8-1 附录一 物料衡算说明书

年产3500吨牛磺酸项目 物料衡算说明书目 录1 总论- 1 -2 物料衡算目的- 1 -3 物料衡算方法- 1 -4 各项目核算- 2 -4.1 物料衡算任务- 2 -4.2 烟气脱硫工段物料衡算- 2 -4.3 碳铵冷却结晶工段- 7 -4.4 牛磺酸合成工段- 17 -4.5 硫酸铵精制工段- 26 -5 总项目核算- 35 -6 硫元素在全厂的流向分析- 37 -6.1 脱硫工段- 37 -6.2 碳铵冷却结晶工段- 37 -6.3 牛磺酸制备工段- 38 -6.4 硫酸铵精制工段- 38 -6.5 结论- 38 -1 总论本项目拟为吉林建龙钢铁厂的烧结烟气设计一套深度脱硫并予以资源化利用的装置。烟气脱硫工段采用氨法脱硫，牛磺酸合成工段采用环氧乙烷-亚硫酸铵法。牛磺酸年产3500吨，生产过程中的副产品碳铵和硫酸铵。这些产品为我们的工艺产生经济效应。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，技术上是否先进，为后阶段的设计提供数据。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。3 物料衡算方法工艺设计中，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。物料衡算是以质量守恒定律为基础对物料平衡进行计算。物料平衡是指“在单位时间内进入系统（体系）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科质量”。物料衡算通式如式：G投入= G产品+ G回收+ G流失式中：G投入投入系统的物料总量；G产品系统产出的产品和副产品总量；G流失系统中流失的物料总量；G回收系统中回收的物料总量。其中产品量应包括产品和副产品：流失量包括除产品、副产品及回收量以外各种形式的损失量，污染物排放量即包括在其中。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。4 各项目核算从原料入厂到产品输出，其工艺路线可分为如下4个工段：（1）烟气脱硫工段；（2）碳铵冷却结晶工段；（3）牛磺酸合成工段；（4）硫酸铵精制工段。4.1 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）确定牛磺酸的实际产量以及质量指标；（2）确定氨水、环氧乙烷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。4.2 烟气脱硫工段物料衡算4-1 烟气脱硫工艺示意图由工艺示意图可知，烟气脱硫工段有换热器、脱硫塔等重要单元过程，需要对它们进行物料衡算。表4-1 E0101换热器前后物流结果表项目进料流股出料流股温度67.720压力bar7.0937.093气相分率00摩尔流量kmol/hr8374.418374.41质量流量kg/hr150000150000体积流量cum/hr166.158159.758焓Gcal/hr-522.212-529.084组分流量kg/hrH2O134990134988N20.000.00SO20.000.00CO20.000.00H+tracetraceOH-9.87610.969HCO3-0.000.00NH3149990.114989NH4+10.47411.633HSO3-0.000.00SO32-0.000.00表4-2 E0102换热器前后物流结果表项目进料流股出料流股温度242.544压力bar7.0937.093气相分率11摩尔流量kmol/hr1331013310质量流量kg/hr404193404193体积流量cum/hr80509.249224.1焓Gcal/hr-181.301-201.207组分流量kg/hrH2O3500.843500.84N2310144310144SO21832.461832.46CO288715.588715.5表4-3 E0103换热器前后物流结果表项目进料流股出料流股温度242.544压力bar7.0937.093气相分率11摩尔流量kmol/hr1331013310质量流量kg/hr404193404193体积流量cum/hr80509.249224.1焓Gcal/hr-181.301-201.207组分流量kg/hrH2O3500.843500.84N2310144310144SO21832.461832.46CO288715.588715.5表4-4 T0101A脱硫塔前后物流结果表项目进料流股进料流股出料流股出料流股温度204446.465.3压力bar7.0937.0937.0937.093气相分率0101摩尔流量kmol/hr8374.41133107915.8613172.5质量流量kg/hr150000404193168816385377体积流量cum/hr159.75849224.1149.90852049.3焓Gcal/hr-529.084-201.207-570.212-160.079组分流量kg/hrH2O1349883500.841198547909.4N20.003101449.151310135SO20.001832.46tracetraceCO20.0088715.596.21963647.5H+trace0.00trace0.00OH-10.9690.000.0380.00HCO3-0.000.0034622.30.00NH3149890.00680.5913684.58NH4+11.6330.0011263.90.00HSO3-0.000.0013.460.00SO32-0.000.002276.830.00表4-5 