设计文档2010设计文档0-Abstract

镇海炼化5.2万吨/年甲基丙烯酸甲酯生产项目AbstractDirectory1. project Introduction12. Process Design23. energy-saving design43.1 Heat exchange network optimization43.2 Rankine cycle43.3 Heat pump technology64. equipment design84.1 Application of ADV differential float valve84.2 The use of clean energy core95. Clean production106. site selection117. The factory layout128. economic analysis149. project summary15151. project IntroductionThis project is to establish a 52,000 ton methyl methacrylate branch factory for zhenhai refining of sinopec. In this project, the high purity methyl methacrylate was produced by two steps of isobutylene oxidation using the extraction of residual C4 from the main plant. This project is divided into three sections, namely the spare C4 pretreatment section, MAL synthesis section and MMA synthesis and refining section. In addition to the main products MMA also include n-butane, 2-butene and other high value-added products. The product structure is shown in table 1-1 below.Table 1-1 product structure tablenumberThe product nameunitproductionpurity(%)1MMATen thousand tons/year5.299.902n-butaneTen thousand tons/year1.199.6632 - buteneTen thousand tons/year2.799.294isobutylene isobutene MixTons/year3556.6696.642. Process DesignThe process flow chart of this project is as follows:FIG. 2-1 process flow chartFrom the storage tank to trace hydrogen and the factory to the raffinate C4 after heat exchange after the butadiene into the reaction rectification tower T0101, under the catalysis of hydrogen and the catalyst will be 1 - butylene into 2 - butene, converting the anti - 2 - butene to shun - 2 - butene. Then isobutane iso-butene is removed from the top of the tower, and n-butane and 2-butene are removed from the bottom of the tower.(1) separation of n-butane and 2-buteneThe mixture of n-butane and 2-butene from the bottom of T0101 tower was decompressed by pressure relief valve. After the heat exchanger, the mixture was vaporized and passed into the adsorption fixed bed, and 2-butene was separated from n-butane.(2) separation of isobutane and isobuteneThe mixture of isobutene and isobutane from the top of T0101 tower is separated from isobutane by NPM extraction agent into T0102 extraction distillation column. Isobutane at the top of the column can bottom and isobutylene and NMP extraction solvent mixture into the solvent recovery after heat exchange tower T0103 extraction separation, the tower isobutylene production into the next section, bottom extractant in T0102 again after heat transfer.(3) Rankine cycleTrifluoropropane is heated and gasified by the mixture of extractant and isobutylene from the booster pump and the bottom of T0102 tower. Then work is done outwards through the turbine.Since T0103 of isobutylene is mixed with air, water, ventilation with fixed bed after pass into the heat exchanger after preheating R0201 tube and tubular plate in tubular reactor, the reaction of isobutylene and water generated MAL, after leaving the reactor by quench boiler into low pressure steam produced utilities in the network, and through the compressor pressurized heat after entering water absorption tower T0201, water will be MAL absorption, not at the top of the column can reaction of isobutylene and a large number of concentrated combustion air back to the factory, the bottom MAL aqueous solution and methanol into the azeotropic distillation with T202, methanol and MAL azeotropic from entering the next section at the top of the column can Water is extracted from the bottom of the tower for water integration.From the last section of the mixture of methanol and MAL after compression, mixed with methanol heated to 80 , and 80 degrees Celsius air R0301 tong state into the slurry bed reactor, respectively, by gas liquid separator gas-liquid separation, exhaust gas back to factory focus on. Liquid mixed with water bubbled into the rectifying column T0301, water and MMA in bottom out, top gas liquid extraction and gas in the gas liquid separator and gas back to send factory focus on combustion, liquid ventilation with methanol solution from the device, access to recovery methanol R0301, remaining back to the main plant burning; The liquid is shunted into T0202 and R0301. MMA and water at the bottom of the tower enter into the static stratification of the storage tank. After the upper MMA is harvested, the product is obtained by passing into the membrane separation device for refining MMA, and T0301 is introduced after the lower water is extracted.3. energy-saving design3.1 Heat exchange network optimizationIn this project, the heat exchange network was optimized, and lanken cycle and heat pump technology were added for energy-saving design.Figure 3-1. Heat transfer network diagram after optimizationTable 3-1 list of optimized energy-saving effectprojectThermal utilityCold utilityBefore heat exchange network optimization3.0231083.245108The heat exchange network is optimized2.0161082.239108Percentage savings33.3%31.0%3.2 Rankine cycleThe organic Rankine cycle usually consists of four parts: pump, evaporator, turbine and condenser, as shown in figure 3. After cooling medium cooling medium through the pump to the evaporator (process), and the heat source fluid after heat exchange become saturated steam or superheated steam (process), the steam into the expansion drive turbine expander is expelled after work, then after entering the condenser and cooling medium heat into liquid medium (process), and then by the pump input system, so cycle, realize the heat into useful work.The organic Rankine cycle is shown in figure 3-2 below.Fig.3-2 organic Rankine cycle diagramThe Aspen Plus process simulation is shown in figure 3-3:Logistics has a lot of calories 122 , 0127 belong to the low temperature heat source, can be