5-1 附录一 物料平衡计算书

南京扬子石化年产6万吨超高分子量PMMA项目 物料平衡计算书目录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 MAL合成与提纯工段21.4.3 MMA合成及分离工段101.4.4PMMA合成工段231.5 总结24 I1.1 概述本项目主要通过对异丁烯的利用，并以该异丁烯与甲醇为主要原料，通过异丁烯两步法工艺合成分子量超过100万的PMMA。年产量为6万吨。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计算出主、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已知物流的流量和组成，通过建立有关物料的平衡式和约束式，求出其他未知物流的流量和组成的过程。系统中物料衡算一般表达式为： 系统中的积累=输入-输出+生成-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料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元素原子物质的量衡算式适用适用1.4 总项目衡算从原料入厂到产品输出，其工艺路线可分为如下3个工段：MAL合成与提纯工段、MMA合成与分离工段、PMMA合成工段。1.4.1 物料衡算任务对于本厂，工艺采取年开工333天（8000小时）的连续操作，其中一年内的四五周（约30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PMMA的实际产量以及质量指标； （2）确定甲醇、正己烷的循环量以及损失率等指标； （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。1.4.2 MAL合成与提纯工段表1-2MAL合成工段总物料衡算进出口单位进口出口流股编号101108116128132FromT0101F0101T0103ToC0101M0101M0201Stream ClassCONVENCONVENCONVENCONVENCONVENMaximum Relative ErrorCost Flow$/hrMIXED SubstreamPhaseVaporVaporVaporMixedLiquidTemperatureC25.0056.6064.0795.4166.20Pressurebar1.015.007.001.001.00Molar Vapor Fraction1.001.001.000.000.00Molar Liquid Fraction0.000.000.001.001.00Molar Solid Fraction0.000.000.000.000.00Mass Vapor Fraction1.001.001.000.000.00Mass Liquid Fraction0.000.000.001.001.00Mass Solid Fraction0.000.000.000.000.00Molar Enthalpykcal/mol0.00-3.56-1.77-66.31-33.55Mass Enthalpykcal/kg-0.06-63.40-63.19-3592.94-481.20Molar Entropycal/mol-K1.02-61.52-3.49-35.45-62.33Mass Entropycal/gm-K0.04-1.10-0.12-1.92-0.89Molar Densitykmol/cum0.040.200.2549.1211.24Mass Densitykg/cum1.1811.236.98906.53783.82Enthalpy FlowGcal/hr0.00-0.27-0.51-4.25-2.49Average MW28.8556.1127.9518.4569.73Mole Flowskmol/hr351.3277.20290.3664.0774.17WATERkmol/hr0.000.009.9363.330.51C3H8kmol/hr0.000.000.000.000.00TR-C4H8kmol/hr0.000.000.000.000.001-C4H8kmol/hr0.000.000.000.000.00ISOBTENEkmol/hr0.0077.202.780.730.00MALkmol/hr0.000.000.000.0173.66CO2kmol/hr0.000.000.090.000.00N2kmol/hr277.550.00277.550.000.00O2kmol/hr73.780.000.000.000.00COkmol/hr0.000.000.020.000.00CH4Okmol/hr0.000.000.000.000.00MMAkmol/hr0.000.000.000.000.00C5H10O2kmol/hr0.000.000.000.000.00HEXkmol/hr0.000.000.000.000.00MAAkmol/hr0.000.000.000.000.00INHIBITOkmol/hr0.000.000.000.000.001.4.2.1 MAL吸收塔（T0101）表1-3 MAL吸收塔物料衡算进出口单位进口出口流股编号114.00127.00116.00117.00FromS0101P0101T0101T0101ToT0101T0101M0102Stream ClassCONVENCONVENCONVENCONVENMaximum Relative ErrorCost Flow$/hrMIXED SubstreamPhaseVaporLiquidVaporLiquidTemperatureC40.0095.9064.0766.57Pressurebar7.008.007.007.00Molar Vapor