年产8.5万吨丙烷资源化利用项目物料平衡计算书

XX石化8.29万吨/年丙烷资源化利用项目可行性研究报告-5-目录总论 -1-物料衡算目的 -1-物料衡算方法 -1-各项目核算 -2-4.1物料衡算任务 -2-4.2丙烷脱氢工段物料衡算 -3-4.3丙烯环氧化工段物料衡算 -6-4.4副产品精制工段物料衡算 -9-总项目核算 -10-1总论本项目使用丙烷脱氢制取丙烯，丙烯环氧化制取环氧乙烷，环氧丙烷年产9万吨，生产过程中的副产品氢气、丙二醇单甲醚、多余的丙烯可以产生经济效益；氧气混合少量丙烯送入火炬；废水、废渣。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1-1所示：表1-1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：丙烷脱氢制取丙烯，丙烯环氧化制取环氧乙烷，丙二醇单甲醚精制。4.1物料衡算任务对于本厂，工艺采取年开工333天（8000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： 确定环氧丙烷的实际产量以及质量指标； 确定丙烷、氧气、过氧化氢、苯、甲醇等原料的循环量以及损失率等指标；③ 确定工艺中的“三废”排放量等公共经济指标；④ 各主要单元过程的物料衡算，并指导工艺设备的尺寸确定；⑤ 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丙烷脱氢工段物料衡算图4.1丙烷脱氢工段工艺示意图由工艺示意图可知，丙烷脱氢工段有反应器、冷凝器、分子筛脱水罐、冷箱、精馏塔等重要单元过程，需要对它们进行物料衡算。表4-1丙烷脱氢反应器前后物流结果表进出口inout流股信息丙烷脱氢原料气丙烷脱氢产物流股编号01080109MassFlowkg/hrC3H818436.49116.918C3H698.30048992.953H25.85E-139386.4483CH44.63E-841.378673O2100H2O720.61121077.076CO24.18E-562.681042C2H63.38E-383.48E-05C4H104.990CO2.76E-1112.559557TotalFlowkmol/hr460.5138672.1838TotalFlowkg/hr19260.319580.01TotalFlowl/min111361157721TemperatureC600573Pressurebar55VaporFrac11Enthalpycal/sec-1510000-120760表4-2冷凝器前后物流结果表进出口inout流股信息丙烷脱氢原料气丙烷脱氢产物流股编号01080109MassFlowkg/hrC3H818436.49116.918C3H698.30048992.953H25.85E-139386.4483CH44.63E-841.378673O2100H2O720.61121077.076CO24.18E-562.681042C2H63.38E-383.48E-05C4H104.990CO2.76E-1112.559557TotalFlowkmol/hr460.5138672.1838TotalFlowkg/hr19260.319580.01TotalFlowl/min111361157721TemperatureC600573Pressurebar55VaporFrac11Enthalpycal/sec-1510000-120760表4-3分子筛吸水罐前后物流结果表进出口inout流股信息脱水前脱水后流股编号01140116C3H89117.0439117.043C3H68993.0058993.005H2386.4508386.4508CH41.3786721.378672H2O165.19680CO22.6811612.681161C2H63.48E-053.48E-05C4H1000CO2.5596852.559685TotalFlowkmol/hr621.5722612.4024TotalFlowkg/hr18668.3218503.12TotalFlowl/min58229.4257396.59TemperatureC4040Pressurebar4.54.5VaporFrac11Enthalpycal/sec-1272800-1125800表4-4冷箱前后物流结果表进出口inout流股信息进料产物丙烷丙烯流股氢气出料丙烷丙烯流股流股编号011801190120MassFlowkg/hrC3H89117.043117.40068999.642C3H68993.005162.03188830.974H2386.4508385.81380.636979CH41.3786721.2547840.123888CO22.6811611.1419461.539215C2H63.48E-055.79E-062.90E-05CO2.5596852.5179870.041698TotalFlowkmol/hr612.4024198.0942414.3081TotalFlowkg/hr18503.12670.16117832.96TotalFlowl/mi987376.45TemperatureC301010Pressurebar1.921.81.8VaporFrac111Enthalpycal/sec-1144200-20964.6-1170400表4-5T0101、T0102精馏塔前后物流结果表进出口inout流股信息A塔进料A塔塔釜出循环料B塔塔顶出料流股编号012101220127MassFlowkg/hrC3H88999.6428978.65620.91823C3H68830.97486.547438744.376H20.6369795.85E-1390.636979CH40.1238884.63E-840.123888CO21.5392154.18E-561.539215C2H62.90E-053.38E-382.90E-05CO0.0416982.76E-1110.041698TotalFlowkmol/hr414.3081205.6704208.635TotalFlowkg/hr17832.969065.2038767.636TotalFlowl/min39967.88284.2269251.0206TemperatureC57.81337-1.793224-25.067Pressurebar4.54.55Enthalpycal