-2 叔丁醇氧化制MAL工段图1-3 MAL的直接氧化酯化工段图1-4 MMA的聚合工段2 能量衡算原理工程依据化工设计中关于热量衡算的基本思想和要求，遵循基本规范与实际工艺相结合的原则，进行热量衡算书的编制。其中一个主要依据是热量平衡方程：其中，表示输入设备热量的总和；表示输出设备热量的总和；表示损失热量的总和。对于连续系统：其中，设备的热负荷；输入系统的机械能；离开设备的各物料焓之和；进入设备的各物料焓之和。在进行全厂热量衡算时，是以单元设备为基本单位，考虑由机械能转换、化学反应释放和单纯的物理变化带来的热量变化。最终对全工艺段进行系统级的热量平衡计算，进而用于指导节能降耗设计工作。3 能量衡算任务（1）确定工艺单元中物料输送机械（如泵）所需要的功率，以便于进行设备的设计和选型；（2）确定精馏等单元操作中所需要的热量或冷量以及传递速率，计算换热设备的尺寸，确定加热剂和冷却剂的消耗量，为后续设计中比如供汽、供冷、供水等专业提供设备条件；（3）确定为保持一定反应温度所需移除或者加入的热传递速率，指导反应器的设计和选型；（4）提高热量内部集成度，充分利用余热，提高能量利用率，降低能耗；（5）最终计算出总需求能量和能量的费用，并由此确定工艺过程在经济上的可行性。4 能量衡算表4.1 异丁烯水合制叔丁醇工段4.1.1 异丁烯热泵提浓塔(T0101-T0102)4.1.1.1 异丁烯热泵提浓塔甲(T0101)表4-1 异丁烯热泵提浓塔甲(T0101)能量衡算表进出口进口出口流股编号1FEED1PRO-D11PRO-B1Temperature()58.295149.8622758.41965Pressure(bar)7.266.008Mole Flow(kmol/hr)88.8292877.1869811.64375Mass Flow(kg/hr)50004342.385657.6956Volume Flow(cum/hr)9.2201877.8461911.181869Vapor Fraction5.54E-0500Enthalpy Flow(Gcal/hr)-0.76694-0.65999-0.1331W（Mcal/hr）Q（Mcal/hr）Hin（Mcal/hr）Hout（Mcal/hr）Error（Mcal/hr）211.95-231.76-766.94-793.096.344.1.1.2 异丁烯热泵提浓塔乙(T0102)表4-2 异丁烯热泵提浓塔乙(T0102)能量衡算表进出口进口出口流股编号2FEED1PRO-D21PROB2Temperature()58.295149.8622258.4197Pressure(bar)7.266.008Mole Flow(kmol/hr)88.8292877.1869811.64409Mass Flow(kg/hr)50004342.385657.7144Volume Flow(cum/hr)9.2201877.846191.181902Vapor Fraction5.54E-0500Enthalpy Flow(Gcal/hr)-0.76694-0.65998-0.1331W（Mcal/hr）Q（Mcal/hr）Hin（Mcal/hr）Hout（Mcal/hr）Error（Mcal/hr）211.95-231.76-766.94-793.086.334.1.2 连续搅拌釜反应器(R0101-R0103)4.1.2.1 连续搅拌釜反应器(R0101)表4-3 连续搅拌釜反应器(R0101)能量衡算表进出口进口出口流股编号1S1TBA1WATER11S9Temperature()49.8622525.7227325.4118370Pressure(bar)6667Mole Flow(kmol/hr)154.3744160251.1721Mass Flow(kg/hr)8684.77296.49122882.44511863.71Volume Flow(cum/hr)15.692440.3781082.90112917.66024Vapor Fraction8.52E-08000Enthalpy Flow(Gcal/hr)-1.31997-0.34286-10.9208-12.8662W（Mcal/hr）Q（Mcal/hr）Hin（Mcal/hr）Hout（Mcal/hr）Error（Mcal/hr）0-608.57-12583.63-12866.2-3264.1.2.2 连续搅拌釜反应器(R0102)表4-4 连续搅拌釜反应器(R0102)能量衡算表进出口进口出口流股编号JJ11JTBA2WATER21S6Temperature()50.1081425.7227325.4118370Pressure(bar)6667Mole Flow(kmol/hr)876795Mass Flow(kg/hr)4914.729148.2456540.45845603.433Volume Flow(cum/hr)8.9053950.1890540.5439629.617166Vapor Fraction0000Enthalpy Flow(Gcal/hr)-0.78185-0.17143-2.04765-3.00405W（Mcal/hr）Q（Mcal/hr）Hin（Mcal/hr）Hout（Mcal/hr）Error（Mcal/hr）0-3.13-3000.93-3004.05-0.014.1.2.3 