50000Nm3 h煤制氫廢氣深度脫硫 及資源化利用初步設(shè)計(jì)說(shuō)明書(shū)

“東華科技-陵鼓杯”

第十一屆大學(xué)或化工殘行競(jìng)賽

50000Nm3/h煤制氫廢氣深度脫硫

及資源化利用

初步設(shè)計(jì)說(shuō)明書(shū)

ChemicalMan團(tuán)隊(duì)

2017年“東華科技一陜鼓杯”

第十一屆大學(xué)生化工設(shè)計(jì)競(jìng)賽

50000Nm3/h煤制氫廢氣深度脫硫

及資源化利用

一體化項(xiàng)目設(shè)計(jì)

初步設(shè)計(jì)說(shuō)明書(shū)

參賽學(xué)校：廣東石油化工學(xué)院

參賽團(tuán)隊(duì)：ChemicalMan

參賽隊(duì)員：肖文順、楊嘉銘

吳秉權(quán)、陳頌佳、葛海

指導(dǎo)老師：陳輝/黃燕青

完成時(shí)間：2017.3-2017.7

目錄

第1章項(xiàng)目總論..............................................................1

1.1項(xiàng)目概況.................................................................1

1.2設(shè)計(jì)依據(jù)和原則..........................................................1

1.2.1項(xiàng)目設(shè)計(jì)依據(jù).......................................................1

1.2.2項(xiàng)目設(shè)計(jì)原則.......................................................2

1.2.3指導(dǎo)思想...........................................................3

1.3原料組成及流量..........................................................3

1.4產(chǎn)品方案及規(guī)格..........................................................3

1.5項(xiàng)目意義.................................................................3

1.6輔助軟件的應(yīng)用..........................................................4

第2章總圖運(yùn)輸..............................................................5

2.1設(shè)計(jì)依據(jù)................................................................5

2.1廠址比較與選擇..........................................................5

2.1.1內(nèi)蒙古包頭九原工業(yè)園................................................6

2.1.2江西九江市潺陽(yáng)區(qū)城東工業(yè)基地.......................................7

2.1.3茂名石化工業(yè)區(qū)......................................................7

2.2廠址的對(duì)比與選擇.........................................................8

2.3廠址概況.................................................................10

2.4區(qū)位優(yōu)勢(shì).................................................................10

2.4.1原料來(lái)源充足......................................................10

2.4.2地理位置優(yōu)越......................................................10

2.4.3交通便利..........................................................11

2.4.4產(chǎn)業(yè)基礎(chǔ)..........................................................11

2.4.5市場(chǎng)優(yōu)勢(shì)..........................................................11

2.4.6豐富水資源........................................................11

2.4.7勞動(dòng)力資源..........................................................12

2.4.8優(yōu)惠政策..........................................................12

2.5設(shè)計(jì)原則.................................................................12

2.6總平面布置...............................................................13

2.6.1廠區(qū)布置............................................................13

2.6.2輔助生產(chǎn)及公用工程設(shè)施.............................................14

2.6.3儲(chǔ)存設(shè)施的布置.....................................................15

2.6.4運(yùn)輸設(shè)施的布置....................................................15

2.6.5生產(chǎn)管理及生活服務(wù)的設(shè)施...........................................15

2.7裝置布置.................................................................16

2.7.1裝置布置原則.......................................................16

2.7.2布置概況..........................................................16

2.7.3裝置安全措施.......................................................17

2.7.4環(huán)境保護(hù)措施.......................................................17

2.8廠內(nèi)運(yùn)輸設(shè)計(jì).............................................................17

2.8.1廠內(nèi)運(yùn)輸設(shè)計(jì)要求...................................................17

2.8.2本廠運(yùn)輸設(shè)計(jì).......................................................18

2.9廠區(qū)綠化.................................................................18

2.10裝置火災(zāi)危險(xiǎn)類別劃分...................................................19

2.11建筑物耐火等級(jí)劃分.....................................................20

2.12界區(qū)內(nèi)裝置間設(shè)計(jì)距離...................................................21

2.13產(chǎn)區(qū)周邊環(huán)境間距.......................................................22

