5-1附录一 物料衡算

中海壳牌年产11.7wt聚甲基丙烯酸甲酯项目物料衡算中山大学Triumph团队24目录1 概述12 物料衡算目的23 物料衡算原理24 物料衡算任务35 物料衡算表45.1 异丁烯水合制叔丁醇工段45.1.1 异丁烯热泵提浓塔(T0101-T0102)45.1.2 连续搅拌釜反应器(R0101-R0103)55.1.3 叔丁醇三级串联提浓塔(T0103-T0105)85.2 叔丁醇氧化制MAL工段105.2.1 叔丁醇氧化鼓泡反应器(R0201)105.2.2 中空纤维膜分离器（V0201）115.2.3 精馏塔（T0201）135.2.4 三元共沸热泵精馏塔(CHP3 T0202)135.3 MAL的直接氧化酯化工段145.3.1 甲基丙烯醛一步氧化酯化反应器(R0301)145.3.2 甲醇膜分离器(V0302、V0303)165.3.3 中空纤维膜分离器（V0301）175.3.4 间接式热泵精馏塔（T0301）195.4 MMA的聚合工段205.4.1 树脂纯化塔(T0401)205.4.2 间歇式釜反应器(R0401-R0402)215.4.3 闪蒸罐(V0401)226 附录：物质说明241 概述本项目以异丁烯为主要原料，通过催化反应合成聚甲基丙烯酸甲酯，年产量为13.8万吨。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。设计过程中利用Aspen Plus对全流程进行模拟，并在此基础上完成物料衡算、能量衡算，Aspen plus全模拟流程如图1-1至1-4所示：图1-1 异丁烯水合制叔丁醇工段图1-2 叔丁醇氧化制MAL工段图1-3 MAL的直接氧化酯化工段图1-4 MMA的聚合工段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 物料衡算原理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已知物流的流量和组成，通过建立有关物料的平衡式和约束式，求出其他未知物流的流量和组成的过程。系统中物料衡算一般表达式为：系统中的积累=输入-输出+生产-消耗可表示为：注：FIN进入系统的物料流率；FOUT流出系统的物料流率；GR反应产生物料速率；CR反应消耗物料速率。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+消耗即:FIN=FOUT-GR+CR对无化学反应的稳定过程，又可表示为：输入=输出即: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2-1所示：表2-1 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元素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。4 物料衡算任务通过对系统整体以及部分主要单元的详细物料衡算，得到主、副产品的产量，原料的消耗量，“三废”的排放量以及最后产品的质量指标等关键经济技术指标，对所选工艺路线、设计流程进行定量评述，为后阶段的设计提供依据。5 物料衡算表5.1 异丁烯水合制叔丁醇工段5.1.1 异丁烯热泵提浓塔(T0101-T0102)5.1.1.1 异丁烯热泵提浓塔甲(T0101)表5-1 异丁烯热泵提浓塔甲(T0101)物料衡算表进出口进口出口流股编号1FEED1PRO-D11PRO-B1Temperature()58.295149.8622758.41965Pressure(bar)7.266.008Mole Flow(kmol/hr)88.8292877.1869811.64375Mass Flow(kg/hr)50004342.385657.6956Volume Flow(cum/hr)9.2201877.8461911.181869Vapor Fraction5.54E-0500Liquid Fraction0.99994511Solid Fraction000Enthalpy Flow(Gcal/hr)-0.76694-0.65999-0.1331Component Mass Flow(kg/hr)NBA332.6205.8576126.7296IBA145144.99460.007159IBE2318.52313.1245.415321BE1531.51530.5051.014541C2BE201.52.014664199.50241,3BDE14.914.84390.056309T2BE456131.0455324.9702Component Mass FractionNBA0.066520.0474070.192687IBA0.0290.0333911.09E-05IBE0.46370.5326850.0082341BE0.30630.3524570.001543C2BE0.04030.0004640.3033361,3BDE0.002980.0034188.56E-05T2BE0.09120.0301780.4941045.1.1.2 异丁烯热泵提浓塔乙(T0102)表5-2 异丁烯热泵提浓塔乙(T0102)物料衡算表进出口进口出口流股编号2FEED1PRO-D21PROB2Temperature()58.295149.8622258.4197Pressure(bar)7.266.008Mole Flow(kmol/hr)88.8292877.1869811.64409Mass Flow(kg/hr)50004342.385657.7144Volume Flow(cum/hr)9.2201877.846191.181902Vapor Fraction5.54E-0500Liquid Fraction0.99994511Solid Fraction000Enthalpy Flow(Gcal/hr)-0.76694-0.65998-0.1331Component Mass Flow(kg/hr)NBA332.6205.8446126.7263IBA145144.99460.007156IBE2318.52313.155.4151281BE1531.51530.5071.01443C2BE201.52.0142199.51281,3BDE14.914.843950.056307T2BE456131.0304324.9823Component