7-1附录一物料衡算

榆炼10万吨/年甲基丙烯酸甲酯生产项目 物料衡算9目录物料衡算11.1总述11.2物料衡算的意义11.3物料衡算的原则11.4物料衡算任务21.5物料衡算21.5.1原料预处理工段21.5.2氧化工段31.5.3氧化酯化工段51.5.4精制工段61.5.5总流程7物料衡算1.1总述本项目是利用榆林炼油厂石油化工企业生产过程中产生的大量的C4馏分中分离出的异丁烯为原料，经过原料预处理工段、氧化工段、氧化酯化工段、精制工段，每年生产10万吨甲基丙烯酸甲酯（MMA）的装置与总厂形成有效融合体系，解决总厂C4原料利用率不足的问题，使这部分资源得到合理有效利用，提高产品经济附加值。1.2物料衡算的意义物料衡算是质量守恒定律的一种表现形式。凡引入某一设备的物料成分、质量或体积比等于操作后所得产物的成分、质量或体积加上物料损失。通过对整个生产系统、生产工段、以及各个重要的生产单元进行详细的物料衡算，计算得到各个产品的实际产量与规格，各个原料的实际消耗定额，“三废”的排放量及组成，从而定量的评述初步设计阶段所采用的生产工艺是否合理，先进，并通过衡算所得数据，来进一步对各个阶段所采用的设备进行初步设计。1.3物料衡算的原则物料平衡是指在单位时间内进入系统的全部物料质量必定等于离开该系统的全部物料质量再加上损失掉的和积累起来的物料质量。进行物料衡算时，先必须确定衡算的体系。（1）对一般的体系而言，物料分布均可表示为：(物料的累积率)=(物料进入率)-(物料流出率)+(反应生成率)-(反应消耗率)（2）当系统没有化学反应时，则可简化为：(物料的累积率)=(物料进入率)-(物料流出率)（3）在稳定状态下有：(物料进入率)=(物料流出率)利用上述关系，可以对整个工艺系统或子系统进行物料衡算。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下表所示：表1-1 物料衡算式适用范围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物料衡算任务对于本厂，工艺采取年开工300天（7200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）确定甲基丙烯酸甲酯的实际产量以及质量指标；（2）确定异丁烯、甲醇、氧气等原料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；（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。1.5物料衡算1.5.1原料预处理工段图1-1 原料预处理工段工艺流程图表1-2原料预处理工段物料衡算Items流入流出StreamsS0101S0118S0123S0125S0126Temperature C-15-12.2282062.48784117-7.38299089.49039465Pressure bar511.461636711.4616367Vapor Frac01000Mass Flow kg/hr12900416.7639331989.920728275.956462217.52362Volume Flow cum/hr20.4486407155.5699873.2399000313.20946883.74856389Enthalpy MMBtu/hr-14.860388-0.938288-1.5528786-6.4814023-5.3850041Density lb/cuft39.38260240.1672412738.342754639.112177136.93027Density VAPOlb/cuft0.16724127Density LIQUlb/cuft39.382602438.342754639.112177136.93027Mass Flow kg/hrIB9842.71.311147241891.36857944.916635.10577234C4H10-012399.49.7757E-101.37007271185.5499582212.41783C4H10-02657.9415.45278597.1821391145.4898751.6754E-05O200000N200000H2O00000MAL00000MAA00000MEOH00000MMA00000C6H6O200000Total1290012900由上表可知，原料预处理工段的进、出物料总体质量保持平衡。1.5.2氧化工段图1-2 氧化工段工艺流程图表1-3 氧化工段物料流入衡算表Items流入StreamsS0123S0125S0201S0215Temperature C2.487841-7.3829953.8213925Pressure bar1.461637111Vapor Frac03.42E-0510Mass Flow kg/hr1989.9218275.95654230.735286.956Volume Flow cum/hr3.239913.3204154269.296.667698Enthalpy MMBtu/hr-1.55288-6.4813-66.4569-37.3121Density lb/cuft38.3427538.786420.06238449.50043Density VAPOlb/cuft0.1587280.062384Density LIQUlb/cuft38.3427539.1121849.50043Mass Flow kg/hrIB1891.3697944.91700C4H10-011.370073185.5500C4H10-0297.18214145.489900O20010266.180N20038612.940H2O005351.6190MAL0000MAA0000MEOH0005286.956MMA0000C6H6O20000Total69783.5681表1-4 