Fraction1.000.001.000.00Molar Liquid Fraction0.001.000.001.00Molar Solid Fraction0.000.000.000.00Mass Vapor Fraction1.000.001.000.00Mass Liquid Fraction0.001.000.001.00Mass Solid Fraction0.000.000.000.00Molar Enthalpykcal/mol-2.39-66.29-1.77-56.63Mass Enthalpykcal/kg-77.31-3592.31-63.19-1688.92Molar Entropycal/mol-K-6.28-35.43-3.49-29.71Mass Entropycal/gm-K-0.20-1.92-0.12-0.89Molar Densitykmol/cum0.2749.100.2524.77Mass Densitykg/cum8.37906.046.98830.57Enthalpy FlowGcal/hr-0.72-3.59-0.51-3.80Average MW30.8818.4527.9533.53Mole Flowskmol/hr303.3454.19290.3667.17WATERkmol/hr3.4653.569.9347.09C3H8kmol/hr0.000.000.000.00TR-C4H8kmol/hr0.000.000.000.001-C4H8kmol/hr0.000.000.000.00ISOBTENEkmol/hr2.380.622.780.22MALkmol/hr19.840.010.0019.85CO2kmol/hr0.090.000.090.00N2kmol/hr277.550.00277.550.01O2kmol/hr0.000.000.000.00COkmol/hr0.020.000.020.00CH4Okmol/hr0.000.000.000.00MMAkmol/hr0.000.000.000.00C5H10O2kmol/hr0.000.000.000.00HEXkmol/hr0.000.000.000.00MAAkmol/hr0.000.000.000.00INHIBITOkmol/hr0.000.000.000.00Mole FractionsMass Flowskg/hr9366.361000.008114.222252.14Mass FractionsVolume Flowcum/hr1119.661.101162.982.711.4.2.2 MAL回收塔（T0102）表1-4 MAL回收塔物料衡算流股编号单位120.00123.00124.00125.00FromM0103T0102T0102T0102ToT0102M0104M0105F0101Stream ClassCONVENCONVENCONVENCONVENMaximum Relative Error0.00Cost Flow$/hrMIXED SubstreamPhaseLiquidVaporLiquidLiquidTemperatureC40.4847.8555.7195.41Pressurebar1.001.001.001.00Molar Vapor Fraction0.001.000.000.00Molar Liquid Fraction1.000.001.001.00Molar Solid Fraction0.000.000.000.00Mass Vapor Fraction0.001.000.000.00Mass Liquid Fraction1.000.001.001.00Mass Solid Fraction0.000.000.000.00Molar Enthalpykcal/mol-64.95-18.76-34.60-66.31Mass Enthalpykcal/kg-3028.39-321.09-525.08-3592.94Molar Entropycal/mol-K-39.88-44.82-61.70-35.45Mass Entropycal/gm-K-1.86-0.77-0.94-1.92Molar Densitykmol/cum42.880.0411.9249.12Mass Densitykg/cum919.642.24785.25906.57Enthalpy FlowGcal/hr-8.23-0.05-0.20-7.84Average MW21.4558.4265.9018.45Mole Flowskmol/hr126.652.575.82118.26WATERkmol/hr117.530.240.39116.90C3H8kmol/hr0.000.000.000.00TR-C4H8kmol/hr0.000.000.000.001-C4H8kmol/hr0.000.000.000.00ISOBTENEkmol/hr2.821.190.291.35MALkmol/hr6.281.125.140.01CO2kmol/hr0.000.000.000.00N2kmol/hr0.020.020.000.00O2kmol/hr0.000.000.000.00COkmol/hr0.000.000.000.00CH4Okmol/hr0.000.000.000.00MMAkmol/hr0.000.000.000.00C5H10O2kmol/hr0.000.000.000.00HEXkmol/hr0.000.000.000.00MAAkmol/hr0.000.000.000.00INHIBITOkmol/hr0.000.000.000.00Mole FractionsMass Flowskg/hr2716.09150.00383.692182.39Mass FractionsVolume Flowcum/hr2.9566.970.492.41Volume