word2010设计文档集0-Design Summary

5.5108Nm3/a COG Processing ProjectDesign Summary/Design Summery/17西南石油大学Infinite目录1 Introduction of Project12. Raw Materials and Product23. Technological Process4Dynamic Control54. Equipment Design and Selection75. Control Scheme96. Energy-saving and Cost-reducing107. Site Selection and Layout12Plant Layout12Workshop & Piping Arrangement138. Safety and Environment149. Analysis of Economic1610. Project Conclusion171 Introduction of ProjectThe project is to design a sulfur-containing waste in coke oven gas (COG) as the main raw material and depth of resource-oriented utilization device. The project effectively combined with the dry process desulphurization and wet desulphurization, make full use of the coke oven gas and coal gas resources, bring about a environmental friendly and achieve the goal of deep desulfurization and using. The project process 550 million coke oven gas annual and output 247 million SNG annual, built triple falls coking park in shanxi luliang city. This team in process design, taking into account economic benefits and cleaner production, clear thinking, highlight outstanding, mainly embodied in the following aspects:1.The raw material of this project all from the coking project in the park, and the thermal power plant emissions of coal-fired flue gas, make full use of park resources, go deep into deep-desulfurization project objective.2.New technological process, combining with the dry process desulphurization and wet desulphurization, and the desulfurization decarburization integration process, realize the depth of utilization of sulfide. At the same time to depth using carbon dioxide.3.Using intermediate condensation technology, so the heat exchange between logistics, reactor innovation, heat produced a large number of low pressure steam.4.Two stage hydrogenation desulfurization, all adopt different catalyst packing, saving device, realize the removing effect. Products by using supersonic separator dehydration, high efficiency and energy saving.5.Innovation design of methanation reactor, adopt the column tube, in different feed temperature, feed dispose into two cold shock, also with high pressure saturated water to maintain constant temperature. Make full use of energy.2. Raw Materials and ProductThe main raw material of the project is coke oven gas, the capacity of process is 550 million annual, its composition is as follows:Table 2-1 the Composition of Coke Oven Gascompoundmole fractioncompoundmole fractionCO20.033CO0.087N20.00495CH40.23O20.004COS1.8610-6C2H40.028C4H82.610-6H20.613C4H4S4.910-6H2S2.4310-5The composition of adding carbon source from flue gas is as follows:Table 2-2 the Composition of Flue Gascompoundmole flow(kmol/h)compoundmole flow(kmol/h)CO20.033SO213.60H2O0.229NO1.902O2161.179N21637.35The product program is as follows:Table 2-3 Product ProgramProjectMethanol SynthesisSystem of UreaSystem of Natural GasAir Comsuption/m3h-13000030003000Sales Revenue/万元年-1264603587020870Profit/万元年-16643105607928Gas Discount/元m-30.280.700.33Project Estimation/万元456509783013830Energy Conversion/%50-82.8Energy Efficiency/%43.26-76.1ElseExcess production capacity, prices are lowExcess production capacity, price fluctuation is slightMarket demand is stable, has a grid conditionsThrough comparison for SNG was finally determined.3. Technological ProcessFigure 3-1 Product Technology RoadmapThis project adopt the hydrogenation desulfurization series zinc oxide desulfurization process groove, and fill carbon ammonia desulphurization process combining production SNG. Mainly divided into three stages: the first stage, carbon capture section;the second stage, preprocessing section of COG;the third stage, SNG production section. Main product is SNG, ammonium sulfate, and other products.Carbon capture section is divided into: flue gas purification system, barren solution regeneration system, carbon recycling system. The main process is flue gas denitration, repass decarburization desulfurization integration, will be one of the sulfur and carbon by ammonia absorption in the form of ammonium sulfate and ammonium carbonate enrichment in the bottom, then into oxidation groove, the ammonium sulfite oxidation. According to the different of ammonium sulfate and ammonium carbonate thermal decomposition temperature, by control temperature, carbon dioxide release in the form of gas adding methanation reaction of the third section. Ammonium sulfate is sent to crystallization. Absorption tower after purification gas flash isolated part of the water emptying,a quarter of the water cycle to the absorption tower, the rest sent to sewage treatment. Seven 8 of the flash off gas before ammonium sulfate crystallization absorbed through rectifying column distillation, high concentration of ammonia circulation to the absorption tower, the remaining one 8 directly back to the absorption tower, feed in different position, at the same time solve the problem of ammonia escape and absorb. Feed gas after heating up to 340 enter into hydrogenation reactor, the main choice fixed bed reactor, used for removing the organic sulfur gases in COG, the sulfur elements COS can be converted to H2S. Bed bottom filled with oxygen catalyst at the same time, to remove a small amount of oxygen in COG.After hydrogenation 320 gas, pass loading the ZnO and active carbon catalyst bed, ZnO mainly used for removal of H2S。