T0101B脱硫塔前后物流结果表项目进料流股进料流股出料流股出料流股温度46.44446.145.6压力bar7.0937.0937.0937.093气相分率0110摩尔流量kmol/hr7915.861331013349.27908.55质量流量kg/hr168816404193405140167870体积流量cum/hr149.90849224.149705.4148.812焓Gcal/hr-570.212-201.207-204.269-567.151组分流量kg/hrH2O1198543500.843319.88120609N29.1513101443101458.677SO2trace1832.460.001traceCO296.21988715.59138290.848H+trace0.000.00traceOH-0.0380.000.000.029HCO3-34622.30.000.0030932.8NH3680.5910.00293.164447.076NH4+11263.90.000.0011200.7HSO3-13.460.000.0033.105SO32-2276.830.000.004547.55表4-6 烟气脱硫工段总物料衡算项目进料流股出料流股流股信息稀氨水烟气1烟气2脱硫气1脱硫气2氨法脱硫残余液温度67.7242.5242.565.346.145.6压力bar7.0937.0937.0937.0937.0937.093气相分率011110摩尔流量kmol/hr8374.41133101331013172.513349.27908.55质量流量kg/hr150000404193404193385377405140167870体积流量cum/hr166.15880509.280509.252049.349705.4148.812焓Gcal/hr-522.212-181.301-181.301-160.079-204.269-567.151组分流量kg/hrH2O1349903500.843500.847909.43319.88120609N20.003101443101443101353101458.677SO20.001832.461832.46trace0.001traceCO20.0088715.588715.563647.59138290.848H+trace-0.000.00traceOH-9.876-0.000.000.029HCO3-0.00-0.000.0030932.8NH3149990.1-3684.58293.164447.076NH4+10.474-0.000.0011200.7HSO3-0.00-0.000.0033.105SO32-0.00-0.000.004547.554.3 碳铵冷却结晶工段图4-2 碳铵冷却结晶工艺示意图由工艺示意图可知，碳铵冷却结晶工段有反应器、闪蒸罐、换热器和结晶器等重要单元过程，需要对他们进行物料衡算。表4-7 E0201换热器前后物流结果表项目进料流股出料流股温度45.690压力bar1.0131.013气相分率00摩尔流量kmol/hr7908.558401.04质量流量kg/hr167870167870体积流量cum/hr148.84385578焓Gcal/hr-567.168-530.562组分流量kg/hrH2O120609129481N28.6778.677SO2trace0.075CO290.69921765.2H+tracetraceOH-0.0290.081HCO3-30933882.153NH3447.0048929.5NH4+11200.82216.55HSO3-33.041485.629SO32-4547.624100.56表4-8 R0201反应器前后物料结果表项目进料流股出料流股温度9090压力bar1.0131.013气相分率00.344摩尔流量kmol/hr8401.048401.07质量流量kg/hr167870167870体积流量cum/hr8557885654.3焓Gcal/hr-530.562-530.544组分流量kg/hrH2O129481129482N28.6778.677SO20.0750.075CO221765.221766.5H+tracetraceOH-0.0810.081HCO3-882.153880.423NH38929.58930.07NH4+2216.552215.95HSO3-485.629486.018SO32-4100.564100.17表4-8 V0201闪蒸罐前后物流结果表项目进料流股出料流股出料流股温度909090压力bar1.0131.0131.013气相分率0.34401摩尔流量kmol/hr8401.075513.152887.93质量流量kg/hr1678701034464425.4体积流量cum/hr85654.3104.18685550.4焓Gcal/hr-530.544-368.957-161.586组分流量kg/hrH2O1294829470634775.9N28.6770.0018.677SO20.0750.0010.075CO221766.58.85221757.7H+tracetrace0.00OH-0.0810.0810.00HCO3-880.423880.3110.00NH38930.071047.097883.05NH4+2215.952215.870.00HSO3-486.018486.2050.00SO32-4100.174099.990.00表4-9 E0202换热器前后物流结果表项目进料流股出料流股温度-49.920压力bar11气相分率10.99摩尔流量kmol/hr26521.726413.5质量流量kg/hr790517790517体积流量cum/hr490816636883焓Gcal/hr-384.309-374.973组分流量kg/hrH2O11229.39279.36N2620280620280SO20.001traceCO2155030150266H+0.00traceOH-0.000.001HCO3-0.006604.35NH33977.742134.41NH4+0.001952.37HSO3-0.00traceSO32-0.000.001表4-10 