/sec-1083300-1674000-11145.7表4-6丙烷脱氢工段总物料衡算inout流股信息丙烷水蒸汽氧气冷凝水分子筛脱水富氢气丙烯流股编号0101010201140113011501190127MassFlow/kg/hrC3H89457.74006.9E-30117.40020.918C3H611.7529000.0020162.0318744.3H20003.86E-050385.8130.6369CH40007.32E-0701.254780.1238O200319.90000H2O0720.61109.12E+02165.190.00E+000.00E+00CO20001.50E-0501.1419461.539215C2H60001.96E-1105.79E-062.90E-05C4H104.994972000000CO0001.31E-0702.517980.0416TotalFlowkmol/hr214.843401050.6179.1698198.094208.63TotalFlowkg/hr9474.48720.61319.9911.881165.19670.1618767.6TotalFlowl/min85759.720592.1227.615.5182.811243214.9251.02TemperatureC20101.5372-161.835404010-25.067Pressurebar15VaporFrac1110010Enthalpycal/sec-1.50E+06-6.35E+05-3790.4-962180-174310-2.10E+04-11145.74.3丙烯环氧化工段物料衡算图4.2丙烯环氧化工段工艺示意图由工艺示意图可知，丙烯环氧化工段有反应器、三个精馏塔等重要单元过程，需要对它们进行物料衡算。表4-7反应器前后物流结果表表4-8T0201丙烯回收塔前后物流结果表inout流股信息产物进料废气粗PO回收丙烯流股编号70020702110206MassFlowkg/hrC3H819.336240.09324719.238040.004945C3H61795.3621720.3988.40E-0674.96379H20.61007010.60992300.000147CH40.22003550.219543.00E-200.000495O2103.8273103.77842.55E-200.048932H2O19072.864.69E-2519072.861.79E-24CO210.369510.275985.95E-120.093518C2H60.0002580.0002541.59E-113.48E-06CO0.05186940.05181705.26E-05PO10558.872.42E-0810558.877.87E-09CH3OH66279.570.53528666278.980.0488541-MET-01582.24350582.243502-MET-01388.16230388.16230TotalFlowkmol/hr3366.68444.696983320.21.786829TotalFlowkg/hr98811.481835.96396900.3675.16074TotalFlowl/min2050.878812.99262646.7492.788674TemperatureC41.0117355178.103955Pressurebar25.52525.525VaporFrac0100Enthalpycal/sec-5437000054152.49-5.1E+071224.286表4-9T0202环氧丙烷分离塔前后物流结果表inout流股信息粗产品水环氧丙烷粗副产品流股编号0213022502140215MassFlowkg/hrC3H819.23804019.238042.45E-11C3H68.40E-0608.40E-063.29E-31CH43.00E-20000O22.55E-20000H2O19072.868013.0746.93928427078.99CO25.95E-12000C2H61.59E-11000PO10558.872.76E-0710411.05147.8236CH3OH66278.9819.8065214.5843666284.211-MET-01582.2435248.1248.04E-20830.3682-MET-01388.1623165.4161.66E-21553.5787TotalFlowkmol/hr3320.2450180.53013589.67TotalFlowkg/hr96900.368446.42110451.8194894.97TotalFlowl/min1992.808144.6505215.03692026.782TemperatureC39.999914033.3744673.58806PressurebarVaporFrac0000Enthalpycal/sec-5.4E+07-8545500-1449100-6.1E+07表4-10T0203甲醇回收塔前后物流结果表inout流股信息粗副产品循环甲醇水流股编号021602170221MassFlowkg/hrC3H82.45E-1100C3H63.29E-3100H2O27078.99262.824726816.43PO147.8236147.87039.25E-07CH3OH66284.2166217.4266.284211-MET-01830.3681.77E-14830.3682-MET-01553.57871.11E-18553.5787BENZENE000TotalFlowkmol/hr3589.672083.7071505.963TotalFlowkg/hr94894.9766628.1228266.66TotalFlowl/min2027.7951696.369567.6317TemperatureC73.90534128.3084170.2349Pressurebar8.188.1VaporFrac000Enthalpycal/sec-6.1E+07-3.1E+07-2.7E+07表4-11丙烯环氧化工段总物料衡算inout流股信息丙烯甲醇双氧水废气环氧丙烷粗副产品流股编号0129X02010202021002140222MassFlowkg/hrC3H819.250000.00219.238040C3H68047.040050.8238.40E-060H20.5861000.58