连续搅拌釜反应器(R0103)表4-5 连续搅拌釜反应器(R0103)能量衡算表进出口进口出口流股编号11TBA3WATER31S20Temperature()50.2025325.7227325.4118370Pressure(bar)6667Mole Flow(kmol/hr)74.6711921690.06703Mass Flow(kg/hr)4212.844148.2456288.24454649.334Volume Flow(cum/hr)7.6422420.1890540.290113120.9851Vapor Fraction0000.315094Enthalpy Flow(Gcal/hr)-0.6809-0.17143-1.09208-1.76728W（Mcal/hr）Q（Mcal/hr）Hin（Mcal/hr）Hout（Mcal/hr）Error（Mcal/hr）0177.1625935-1944.41-1767.28-0.03 4.1.3 叔丁醇三级串联提浓塔(T0103-T0105)4.1.3.1 一级提浓塔(T0103)表4-6 一级提浓塔(T0103)能量衡算表进出口进口出口流股编号1S9JJ11JJ10JTemperature()7050.10814139.8054Pressure(bar)766.2Mole Flow(kmol/hr)251.172187.17931163.9928Mass Flow(kg/hr)11863.714914.7296948.978Volume Flow(cum/hr)17.660248.90539510.15413Vapor Fraction000Enthalpy Flow(Gcal/hr)-12.8662-0.78185-11.5446W（Mcal/hr）Q（Mcal/hr）Hin（Mcal/hr）Hout（Mcal/hr）Error（Mcal/hr）0-282.63-12866.2-12326.45-822.384.1.3.2 二级提浓塔(T0104)表4-7 二级提浓塔(T0104)能量衡算表进出口进口出口流股编号1S61011Temperature()70139.674950.20253Pressure(bar)76.26Mole Flow(kmol/hr)106.679532.0083574.67119Mass Flow(kg/hr)5603.4331390.5894212.844Volume Flow(cum/hr)9.6171662.0395977.642242Vapor Fraction000Enthalpy Flow(Gcal/hr)-3.00405-2.26107-0.6809W（Mcal/hr）Q（Mcal/hr）Hin（Mcal/hr）Hout（Mcal/hr）Error（Mcal/hr）062.10-3004.05-2941.970.024.1.3.3 三级提浓塔(T0105)表4-8 三级提浓塔(T0105)能量衡算表进出口进口出口流股编号1S201BET10JJTemperature()7050.22643141.3073Pressure(bar)766.2Mole Flow(kmol/hr)90.0670372.0669618.00007Mass Flow(kg/hr)4649.3344066.727582.6067Volume Flow(cum/hr)120.98517.3792220.811223Vapor Fraction0.31509400Enthalpy Flow(Gcal/hr)-1.76728-0.66-1.22902W（Mcal/hr）Q（Mcal/hr）Hin（Mcal/hr）Hout（Mcal/hr）Error（Mcal/hr）0-121.76-1767.28-1889.02-0.024.2 叔丁醇氧化制MAL工段4.2.1 叔丁醇氧化鼓泡反应器(R0201)表4-9 叔丁醇氧化鼓泡反应器(R02021)能量衡算表进出口进口出口流股编号2S32S191S252S4Temperature()241.702680139.6771389.85Pressure(bar)51.013256.24.95Mole Flow(kmol/hr)874.5076217.7779214.00121397.251Mass Flow(kg/hr)25195.043923.338922.17338040.54Volume Flow(cum/hr)7486.934.1773912.9983615560.01Vapor Fraction1001Enthalpy Flow(Gcal/hr)1.334553-14.6471-15.0347-27.4848W（Mcal/hr）Q（Mcal/hr）Hin（Mcal/hr）Hout（Mcal/hr）Error（Mcal/hr）0862.67-28347.25-27484.80.224.2.2 空气压缩机（C0201）表4-10 空气压缩机（C0201）的物料衡算进出口进口出口流股编号2F22S3Temperature()20241.7026Pressure(bar)1.013255Mole Flow(kmol/hr)874.5076874.5076Mass Flow(kg/hr)25195.0425195.04Volume Flow(cum/hr)21036.057486.93Vapor Fraction11Enthalpy