6 1-附录1-物料衡算

惠州炼化年产11万吨甲基丙烯酸甲酯项目设计物料衡算惠州炼化11万吨甲基丙烯酸甲酯/年项目设计 物料衡算广东石油化工学院烯时代 第26页2018“东华科技-陕鼓杯”第十二届全国大学生化工设计竞赛惠州炼化年产11万吨甲基丙烯酸甲酯项目设计物料衡算参赛学校： 广东石油化工学院 参赛团队： 烯时代团队 参赛队员： 黄小婵 刘洪彬 凌高业 黄健敏 林金鸿 指导老师： 陈辉、黄燕青 完成时间： 2018.3-2018.8 目录物料衡算11.1概述11.2物料衡算的意义11.3物料衡算遵循的原则11.3物料衡算的步骤21.4项目物料衡算31.4.1车间总物料衡算41.4.2各单元物料衡算6惠州炼化年产11万吨甲基丙烯酸甲酯项目设计物料衡算物料衡算1.1概述物料衡算是确定化工生产过程中物料比例和物料转变的定量关系的过程，是化工工艺计算中最基本、最重要的内容之一。在化学工程中，设计或改造工艺流程和设备，了解和控制生产操作过程，核算生产过程的经济效益，确定主副产品的产率，确定原材料消耗定额，确定生产过程的损耗量，便于技术人员对现有的工艺过程进行分析，选择最有效的工艺路线，确定设备容量、数量及主要尺寸，对设备进行最佳设计以及确定最佳操作条件等都要进行物料衡算。毫不夸张地说，一切化学工程的开发与放大都是以物料衡算为基础的。1.2物料衡算的意义物料衡算，是在已知产品规格和产量前提下算出所需原料量、废品量及消耗量。同时，还可拟定出原料消耗定额，并在此基础上做能量平衡计算。通过物料衡算可算出：（1）实际动力消耗量；（2）生产过程所需热量或冷量；（3）为设备选型、决定规格、台数（或台时产量）提供依据；（4）在拟定原料消耗定额的基础上，可进一步计算日消耗量，每小时消耗量等设备所需的基础数据。综上所述，物料衡算是紧密配合车间生产工艺设计而进行的，因此，物料衡算是工艺设计过程的一项重要的计算内容。1.3物料衡算遵循的原则物料衡算的理论基础是质量守恒定理。它是研究某一体系内进出的物料量及组成的变化情况。进行物料衡算时，必须先确定衡算的体系。对一般体系，均可用如下表示：系统中的积累输入输出生成消耗在稳定状态下有：输入输出生成消耗特别地，当系统没有化学反应时，则可简化为：输入输出1.3物料衡算的步骤（1）确定物料衡算范围，画出物料衡算示意图，注上与物料衡算有关的数据。物料衡算示意图如下：加工设备合格产品废品+损耗（2）说明计算任务。如：年产量、年工时数等；（3）选定计算基准。生产上常用的计算基准有：单位时间产品数量或单位时间原谅投入量，如：kg/h、件/h、t/h（连续操作常采用此种基准）；加入设备的原料量（间歇操作常采用此种基准）。（4）由已知数据，根据下列公式进行物料衡算：G1=G2+G3式中：G1进入设备的物料量总和；G2离开设备的正品量和次品量总和；G3加工过程中物料损失量总和；（5）收集数据资料。一般包括以下方面：年生产时间：连续生产300350d间歇生产200250d；连续生产时，年生产的天数较多，在300d左右，其他时间将考虑全长检修，车间检修或5%10%意外停机。当间歇生产时，就要减去全年的休息日，目前为双休日加上法定假日全年约为110d，所以间歇生产比连续生产少110个工作日。总之，确定了每年有效地工作时数后就能正确定出物料衡算的时间基准，算出每小时的生产任务，进而在以后的计算中选定设备的规格具体的选择天数要通过分析得出。有关定额、合格率、废品率、消耗率、回收率等。在任何一个产品加工过程中，合格产品都不是百分之百。由于设备原因、原材料原因以及人为原因都可能造成废品的出现。加工不同的产品出现废品的几率有差异，要具体情况具体分析。才外还应考虑车间管理水平、设备先进水平等，取高值与低值都应有充分的论据。经过电铲研究后发现：塑料制品合格率为85%95%、自然损耗率为0.1%0.15%，这主要是贮存、运输、加工前的消耗。回收率则应根据具体情况（如：原料品种或制品情况等）考虑，但又不可能百分之百的回收再利用，所以，回收率一般在80%90%，而回收利用率小于原料的10%。（6）物料衡算结果应列成物料衡算汇总表，必要时画出物料衡算图。1.4项目物料衡算拟建项目以抽余碳四液为原料，经原料预处理工段、异丁烯生产MMA工段、MMA精制工段、甲醇回收工段四个工段后得到聚合级MMA产品，以下将对四个工段进行物料衡算。1.4.1车间总物料衡算表1.4.1.1 车间总物料衡算表1（进料）ITEMIN010101030103102020203020402050217022403030306Temperature C56586025252510125252525Pressure bar171781.051.0131.0131.0131.2411.0131.013Vapor Frac00001110100Total Flow kmol/hr492.6813050.74449.95810307.9162064344258176.021848116.045550.846Total Flow kg/hr277785496090018570057819.82311007.5874647.9425640.124498.93210000100000Mass Flow kg/kmol482952.384Total Flow cum/hr50.79457.1590.938186.82950501.7198412.1497854.3567.11321021.09915.206100000Mass Flow00H2O054960900185700004647.9420000SDX1944.460000000000FDX2500.020000000000ZDW3055.580000000000ZDX6944.50000000000IB12500.10000000000YDW833.340000000000SDC00000000000N2000057819.82300018529.23600O20000011007.587005969.69600MAL00000000000JC00000005640.1000MMA00000000010000100000ZJW00000000000表1.4.1.2 