Mass FractionNBA0.066520.0474040.192677IBA0.0290.0333911.09E-05IBE0.46370.5326910.0082331BE0.30630.3524580.001542C2BE0.04030.0004640.3033431,3BDE0.002980.0034188.56E-05T2BE0.09120.0301750.4941095.1.2 连续搅拌釜反应器(R0101-R0103)5.1.2.1 连续搅拌釜反应器(R0101)表5-3 连续搅拌釜反应器(R0101)物料衡算表进出口进口出口流股编号1S1TBA1WATER11S9Temperature()49.8622525.7227325.4118370Pressure(bar)6667Mole Flow(kmol/hr)154.3744160251.1721Mass Flow(kg/hr)8684.77296.49122882.44511863.71Volume Flow(cum/hr)15.692440.3781082.90112917.66024Vapor Fraction8.52E-08000Liquid Fraction1111Solid Fraction0000Enthalpy Flow(Gcal/hr)-1.31997-0.34286-10.9208-12.8662Component Mass Flow(kg/hr)NBA411.702200411.7022IBA289.989300289.9893IBE4626.27400855.74281BE3061.013003061.013C2BE4.028864004.0288641,3BDE29.687850029.68785T2BE262.075900262.0759TBA0296.491205277.683H2O002882.4451671.784Component Mass FractionNBA0.047405000.034703IBA0.033391000.024443IBE0.532688000.0721311BE0.352458000.258015C2BE0.000464000.000341,3BDE0.003418000.002502T2BE0.030177000.022091TBA0100.44486H2O0010.1409165.1.2.2 连续搅拌釜反应器(R0102)表5-4 连续搅拌釜反应器(R0102)物料衡算表进出口进口出口流股编号JJ11JTBA2WATER21S6Temperature()50.1081425.7227325.4118370Pressure(bar)6667Mole Flow(kmol/hr)876795Mass Flow(kg/hr)4914.729148.2456540.45845603.433Volume Flow(cum/hr)8.9053950.1890540.5439629.617166Vapor Fraction0000Liquid Fraction1111Solid Fraction0000Enthalpy Flow(Gcal/hr)-0.78185-0.17143-2.04765-3.00405Component Mass Flow(kg/hr)NBA411.661100411.6611IBA289.989100289.9891IBE855.738400154.40721BE3061.009003061.009C2BE4.028233004.0282331,3BDE29.687850029.68785T2BE262.066800262.0668TBA0.527768148.245601075.291H2O0.02050540.4584315.292Component Mass FractionNBA0.083761000.073466IBA0.059004000.051752IBE0.174117000.0275561BE0.622824000.546274C2BE0.00082000.0007191,3BDE0.006041000.005298T2BE0.053323000.046769TBA0.000107100.191899H2O4.17E-06010.0562685.1.2.3 连续搅拌釜反应器(R0103)表5-5 连续搅拌釜反应器(R0103)物料衡算表进出口进口出口流股编号11TBA3WATER31S20Temperature()50.2025325.7227325.4118370Pressure(bar)6667Mole Flow(kmol/hr)74.6711921690.06703Mass Flow(kg/hr)4212.844148.2456288.24454649.334Volume Flow(cum/hr)7.6422420.1890540.290113120.9851Vapor Fraction0000.315094Liquid Fraction1110.684906Solid Fraction0000Enthalpy Flow(Gcal/hr)-0.6809-0.17143-1.09208-1.76728Component Mass Flow(kg/hr)NBA411.656900411.6569IBA289.989100289.9891IBE154.4072008.2942731BE3061.008003061.008C2BE4.028139004.0281391,3BDE29.687850029.68785T2BE262.065300262.0653TBA0.001075148.24560341.2742H2O3.60E-050288.2445241.3299Component Mass FractionNBA0.097715000.088541IBA0.068835000.062372IBE0.036652000.0017841BE0.72659000.658376C2BE0.000956000.0008661,3BDE0.007047000.006385T2BE0.062206000.056366TBA2.55E-07100.073403H2O8.54E-09010.0519065.1.3 