Flow(Gcal/hr)-0.030461.334553W（Mcal/hr）Q（Mcal/hr）Hin（Mcal/hr）Hout（Mcal/hr）Error（Mcal/hr）1437.120-30.461334.5572.114.2.3 换热器(E0201E0202)4.2.3.1 换热器(E0201)表4-11 换热器(E0201)能量衡算表进出口进口出口流股编号2S182S22Temperature()389.85327.7Pressure(bar)4.954.95Mole Flow(kmol/hr)916.5966916.5966Mass Flow(kg/hr)24954.624954.6Volume Flow(cum/hr)10207.379250.525Vapor Fraction11Enthalpy Flow(Gcal/hr)-18.03-18.586W（Mcal/hr）Q（Mcal/hr）Hin（Mcal/hr）Hout（Mcal/hr）Error（Mcal/hr）0-556.08-18030-18586.0-0.084.2.3.2 换热器(E0202)表4-12 换热器(E0202)能量衡算表进出口进口出口流股编号2S232S5Temperature()104.671845Pressure(bar)4.955Mole Flow(kmol/hr)1397.2511397.251Mass Flow(kg/hr)38040.5438040.54Volume Flow(cum/hr)7175.6124357.799Vapor Fraction0.8085190.587377Enthalpy Flow(Gcal/hr)-33.6916-37.5398W（Mcal/hr）Q（Mcal/hr）Hin（Mcal/hr）Hout（Mcal/hr）Error（Mcal/hr）0- 3848.90-33691.6-37539.8-0.704.2.4 中空纤维膜分离器（V0201）表4-13 中空纤维膜分离器(V0201)进出口进口出口流股编号2S52S12S2Temperature()454545Pressure(bar)555Mole Flow(kmol/hr)1397.251794.1563603.0947Mass Flow(kg/hr)38040.5422655.5415385.01Volume Flow(cum/hr)4357.7994201.41117.38108Vapor Fraction0.58737710Enthalpy Flow(Gcal/hr)-37.5398-0.13686-37.6399W（Mcal/hr）Q（Mcal/hr）Hin（Mcal/hr）Hout（Mcal/hr）Error（Mcal/hr）00-37539.8-37776.76236.964.2.5 精馏塔（T0201）表4-14 精馏塔（T0201）能量衡算表进出口进口出口流股编号2S22S3J2S4JTemperature()4538.74892144.664Pressure(bar)54.54.508Mole Flow(kmol/hr)603.094710.61474592.4799Mass Flow(kg/hr)15385.01595.578314789.43Volume Flow(cum/hr)17.381081.04406119.10782Vapor Fraction000Enthalpy Flow(Gcal/hr)-37.6399-0.08953-36.2458W（Mcal/hr）Q（Mcal/hr）Hin（Mcal/hr）Hout（Mcal/hr）Error（Mcal/hr）01304.76-37639.9-36335.30.164.2.6 三元共沸热泵精馏塔（T0202）表4-15 三元共沸热泵精馏塔（T0202）能量衡算表进出口进口出口流股编号CFEEDPRO-BPRO-DTemperature()140.1179120.174290.1804Pressure(bar)4.5082.0082Mole Flow(kmol/hr)610.4799514.248696.23213Mass Flow(kg/hr)15366.199305.8176060.362Volume Flow(cum/hr)34.2683510.39768.065981Vapor Fraction0.00311300Enthalpy Flow(Gcal/hr)-37.2707-34.1531-3.52965W（Mcal/hr）Q（Mcal/hr）Hin（Mcal/hr）Hout（Mcal/hr）Error（Mcal/hr）0-1029.38-37270.7-37682.75-617.334.3 MAL直接氧化酯化工段4.3.1 甲基丙烯醛一步氧化酯化反应器(R0301)表4-16 甲基丙烯醛一步氧化酯化反应器(R0301)能量衡算表进出口进口出口流股编号2S72S8PRO-D2S9Temperature()106.497348.3833390.180450Pressure(bar)21.0132521.01325Mole Flow(kmol/hr)9005868.00896.232136825.269Mass Flow(kg/hr)25929.491880246060.362220014Volume