车间总物料衡算表2（出料1）ITEMOUT0102011201150118020102220223Temperature C57.540105.656137.21615.0105.38025.392103.903Pressure bar6.971.245.182.550.9711.17Vapor Frac0000110Total Flow kmol/hr330.5312777.955294.9397.2822255.12813.98310675.460Total Flow kg/hr17826.66650061.3275750.02223063850.041435.673192477.5Mass Flow kg/hr330631.229Total Flow cum/hr32.10354.8826.7760.29053828.026346.406210.680Mass FlowH2O403.69950040.6010.90087.504376.8671.636192121.025SDX1847.6941.81E-097.3E-0881.88514.7130.0407.3E-18FDX2457.4466.2E-102.3E-0826.35516.0500.0435.5E-18ZDW3055.5807.2E-161.2E-137.1E-060.00022.4E-073.0E-24ZDX6881.0415.4E-101.2E-080.08762.6690.2021.2E-17IB2347.3872.2E-111.3E-057.702287.8560.7493.6E-17YDW833.3401E-181.5E-162.3E-138.0E-078.2E-102.6E-27SDC0.47920.7260.10026.4672.4E-113.3E-084.3E-11N2000057522.623270.6393.8E-15O200005567.87369.3345.0E-13MAL00001.37850.4230.00017JC0000042.506356.375MMA0000000ZJW0000000表1.4.1.3 车间总物料衡算表3（出料2）ITEMOUT0305031703200321041504160418Temperature C5049.46367.817114.577181.632162.291137.946Pressure bar10.970.971.5410.4215.979.97Vapor Frac1000000Total Flow kmol/hr769.2651705.457154.5415676.28729.3439.259Total Flow kg/hr21976.80410862.697476.30515472102833.028531.521168.8Mass Flow kg/hr152321.155Total Flow cum/hr20672.86615.9850.75118.641124.8430.6280.194Mass FlowH2O00.09304.2E-12102057.3780165.792SDX0.127000000FDX0.127000000ZDW4.1E-07000000ZDX0.500000000IB1.734000000YDW1.0E-0900002.1E-050SDC03.8E-1200000N218555.797000000O23418.51702.3E-06003.5430MAL08.7E-071.6E-087.5E-07400.1160.3651.938JC00.0006742.3577.5E-1483.9760.1280.868MMA00.026433.94715470.330291.5480.00060.181ZJW00.88001.6700001.4.2各单元物料衡算拟建项目一共有原料预处理单元、MMA产品生产单元、MMA精制单元、甲醇回收单元四个单元。以下将对其进行确切的物料衡算。1.4.2.1原料预处理单元原料预处理单元主要包括异丁烯水合反应器、异丁烯水合反应精馏塔、叔丁醇分离塔、叔丁醇催化精馏塔、异丁烯精制塔等。表1.4.2.2.1 原料预处理单元进出口物料衡算表1（进料）ITEMIN0101010301031Temperature C565860Pressure bar17178Vapor Frac000Total Flow kmol/hr492.6813050.74449.958Total Flow kg/hr2777854960900Mass Flow kg/hr83638Total Flow cum/hr50.79457.1590.938Mass FlowH2O054960900SDX1944.4600FDX2500.0200ZDW3055.5800ZDX6944.50000IB12500.100YDW833.34000SDC000N2000O2000MAL000JC000MMA000ZJW000表1.4.2.2.2 原料预处理单元进出口物料衡算表2（出料）ITEMOUT01020112011501170118Temperature C57.540105.654137.2162.94915.010Pressure bar6.971.245.181.472.55Vapor Frac00010Total Flow kmol/hr330.5312777.955294.939174.2527.282Total Flow kg/hr17826.66550061.3175750.0219770.000230.000Mass Flow kg/hr83638Total Flow cum/hr32.10354.8826.7762601.0060.290Mass