5-1物料衡算计算书

镇海炼化年产20万吨醋酸乙烯项目 物料衡算计算书1/47目录1.1概述11.2物料衡算目的11.3物料衡算方法21.4总项目衡算21.4.1物料衡算任务31.4.2 VAC合成工段11.4.3 VAC合成工段21.4.4 VAC精制工段11.4.5总物料衡算141.5总结20HUGE华格一队物料衡算书1.1概述本项目主要通过乙烯气相法生产VAC，该反应主要副反应生成二氧化碳，还伴有醋酸甲酯，乙酯，乙醛等重要化工产品的生成，通过隔壁塔，萃取精馏，非均相共沸分离副产物的时候提纯VAC。VAC产量年产20万吨，纯度高达99.9%wt。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。本项目主要通过乙烯气相法生产VAC，该反应主要副反应生成二氧化碳，还伴有醋酸甲酯，乙酯，乙醛等重要化工产品的生成，通过隔壁塔，萃取精馏，非均相共沸分离副产物的时候提纯VAC。VAC产量年产20万吨，纯度高达99.9%wt。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总项目衡算工艺路线可分为如下3个工段：VAC合成工段、VAC粗分离工段、VAC精制工段。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4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VAC以及副产品的实际产量以及质量指标；(2)确定水、甲醇、乙二醇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。HUGO华格一队 221.4.2 VAC合成工段图1-1 VAC合成工段表1-2 VAC合成工段物料信息进出口进口出口流股编号 0105010301010283022001150111流股信息醋酸乙烯氧气醋酸混合气体混合气相醋酸Temperature C 2525252518.8160117Pressure bar 1111181Vapor Frac 0110110Mole Flow kmol/hr 342.021447.71282.2311077.9794270.1176190.05820Mass Flow kg/hr 20539.23712559.959031.05364720.5139404.7245054.41201.044Volume Flow cum/hr 18.03111034.496991.04560.347103054.526263.191.27Enthalpy MMBtu/hr -147.47322.264-0.002-493.605-301.822-927.299-8.939Mass Flow kg/hr CO2 000052811.7654900.580 C2H4 012559.950082824.5283090.60 O2 009031.05303768.4033977.7940 CH3COOH 20539.2370064714.12064716.571201.044 VAC 00000268820 H2O 0006.38506486.7620 ETHYL-01 00000113.3950 CH3CHO 000004261.4280 METHY-01 00000625.2410 EG 0000000 CH3OH 0000000 H3O+ 0000000 OH- 0000000 HCO3- 0000000 CO3-2 0000000 K+ 0000000 K2CO3 0000000总计246255.84246255.84Mass Frac CO2 00000.3790.2240 C2H4 01000.5940.3390 O2 00100.0270.0160 CH3COOH 100100.2641 VAC 000000.110 H2O 000000.0260 ETHYL-01 0000000 CH3CHO 000000.0170 METHY-01 000000.0030 EG 0000000 CH3OH 0000000 H3O+ 0000000 OH- 0000000 HCO3- 0000000 CO3-2 0000000 K+ 0000000 K2CO3 00000001.4.2.1 VAC合成反应器（R0101）图1-2 VAC合成反应器（R0101）表1-3VAC合成反应器物料衡算表流股编号01160118流股信息原料气反应气Temperature C 171.5160Pressure bar 88Vapor Frac 11Mole Flow kmol/hr 6400.0586190.058Mass Flow kg/hr 245054.4245054.4Volume Flow cum/hr 26890.7226263.19Enthalpy MMBtu/hr -830.493-927.299Mass Flow kg/hr CO2 52811.7654900.58 C2H4 95384.4783090.6 O2 12799.463977.794 CH3COOH 84052.364716.57 VAC 026882 H2O 6.3856486.762 ETHYL-01 0113.395 CH3CHO 04261.428 METHY-01 0625.241 EG 00 CH3OH 00 H3O+ 00 OH- 00 HCO3- 00 CO3-2 00 K+ 00 K2CO3 00总计245054.4245054.4Mass Frac CO2 0.2160.224 C2H4 0.3890.339 O2 0.0520.016 CH3COOH 0.3430.264 VAC 00.11 H2O 00.026 ETHYL-01 00 CH3CHO 00.017 METHY-01 00.003 EG 00 CH3OH 00 H3O+ 00 OH- 00 HCO3- 00 CO3-2 00 K+ 00 K2CO3 001.4.3 VAC合成工段图1-3VAC粗分离段表1-4VAC粗分离段物料衡算表进出口进口出口流股编号01180205021602810301流股信息反应气废水循环气体醋酸VAC混合物Temperature C 160-10-30252.2Pressure bar 81811Vapor Frac 10100Mole Flow kmol/hr 6190.058129.124348.2651077.979433.614Mass Flow kg/hr 245054.42326.14142616.664720.531768.64Volume Flow cum/hr 26263.192.32910256.4160.34733.644Enthalpy MMBtu/hr -927.299-35.304-330.657-493.605-132.543Mass Flow kg/hr CO2 54900.58054900.5600 C2H4 83090.6083090.5800 O2 3977.79403977.79400 CH3COOH 64716.5702.4464714.120 VAC 