6-物料平衡一览表

洛阳石化8.29万吨/年丙烷资源化利用项目 可行性研究报告 物料平衡一览表I山东裕华化工有限公司年产6万吨甲基丙烯酸甲酯（MMA）项目物料平衡一览表目录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- 3 -4.2异丁烯两步氧化制取甲基丙烯酸工段- 3 -4.3甲基丙烯酸分离纯化工段- 11 -4.4甲基丙烯酸酯化及分离纯化工段- 15 -5总项目核算- 22 -中国海洋大学-学贯中烯团队- 25 -1 总论本项目使用异丁烯氧化法制取甲基丙烯酸甲酯，甲基丙烯酸年产6万吨，生产过程中的废弃物如CO、CO2混合少量乙醛、丙烯、丙酸、氧气混合送入火炬；废水、废渣经过下游处理工段得到资源化利用。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。各种衡算方法的适用情况如表 3-1 所示：表3-1 物料横算式适用范围类别物料衡算形式无化学反应有化学反应总衡算式总物料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3个工段：异丁烯两步氧化制取甲基丙烯酸，甲基丙烯酸分离纯化工段，甲基丙烯酸酯化及分离纯化工段。4.1物料衡算任务对于本厂，工艺采取年开工333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： 确定甲基丙烯酸甲酯的实际产量以及质量指标； 确定异丁烯、氧气、水、甲苯、乙二醇、正己烷等原料的循环量以及损失率等指标；确定工艺中的“三废”排放量等公共经济指标；各主要单元过程的物料衡算，并指导工艺设备的尺寸确定；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异丁烯两步氧化制取甲基丙烯酸工段图4.1异丁烯氧化制取甲基丙烯酸工段工艺示意图由工艺示意图可知，异丁烯氧化制取甲基丙烯酸工段有混合器、反应器、闪蒸罐、精馏塔等单元过程，需要对它们进行物料衡算。表4-2-1混合器前后物流结果表进出口inout流股信息原料混合物料流股编号0111011201130114Mass Flow kg/hrC4H85610.752005610.752H2O003603.0563603.056O206399.7606399.76MAL0000C3H6O0000C2H4O0000C8H6O40000CO20000CO0000MAA0000C3H6O20000CH4O0000MMA0000C6H140000C2H6O20000C7H80000Total Flow kmol/hr100200200500Total Flow kg/hr5610.7526399.763603.05615613.57Temperature C35025100213.0925Pressure bar1111Vapor Frac0000表4-2-2 MAL生成器前后物流结果表进出口inout流股信息异丁烯原料气异丁烯氧化产物流股编号01510161Mass Flow kg/hrC4H85610.75295.38278H2O3603.0565644.187O26399.762609.502MAL06322.212C3H6O052.27204C2H4O072.06307C8H6O40199.3599CO20352.0784CO0249.2926MAA017.21809C3H6O200CH4O00MMA00C6H1400C2H6O200C7H800Total Flow kmol/hr500507.15Total Flow kg/hr15613.5715613.57Temperature C350350Pressure bar11Vapor Frac00表4-2-3 MAA生成器前后物流结果表进出口inout流股信息第一步氧化产物第二步氧化产物流股编号01510161Mass Flow kg/hrC4H895.5971695.59679H2O7931.5577931.539O22610.0831160.038MAL6974.55683.4982C3H6O56.580235.657923C2H4O72.1827972.18274C8H6O4199.3599199.3599CO2356.7851356.7768CO249.3851249.3849MAA319.93398046.881C3H6O20.00277864.95147CH4O00MMA00C6H1400C2H6O200C7H800Total Flow kmol/hr647.15601.8316Total Flow kg/hr18866.0218865.87Temperature C320320Pressure bar11Vapor Frac00表4-2-3 对苯二甲酸分离器前后物流结果表进出口inout流股信息氧化产物对苯二甲酸（除对苯二甲酸）分离产物流股编号015101820181Mass Flow kg/hrC4H80.214trace95.597H2O2287.373.4827928.075O20.581trace1160.023MAL652.3460.141683.365C3H6O4.3080.0015.657C2H4O0.120.0772.113C8H6O4trace192.7916.568CO24.707 0.001356.785CO0.092trace249.385MAA302.70638.7138008.295C3H6O20.0030.15664.797CH4OMMACHCL3C6H14C5H12C2H6O2N2C7H8Pressure bar10.150.15Vapor Frac101表4-2-4 惰性气体分离器前后物流结果表进出口inout流股信息（除对苯二甲酸）分离产物水废气（除对苯二甲酸）分离产物流股编号0181019101920181Mass Flow