FlowH2O403.69950040.6005173.2073.22987.504SDX1847.6941.8E-090.000414.88081.885FDX2457.4466.2E-100.000116.21926.357ZDW3055.5807.2E-167.1E-100.00027.1E-06ZDX6881.0415.4E-107.3E-0563.3710.087IB2347.3872.2E-110.0779672.3007.702YDW833.3401.0E-188.7E-138.0E-072.3E-13SDC0.47920.726576.7362.1E-0526.467N200000O200000MAL00000JC00000MMA00000ZJW00000表1.4.2.2.3 异丁烯水合反应器R0101ITEMR0101INOUT01060107Temperature C41.85860Pressure bar1717Vapor Frac0.24600Total Flow kmol/hr3543.4253406.087Total Flow kg/hr8273882738Mass Flow kg/hr8273882738Total Flow cum/hr374.676100.226Mass FlowH2O5496052485.826SDX1944.461944.46FDX2500.022500.020ZDW3055.583055.580ZDX6944.56944.500IB12500.14794.430YDW833.340833.34SDC010179.844表1.4.2.1.4 异丁烯水合反应精馏塔T0101ITEMT0101INOUT01031010801020109Temperature C6059.9957.54140.63Pressure bar8156.977.99Vapor Frac0000Total Flow kmol/hr49.9563406.087330.5313081.953Total Flow kg/hr9008273817826.765811.3Mass Flow kg/hr8363883638Total Flow cum/hr0.938100.22432.10380.888Mass FlowH2O90052485.826403.69952197.362SDX01944.461847.69496.766FDX02500.020012457.44642.574ZDW03055.5803055.5800.0002ZDX06944.56881.04163.459IB04794.4302347.3872.939YDW0833.34833.3408.025SDC010179.8440.47913408.235表1.4.2.1.5 叔丁醇分离塔T0102ITEMT0102INOUT011001110112Temperature C140.62570.129105.654Pressure bar7.9900.9701.240Vapor Frac000Total Flow kmol/hr3081.953303.9982777.955Total Flow kg/hr65811.33515750.02150061.314Mass Flow kg/hr65811.33565811.335Total Flow cum/hr80.88820.63854.882Mass FlowH2O52197.3612156.75750040.600SDX96.76696.7661.8E-09FDX42.57442.5746.2E-10ZDW0.00020.00027.2E-16ZDX63.45963.4595.4E-10IB2.9392.9392.2E-11YDW8.0E-078.02E-071.0E-18SDC13408.23513387.52620.726表1.4.2.1.6 叔丁醇催化反应精馏塔T0103ITEMT0103INOUT011301160115Temperature C70.33742.310137.216Pressure bar5.2904.9705.180Vapor Frac000Total Flow kmol/hr303.998181.534294.939Total Flow kg/hr15750.021100005750.021Mass Flow kg/hr15750.02115750.021Total Flow cum/hr20.64517.5246.776H2O2156.75790.7335173.207SDX96.76696.7650.0004FDX42.57442.5740.0001ZDW0.00020.00027.1E-10ZDX63.45963.4597.354E-05IB2.9399680.0010.077SDC13387.52626.467576.736表1.4.2.1.7 异丁烯精制塔T0104ITEMT0104INOUT011601170118Temperature C42.3102.94915.010Pressure bar4.971.472.55Vapor Frac010Total Flow kmol/hr181.534174.2527.282Total Flow kg/hr100009770230Mass Flow kg/hr1000010000Total Flow cum/hr17.5242601.0060.290Mass FlowH2O90.7333.22987.504SDX96.76514.88081.885FDX42.57416.21926.355ZDW0.00020.00027.1E-06ZDX63.45863.3710.087IB9680.0019672.37.702YDW8.0E-078.0E-072.338E-13SDC26.4662.1E-0526.4671.4.2.2异丁烯催化氧化生产MMA工段物料衡算MMA产品生产工段主要包括异丁烯催化氧化反应器、甲基丙烯醛氧化酯化反应器等。