Flow(cum/hr)14204.31245.9498.06598150154.68Vapor Fraction1000.275965Enthalpy Flow(Gcal/hr)0.512382-330.97-3.52965-330.964W（Mcal/hr）Q（Mcal/hr）Hin（Mcal/hr）Hout（Mcal/hr）Error（Mcal/hr）03024.32-333987.27-3309641.054.3.2 甲醇膜分离器(V0302V0103)4.3.2.1 甲醇膜分离器(V0302)表4-17 甲醇膜分离器(V0302)能量衡算进出口进口出口流股编号3S1O3FEED3S2Temperature()404040Pressure(bar)222Mole Flow(kmol/hr)5964.241640.4514323.789Mass Flow(kg/hr)19533156787.48138544Volume Flow(cum/hr)249.886171.07684178.8052Vapor Fraction000Enthalpy Flow(Gcal/hr)-341.425-96.6808-244.741W（Mcal/hr）Q（Mcal/hr）Hin（Mcal/hr）Hout（Mcal/hr）Error（Mcal/hr）00-341425-341421.8-3.24.3.2.2 甲醇膜分离器（V0303）表4-18 甲醇膜分离器（V0303）能量衡算表进出口进口出口流股编号2S122S132S14Temperature()64.4174864.4109464.41094Pressure(bar)1.013251.013251.01325Mole Flow(kmol/hr)1561.71486.84174.85883Mass Flow(kg/hr)55131.847641.67490.114Volume Flow(cum/hr)17689.1764.019528.394Vapor Fraction0.40793300Enthalpy Flow(Gcal/hr)-84.8443-83.2536-6.99099W（Mcal/hr）Q（Mcal/hr）Hin（Mcal/hr）Hout（Mcal/hr）Error（Mcal/hr）00-84844.3-90244.595400.294.3.3 中空纤维膜分离器（V0301）表4-19 中空纤维膜分离器（V0302）能量衡算表进出口进口出口流股编号2S9AIRAZE-MMATemperature()5049.9629449.96294Pressure(bar)1.013251.013251.01325Mole Flow(kmol/hr)6825.269861.02945964.24Mass Flow(kg/hr)22001424682.48195331Volume Flow(cum/hr)50154.6822828.79253.9016Vapor Fraction0.27596510Enthalpy Flow(Gcal/hr)-330.9640.149796-339.936W（Mcal/hr）Q（Mcal/hr）Hin（Mcal/hr）Hout（Mcal/hr）Error（Mcal/hr）00-330964-339786.208822.24.3.4 间接式热泵精馏塔（T0301）表4-20 间接式热泵精馏塔（T0301）能量衡算表进出口进口出口流股编号O3FEED3PRO-B2S10Temperature()4098.5486564.41704Pressure(bar)21.021251.01325Mole Flow(kmol/hr)1640.45178.743461561.7Mass Flow(kg/hr)56787.481655.21855131.8Volume Flow(cum/hr)71.076841.82597172.14128Vapor Fraction000Enthalpy Flow(Gcal/hr)-96.6808-5.33327-90.2037W（Mcal/hr）Q（Mcal/hr）Hin（Mcal/hr）Hout（Mcal/hr）Error（Mcal/hr）13149.68-10691.08-96680.8-95536.971314.774.3.5 换热器（E0304E0305）4.3.5.1 换热器(E0304)表4-21 换热器（E0304）能量衡算进出口进口出口流股编号2S112S162S152S21Temperature()389.8546.542948.60025327.7Pressure(bar)4.951.013251.013254.95Mole Flow(kmol/hr)480.65435810.635810.63480.6543Mass Flow(kg/hr)13085.9518618518618513085.95Volume Flow(cum/hr)5352.645242.8177243.63024850.885Vapor Fraction1000Enthalpy Flow(Gcal/hr)-9.45475-327.995-327.703-9.74631W（Mcal/hr）Q（Mcal/hr）Hin（Mcal/hr）Hout（Mcal/hr）Error（Mcal/hr）00-337449.75-337449.31-0.444.3.5.2 流股间换热器(E0305)表4-22 