recycled. Three fluorine propane as an organic working medium by the turbine D0101, all through the condenser E0111 condensation, P0104 after booster pump to pressurize, E0105 into the evaporator and heat exchange, low heat for superheated steam gasification, avoid condensation out part of the droplets in the pipeline, impact turbine. The high pressure superheated steam drives the turbine to generate electricity through the expansion and pressure lowering and cooling of turbine D0101, completing a cycle.The simulation results of turbine are shown in table 3-2below.Table 3-2 results of turbine simulationprojecttemperature /Pressure /barRate of gasification /%power /KwCirculating trifluoropropane imports95.48101263.13Circulating trifluoropropane outlet64.65213.3 Heat pump technologyThe starting point of heat pump rectification is to improve part of the energy grade in the rectification process for its own reboiler heater. Consulting relevant literature, according to the different energy consumed by a heat pump, heat pump distillation is divided into vapor compression heat pump and the absorption heat pump distillation, depending on the compressor working medium, vapor compression heat pump is divided into overhead vapor compression type directly, bottom liquid flash type and indirect steam compression type three types. Vapor compression heat pump distillation structure can be used for the following process: usually smaller column overhead and bottom temperature difference, difficult separation system of the separated material near the boiling point, low pressure distillation tower products need to use a refrigerant condensing system, etc.Reaction distillation column top temperature in the design of this project are: 55 , bottom temperature for; Temperature of 12 67 , temperature difference is small, can set up the overhead vapor compression heat pump heating up as heat source of bottom reboiler, eliminating reboiler and condenser, save energy. The following table shows the data obtained after the energy consumption analysis before and after setting up the heat pump through Aspen Plus software. It can be seen from the calculation that the energy consumption of setting up the heat pump is about 86.82%. Therefore, it is recommended to set up heat pump for reactive distillation column in the actual production process to achieve the purpose of energy saving.The comparison between heat pump and heat pump is shown in figure 3-4.Figure 3-4 comparison diagram of heat pump with or without heat pump4. equipment design4.1 Application of ADV differential float valveThe new design of adv-differential floating valve tray, in addition to adopting adv-floating valve, has adopted the following improvement measures:(1) new type of downflow pipe: the new type of downflow pipe can effectively reduce the receiving area, thus increasing the area of bubbling zone and increasing the capacity of tray handling.(2) bubble booster: improve the uniformity of bubble and strengthen gas-liquid contact, so as to reduce fluid leakage.(3) new plate-plate connection mode: improve the evenness of floating valve arrangement, increase the maximum opening rate of the plate-plate, and improve the installation speed of the plate-plate.The new designed advan-floating valve tray further optimizes the flow and contact state of gas-liquid two-phase on the tray, thus further improving the handling capacity and separation efficiency of the tray.FIG. 4-1 a schematic diagram of ADV differential float valve4.2 The use of clean energy corePower is one of the most energy-consuming industries, and it is also an industry with huge tasks and potential of energy conservation and emission reduction. Making full use of efficient heat exchange technology and equipment in the production process of thermal power generation is an important way to improve energy efficiency and realize energy saving and emission reduction. Therefore, research, development and application of efficient heat transfer technology and equipment must be further strengthened to ensure the realization of the strategic goal of energy conservation and emission reduction. The problem of heat transfer degradation caused by low heat transfer efficiency and fouling and scaling of heat transfer surface area is a difficult problem in the heat transfer process that has not been solved for many years in the world, and also a bottleneck problem that restricts the high energy consumption industries such as chemical industry to improve the utilization rate of energy consumption. Considering the above factors, clean energy core is used in the ammonia decarburization section heat exchanger in this project.Clean energy core is a high-tech product initiated by Beijing university of chemical technology in the world with remarkable efficiency in energy conservation and consumption reduction. The clean energy core can be directly installed in the heat transfer tube, which can effectively solve the problem of low efficiency of the shell-and-tube heat exchanger without changing the structure of the heat exchanger. The main technical features of the cleaning energy core are: automatic cleaning and enhanced heat transfer online dual functions; The air conditioner has a self-regulating function to avoid scratching the pipe wall and ensure the safety of the heat exchanger. Shou has high efficiency, high reliability and other advantages, energy saving and consumption reduction, huge benefits; Jieyang has strong adaptability and can be used in various working conditions of heat transfer medium from low flow rate to high flow rate. The rotational speed of the clean energy core determined by the structure of the vessel is only related to the flow rate of medium, is not limited by the length of the heat exchanger, and can be adapted to the bending