表1.4.2.2.1 生产MMA进出口物料衡算表1（进料）ITEMIN01170202020302040205MEOH0224Temperature C2.9492525251012525Pressure bar1.471.051.0131.0131.0131.241.000Vapor Frac1011101Total Flow kmol/hr174.25210307.9162064344.000258372.419848Total Flow kg/hr977018570057819.82311007.5874647.94211933.13024498.932Mass Flo kg/hr305377.414Total Flow cum/hr2601.006186.82950501.7198412.1497854.35615.05021021.099Mass FlowH2O3.229185700004647.94200SDX14.880000000FDX16.219000000ZDW0.0002000000ZDX63.371000000IB9672.300000000YDW8.0E-07000000SDC2.1E-05000000N20057819.82300018529.236O200011007.5870.00005969.696MAL0000000JC0000011933.1300MMA0000000ZJW0000000表1.4.2.2.2 生产MMA进出口物料衡算表2（出料）ITEMOUT0201022202230304Temperature C5.38025.392103.90350Pressure bar0.9701.0001.1701Vapor Frac1100.960Total Flow kmol/hr2255.12813.98310675.4601343.673Total Flow kg/hr63850.031435.572192477.40148614.411Mass Flo kg/hr305377.414Total Flow cum/hr53828.026346.410210.68033439.233Mass FlowH2O376.8691.636192121.0253758.887SDX14.7130.0407.37E-180.127FDX16.0500.0435.54E-180.127ZDW0.00022.E-073.0E-244.2E-07ZDX62.6690.2021.2E-170.501IB287.8560.7493.6E-171.734YDW8.0E-078.3E-102.6E-271.0E-09SDC2.4E-113.3E-084.3E-112.1E-05N257522.623270.6393.8E-1518555.797O25567.87369.3345.0E-133418.517MAL1.37850.4230.000169405.607JC042.506356.3756385.456MMA00016087.658ZJW0000表1.4.2.2.3 异丁烯催化氧化反应器R0201ITEMR0201INOUT02070208Temperature C42.409460Pressure bar1.0131.013Vapor Frac0.9921Total Flow kmol/hr2840.2512840.251Total Flow kg/hr83245.35283245.352Mass Flow kg/hr83245.35283245.352Total Flow cum/hr72871.639170900.221Mass FlowH2O4651.1717663.577SDX14.88014.8801967289045FDX16.219361081513616.2193610815135ZDW0.00020.0002ZDX63.37163.371IB9672.300290.339YDW8.0E-078.01E-07SDC2.2E-052.2E-05N257819.82357819.823O211007.5875656.941MAL011720.200JC00MMA00ZJW00表1.4.2.2.4 MAL氧化反应器R0202ITEMR0202INOUT02260301Temperature C50.242110Pressure bar11Vapor Frac11Total Flow kmol/hr1424.0171343.673Total Flow kg/hr48614.41148614.411Mass Flow kg/hr48614.41148614.411Total Flow cum/hr38084.58342668.425Mass FlowH2O864.0473758.887SDX0.1270.127FDX0.120.127ZDW4.1E-074.1E-07ZDX0.5000.500IB1.7341.734YDW1.0E-091.0E-09SDC2.2E-052.1E-05N218555.79718555.797O25989.4303418.517MAL11668.400405.607JC11534.2486385.456MMA016087.658ZJW00表1.4.2.2.5 MAL水吸收塔T0201ITEMT0201INOUT0202021102010212Temperature C251105.38049.428Pressure bar1.0501.2300.9701.240Vapor Frac0110Total Flow kmol/hr10307.9162840.2522255.12810893.040Total Flow kg/h35263850.031205095.321Mass Flow kg/hr193363.577193363.577Total Flow cum/hr186.82973510.61753828.026214.404Mass