Flowcum/hr2.9566.970.492.411.4.2.3 MAL精制塔（T0103）表1-5 MAL精制塔物料衡算进出口单位进口出口流股编号129.00122.00130.00132.00FromM0105T0103T0103T0103ToT0103M0103M0104M0201Stream ClassCONVENCONVENCONVENCONVENMaximum Relative ErrorCost Flow$/hrMIXED SubstreamPhaseLiquidLiquidVaporLiquidTemperatureC41.1357.4349.2066.20Pressurebar1.001.001.001.00Molar Vapor Fraction0.000.001.000.00Molar Liquid Fraction1.001.000.001.00Molar Solid Fraction0.000.000.000.00Mass Vapor Fraction0.000.001.000.00Mass Liquid Fraction1.001.000.001.00Mass Solid Fraction0.000.000.000.00Molar Enthalpykcal/mol-35.14-63.71-19.82-33.55Mass Enthalpykcal/kg-522.98-2864.31-338.07-481.20Molar Entropycal/mol-K-63.51-39.45-44.16-62.33Mass Entropycal/gm-K-0.95-1.77-0.75-0.89Molar Densitykmol/cum12.0439.840.0411.24Mass Densitykg/cum808.96886.072.24783.82Enthalpy FlowGcal/hr-2.88-0.22-0.08-2.49Average MW67.1822.2458.6169.73Mole Flowskmol/hr81.833.394.2774.17WATERkmol/hr4.033.080.440.51C3H8kmol/hr0.000.000.000.00TR-C4H8kmol/hr0.000.000.000.001-C4H8kmol/hr0.000.000.000.00ISOBTENEkmol/hr1.950.121.830.00MALkmol/hr75.830.191.9873.66CO2kmol/hr0.000.000.000.00N2kmol/hr0.010.000.010.00O2kmol/hr0.000.000.000.00COkmol/hr0.000.000.000.00CH4Okmol/hr0.000.000.000.00MMAkmol/hr0.000.000.000.00C5H10O2kmol/hr0.000.000.000.00HEXkmol/hr0.000.000.000.00MAAkmol/hr0.000.000.000.00INHIBITOkmol/hr0.000.000.000.00Mole FractionsMass Flowskg/hr5497.4475.39250.005172.05Mass FractionsVolume Flowcum/hr6.800.09111.696.601.4.3 MMA合成及分离工段表1-6总物料的进口流量进出口单位进口流股编号132.00219.00water224.00225.00FromT0103ToM0201C0201T0201M0203M0202Stream ClassCONVENCONVENCONVENCONVENCONVENMaximum Relative ErrorCost Flow$/hrMIXED SubstreamPhaseLiquidVaporLiquidLiquidLiquidTemperatureC66.2025.0025.0040.0040.00Pressurebar1.001.003.001.001.00Molar Vapor Fraction0.001.000.000.000.00Molar Liquid Fraction1.000.001.001.001.00Molar Solid Fraction0.000.000.000.000.00Mass Vapor Fraction0.001.000.000.000.00Mass Liquid Fraction1.000.001.001.001.00Mass Solid Fraction0.000.000.000.000.00Molar Enthalpykcal/mol-33.550.00-68.23-46.70-56.62Mass Enthalpykcal/kg-481.20-0.06-3787.43-541.88-1766.99Molar Entropycal/mol-K-62.331.04-38.85-153.43-56.37Mass Entropycal/gm-K-0.890.04-2.16-1.78-1.76Molar Densitykmol/cum11.240.0455.177.4724.18Mass Densitykg/cum783.821.16993.96643.51774.83Enthalpy FlowGcal/hr-2.490.00-113.62-0.01-4.63Average MW69.7328.8518.0286.1832.04Mole