叔丁醇三级串联提浓塔(T0103-T0105)5.1.3.1 一级提浓塔(T0103)表5-6 一级提浓塔(T0103)物料衡算表进出口进口出口流股编号1S9JJ11JJ10JTemperature()7050.10814139.8054Pressure(bar)766.2Mole Flow(kmol/hr)251.172187.17931163.9928Mass Flow(kg/hr)11863.714914.7296948.978Volume Flow(cum/hr)17.660248.90539510.15413Vapor Fraction000Liquid Fraction111Solid Fraction000Enthalpy Flow(Gcal/hr)-12.8662-0.78185-11.5446Component Mass Flow(kg/hr)NBA411.7022411.66110.04117IBA289.9893289.98910.000123IBE855.7428855.73840.0044161BE3061.0133061.0090.003868C2BE4.0288644.0282330.0006311,3BDE29.6878529.687851.03E-12T2BE262.0759262.06680.009182TBA5277.6830.5277685277.155H2O1671.7840.02051671.764Component Mass FractionNBA0.0347030.0837615.92E-06IBA0.0244430.0590041.76E-08IBE0.0721310.1741176.36E-071BE0.2580150.6228245.57E-07C2BE0.000340.000829.08E-081,3BDE0.0025020.0060411.49E-16T2BE0.0220910.0533231.32E-06TBA0.444860.0001070.759415H2O0.1409164.17E-060.2405775.1.3.2 二级提浓塔(T0104)表5-7 二级提浓塔(T0104)物料衡算表进出口进口出口流股编号1S61011Temperature()70139.674950.20253Pressure(bar)76.26Mole Flow(kmol/hr)106.679532.0083574.67119Mass Flow(kg/hr)5603.4331390.5894212.844Volume Flow(cum/hr)9.6171662.0395977.642242Vapor Fraction000Liquid Fraction111Solid Fraction000Enthalpy Flow(Gcal/hr)-3.00405-2.26107-0.6809Component Mass Flow(kg/hr)NBA411.66110.004117411.6569IBA289.98911.70E-05289.9891IBE154.40728.11E-05154.40721BE3061.0090.0006033061.008C2BE4.0282339.45E-054.0281391,3BDE29.687854.80E-1129.68785T2BE262.06680.001483262.0653TBA1075.2911075.290.001075H2O315.292315.2923.60E-05Component Mass FractionNBA0.0734662.96E-060.097715IBA0.0517521.22E-080.068835IBE0.0275565.83E-080.0366521BE0.5462744.34E-070.72659C2BE0.0007196.80E-080.0009561,3BDE0.0052983.45E-140.007047T2BE0.0467691.07E-060.062206TBA0.1918990.7732632.55E-07H2O0.0562680.2267338.54E-095.1.3.3 三级提浓塔(T0105)表5-8 三级提浓塔(T0105)物料衡算表进出口进口出口流股编号1S201BET10JJTemperature()7050.22643141.3073Pressure(bar)766.2Mole Flow(kmol/hr)90.0670372.0669618.00007Mass Flow(kg/hr)4649.3344066.727582.6067Volume Flow(cum/hr)120.98517.3792220.811223Vapor Fraction0.31509400Liquid Fraction0.68490611Solid Fraction000Enthalpy Flow(Gcal/hr)-1.76728-0.66-1.22902Component Mass Flow(kg/hr)NBA411.6569411.65280.004117IBA289.9891289.98912.67E-05IBE8.2942738.2942667.61E-061BE3061.0083061.0080.000706C2BE4.0281394.0280677.16E-051,3BDE29.6878529.687851.00E-12T2BE262.0653262.0640.001266TBA341.27420.003413341.2708H2O241.32990.000134241.3297Component Mass FractionNBA0.0885410.1012257.07E-06IBA0.0623720.0713084.58E-08IBE0.0017840.002041.31E-081BE0.6583760.7526961.21E-06C2BE0.0008660.000991.23E-071,3BDE0.0063850.00731.72E-15T2BE0.0563660.0644412.17E-06TBA0.0734038.39E-070.585765H2O0.0519063.29E-080.4142245.2 叔丁醇氧化制MAL工段5.2.1 