年產(chǎn)8.5萬噸丙烷資源化利用項目物料平衡計算書

XX石化8.29萬噸/年丙烷資源化利用項目可行性研究報告-5-目錄總論 -1-物料衡算目的 -1-物料衡算方法 -1-各項目核算 -2-4.1物料衡算任務(wù) -2-4.2丙烷脫氫工段物料衡算 -3-4.3丙烯環(huán)氧化工段物料衡算 -6-4.4副產(chǎn)品精制工段物料衡算 -9-總項目核算 -10-1總論本項目使用丙烷脫氫制取丙烯，丙烯環(huán)氧化制取環(huán)氧乙烷，環(huán)氧丙烷年產(chǎn)9萬噸，生產(chǎn)過程中的副產(chǎn)品氫氣、丙二醇單甲醚、多余的丙烯可以產(chǎn)生經(jīng)濟效益；氧氣混合少量丙烯送入火炬；廢水、廢渣。在已確定化學(xué)生產(chǎn)工藝和流程后，由定性階段轉(zhuǎn)向定量階段，通過對整個生產(chǎn)系統(tǒng)、生產(chǎn)車間，以及部分重要的生產(chǎn)單元進行物料衡算計算出主、副產(chǎn)品的產(chǎn)量，原材料的消耗定額、“三廢”排放量及組成，以及產(chǎn)品收率等各項經(jīng)濟技術(shù)指標(biāo)，從而定量地評述初步設(shè)計所選擇的工藝路線、生產(chǎn)方法及工藝流程在經(jīng)濟上是否合理，技術(shù)上是否先進，為后階段的設(shè)計提供數(shù)據(jù)。2物料衡算目的工藝設(shè)計中，物料衡算是在工藝流程確定后進行的。目的是根據(jù)原料與產(chǎn)品之間的定量轉(zhuǎn)化關(guān)系，計算原料的消耗量，各種中間產(chǎn)品、產(chǎn)品和副產(chǎn)品的產(chǎn)量，生產(chǎn)過程中各階段的消耗量以及組成，進而為熱量衡算、其他工藝計算及設(shè)備計算打基礎(chǔ)。對于已有裝置，物料衡算可以弄清原料的來龍去脈，找出生產(chǎn)中的薄弱環(huán)節(jié)，為改進生產(chǎn)、完善管理提供可靠的依據(jù)和明確方向，并可作為檢查原料利用率及三廢處理完善程度的一種手段。3物料衡算方法工藝設(shè)計中，物料衡算是在工藝流程確定后進行的。目的是根據(jù)原料與產(chǎn)品之間的定量轉(zhuǎn)化關(guān)系，計算原料的消耗量，各種中間產(chǎn)品、產(chǎn)品和副產(chǎn)品的產(chǎn)量，生產(chǎn)過程中各階段的消耗量以及組成，進而為熱量衡算、其他工藝計算及設(shè)備計算打基礎(chǔ)。物料衡算是以質(zhì)量守恒定律為基礎(chǔ)對物料平衡進行計算。物料平衡是指“在單位時間內(nèi)進入系統(tǒng)(體系)的全部物料質(zhì)量必定等于離開該系統(tǒng)的全部物料質(zhì)量再加上損失掉的和積累起來的物科質(zhì)量”。物料衡算通式如式：∑G投入=∑G產(chǎn)品+∑G回收+∑G流失式中：∑G投入—投入系統(tǒng)的物料總量；∑G產(chǎn)品—系統(tǒng)產(chǎn)出的產(chǎn)品和副產(chǎn)品總量；∑G流失—系統(tǒng)中流失的物料總量；∑G回收—系統(tǒng)中回收的物料總量。其中產(chǎn)品量應(yīng)包括產(chǎn)品和副產(chǎn)品：流失量包括除產(chǎn)品、副產(chǎn)品及回收量以外各種形式的損失量，污染物排放量即包括在其中。系統(tǒng)中物料衡算一般表達式為：系統(tǒng)中的積累=輸入-輸出+生成-消耗式中，生成或消耗項是由于化學(xué)反應(yīng)而生成或消耗的量；積累量可以是正值，也可以是負(fù)值，當(dāng)系統(tǒng)中積累量不為零時稱為非穩(wěn)定狀態(tài)過程；積累量為零時，稱為穩(wěn)定狀態(tài)過程。穩(wěn)定狀態(tài)過程時，可以簡化為：輸入=輸出-生成+消耗對無化學(xué)反應(yīng)的穩(wěn)定過程，又可表示為：輸入=輸出物料衡算包括總質(zhì)量衡算、組分衡算和元素衡算。各種衡算方法的適用情況如表1-1所示：表1-1物料橫算式適用范圍類別物料衡算形式無化學(xué)反應(yīng)有化學(xué)反應(yīng)總衡算式總物料衡算式適用適用總物質(zhì)的量衡算式適用不適用組分衡算式組分質(zhì)量衡算式適用不適用組分物質(zhì)的量衡算式適用不適用元素原子衡算式元素原子質(zhì)量衡算式適用適用元素原子物質(zhì)的量衡算式適用適用4各項目核算從原料入廠到產(chǎn)品輸出，其工藝路線可分為如下3個工段：丙烷脫氫制取丙烯，丙烯環(huán)氧化制取環(huán)氧乙烷，丙二醇單甲醚精制。4.1物料衡算任務(wù)對于本廠，工藝采取年開工333天（8000小時）的連續(xù)操作，其中一年內(nèi)的四~五周（約30天）用于固定的停車設(shè)備檢修及緊急情況處理。