Flowskmol/hr74.171089.691665.250.2181.75WATERkmol/hr0.510.001665.250.000.00C3H8kmol/hr0.000.000.000.000.00TR-C4H8kmol/hr0.000.000.000.000.001-C4H8kmol/hr0.000.000.000.000.00ISOBTENEkmol/hr0.000.000.000.000.00MALkmol/hr73.660.000.000.000.00CO2kmol/hr0.000.000.000.000.00N2kmol/hr0.00860.850.000.000.00O2kmol/hr0.00228.830.000.000.00COkmol/hr0.000.000.000.000.00CH4Okmol/hr0.000.000.000.0081.75MMAkmol/hr0.000.000.000.000.00C5H10O2kmol/hr0.000.000.000.000.00HEXkmol/hr0.000.000.000.210.00MAAkmol/hr0.000.000.000.000.00INHIBITOkmol/hr0.000.000.000.000.00Mole FractionsMass Flowskg/hr5172.0531437.8830000.0018.212619.54Mass FractionsVolume Flowcum/hr6.6027000.0030.180.033.38表1-7总物料的出口流量进出口单位出口流股编号203.00222.00221.00FromT0201T0204T0204ToStream ClassCONVENCONVENCONVENMaximum Relative ErrorCost Flow$/hrMIXED SubstreamPhaseVaporLiquidLiquidTemperatureC42.8054.44114.27Pressurebar1.000.200.20Molar Vapor Fraction1.000.000.00Molar Liquid Fraction0.001.001.00Molar Solid Fraction0.000.000.00Mass Vapor Fraction1.000.000.00Mass Liquid Fraction0.001.001.00Mass Solid Fraction0.000.000.00Molar Enthalpykcal/mol-4.95-93.99-94.61Mass Enthalpykcal/kg-177.71-939.15-1098.94Molar Entropycal/mol-K0.90-106.06-77.41Mass Entropycal/gm-K0.03-1.06-0.90Molar Densitykmol/cum0.049.0310.69Mass Densitykg/cum1.06904.06920.55Enthalpy FlowGcal/hr-5.72-6.62-0.03Average MW27.85100.0886.09Mole Flowskmol/hr1155.2070.470.27WATERkmol/hr99.270.020.00C3H8kmol/hr0.000.000.00TR-C4H8kmol/hr0.000.000.001-C4H8kmol/hr0.000.000.00ISOBTENEkmol/hr0.000.000.00MALkmol/hr0.420.000.00CO2kmol/hr0.000.000.00N2kmol/hr860.850.000.00O2kmol/hr192.210.000.00COkmol/hr0.000.000.00CH4Okmol/hr2.260.000.00MMAkmol/hr0.0070.410.00C5H10O2kmol/hr0.000.000.00HEXkmol/hr0.180.030.00MAAkmol/hr0.000.010.27INHIBITOkmol/hr0.000.000.00Mole FractionsMass Flowskg/hr32172.027052.6523.00Mass FractionsVolume Flowcum/hr30320.947.800.021.4.3.1 MMA吸收塔（T0201）表1- 8 MMA吸收塔物料衡算进口单位空气出口流股编号201.00206.00water203.00212.00FromE0201R0202BT0201T0201ToT0201T0201T0201P0201Stream ClassCONVENCONVENCONVENCONVENCONVENMaximum Relative Error0.00Cost Flow$/hrMIXED SubstreamPhaseLiquidMixedLiquidVaporLiquidTemperatureC25.0050.0025.0042.8044.02Pressurebar1.102.303.001.001.00Molar Vapor Fraction0.000.880.001.000.00Molar Liquid Fraction1.000.121.000.001.00Molar Solid Fraction0.000.000.000.000.00Mass Vapor Fraction0.000.830.001.000.00Mass Liquid Fraction1.000.171.000.001.00Mass Solid Fraction0.000.000.000.000.00Molar Enthalpykcal/mol-67.73-17.30-68.23-4.95-67.35Mass Enthalpykcal/kg-2941.39-534.25-3787.43-177.71-2924.64Molar Entropycal/mol-K-43.53-12.66-38.850.90-42.29Mass Entropycal/gm-K-1.89-0.39-2.160.03-1.84Molar Densitykmol/cum40.600.1055.170.0439.69Mass Densitykg/cum934.863.18993.961.06914.03Enthalpy