600CH40.11400000.11400O200093.48900H2O1.80E-13015281.706.93918803.36CO21.416001.41600C2H62.67E-05002.67E-0500CO0.0383000.03800H2O2006662.000PO0005.39E-1110411.056.49E-07CH3OH0406.100.003114.58446.4771-MET-0100008.04E-20582.2442-MET-0100001.66E-21388.1627TotalFlowkmol/hr191.99712.61044.14.461180.531055.93TotalFlowkg/hr8068.4540621944146.473910451.8119820.24TotalFlowl/min231.078.54331.5568.77806215.03398.01TemperatureC-24.9225.725.24533.37170.23Pressurebar6662518.1VaporFrac000100Enthalpycal/sec-10060-200400-1.9E+07506.01-1.449E+06-1.9E+074.4副产品精制工段物料衡算图4.3副产品精制工段工艺示意图由工艺示意图可知，丙烷脱氢工段有两个个精馏塔等重要单元过程，需要对它们进行物料衡算。表4-12T0301脱水塔前后物流结果表inout流股信息粗副产品含醚废水粗丙二醇甲醚流股编号030203030312MassFlowkg/hrH2O18803.3610532.478270.912PO6.49E-071.10E-446.49E-07CH3OH46.477681.65E-1646.4791-MET-01582.2441.15E-07582.2732-MET-01388.162745.52231342.4731TotalFlowkmol/hr1055.963585.146470.817TotalFlowkg/hr19820.2410577.999242.138TotalFlowl/min339.434210.4805320.993TemperatureC40171.007169.352Pressurebar8.18.18VaporFrac000.143Enthalpycal/sec-2E+07-1.1E+07-8480000表4-13T0301脱水塔前后物流结果表inout流股信息粗丙二醇甲醚苯废水粗丙二醇甲醚流股编号031503200140X0316MassFlowkg/hrH2O8270.91261.4298332.3415.62E-11PO6.49E-070.0001190.0001192.11E-21CH3OH46.47951.7893798.2694.19E-201-MET-01582.2730.0963990.096503582.27292-MET-01342.47314.54E-053.55E-05342.4731BENZENE085999.0185999.011.66E-16H2O0.8949130.0007130.0882396.08E-14PO7.02E-111.38E-091.26E-092.29E-24CH3OH0.0050290.0006010.0010414.54E-231-MET-010.0630021.12E-061.02E-060.6296572-MET-010.0370565.28E-103.76E-100.370343BENZENE00.9986840.910721.80E-19TotalFlowkmol/hr470.8171105.9751566.53110.26102TotalFlowkg/hr9242.13886112.3394429.72924.746TotalFlowl/min159.29941644.83774244420.87086TemperatureC402568.86794124.165Pressurebar1.1111.05VaporFrac0010Enthalpycal/sec-89954003489290-1076000-289420表4-14副产品精制工段总物料衡算inout流股信息粗副产品苯丙二醇甲醚含醇、苯废水含醚废水流股编号03020321031603180303MassFlowkg/hrH2O18803.3605.62E-118270.91610532.47PO6.49E-0702.11E-212.84E-061.10E-44CH3OH46.4776804.19E-2046.480111.65E-161-MET-01582.2440582.27290.0058421.15E-072-MET-01388.16270342.47314.30E-0645.52231BENZENE014.98941.66E-1614.989370TotalFlowkmol/hr1055.9630.1918910.26102460.7482585.146TotalFlowkg/hr19820.2414.9894924.7468332.39210577.99TotalFlowl/min339.43460.2864720.87086139.9418210.4808TemperatureC4025124.16525171.007Pressurebar8.111.0518.1VaporFrac00000Enthalpycal/sec-2E+07623.943-289420-8728000-1.1E+075总项目核算表4-15全流程物料平衡表in流股信息丙烷水蒸汽氧气甲醇双氧水苯流股编号01010102O2020102020321MassFlowkg/hrC3H89457.7400000C3H611.752900000H2000000CH4000000O200319.988000H2O0720.6110015281.730CO2000000C2H6000000C4H104.9949700000CO000000H2O200006662.270PO000000CH3OH000406.1001-MET-010000002-MET-01000000BENZENE0000014.9894TotalFlowkmol/hr214.843401012.67391044.1290.191TotalFlowkg/hr9474.48720.611319.988406.12194414.9894TotalFlowl/min85759.7205924.