of the heat exchanger. It is made of macromolecular material, with features of self-lubrication, corrosion resistance, wear resistance, high temperature resistance and aging resistance. The flow resistance of medium is not obviously increased, which is completely within the allowable scope of the project. The utility model has the characteristics of simple installation and does not require any changes to the structure of the original heat exchanger equipment.5. Clean productionIn order to ensure orderly, clean production environment, and meet the requirements of special process parameters to the environment, make plant resources get reasonable configuration and reasonable use, so as to achieve factory quality policy and objectives, the project design attaches great importance to the factory and the protection of the surrounding environment.This project in the whole process in gas-liquid separator, membrane separation device, produce a large amount of waste gas molecular sieve dehydration, 33231.5437 kg/hr, its main ingredients for the O2, N2, CO2, and a small number of alkane olefin.The waste gas produced by several devices is sent directly back to the incinerator of the main plant for burning and recycling.This project in the whole process in azeotropic rectification tower, gas-liquid separator, produce large amounts of waste liquid phase separation tank, 10460.817 kg/hr, most of them are water, there is a small amount of MMA, n-butane, carbon dioxide, etc. The waste water will be recycled into water for recycling.The waste solid produced by this project is mainly the failure catalyst, the production packaging and the household garbage. The catalyst yield of Pd5Bi2PbFe/CaCO3 was 0.232t/a, that of MoBiFeCoCe was 5.452t/a, and that of Ni/Al2O3 was 0.864t/a. The deactivated catalyst produced in this project was sent back to the manufacturer for reprocessing and continued to be used.6. site selectionNingbo chemical industry zone is located on the south bank of hangzhou bay, and on the vast sea painting on the northwest side of ningbo zhenhai district, with a planned area of 56.22 square kilometers. The terrain is flat, the water is abundant, the environment capacity is large, the natural conditions are superior, and the park provides jiutong and yiping, the supporting facilities are complete. The rapid economic development of ningbo and its surrounding areas and the construction of ningbo hangzhou bay bridge have brought unlimited business opportunities and development opportunities to the park. The park is only 14 kilometers away from ningbo city, only 24 kilometers away from beilun port, lianggang port in deep water of the east, and close to Chinas largest liquid chemical wharf. Coastal avenue, 329 state road, the future century avenue, bridge, the zhoushan islands, such as well versed in the district, with the hangzhou bay bridge is completed and the construction of railway private sidings, ningbo chemical industry area and the whole Yangtze river delta will be much closer distance.图6-1 site selection7. The factory layoutFIG. 7-1 plant layoutThe layout of the factory is rectangular, 317m long, 195m wide and 61815m2 in total.This factory area is centrally controlled according to function distribution, namely material loading and unloading area, storage facility area, process equipment area, auxiliary production area, administrative management area and other facilities area.This item the factory in the middle of a transcontinental factory main, width is 12 meters, as the main line of logistics, there are a many side on both sides of the main road, through the whole factory area, ring fire escape in production area, storage area.Inside the factory, there are guard room, fire station, distribution station, central control room, analysis room, maintenance room and public works, etc. The facilities are complete and functional.Factory in the terminal that may cause pollution, wastewater collection pool area is arranged on the upper side of the factory the minimum frequency wind, is, as far as possible to reduce the central administration building, office and other people relatively dense area of influence.The factory has four imports and exports. The east gate is the front gate of the factory area, facing the front area of the factory. It is mainly used for the commuting of company employees. The west gate and north gate are connected with the main road and are specially used for transporting goods (raw materials and products) by truck. The east gate and the west gate are fire exits and exits, close to the tank area, the production equipment area and the fire station. In case of an emergency, it is convenient for fire engines to enter and exit, so as to provide the first time fire fighting.8. economic analysisThe main sources of capital for chemical projects are equity capital, debt capital, quasi-equity capital fund and finance lease. The capital source of this project is equity capital and debt capital, and the total investment amount is RMB 710.37 million. According to the state council on adjusting project of investment in fixed assets capital ratio of the circular (guo fa (2009) 27) regulation, the chemical industry project minimum capital ratio of 20%, so the loans of 250 million yuan, the loan interest rate is 4.75%, the rest of the money by their own capital injection. Among them, the loan part through mortgaging part of the fixed assets of the factory to obtain loans; The rest will be raised by the general meeting of shareholders or allocated by the general plant, and all funds will be in place within 4 months.Table 8-1 main economic data tableNumberThe project nameunitNumberNo.1Construction scale1production MMATen thousand tons/year5.2No.2Product solutions1MMATen thousand tons/year5.22n-butaneTen thousand tons/year1.132 -