FlowGcal/hr-165.45-25.75-113.62-5.72-299.10Average MW23.0332.3818.0227.8523.03Mole Flowskmol/hr2442.571488.411665.251155.204441.03WATERkmol/hr2003.1872.981665.2599.273642.15C3H8kmol/hr0.000.000.000.000.00TR-C4H8kmol/hr0.000.000.000.000.001-C4H8kmol/hr0.000.000.000.000.00ISOBTENEkmol/hr0.000.010.000.000.00MALkmol/hr0.180.560.000.420.32CO2kmol/hr0.000.000.000.000.00N2kmol/hr0.04860.880.00860.850.07O2kmol/hr0.01192.230.00192.210.03COkmol/hr0.000.000.000.000.00CH4Okmol/hr349.56288.260.002.26635.56MMAkmol/hr87.7971.830.000.00159.62C5H10O2kmol/hr0.000.000.000.000.00HEXkmol/hr0.000.190.000.180.00MAAkmol/hr1.801.480.000.003.28INHIBITOkmol/hr0.000.000.000.000.00Mole FractionsMass Flowskg/hr56247.4848192.7030000.0032172.02102268.15Mass FractionsVolume Flowcum/hr60.1715170.8730.1830320.94111.891.4.3.2MMA萃取塔 （T0202）表1-9 MMA吸收塔物料衡算进出口单位进口出口流股编号209.00218.00213.00217.00FromF0201M0203T0202T0202ToT0202T0202T0205AP0203Stream ClassCONVENCONVENCONVENCONVENMaximum Relative Error0.00Cost Flow$/hrMIXED SubstreamPhaseLiquidLiquidLiquidLiquidTemperatureC44.0250.1644.4042.67Pressurebar1.101.001.001.00Molar Vapor Fraction0.000.000.000.00Molar Liquid Fraction1.001.001.001.00Molar Solid Fraction0.000.000.000.00Mass Vapor Fraction0.000.000.000.00Mass Liquid Fraction1.001.001.001.00Mass Solid Fraction0.000.000.000.00Molar Enthalpykcal/mol-67.35-49.97-66.33-71.93Mass Enthalpykcal/kg-2924.64-660.99-3282.29-821.94Molar Entropycal/mol-K-42.29-129.32-40.17-118.35Mass Entropycal/gm-K-1.84-1.71-1.99-1.35Molar Densitykmol/cum39.698.7745.209.03Mass Densitykg/cum914.03662.64913.42790.20Enthalpy FlowGcal/hr-134.59-3.71-127.89-10.42Average MW23.0375.5920.2187.51Mole Flowskmol/hr1998.4774.351927.94144.87Mole FractionsMass Flowskg/hr46020.675620.2138963.2212677.65Mass FractionsVolume Flowcum/hr50.358.4842.6616.041.4.3.3 正己烷回收塔（T0203）表1-10 MMA吸收塔物料衡算进出口单位进口出口流股编号223.00207.00208.00FromP0203T0203T0203ToT0203M0203T0204Stream ClassCONVENCONVENCONVENMaximum Relative ErrorCost Flow$/hrMIXED SubstreamPhaseLiquidLiquidLiquidTemperatureC42.5850.2099.68Pressurebar1.201.001.00Molar Vapor Fraction0.000.000.00Molar Liquid Fraction1.001.001.00Molar Solid Fraction0.000.000.00Mass Vapor Fraction0.000.000.00Mass Liquid Fraction1.001.001.00Mass Solid Fraction0.000.000.00Molar Enthalpykcal/mol-71.93-49.98-91.82Mass Enthalpykcal/kg-821.93-661.38-917.91Molar Entropycal/mol-K-118.19-129.25-99.69Mass Entropycal/gm-K-1.35-1.71-1.00Molar Densitykmol/cum9.038.778.49Mass Densitykg/cum790.29662.69849.52Enthalpy FlowGcal/hr-10.42-3.71-6.49Average MW87.5175.56100.03Mole Flows