kg/hrC4H895.59795.3830.214H2O7928.075370039.4711588.605O21160.0231159.4420.581MAL683.3656.335677.03C3H6O5.6571.3494.308C2H4O72.1130.06972.043C8H6O46.568trace6.568CO2356.785352.0784.707CO249.385249.2930.092MAA8008.2952.7558005.54C3H6O264.7970.01564.782CH4OMMAC6H14C2H6O2C7H8Total Flow kmol/hrTotal Flow kg/hr18630.513700235.353420424.32Temperature C95202525Pressure bar0.1510.80.8Vapor Frac1011表4-2-5 MAL回收塔T0101前后物流结果表进出口inout流股信息MAA-MAL-H2OMAL-H2OMAA-H2O流股编号01I101I201I3Mass Flow kg/hrC4H80.2140.214traceH2O11588.6052287.3679301.238O20.5810.581traceMAL677.03652.35524.675C3H6O4.3084.308traceC2H4O72.0430.1271.923C8H6O46.568trace6.568CO24.7074.707traceCO0.0920.092traceMAA8005.54302.7077702.833C3H6O264.7820.00364.779CH4OMMAC6H14C2H6O2C7H8Total Flow kmol/hrTotal Flow kg/hrTemperature CPressure bar111Vapor Frac000表4-2-6 异丁烯氧化制取甲基丙烯酸工段总物料衡算inout流股信息异丁烯氧气水水MAA-H2O对苯二甲酸废气流股编号011101120113019101I301820192Mass Flow kg/hrC4H85610.752tracetrace95.383H2O3603.05637009301.2383.48239.47O26399.76tracetrace1159.442MAL24.6750.1416.335C3H6Otrace0.0011.349C2H4O71.9230.070.069C8H6O46.568192.791traceCO2trace 0.001352.078COtracetrace249.293MAA7702.83338.7132.755C3H6O264.7790.1560.015CH4OMMAC6H14C2H6O2C7H8Total Flow kmol/hrTotal Flow kg/hrTemperature CPressure bar111110.151Vapor Frac11100014.3甲基丙烯酸分离纯化工段图4.2 甲基丙烯酸分离纯化工段工艺示意图由工艺示意图可知，甲基丙烯酸分离纯化工段包括一个萃取塔、一个精馏塔单元过程，需要对它们进行物料衡算。表4-3-1 萃取塔ET0201前后物流结果表进出口inout流股信息MAA-H2O甲苯废液MAA-C7H8流股编号01I3021302210222Mass Flow kg/hrC4H8traceH2O9301.23815.7748763.635553.377O2traceMAL24.6757.21922.8069.089C3H6OtraceC2H4O71.92321.04366.47526.492C8H6O46.5684.1492.419CO2traceCOtraceMAA7702.8330.0070.0017702.839C3H6O264.7797.97148.88923.861CH4OMMAC6H14C2H6O2C7H8Total Flow kmol/hrTotal Flow kg/hrTemperature C1000025.1869974.814Pressure bar1111Vapor Frac0000表4-3-2 T0201 萃取剂回收塔前后物流结果表进出口inout流股信息MAA-C7H8C7H8MAA流股编号022202310232Mass Flow kg/hrC4H8H2O553.377553.377traceO2MAL9.0899.089traceC3H6OC2H4O26.49226.492traceC8H6O42.419trace2.419CO2COMAA7702.8390.0077702.832C3H6O223.86110.03413.827CH4OMMAC6H14C2H6O2C7H8Total Flow kmol/hrTotal Flow kg/hrTemperature C9974.8149974.814tracePressure bar0.80.80.8Vapor Frac000表4-3-3 甲基丙烯酸分离纯化工段总物料衡算进出口inout流股信息MAA-H2O甲苯废水废水MAA流股编号01I3021202210231-2232Mass Flow kg/hrC4H8traceH2O9301.2388763.635537.604traceO2traceMAL24.67522.8061.869traceC3H6OtraceC2H4O71.92366.4755.449traceC8H6O46.5684.1492.419CO2traceCOtraceMAA7702.8330.001 0.0017702.832C3H6O264.77948.8892.06413.827CH4OMMACHCL3C6H14C5H12C2H6O2N2C7H825.85525.1860.669traceTotal Flow kmol/hr608.235488.84629.99489.675Total Flow kg/hr17172.028931.141547.6557719.078Temperature C99.376.855.8153.44.4甲基丙烯酸酯化及分离纯化工段图4.3 甲基丙烯酸酯化及分离工段示意图由工艺示意图可知，甲基丙烯酸酯化及分离纯化工段有六个精馏塔等重要单元过程，需要对它们进行物料衡算。