第3章脫硫工藝.............................................................23

3.1原料路線確定的原則和依據(jù)................................................23

3.2工藝概述.................................................................23

3.3脫硫工藝方案比較和確定..................................................24

3.3.1Claus+LT-Scot工藝...................................................25

3.3.2氨法脫硫技術(shù)工藝...................................................27

3.3.3雙堿法煙氣脫硫技術(shù)工藝.............................................31

3.3.4離子液脫硫工藝.....................................................33

3.4工藝比較與選擇..........................................................36

2

3.4.1吸收劑消耗對(duì)比.....................................................36

3.4.2流程繁簡(jiǎn)的對(duì)比.....................................................36

3.4.3方案投資對(duì)比.......................................................37

3.4.4各工藝的優(yōu)缺點(diǎn)對(duì)比.................................................37

3.4.5工藝技術(shù)對(duì)比.......................................................38

3.4.6工藝確定...........................................................40

3.5反應(yīng)機(jī)理.................................................................40

3.5.1Claus反應(yīng)機(jī)理.......................................................40

3.5.2LT-Scot反應(yīng)機(jī)理.....................................................42

3.6反應(yīng)動(dòng)力學(xué)方程..........................................................43

3.6.1Claus反應(yīng)動(dòng)力學(xué)方程.................................................43

3.6.2LT-Scot反應(yīng)動(dòng)力學(xué)...................................................45

3.7反應(yīng)熱力學(xué)方程.........................................................47

3.7.1Claus工藝反應(yīng)熱力學(xué)方程:...........................................47

3.7.2LT-Scot工藝反應(yīng)熱力學(xué)方程..........................................47

3.8Claus工藝的對(duì)比與選擇.................................................48

3.8.1催化劑的對(duì)比.......................................................48

3.8.2設(shè)備選擇..........................................................49

3.9LT-Scot工藝對(duì)比與選擇..................................................52

3.9.1催化劑及吸收劑的對(duì)比...............................................52

3.9.2設(shè)備選擇..........................................................54

3.10工藝流程描述...........................................................55

3.10.1Claus單元流程描述..................................................55

3.10.2LT-Scot單元流程描述................................................58

3.10.3酸性水汽提單元....................................................62

第4章脫碳及資源化利用....................................................63

4.1原料路線確定的原則和依據(jù)................................................63

4.2工藝概述.................................................................63

4.3二氧化碳的分離工藝對(duì)比..................................................64

3

4.3.I乙醇胺吸收法.......................................................64

4.3.2膜分離法.........................................................66

4.3.3變壓吸附工藝.......................................................67

4.3.4液化提純工藝.......................................................69

4.4C02分離工藝工藝對(duì)比及確定..............................................71

4.4.1流程繁簡(jiǎn)及能耗對(duì)比...............................................71

4.4.2過(guò)程消耗對(duì)比.....................................................72

4.4.3工藝參數(shù)對(duì)比.....................................................72

4.4.4工藝優(yōu)缺點(diǎn)對(duì)比...................................................73