氧化工段物料流出衡算表Items流出StreamsS0212S0213S0219S0220Temperature C252568.15018103.0147Pressure bar1111.144692Vapor Frac1110Mass Flow kg/hr4651.8766540395.116076.738659.864Volume Flow cum/hr3603.7658934945.829455.5919.517764Enthalpy MMBtu/hr-5.133E-16-4.23601-50.4639-120.632Density lb/cuft0.080584360.0721630.10614256.8009Density VAPO lb/cuft0.080584360.0721630.106142Density LIQU lb/cuft56.8009Mass Flow kg/hrIB0142.055662.226097.84E-17C4H10-010120.249666.670411.88E-15C4H10-020176.829865.842232E-17O24651.8766505.6916083.95E-52N2038576.236.743822.42E-52H2O0129.3962309.91348005.001MAL01249.49510242.6935.01187MAA00.8736850.001157619.8509MEOH005286.9568.53E-08MMA0000C6H6O20000Total69783.568由表1-3、表1-4可知，氧化工段的进、出物料总体质量保持平衡。1.5.3氧化酯化工段图1-3 氧化酯化工段工艺流程图表1-5氧化酯化工段物料衡算表Items流入流出StreamsS0219S0301S0305S0306S0312Temperature C66.3118625252570Pressure bar11112.7Vapor Frac11001Mass Flow kg/hr17547.914287.8392159571.18237793.92Volume Flow cum/hr9825.2613321.7494420.124320.0009079509.126Enthalpy MMBtu/hr-50.9395-4.731E-16-112.615-0.00362-188.273Density lb/cuft0.1114960.0805843649.5004381.324350.248119Density VAPO lb/cuft0.1114960.080584360.248119Density LIQU lb/cuft49.5004381.32435Mass Flow kg/hrIB70.2341300070.23413C4H10-01186.9203000186.9203C4H10-02242.6709000242.6709O25.8456394287.8392001726.402N238.490700038.4907H2O139.48990003030.243MAL11577.3000330.4078MAA9.30E-050009.30E-05MEOH5286.956015957016102.43MMA000016064.94C6H6O20001.1821.182Total37793.9237793.921.5.4精制工段图1-4 精制工段工艺流程图表1-6 精制工段物料衡算表Items流入流出StreamsS0312S0404S0408S0413S0414S0415Temperature C701236.6468211184.837264.37604103.1264Pressure bar2.70.517.44096611.137802Vapor Frac110000Mass Flow kg/hr40278.482743.40413844.274915781.634727.1233182.048Volume Flow cum/hr9806.7323642.5217.421132321.688296.3175563.508857Enthalpy MMBtu/hr-195.923-3.5264-88.426505-54.3017-31.2823-44.8137Density lb/cuft0.2564060.04701849.610428945.4261346.7118456.61353Density VAPOlb/cuft0.2564060.047018 Density LIQUlb/cuft 49.610428945.4261346.7118456.61353Mass Flow kg/hr IB87.4159670.2341717.18179151.38E-357.39E-071.15E-14 C4H10-01231.4243186.920444.50389859.51E-332.66E-061.94E-13 C4H10-02586.8691242.6672344.197523.40E-320.0044414.77E-11 O21741.0671732.6398.4277243000 N238.6369838.49070.1462822000 H2O3023.220.0032231.12E-070.10735416.488943006.621 MAL364.73153.2889127.004541191.61E-06305.179549.25852 MAA9.30E-0502.17E-489.30E-0500 MEOH16114.92373.340611359.04395.27E-264382.3350.200826 MMA18089.0195.819712063.7691815780.3423.11576125.9683 C6H6O21.18203.763E-1111.18200Total40278.4840278.48 由上表可知，氧化酯化工段的进、出物料总体质量保持平衡。