表4-4-1反应精馏塔T0301前后物流结果表进出口inout流股信息MAA甲醇甲醇-MMAMAA-H2O流股编号0311032103220323Mass Flow kg/hrC4H8H2Otracetrace0.041511.72O2MALtraceC3H6OC2H4OtracetracetraceC8H6O42.4192.419CO2COMAA7702.832trace478.519C3H6O213.827trace13.827CH4O11214.6148525.784traceMMA0.5521821.916580.026C6H14C2H6O2C7H8Total Flow kmol/hr0.0140.014Total Flow kg/hrTemperature CtracetracetracetracePressure bar1111Vapor Frac0000表4-4-2萃取精馏塔T0302前后物流结果表进出口inout流股信息MMA乙二醇甲醇-MMAMAA-H2O流股编号0331036103330337Mass Flow kg/hrC4H8H2O0.04tracetrace0.04O2MALC3H6OC2H4OtraceC8H6O4CO2COMAAtraceC3H6O2traceCH4O8525.784trace8525.1640.619MMA1821.91 0.0010.5521821.358C6H14C2H6O2C7H8Total Flow kmol/hr7499.6220.0147499.608Total Flow kg/hrTemperature CtracetracetracePressure bar1111Vapor Frac0000表4-4-3萃取剂回收塔T0303前后物流结果表进出口inout流股信息MMA-乙二醇乙二醇MMA流股编号033703410342Mass Flow kg/hrC4H8H2O0.040.04traceO2MALC3H6OC2H4OC8H6O4CO2COMAAC3H6O2CH4O0.6190.619traceMMA1821.3581821.358 0.001C6H14C2H6O2C7H8Total Flow kmol/hr7499.6080.1037499.505Total Flow kg/hrTemperature CtracePressure bar11.251.25Vapor Frac000表4-4-4共沸精馏塔T0304前后物流结果表进出口inout流股信息MAA-H2O正己烷正己烷-H2O正己烷-MMA流股编号0323-103I103720373Mass Flow kg/hrC4H8H2O1511.729.3551521.075traceO2MALC3H6OC2H4OtracetracetracetraceC8H6O42.419tracetrace2.419CO2COMAA478.519tracetrace478.519C3H6O213.827tracetrace13.827CH4OtracetracetracetraceMMA6580.02614.98912.9536582.062C6H14C2H6O22500022276.142723.86C7H8Total Flow kmol/hr0.014tracetrace0.014Total Flow kg/hrTemperature CtracePressure bar1111Vapor Frac0010表4-4-5萃取剂回收塔T0305前后物流结果表进出口inout流股信息MMA-正己烷正己烷MMA流股编号037303820383Mass Flow kg/hrC4H8H2OtracetracetraceO2MALC3H6OC2H4OtracetracetraceC8H6O42.419trace2.419CO2COMAA478.519trace478.519C3H6O213.827trace13.827CH4OtraceMMA6582.0627.9416574.121C6H14C2H6O22723.862723.859 0.001C7H8Total Flow kmol/hr0.014trace0.014Total Flow kg/hrTemperature CPressure bar110.6Vapor Frac000表4-4-6MMA精制塔T0306前后物流结果表进出口inout流股信息MMA(少量杂质）MMAMAA流股编号039403I203I3Mass Flow kg/hrC4H8H2OtracetracetraceO2MALC3H6OC2H4OtracetracetraceC8H6O42.419trace2.419CO2COMAA478.5197.174471.345C3H6O213.8271.90511.922CH4OMMA6574.1216561.84112.28C6H14C2H6O2 0.001 0.001traceC7H8Total Flow kmol/hr0.014trace0.014Total Flow kg/hrTemperature CPressure bar111Vapor Frac000表4-4-7 甲基丙烯酸甲酯分离纯化工段总物料衡算进出口inout流股信息MAA乙二醇甲醇正己烷废水废水MMA流股编号031103520335039303I332503X3Mass Flow kg/hrC4H8H2Otracetrace1511.720.04O2MALtraceC3H6OC2H4OtracetracetraceC8H6O42.4192.419traceCO2COMAA7702.832471.3457.174C3H6O213.82711.9221.905CH4O2689.45trace0.619MMA12.285.9058383.199CHCL3C6H140.066trace0.064 0.001C5H12C2H6O20.110.0140.103N2C7H8traceTotal Flow kmol/hr89.6750.00283.9350.0015.77383.97383.866Total Flow kg/hr7719.0780.112689.450.066497.981517.6898393.04Temperature C153.4252525157.635.8885总