E0203换热器前后物流结果表项目进料流股出料流股温度9020压力bar1.0131气相分率10.014摩尔流量kmol/hr2887.932426.33质量流量kg/hr64425.464425.4体积流量cum/hr85550.4862.555焓Gcal/hr-161.586-194.312组分流量kg/hrH2O34775.926460.1N28.6778.677SO20.075traceCO221757.71443.15H+0.00traceOH-0.000.002HCO3-0.0028165.3NH37883.0521.845NH4+0.008326.21HSO3-0.000.001SO32-0.000.093表4-11 E0204换热器前后物流结果表项目进料流股出料流股温度19.4-40压力bar11气相分率0.910.887摩尔流量kmol/hr28805.928713.2质量流量kg/hr854942854942体积流量cum/hr636892492745焓Gcal/hr-569.285-591.124组分流量kg/hrH2O3512933458.8N2620289620289SO2tracetraceCO2150218146137H+tracetraceOH-0.013traceHCO3-36837.542494.5NH31579.080.165NH4+10889.912562.2HSO3-0.0010.001SO32-0.0940.094表4-12 V0202A闪蒸罐前后物流结果项目进料流股出料流股出料流股温度-40-40-40压力bar111气相分率0.88710摩尔流量kmol/hr28713.225469.13244.14质量流量kg/hr85494276653388409体积流量cum/hr49274549267866.908焓Gcal/hr-591.124-324.611-266.513组分流量kg/hrH2O33458.8109.39533349.4N26202896202862.644SO2tracetracetraceCO21461371461370.092H+trace0.00traceOH-trace0.00traceHCO3-42494.50.0042494.5NH30.1650.0640.101NH4+12562.20.0012562.2HSO3-0.0010.000.001SO32-0.0940.000.094表4-13 E0205换热器前后物流结果表项目进料流股出料流股温度-400压力bar11气相分率00.001摩尔流量kmol/hr3244.143244.41质量流量kg/hr8840988409体积流量cum/hr66.90871.872焓Gcal/hr-266.513-264.556组分流量kg/hrH2O33349.433354.3N22.6442.644SO2tracetraceCO20.09212.225H+tracetraceOH-trace0.001HCO3-42494.542477.7NH30.1014.796NH4+12562.212557.2HSO3-0.0010.001SO32-0.0940.093表4-14 V0202B闪蒸罐前后物流结果表项目进料流股出料流股出料流股温度000压力bar111气相分率0.00110摩尔流量kmol/hr3244.410.233244.18质量流量kg/hr884098.78288400.2体积流量cum/hr71.8725.19766.675焓Gcal/hr-264.556-0.014-264.542组分流量kg/hrH2O33354.30.02533354.3N22.6442.2620.381SO2tracetracetraceCO212.2256.4945.73H+trace0.00traceOH-0.0010.000.001HCO3-42477.70.0042477.7NH34.7960.0014.796NH4+12557.20.0012557.2HSO3-0.0010.000.001SO32-0.0930.000.093表4-15 M0201结晶器前后物流结果表项目进料流股出料流股温度00压力bar11气相分率00摩尔流量kmol/hr3244.182595.92质量流量kg/hr88400.288400.2体积流量cum/hr66.67567.791焓Gcal/hr-264.542-268组分流量kg/hrH2O33354.333358.1N20.3810.381SO2tracetraceCO25.7315.119H+tracetraceOH-0.0010.001HCO3-42477.72896.05NH34.7968.429NH4+12557.2856.166HSO3-0.0010.002SO32-0.0930.092NH4HCO30.0051265.9表4-16 S0201分离器前后物流结果表项目进料流股出料流股出料流股温度000压力bar111固相分率0.2501摩尔流量kmol/hr2595.921947.44648.478质量流量kg/hr88400.237134.451265.9体积流量cum/hr67.79110.31532.324焓Gcal/hr-268-136.728-131.738组分流量kg/hrH2O33358.133358.10.001N20.3810.381traceSO2tracetracetraceCO215.11915.111traceH+tracetracetraceOH-0.0010.001traceHCO3-2896.052898.06traceNH38.4298.426traceNH4+856.166856.17traceHSO3-0.0020.002traceSO32-0.0920.092traceNH4HCO351265.90.0051265.9表4-17 