2688202.008026880 H2O 6486.7622326.140.0016.385531.774 ETHYL-01 113.39500.0010113.393 CH3CHO 4261.4280642.56203618.857 METHY-01 625.24100.6090624.617 EG 00000 CH3OH 00000 H3O+ 00000 OH- 00000 HCO3- 00000 CO3-2 00000 K+ 00000 K2CO3 00000总计245054.4245054.368Mass Frac CO2 0.22400.38500 C2H4 0.33900.58300 O2 0.01600.02800 CH3COOH 0.2640010 VAC 0.110000.846 H2O 0.0261000.017 ETHYL-01 00000.004 CH3CHO 0.01700.00500.114 METHY-01 0.0030000.02 EG 00000 CH3OH 00000 H3O+ 00000 OH- 00000 HCO3- 00000 CO3-2 00000 K+ 00000 K2CO3 000001.4.3.1 气液粗分离塔（T0201）图1-4气液分离塔（T0201）表1-5气液粗分离塔（T0201）衡算表进出口进口出口流股编号0118021502010207流股信息Temperature C160-7.341.767.4Pressure bar8111Vapor Frac10.00210Mole Flow kmol/hr6190.0583224.596852.4862562.162Mass Flow kg/hr245054.368221705.076315196.042151563.402Volume Flow cum/hr26263.185383.035176265.725155.041Enthalpy MMBtu/hr-927.299-1147.055-1009.255-1065.098Mass Flow kg/hrCO254900.582306.05456891.812314.822C2H483090.6042848.17185393.85544.925O23977.79435.7014007.8065.689CH3COOH64716.56759551.6545588.265118679.956VAC26881.999114435.126114474.33226842.793H2O6486.762609.3132930.6154165.46ETHYL-01113.3952.9852.985113.395CH3CHO4261.42816190.55720154.685297.299METHY-01625.24125725.51525751.693599.063EG0000CH3OH0000H3O+0000OH-0000HCO3-0000CO3-20000K+0000K2CO30000Mass FracCO20.2240.010.180.002C2H40.3390.0130.2710.004O20.016161 PPM0.01338 PPMCH3COOH0.2640.2690.0180.783VAC0.110.5160.3630.177H2O0.0260.0030.0090.027ETHYL-01463 PPM13 PPM9 PPM748 PPMCH3CHO0.0170.0730.0640.002METHY-010.0030.1160.0820.004EG0000CH3OH0000H3O+0000OH-0000HCO3-0000CO3-20000K+0000K2CO30000总计466759.44466759.441.4.3.2 酸洗塔（T0202）图1-6酸洗塔（T0202）表1-7酸洗塔物料衡算表进出口进料出口流股编号0202028202080213流股信息混合气液醋酸液相混合物气相Temperature C-102517.62.9Pressure bar1111Vapor Frac1010Mole Flow kmol/hr4586.08910004498.7751087.314Mass Flow kg/hr156404.38260038.739151203.59465239.527Volume Flow cum/hr99426.57155.982107021.29761.857Enthalpy MMBtu/hr-381.094-457.898-376.484-462.508Mass Flow kg/hrCO255124.015054585.745538.27C2H483228.975082545.659683.316O23980.7903972.1058.685CH3COOH8.62460032.8166069.45453971.986VAC5628.644039.2675589.377H2O133.4485.9231.085138.285ETHYL-010.0930 0.0010.093CH3CHO6239.25603964.1142275.142METHY-012060.537026.1652034.372EG0000CH3OH0000H3O+0000OH-0000HCO3-0000CO3-20000K+0000K2CO30000Mass FracCO20.35200.3610.008C2H40.53200.5460.01O20.02500.026133 PPMCH3COOH55 PPM10.040.827VAC0.0360260 PPM0.086H2O853 PPM99 PPM7 PPM0.002ETHYL-01595 PPB001 PPMCH3CHO0.0400.0260.035METHY-010.0130173 PPM0.031EG0000CH3OH0000H3O+0000OH-0000HCO3-0000CO3-20000K+0000K2CO30000总计216443.121216443.1211.4.3.3二氧化碳吸收段图1-7二氧化碳吸收段表1-8二氧化碳吸收段物料衡算表进出口进口出口流股编号物流信息02230224022702350238混合气体碳酸钾溶液乙烯气二氧化碳碳酸钾溶液Temperature C 18.890-302548.9Pressure bar 120111Vapor Frac 10110.001Mole Flow kmol/hr 63.49208614.39447.4062086.104Mass Flow kg/hr 2564.25242797.792428.8692046.47442886.701Volume Flow cum/hr 1532.11737.428289.3341169.13883.111Enthalpy MMBtu/hr -17.247-574.1450.368-17.459-579.292Mass Flow kg/hr CO2 2088.8010.0010.3152018.670.004 C2H4 266.0580225.3680.23940.452 O2 209.3910203.0540.076.267 CH3COOH 00000 VAC 00000 H2O 