Activated carbon is used for removing thiophene, the sulfur content of COG can dropped to 0.1 PPM by the catalyst combination, sent to the methanation reaction. After pretreatment of COG, first go through a period of methane, the isothermal tubular reactor which the bed temperature is 320 for a period of methanation, residual hydrogen containing 40% (mol) system of rich hydrogen and carbon capture section of 320 , 6 bar CO2 gas mixed into the second period of methanation reactor. By the second period of methanation reactor was out of gas, after heat exchange cooling flash twice to 30 , removing most of the water. The rest into the supersonic separator dehydration, product gas into the tank.Dynamic ControlFor the process, we take T0301 has carried on the dynamic simulation, respectively for the overhead condenser pressure respectively, the top level and column reactor to control the liquid level, the following is a dynamic control chart:Figure 3-2 the Top Pressure ControlFigure 3-3 the Top Level ControlFigure 3-4 the Kettle Level ControlFigure 3-5 the Top and Kettle Flow Graph (Green Column Reactor)By dynamic analysis above,after a certain period of time,achieve the stable value.4. Equipment Design and SelectionThis project based on Aspen Plus simulation results, we has carried on the detailed design to the process of methanation reactor R0301, ammonia tower T0103, heat exchanger E0302; including the basic equipment design parameters and the special internal component design. Using COMSOL Multiphysics simulation of methanation reactor for reaction volume and length to diameter ratio optimization, and to determine the reactor.Using SW6-2011 and KG - Tower software to process all the tower equipment of process design, basic parameter design and mechanical strength check. Using the EDR and SW6-2011 was carried out on the heat exchanger process design, selection, basic parameters design and mechanical intensity. In addition, the pump,compression engine, storage tank,liquid-vapor separator,reflux drum and so on equipment has carried on the reasonable selection.For methanation reactor as an example, the specific design as follows:Although home and abroad mainly in the coke oven gas of methane SNG technology are different, but its main idea is similar. All used in high temperature and adiabatic reactor, a few main reactor is the core of the methanation reaction processing, most of the reactions will occur in the first and second methanation reactor, thus more heat is concentrated in this. But high temperature also creates the carbonization of the catalysts, how to get the temperature down conquer methanation technology is the main problem. This design use column tubular reactor, in order to maintain methanation reaction at lower temperature range. Through COMSOL simulation, the traditional tube reactor can not meet the requirement at low temperature, we improve on the structure, increase the center tube into the feed gas shock gas, can be a very good maintain methanation reaction at low range. The reactor structure diagram as shown in figure 4-1:Figure 4-1 the Reactor Diagram5. Control SchemeIn the design of this project, first consider the normal production of the steady-state control strategy. In control system is mainly composed of DCS distributed control system, and combining with the SIS control, mainly use message feedback to control the opening of relief valves, valve flow and shows that the pressure vessel and pipeline pressure, temperature, liquid level, achieve management, decentralized control to strengthen security. Our factory production plant, utilities and auxiliary facilities use DCS collecting and distributing control system for centralized operation, control and management; In addition, in order to deal with the risk of production process may occur, the project design the SIS safety instrument system of heating furnace, SCR denitration reactor, methanation reactor, fully guarantee the use of heating furnace and reactor safety; Factory adopted the ESD emergency shutdown system at the same time, once the accident occur can be effectively controlled. The control system of choice in addition to meet the above requirements, also from SNG production scale, system input, the system performance and practicability of all-round consideration. For some key equipment, especially the tower equipment, we consider the abnormal conditions (feed flow) control, using Aspen Dynamics software for T0103 its dynamic simulation was carried out.Detailed drawing of each section in the design of the P&ID flow chart of process piping and instrument, concrete can be found in the source files and project drawings AutoCAD drawing set.6. Energy-saving and Cost-reducingThe project in order to make full use of energy, by using the Aspen Energy Analyzer software, according to the pinch design method, combined with the actual situation, carries through flow matching, and designed a kind of optimal cold heat flow matching scheme. At the same time return the optimization heat exchange network back to the process simulation and PID drawings, comparison and analysis then concluded the optimal. See the Aspen process simulation source files and PID drawings. The following is before or after a hot and cold flows heat matching scheme.Figure 6-1 Before the MatchFigure 6-2 After the MatchPlant energy saving effect shown in the table below:Table 6-1 Hot and Cold UtilitiesProjectHot Utility / kJ/hCold Utility / kJ/hHeat Exchange Unit Number /个Before the Match1.0681081.80210817After the Match6.8341071.73510820Energy Saving36.01%3.72%Other energy saving: Methanation reaction produces a large number of high pressure steam, except for the self-use, the rest was sent to the generator to generate electricity.7. Site Selection and LayoutCompany located at triple falls coking industrial park in Shanxi luliang city,the park as one of the important chemical industrial base in the development of petrochemical industry in shanxi, public facilities consummate, the cluster to internal industrial chain advantage obviously. Raw materials coke oven gas directly from the Shanxi coking coal group five Lin coal development limited liability company in the park, convenient