叔丁醇氧化鼓泡反应器(R0201)表5-9 叔丁醇氧化鼓泡反应器(R0201)物流衡算表进出口进口出口流股编号2S32S191S252S4Temperature()241.702680139.6771389.85Pressure(bar)51.013256.24.95Mole Flow(kmol/hr)874.5076217.7779214.00121397.251Mass Flow(kg/hr)25195.043923.338922.17338040.54Volume Flow(cum/hr)7486.934.1773912.9983615560.01Vapor Fraction1001Liquid Fraction0110Solid Fraction0000Enthalpy Flow(Gcal/hr)1.334553-14.6471-15.0347-27.4848Component Mass Flow(kg/hr)NBA000.0494040.049404IBA000.0001660.000166IBE000.004505595.46881BE000.0051770.005177C2BE000.0007970.0007971,3BDE005.00E-115.00E-11T2BE000.0119320.011932TBA006693.7160.009597H2O03923.332228.3859249.878O25596.638002941.195N219598.40019598.4CO2000115.9392MAL0005539.584MEOH05.16E-1105.16E-11Component Mass FractionNBA005.54E-061.30E-06IBA001.86E-084.37E-09IBE005.05E-070.0156541BE005.80E-071.36E-07C2BE008.93E-082.09E-081,3BDE005.61E-151.31E-15T2BE001.34E-063.14E-07TBA000.7502342.52E-07H2O010.2497580.243158O20.222133000.077317N20.777868000.515198CO20000.003048MAL0000.145623MEOH01.32E-1401.36E-155.2.2 中空纤维膜分离器（V0201）表5-10 中空纤维膜分离器（V0201）物料衡算进出口进口出口流股编号2S52S12S2Temperature()454545Pressure(bar)555Mole Flow(kmol/hr)1397.251794.1563603.0947Mass Flow(kg/hr)38040.5422655.5415385.01Volume Flow(cum/hr)4357.7994201.41117.38108Vapor Fraction0.58737710Liquid Fraction0.41262401Solid Fraction000Enthalpy Flow(Gcal/hr)-37.5398-0.13686-37.6399Component Mass Flow(kg/hr)NBA0.04940400.049404IBA0.00016600.000166IBE595.46880595.46881BE0.00517700.005177C2BE0.00079700.0007971,3BDE5.00E-1100T2BE0.01193200.011932TBA0.00959700.009597H2O9249.87809249.878O22941.1952941.1950N219598.419598.40CO2115.9392115.93920MAL5539.58405539.584MEOH5.16E-1100Component Mass FractionNBA1.30E-0603.21E-06IBA4.37E-0901.08E-08IBE0.01565400.0387041BE1.36E-0703.36E-07C2BE2.09E-0805.18E-081,3BDE1.31E-1500T2BE3.14E-0707.76E-07TBA2.52E-0706.24E-07H2O0.24315800.601227O20.0773170.1298220N20.5151980.865060CO20.0030480.0051170MAL0.14562300.360064MEOH1.36E-15005.2.3 精馏塔（T0201）表5-11 精馏塔（T0201）的物料衡算进出口进口出口流股编号2S22S3J2S4JTemperature()4538.74892144.664Pressure(bar)54.54.508Mole Flow(kmol/hr)603.094710.61474592.4799Mass Flow(kg/hr)15385.01595.578314789.43Volume Flow(cum/hr)17.381081.04406119.10782Vapor Fraction000Liquid Fraction111Solid Fraction000Enthalpy Flow(Gcal/hr)-37.6399-0.08953-36.2458Component Mass Flow(kg/hr)NBA0.0494040.0493871.69E-05IBA0.0001660.0001664.24E-10IBE595.4688595.46280.0059551BE0.0051770.0051767.50E-08C2BE0.0007970.0007967.91E-071,3BDE000T2BE0.0119320.0119292.82E-06TBA0.0095970.0095915.89E-06H2O9249.8780.0001699249.878MAL5539.5840.0382645539.545Component Mass FractionNBA3.21E-068.29E-051.14E-09IBA1.08E-082.79E-072.87E-14IBE0.0387040.9998064.03E-071BE3.36E-078.69E-065.07E-12C2BE5.18E-081.34E-065.35E-111,3BDE000T2BE7.76E-072.00E-051.91E-10TBA6.24E-071.61E-053.98E-10H2O0.6012272.84E-070.625439MAL0.3600646.42E-050.3745615.2.4 