流股间换热器（E0305）能量衡算进出口进口出口流股编号2S102S272S122S23Temperature()64.41704327.764.41748104.6718Pressure(bar)1.013254.951.013254.95Mole Flow(kmol/hr)1561.71397.2511561.71397.251Mass Flow(kg/hr)55131.838040.5455131.838040.54Volume Flow(cum/hr)72.1412814101.4117689.177175.612Vapor Fraction010.4079330.808519Enthalpy Flow(Gcal/hr)-90.2037-28.3323-84.8443-33.6916W（Mcal/hr）Q（Mcal/hr）Hin（Mcal/hr）Hout（Mcal/hr）Error（Mcal/hr）00-118536-118535.9-0.14.4 MMA聚合工段4.4.1 树脂纯化塔(T0401)表4-23 树脂纯化塔(T0401)能量衡算进出口进口出口流股编号2S143S43S343S2Temperature()64.410942564.8061164.80611Pressure(bar)1.013251.013251.013251.01325Mole Flow(kmol/hr)74.858830.0126780.14980774.7217Mass Flow(kg/hr)7490.1141.26928710.446637480.936Volume Flow(cum/hr)8.3940.0013540.0133028.386709Vapor Fraction0000Enthalpy Flow(Gcal/hr)-6.99099-0.00121-0.00503-6.98717W（Mcal/hr）Q（Mcal/hr）Hin（Mcal/hr）Hout（Mcal/hr）Error（Mcal/hr）00-6992.2-6992.204.4.2 间歇式釜反应器(R0401-R0402)4.4.2.1 间歇式釜反应器(R0401)表4-24 间歇式釜反应器(R0401)能量衡算表进出口进口出口流股编号4S14S3Temperature()28.7727749.85036Pressure(bar)11.01325Mole Flow(kmol/hr)153.1471153.1909Mass Flow(kg/hr)14123.6814123.68Volume Flow(cum/hr)15.6603815.40367Vapor Fraction00Enthalpy Flow(Gcal/hr)-16.5254-16.7357W（Mcal/hr）Q（Mcal/hr）Hin（Mcal/hr）Hout（Mcal/hr）Error（Mcal/hr）0-211.4-16525.4-16735.7-1.14.4.2.2 间歇式釜反应器(R0402)表4-25 间歇式釜反应器(R0402)能量衡算表进出口进口出口流股编号28.7727749.85036Temperature()11.01325Pressure(bar)153.1471153.1909Mole Flow(kmol/hr)14123.6814123.68Mass Flow(kg/hr)15.6603815.40367Volume Flow(cum/hr)00Vapor Fraction28.7727749.85036Enthalpy Flow(Gcal/hr)-16.5254-16.7357W（Mcal/hr）Q（Mcal/hr）Hin（Mcal/hr）Hout（Mcal/hr）Error（Mcal/hr）0-211.4-16525.4-16735.7-1.14.4.3 闪蒸罐(V0401)表4-26 闪蒸罐(V0401)能量衡算表进出口进口出口流股编号4S64S74S8Temperature()49.85036100100Pressure(bar)1.013250.50.5Mole Flow(kmol/hr)306.381984.7188221.6631Mass Flow(kg/hr)28247.378475.06819772.3Volume Flow(cum/hr)30.807338.38050813593.67Vapor Fraction001Enthalpy Flow(Gcal/hr)-33.4714-8.48218-22.6451W（Mcal/hr）Q（Mcal/hr）Hin（Mcal/hr）Hout（Mcal/hr）Error（Mcal/hr）00-33471.4-31127.3-2344.14.4.4 混合器（M0401M0402）4.4.4.1 混合器(M0401)表27 混合器（M0401）能量衡算表进出口进口出口流股编号3S104F14S104S14S2Temperature()402025.0402128.7727728.77277Pressure(bar)11.013251.0132511Mole Flow(kmol/hr)74.72179.907242221.6652153.1471153.1471Mass Flow(kg/hr)7480.936993.931819772.514123.6814123.68Volume Flow(cum/hr)8.1248511.244