0.00134176.120.13327.49534163.029 ETHYL-01 00000 CH3CHO 00000 METHY-01 00000 EG 00000 CH3OH 00000 H3O+ 00000 OH- 049.954009.25 HCO3- 0179.21200226.774 CO3-2 03544.384003592.804 K+ 04848.121004848.121 K2CO3 00000总计45362.04445362.044Mass Frac CO2 0.81500.0010.9860 C2H4 0.10400.52500.001 O2 0.08200.47300 CH3COOH 00000 VAC 00000 H2O 00.79900.0130.797 ETHYL-01 00000 CH3CHO 00000 METHY-01 00000 EG 00000 CH3OH 00000 H3O+ 00000 OH- 00.001000 HCO3- 00.004000.005 CO3-2 00.083000.084 K+ 00.113000.113 K2CO3 000001.4.3.4脱气塔(T0207)图1-8气液分离塔(T0207)表1-9气液分离塔(T0207)物料衡算表进出口进口出口流股编号024002460251流股信息气液混合物塔顶出料釜液Temperature C55.9-18.289Pressure bar111Vapor Frac0.10410Mole Flow kmol/hr2962.6722502712.672Mass Flow kg/hr168715.2868564.843160150.449Volume Flow cum/hr8144.9965245.386169.043Enthalpy MMBtu/hr-1148.735-25.016-1116.005Mass Flow kg/hrCO23548.7423548.737traceC2H44364.7964364.788traceO239.33339.332traceCH3COOH124751.4954.525124746.971VAC26999.772119.72126880.056H2O4167.8131.2684166.544ETHYL-01113.5730.18113.394CH3CHO4102.089483.2383618.866METHY-01627.6733.054624.619EG000CH3OH000H3O+000OH-000HCO3-000CO3-2000K+000K2CO3000Mass FracCO20.0210.414traceC2H40.0260.51traceO2233 PPM0.005traceCH3COOH0.739528 PPM0.779VAC0.160.0140.168H2O0.025148 PPM0.026ETHYL-01673 PPM21 PPM708 PPMCH3CHO0.0240.0560.023METHY-010.004357 PPM0.004EG000CH3OH000H3O+000OH-000HCO3-000CO3-2000K+000K2CO3000总计168715.286168715.2861.4.3.5醋酸分离塔（T0208-T0209）图1-9醋酸分离塔（T0208-T0209）表1-10醋酸分离塔（T0208-T0209）物料衡算表进出口进料出料流股编号02510258027002520277流股信息醋酸混合物混合物热耦合塔顶气轻组分醋酸Temperature C89161.762.672.1Pressure bar11111Vapor Frac00010Mole Flow kmol/hr2712.6721069.695283.0131704.3862077.979Mass Flow kg/hr160150.44979489.620501.729114880.693124759.239Volume Flow cum/hr169.04383.82323.16145943.397123.481Enthalpy MMBtu/hr-1116.005-331.235-89.36-451.519-940.497Mass Flow kg/hrCO2trace0000C2H4trace0000O2trace0000CH3COOH124746.971000124746.931VAC26880.05668665.27319096.14695545.2560H2O4166.5441340.2581015.4365494.49112.308ETHYL-01113.394286.041205.039399.435CH3CHO3618.8667639.9910.76711258.857METHY-01624.6191558.037184.342182.654EG00000CH3OH00000H3O+00000OH-00000HCO3-00000CO3-200000K+00000K2CO300000Mass FracCO2trace0000C2H4trace0000O2trace0000CH3COOH0.7790001VAC0.1680.8640.9310.8320H2O0.0260.0170.050.04899 PPMETHYL-01708 PPM0.0040.010.0030CH3CHO0.0230.09637 PPM0.0980METHY-010.0040.020.0090.0190EG00000CH3OH00000H3O+00000OH-00000HCO3-00000CO3-200000K+00000K2CO300000总计239639.932239639.9321.4.3.6脱水塔（T0210）图1-10脱水塔（T0210）表1-11脱水塔（T0210）物料衡算表进出口进口出口流股编号025402890293流股信息水相VAC混合物水Temperature C12399.6Pressure bar111Vapor Frac000Mole Flow kmol/hr217.07716201.077Mass Flow kg/hr4358.001735.5433622.458Volume Flow cum/hr4.4530.923.943Enthalpy MMBtu/hr-58.478-3.227-53.424Mass Flow kg/hrCO2000C2H4000O2000CH3COOH000VAC72.77372.773traceH2O3630.9898.5313622.458ETHYL-011.7211.721traceCH3CHO636.166636.166traceMETHY-0116.35216.352traceEG000CH3OH000H3O+000OH-000HCO3-000CO3-2000K+000K2CO3000Mass FracCO2000C2H4000O2000CH3COOH000VAC0.0170.099traceH2O0.8330.0121ETHYL-01395 PPM0.002traceCH3CHO0.1460.865traceMETHY-010.0040.022traceEG000CH3OH0