1.5.5总流程图1-5 总工艺流程图表1-7 总流程物料流入质量表Items流入流入流入流入流入StreamsS0101S0123S0125S0201S0215Temperature C-152.487841-7.3829953.8213925Pressure bar51.461637111Vapor Frac003.42E-0510Mass Flow kg/hr129001989.9218275.95654230.735286.956Volume Flow cum/hr20.448643.239913.3204154269.296.667698Enthalpy MMBtu/hr-14.8604-1.55288-6.4813-66.4569-37.3121Density lb/cuft39.382638.3427538.786420.06238449.50043Density VAPOlb/cuft 0.1587280.062384 Density LIQUlb/cuft39.382638.3427539.11218 49.50043Mass Flow kg/hr IB9842.71891.3697944.91700 C4H10-012399.41.370073185.5500 C4H10-02657.997.18214145.489900 O200010266.180 N200038612.940 H2O0005351.6190 MAL00000 MAA00000 MEOH00005286.956 MMA00000 C6H6O200000表1-8 总流程物料流入质量表Items流入流入流入流入流入StreamsS0219S0301S0305S0306S0312Temperature C66.3118625252570Pressure bar11112.7Vapor Frac11001Mass Flow kg/hr17547.914287.839159571.18240278.48Volume Flow cum/hr9825.2613321.74920.124320.0009079806.732Enthalpy MMBtu/hr-50.9395-4.7E-16-112.615-0.00362-195.923Density lb/cuft0.1114960.08058449.5004381.324350.256406Density VAPO lb/cuft0.1114960.0805840.256406Density LIQU lb/cuft49.5004381.32435Mass Flow kg/hrIB70.2341300087.41596C4H10-01186.9203000231.4243C4H10-02242.6709000586.8691O25.8456394287.839001741.067N238.490700038.63698H2O139.48990003023.22MAL11577.3000364.7315MAA9.3E-050009.3E-05MEOH5286.956015957016114.92MMA000018089.01C6H6O20001.1821.182Total160755.9718（kg/h）表1-9 总流程物料流出质量表Items流出流出流出流出流出流出流出StreamsS0312S0118S0123S0125S0126S0212S0213Temperature C70-12.22822.487841-7.382999.4903952525Pressure bar2.711.46163711.46163711Vapor Frac1100011Mass Flow kg/hr37793.92416.76391989.9218275.9562217.5244651.8766540395.1Volume Flow cum/hr9509.126155.573.239913.209473.7485643603.7658934945.82Enthalpy MMBtu/hr-188.273-0.93829-1.55288-6.4814-5.385-5.133E-16-4.23601Density lb/cuft0.2481190.16724138.3427539.1121836.930270.080584360.072163Density VAPOlb/cuft0.2481190.1672410.080584360.072163Density LIQUlb/cuft38.3427539.1121836.93027Mass Flow kg/hrIB70.234131.3111471891.3697944.9175.1057720142.0556C4H10-01186.92039.78E-101.370073185.552212.4180120.2496C4H10-02242.6709415.452897.18214145.48991.68E-050176.8298O21726.40200004651.876650N238.49070000038576.2H2O3030.24300000129.3962MAL330.4078000001249.495MAA9.3E-05000000.873685MEOH16102.43000000MMA16064.94000000C6H6O21.182000000表1-10 总流程物料流出质量表Items流出流出流出流出流出流出StreamsS0220S0404S0408S0413S0414S0415Temperature C103.01471236.64682184.837264.37604103.1264Pressure bar1.1446920.517.44096611.137802Vapor Frac010000Mass Flo