三元共沸热泵精馏塔(CHP3 T0202)表5-12 三元共沸热泵精馏塔(T0202)物料衡算表进出口进口出口流股编号CFEEDPRO-BPRO-DTemperature()140.1179120.174290.1804Pressure(bar)4.5082.0082Mole Flow(kmol/hr)610.4799514.248696.23213Mass Flow(kg/hr)15366.199305.8176060.362Volume Flow(cum/hr)34.2683510.39768.065981Vapor Fraction0.00311300Liquid Fraction0.99688711Solid Fraction000Enthalpy Flow(Gcal/hr)-37.2707-34.1531-3.52965Component Mass Flow(kg/hr)NBA1.69E-0501.69E-05IBA4.24E-1004.24E-10IBE0.0059553.39E-120.0059551BE7.50E-0807.50E-08C2BE7.91E-0707.90E-071,3BDE000T2BE2.82E-0602.81E-06TBA5.89E-062.24E-125.71E-06H2O9249.8789249.8720.000946MAL5539.54555.680315483.795MEOH576.75890.264584576.5602Component Mass FractionNBA1.10E-0902.79E-09IBA2.76E-1407.00E-14IBE3.88E-073.64E-169.83E-071BE4.88E-1201.24E-11C2BE5.15E-1101.30E-101,3BDE000T2BE1.83E-1004.64E-10TBA3.83E-102.40E-169.42E-10H2O0.6019630.9939881.56E-07MAL0.3605020.0059830.904863MEOH0.0375342.84E-050.0951365.3 MAL的直接氧化酯化工段5.3.1 甲基丙烯醛一步氧化酯化反应器(R0301)表5-13 甲基丙烯醛一步氧化酯化反应器(R0301)物料衡算表进出口进口出口流股编号2S72S8PRO-D2S9Temperature()106.497348.3833390.180450Pressure(bar)21.0132521.01325Mole Flow(kmol/hr)9005868.00896.232136825.269Mass Flow(kg/hr)25929.491880246060.362220014Volume Flow(cum/hr)14204.31245.9498.06598150154.68Vapor Fraction1000.275965Liquid Fraction0110.724035Solid Fraction0000Enthalpy Flow(Gcal/hr)0.512382-330.97-3.52965-330.964Component Mass Flow(kg/hr)NBA001.69E-051.69E-05IBA004.24E-104.24E-10IBE000.0059550.0059551BE007.50E-087.50E-08C2BE007.90E-077.90E-07T2BE002.81E-062.81E-06TBA005.71E-065.71E-06H2O000.0009461345.99O25759.784004512.771N220169.710020169.71MAL005483.79520.81222MEOH0188024576.5602186206MMA0007480.14MAA000277.8563Component Mass FractionNBA002.79E-097.68E-11IBA007.00E-141.93E-15IBE009.83E-072.71E-081BE001.24E-113.41E-13C2BE001.30E-103.59E-12T2BE004.64E-101.28E-11TBA009.42E-102.59E-11H2O001.56E-070.006118O20.222133000.020511N20.777867000.091675MAL000.9048639.46E-05MEOH010.0951360.84634MMA0000.033999MAA0000.0012635.3.2 甲醇膜分离器(V0302、V0303)5.3.2.1 甲醇膜分离器(V0302)表5-14 甲醇膜分离器(V0302)物料衡算进出口进口出口流股编号3S1O3FEED3S2Temperature()404040Pressure(bar)222Mole Flow(kmol/hr)5964.241640.4514323.789Mass Flow(kg/hr)19533156787.48138544Volume Flow(cum/hr)249.886171.07684178.8052Vapor Fraction000Liquid Fraction111Solid Fraction000Enthalpy Flow(Gcal/hr)-341.425-96.6808-244.741Component Mass Flow(kg/hr)NBA1.69E-051.69E-050IBA4.24E-104.24E-100IBE0.0059550.00595501BE7.50E-087.50E-080C2BE7.90E-077.90E-070T2BE2.81E-062.81E-060TBA5.71E-065.71E-060H2O1345.991345.990MAL20.8122220.812220MEO67138544MMA7480.147480.140MAA277.8563277.85630Component Mass FractionNBA8.65E-11