and quick. Three wastes treatment, utilities are supporting industry supply. Park has the governments preferential policy support and technical support, pay attention to the health of the industry sustainable development.Plant LayoutThe plant layout follows the basic national policy of treasure and make rational use of every inch of land, and earnestly protect cultivated land. It adjusts measures to local conditions, economical use of land and improves the land utilization rate.We adhere to be in line with the national conditions,layout reasonably,safely produced, take advanced technology,protect environment,save investment,lower operating costs. According to the concept of separation of people and vehicles,the road is divided into traffic channel and personnel channel to reduce traffic resistance.We use the parallel arrangement,and the production area and living area in the plant area of the radial artery,so that the interaction between the two. And according to the idea of compact set,we arrange the plant construction and workshop location reasonably to achieve efficient and stable production layout. This Plants length is 360m,width is 260m,total floor area is 93600m2,mainly including administrative office and life service areas,production auxiliary area,production process area and storage area,etc.We use Auto CAD to design the plant area (the factory floor plan is as shown in Figure 7-1),and use Plant 3D, Sketch Up,Lumion,and other software to draw the 3D effect of the plant.It helps to understand the whole picture of the plant.Figure 7-1 The Factory Floor PlanWorkshop & Piping ArrangementThe project used Plant 3D software to do equipment layout and detailed piping layout of SNG sections,and determined the direction of the pipe,and the got the axonometric drawing with each pipe.In addition,we used Auto CAD software to draw the layout of the equipment.Workshop 3D layout is shown in Figure 7-2.Figure 7-2 Workshop 3D layout8. Safety and Environment 1.This project adopts the RiskSystem software carry through the major hazard identification of tank farm to the factory and production, and according to the material physical property are analyzed in the terminal material source, then according to the results from the analysis to predict pool fire accident model, boiling liquid expanding vapor explosion, vapor cloud explosion model prediction analysis of the damage range of the accident. With dow chemical fire and explosion danger index assessment the risk of major hazards.2. HAZOP analysis method is applied in this project, respectively by T0103 towers, SNG tanks, T0103 overhead condenser for the node is analyzed. Deviation may be produced according to the equipment such as feed flow rate and reflux ratio increases carry through systems analysis, according to the results of the analysis carry through an effective prediction to possible hazards and hidden dangers, research deviating from the consequences of such as: the heat transfer effect and separation effect declined etc., adopt a series of security measures, such as: liquid level indicator, feed flow control, etc., in order to realize stable control of the equipment and systems.3. ALOHA software is used in the layout to simulation the dangerous and harmful material of the damage range of the accident, general layout in strict accordance with the code for fire protection design of petrochemical enterprises etc. design specifications.4.Treatment of three wastes: The chemical reaction precipitation, oil separation, secondary gas floating, A/O biochemical process used in this project. It can effectively remove organic matter, Nh3-N and TN, and high efficiency of wastewater treatment. In order to ensure that meet the national wastewater discharge standard after biochemical treatment in biochemical treatment after flocculation precipitation and activated carbon adsorption process, in order to effectively remove suspended solids and some organic matter, reduce the COD in the wastewater. Sewage treatment facilities also have sludge treatment facilities, which can be processed by the three mud, and the final external transportation or comprehensive utilization. Process, such as 8-1 sewage after grille well to remove large particles impurities into the pool, 5000 m regulating tank by the lift pump, again by regulating tank themselves go into the advective separation tank, in the separation tank dirty oil in the wastewater is collected by dirty oil pool, by pumping into the slop tank, sludge through scraping mud system into the sludge scum pool, and then from the pump to three mud treatment system. The sewage is pumped up by the pump and then into the flotation device, where a large amount of emulsified oil is removed. The biochemical devices are composed of anoxic pool, aerobic pool, and sedimentation tank. All of them flow into the water, and from the sedimentation tank to the hypoxia pool, 200% of the nitrate liquid is returned, and the best oxygen pool has 50% 100% of the active sludge reflux. The treated sewage water can meet the standard of gb8978-1988 (new expansion) standard and GB 3351-1983 standard of the first class of coal refining industrial sewage discharge standard.Figure 8-1 Wastewater Treatment Process Flow DiagramThe catalyst is recovered and reused by the factory. No pollution from safe emissions. Furthermore, low noise equipment is used to make sound insulation, sound absorption and sound absorption. In addition, the plant is landscaping to improve the ecological balance.9. Analysis of EconomicAfter the investment evaluation and financial evaluation of the project,the plants comprehensive economic and technical indicators are shown in Table 9-1.Table9-1 Comprehensive Economic And Technical IndicatorsNumbermberIndicatorCompanyAmount1Design ScaleNm3/a5.51082Are