物料衡算的主要任務(wù)在于： 確定環(huán)氧丙烷的實際產(chǎn)量以及質(zhì)量指標(biāo)； 確定丙烷、氧氣、過氧化氫、苯、甲醇等原料的循環(huán)量以及損失率等指標(biāo)；③ 確定工藝中的“三廢”排放量等公共經(jīng)濟指標(biāo)；④ 各主要單元過程的物料衡算，并指導(dǎo)工藝設(shè)備的尺寸確定；⑤ 匯總?cè)鞒涛锪虾馑?，?shù)據(jù)用于完成物料流程圖等后續(xù)設(shè)計任務(wù)。4.2丙烷脫氫工段物料衡算圖4.1丙烷脫氫工段工藝示意圖由工藝示意圖可知，丙烷脫氫工段有反應(yīng)器、冷凝器、分子篩脫水罐、冷箱、精餾塔等重要單元過程，需要對它們進行物料衡算。表4-1丙烷脫氫反應(yīng)器前后物流結(jié)果表進出口inout流股信息丙烷脫氫原料氣丙烷脫氫產(chǎn)物流股編號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冷凝器前后物流結(jié)果表進出口inout流股信息丙烷脫氫原料氣丙烷脫氫產(chǎn)物流股編號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分子篩吸水罐前后物流結(jié)果表進出口inout流股信息脫水前脫水后流股編號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冷箱前后物流結(jié)果表進出口inout流股信息進料產(chǎn)物丙烷丙烯流股氫氣出料丙烷丙烯流股流股編號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精餾塔前后物流結(jié)果表進出口inout流股信息A塔進料A塔塔釜出循環(huán)料B塔塔頂出料流股編號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丙烷脫氫工段總物料衡算inout流股信息丙烷水蒸汽氧氣冷凝水分子篩脫水富氫氣丙烯流股編號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丙烯環(huán)氧化工段物料衡算圖4.2丙烯環(huán)氧化工段工藝示意圖由工藝示意圖可知，丙烯環(huán)氧化工段有反應(yīng)器、三個精餾塔等重要單元過程，需要對它們進行物料衡算。表4-7反應(yīng)器前后物流結(jié)果表表4-8T0201丙烯回收塔前后物流結(jié)果表inout流股信息產(chǎn)物進料廢氣粗PO回收丙烯流股編號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環(huán)氧丙烷分離塔前后物流結(jié)果表inout流股信息粗產(chǎn)品水環(huán)氧丙烷粗副產(chǎn)品流股編號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結(jié)果表inout流股信息粗副產(chǎn)品循環(huán)甲醇水流股編號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丙烯環(huán)氧化工段總物料衡算inout流股信息丙烯甲醇雙氧水廢氣環(huán)氧丙烷粗副產(chǎn)品流股編號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副產(chǎn)品精制工段物料衡算圖4.3副產(chǎn)品精制工段工藝示意圖由工藝示意圖可知，丙烷脫氫工段有兩個個精餾塔等重要單元過程，需要對它們進行物料衡算。表4-12T0301脫水塔前后物流結(jié)果表inout流股信息粗副產(chǎn)品含醚廢水粗丙二醇甲醚流股編號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脫水塔前后物流結(jié)果表inout流股信息粗丙二醇甲醚苯廢水粗丙二醇甲醚流股編號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副產(chǎn)品精制工段總物料衡算inout流股信息粗副產(chǎn)品苯丙二醇甲醚含醇、苯廢水含醚廢水流股編號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總項目核算表4-15全流程物料平衡表in流股信息丙烷水蒸汽氧氣甲醇雙氧水苯流股編號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.