碳铵冷却结晶工段总物料衡算项目进料流股出料流股流股信息脱硫烟气氨法脱硫残余液亚硫酸铵溶液废气副产品-碳铵废气温度-49.945.690-4000压力bar11.0131.013111气相分率100101固相分率000010摩尔流量kmol/hr26521.77908.555513.1525469.1648.4781947.44质量流量kg/hr7905171678701034476653351265.937134.4体积流量cum/hr490816148.84310432410.315焓Gcal/hr-384.309-567.168-368.957-324.611-131.738-136.728组分流量kg/hrH2O11229.312060994706109.3950.00133358.1N26202808.6770.001620286trace0.381SO20.001trace0.001tracetracetraceCO215503090.6998.852146137trace15.111H+0.00tracetrace0.00tracetraceOH-0.000.0290.0810.00trace0.001HCO3-0.0030933880.3110.00trace2898.06NH33977.74447.0041047.090.064trace8.426NH4+0.0011200.82215.870.00trace856.17HSO3-0.0033.041486.2050.00trace0.002SO32-0.004547.624099.990.00trace0.092NH4HCO3-51265.9-4.4 牛磺酸合成工段图4-3 牛磺酸合成工艺示意图由工艺示意图可知，牛磺酸合成工段包括反应器、换热器、闪蒸罐和结晶器等重要单元过程，需要对它们进行物料衡算。表4-18 E0302换热器前后物流结果表项目进料流股出料流股温度122.5150压力bar55气相分率11摩尔流量kmol/hr8484质量流量kg/hr3700.473700.47体积流量cum/hr530.828571.852焓Gcal/hr-0.956-0.919组分流量kg/hrC2H4O3700.473700.47表4-19 E0301换热器前后物流结果表项目进料流股出料流股温度90.1150压力bar55气相分率00.234摩尔流量kmol/hr5513.155527.67质量流量kg/hr103444103444体积流量cum/hr104.1748979.65焓Gcal/hr-368.945-349.897组分流量kg/hrH2O9470694967.8N20.0010.001SO20.0019.616CO28.879641.621H+trace0.001OH-0.0810.02HCO3-880.2723.004NH31047.492130.47NH4+2215.451068.41HSO3-488.0784453.28SO32-4098.14170.186表4-20 R0301牛磺酸反应器前后物流结果表项目进料流股进料流股出料流股温度150150150压力bar555气相分率0.23410.243摩尔流量kmol/hr5527.67845568.95质量流量kg/hr1034443700.47107145体积流量cum/hr8979.65571.8529638.59焓Gcal/hr-349.897-0.919-341.778组分流量kg/hrH2O94967.80.0095741.8N20.0010.000.001SO29.6160.0014.794CO2641.6210.00643.461H+0.0010.000.001OH-0.020.000.003HCO3-3.0040.000.452NH32130.470.001438.8NH4+1068.410.001028.15HSO3-4453.280.001144.06SO32-170.1860.001.416C2H4O0.003700.471813.01C2H6NO3S0.000.005318.83表4-21 E0303换热器前后物流结果表项目进料流股出料流股温度123.3150压力bar50.5气相分率11摩尔流量kmol/hr1818质量流量kg/hr792.957792.957体积流量cum/hr114.0151262.53焓Gcal/hr-0.205-0.196组分流量kg/hrC2H4O792.957792.957表4-22 E0304换热器前后物流情况表项目进料流股出料流股温度15090压力bar55气相分率0.2680摩尔流量kmol/hr5575.715561.34质量流量kg/hr107938107938体积流量cum/hr10348.4111.037焓Gcal/hr-353.035-372.755组分流量kg/hrH2O95935.995677N20.0010.001SO21.0690.001CO2642.64311.017H+0.001traceOH-0.0010.072HCO3-1.586877.309NH31246.77954.998NH4+10331342.03HSO3-266.20343.789SO32-4.239225.226C2H4O2121.072121.07C2H6NO3S6685.256685.25表4-23 