FlowH2O185700.0007663.577376.869192986.708SDX014.88014.7130.167FDX016.21916.0500.170ZDW0006.63E-07ZDX063.37162.6690.703IB0290.339287.8562.483YDW08.0E-078.0E-071.8E-09SDC02.2E-052.4E-112.2E-05N2057819.82357522.623297.200O205656.9415567.87389.068MAL011720.2001.37811718.823JC0000MMA0000ZJW0000表1.4.2.2.6 共沸精馏塔T0202ITEMT0202INOUT0219022002220223Temperature C26.39925.39225.392103.903Pressure bar1.240111.170Vapor Frac0010Total Flow kmol/hr11265.460576.01713.98310675.460Total Flow kg/hr217028.45124115.478435.572192477.401Mass Flow kg/hr217028.451217028.451Total Flow cum/hr224.66429.411346.410210.680Mass FlowH2O192986.708864.0471.636192121.025SDX0.1670.1270.0400FDX0.1700.1270.0430ZDW0000ZDX0.7030.5010.2020IB2.4831.7340.7490YDW0000SDC0000N2297.20026.561270.6390O289.06819.73369.3340MAL11718.82311668.40050.4230JC11933.13011534.24842.506356.375MMA0000ZJW00001.4.2.3MAA精制工段物料衡算表1.4.2.3.1 MMA精制工段进出口物料衡算表ITEMINOUT0303030603070316031703200321Temperature C25255013049.46367.817114.577Pressure bar1.0131.01314.3900.9700.9701.540Vapor Frac0000000Total Flow kmol/hr116.0405550.844574.4085911.2871705.459154.541Total Flow kg/hr1000010000026637.607109826.51810862.784476.30515472.000Mass Flow kg/hr136637.607136637.210Total Flow cum/hr15.206100.60830.091126.65215.9850.75118.641Mass FlowH2O01000003758.887102750.6551008.2321.1E-054.2E-12SDX0000000FDX0000000ZDW0000000ZDX0000000IB0000000YDW0000000SDC002.2E-052.2E-054.2E-0800N20000000O20000000MAL00405.607405.59702.4E-067.5E-07JC006385.4566378.2097.2461.6E-087.5E-14MMA0016087.658291.856283.11442.35715470.330ZJW10000000.00069563.984433.9471.670表1.4.2.3.2 MMA萃取塔T0301ITEMT0301INOUT03110312031303140315Temperature C25.03950.12325.330139.40898.055Pressure bar44.184.364.3903.970Vapor Frac00000Total Flow kmol/hr5550.843574.408116.0405911.287330Total Flow kg/hr10000026637.60710000109826.71826810.889Mass Flow kg/hr136637.607136637.607Total Flow cum/hr100.61130.09715.213128.24636.302Mass FlowH2O1000003758.8870102750.6551008.232SDX00000FDX00000ZDW00000ZDX00000IB00000YDW00000SDC02.1E-05000N20002.1E-054.2E-08O200000MAL0405.6070405.5970.010JC06385.45606378.2097.246MMA016087.6580291.85615795.802ZJW00100000.0019999.602表1.4.2.3.3 正己烷回收塔T0302ITEMT0302INOUT031503170318Temperature C98.05549.463108.593Pressure bar3.9700.9701.45Vapor Frac000Total Flow kmol/hr330170160Total Flow kg/hr26810.88910862.68415948.205Mass Flow kg/hr26810.88926810.889Total Flow cum/hr36.30215.98519.263Mass FlowH2O1008.2321008.2321.1E-05SDX000FDX000ZDW000ZDX000IB000YDW000SDC04.2E-088.2E-12N24.2E-0800O2000MAL0.01003.1E-06JC7.2467.2461.6E-08MMA15795.802283.11415512.687ZJW9999.6029563.984435.618表1.4.2.3.4 MMA精制塔T0303ITEMT0303INOUT031903200321Temperature C5067.817114.577Pressure bar1.450.9