V0301闪蒸罐前后物流情况表项目进料流股出料流股出料流股温度909090压力bar0.40.40.4气相分率010摩尔流量kmol/hr5561.345301.52277.292质量流量kg/hr1079389720910728.8体积流量cum/hr111.0563989809.795焓Gcal/hr-372.764-298.469-22.209组分流量kg/hrH2O95677929473044.82N20.0010.001traceSO20.001198.2450.005CO211643.7830.003H+trace0.000.001OH-0.0720.00traceHCO3-877.3320.000.001NH3954.9731300.010.338NH4+ 1342.060.00976.257HSO3-43.7010.0020.016SO32-225.3130.000.939C2H4O2121.072119.921.153C2H6NO3S 6685.250.006685.25表4-24 E0305换热器前后物流情况表项目进料流股出料流股温度904压力bar11气相分率00摩尔流量kmol/hr277.292277.292质量流量kg/hr10728.810728.8体积流量cum/hr9.7959.451焓Gcal/hr-22.209-22.622组分流量kg/hrH2O3044.823044.82N20.000.00SO20.0050.001CO20.0030.001H+0.0010.001OH-tracetraceHCO3-0.0010.005NH30.3380.001NH4+976.257976.614HSO3-20.01718.424SO32-0.9382.516C2H4O1.1531.153C2H6NO3S6685.256685.25表4-25 M0301结晶器前后物流情况表项目进料流股出料流股温度3.320压力bar11气相分率00固相分率00.14摩尔流量kmol/hr437.261383.404质量流量kg/hr15372.615372.6体积流量cum/hr11.2518.02焓Gcal/hr-33.958-30.286组分流量kg/hrH2O3770.073769.98N20.000.00SO216.49116.174CO20.0040.004H+80.326.05OH-tracetraceHCO3-tracetraceNH3tracetraceNH4+976.615976.615HSO3-0.1050.506SO32-tracetraceSO42-3842.593842.59C2H4O1.1531.153C2H6NO3S6685.250.00C2H7NO3S0.006739.53表4-26 S0301固液分离器前后物流情况表项目进料流股出料流股出料流股温度202020压力bar111气相分率000固相分率0.1410摩尔流量kmol/hr383.40453.852329.552质量流量kg/hr15372.66739.538633.07体积流量cum/hr8.022.15.919焓Gcal/hr-30.286-5.617-24.669组分流量kg/hrH2O3769.98trace3769.98N20.000.000.00SO216.174trace16.174CO20.004trace0.004H+26.05trace26.05OH-tracetracetraceHCO3-tracetracetraceNH3tracetracetraceNH4+976.615trace976.615HSO3-0.506trace0.506SO32-tracetracetraceSO42-3842.59trace3842.59C2H4O1.153trace1.153C2H7NO3S6739.536739.530.00C2H6NO3S0.000.000.00表4-27 牛磺酸合成工段总物料衡算项目进料流股出料流股流股信息环氧乙烷1环氧乙烷2亚硫酸铵溶液硫酸产品-牛磺酸牛磺酸合成残余液废气温度122.5123.390.110202090压力bar5551110.4气相分率1100001固相分率0000100摩尔流量kmol/hr84185513.1516053.852329.5525301.52质量流量kg/hr3700.47792.957103444156806739.538633.0797209体积流量cum/hr530.828114.015104.174-2.15.919398980焓Gcal/hr-0.956-0.205-368.945-5.617-24.669-298.469组分流量kg/hrH2O-94706720trace3769.9892947N2-0.001-0.000.000.001SO2-0.001-trace16.174198.245CO2-8.879-trace0.004643.783H+-trace80trace26.050.00OH-0.081-tracetrace0.00HCO3-880.272-tracetrace0.00NH3-1047.49-tracetrace1300.01NH4+-2215.45-trace976.6150.00HSO3-488.078-trace0.5060.00SO32-4098.14-tracetrace0.00SO42-3840trace3842.592119.92C2H4O3700.47792.957-trace1.1530.00C2H7NO3S-6739.530.00-C2H6NO3S-0.000.00-4.5 硫酸铵精制工段图4-4 硫酸铵精制工艺示意图由工艺示意图可知，硫酸铵精制工段包括换热器、闪蒸罐和结晶器等重要单元过程，需要对他们进行物料衡算。表4-28 E0401换热器前后物流情况表项目进料流股出料流股温度2087.6压力bar0.30.3气相分率00.316固相分率00摩尔流量kmol/hr329.552329.552质量流量kg/hr8633.078633.07体积流量cum/hr5.91910376.1焓Gcal/hr-24.669-23.394组分流量kg/hrH2O3769.983770.09N20.000.00SO226.0516.5