4.5食品級(jí)CO?生產(chǎn)工藝......................................................74

4.5.1工藝流程...........................................................74

4.5.2催化劑的對(duì)比及選擇...............................................76

4.5.3催化劑反應(yīng)原理及其動(dòng)力學(xué)方程.....................................77

4.5.4設(shè)備介紹...........................................................77

第5章工藝流程模擬........................................................79

5.1概述.....................................................................79

5.2物性方法選擇...........................................................79

5.2.IClaus單元模擬.....................................................80

5.2.2LT-Scot單元模擬..................................................81

5.2.3汽提單元模擬.....................................................82

5.2.4脫碳單元模擬.....................................................83

5.3工藝流程優(yōu)化...........................................................83

5.3.1急冷塔T201的優(yōu)化................................................83

5.3.2提純塔T401的優(yōu)化................................................85

第6章物料衡算.............................................................88

6.1物料衡算的意義.........................................................88

6.2物料衡算遵循的原則....................................................88

6.3物料衡算的步驟.........................................................88

4

6.4物料衡算.................................................................89

6.4.1Claus單元..........................................................89

6.4.2LT-Scot尾氣處理單元...............................................91

6.4.3汽提單元..........................................................95

6.4.4脫碳單元物料衡算...................................................97

第7章能量衡算.............................................................98

7.1能量衡算的意義..........................................................98

7.2能量衡算的原則..........................................................98

7.3全流程能量衡算..........................................................99

7.3.1Claus單元..........................................................99

7.3.2LT-Scot尾氣處理單元...............................................100

7.3.3汽提單元..........................................................102

7.3.4脫碳單元........................................................103

第8章過(guò)程節(jié)能及能耗計(jì)算.................................................105

8.1概述..................................................................105

8.2換熱網(wǎng)絡(luò)設(shè)計(jì)任務(wù)......................................................106

8.2.1工藝流股的提取...................................................106

8.2.2確定能量目標(biāo).....................................................107

8.2.3工藝換熱網(wǎng)絡(luò)設(shè)計(jì)................................................108

8.3項(xiàng)目綜合能耗及計(jì)算....................................................110

8.4每噸產(chǎn)品能耗計(jì)算表....................................................111

8.5每噸產(chǎn)品能耗比較.....................................................112

8.6萬(wàn)元產(chǎn)值綜合能耗......................................................112

8.7能源合理性分析........................................................113

8.8節(jié)能措施...............................................................113

第9章自動(dòng)控制及儀表.....................................................115

9.1工廠及控制概況........................................................115

9.2化工自動(dòng)化內(nèi)容.........................................................116

5

9.2.1儀表概述.........................................................116

9.2.2儀表選用原則.....................................................116

9.2.3控制系統(tǒng).........................................................116

9.3過(guò)程控制與檢測(cè).........................................................117

9.3.1離心泵的基本控制..................................................117

9.3.2離心式壓縮機(jī)的控制方案............................................118

9.3.3換熱器的控制方案................................................119

9.3.4精儲(chǔ)塔的控制方案..................................................119

9.3.5反應(yīng)器的控制方案..................................................121

9.3.6儲(chǔ)罐控制.........................................................121

9.3.7氣液分離罐的控制..................................................122

9.4ESD緊急停車系統(tǒng)....................................................123

9.5安全儀表系統(tǒng)SIS應(yīng)用.................................................124

第10章設(shè)備選型...........................................................127

10.1概述.................................................................127

10.2設(shè)計(jì)原則..............................................................127

10.3設(shè)備選型..............................................................127

第11章配管布置...........................................................128

11.1設(shè)計(jì)依據(jù).............................................................128

11.2布置要求..............................................................128

11.3管道設(shè)計(jì)..............................................................129

11.3.1管道的確定......................................................129

11.3.2壁厚及材料......................................................130

11.3.3管路閥門(mén)和管件的選擇............................................130

11.3.4管路絕熱設(shè)計(jì)....................................................131

11.3.5管道一覽表....................................................132

11.4管道布置...............................................................132

11.4.1管道敷設(shè)原則....................................................132

6

11.4.2管道連接........................................................133

11.5常見(jiàn)設(shè)備的管道布置....................................................133

11.5.1泵的管道設(shè)置....................................................133

11.5.2換熱器的管道布置................................................134

11.5.3塔的管道布置....................................................134

11.5.4容器的管道布置..................................................134

11.5.5壓縮機(jī)的管道布置................................................135

11.5.6調(diào)節(jié)閥的管道布置................................................135

11.5.7管廊的管道布置..................................................136

11.5.8其他管道布置....................................................136

11.5.9配管示例.....................................................137

第12章儲(chǔ)運(yùn)系統(tǒng)...........................................................138

12.1設(shè)計(jì)依據(jù).............................................................138

12.2設(shè)計(jì)原則...............................................................138

12.3儲(chǔ)存系統(tǒng)...............................................................139

12.3.1儲(chǔ)罐設(shè)置方案....................................................139

12.3.2儲(chǔ)罐的安全間距....................................................139

12.3.3罐區(qū)的安全措施....................................................140

12.3.4罐區(qū)管理制度....................................................140

12.4運(yùn)輸系統(tǒng)...............................................................140

12.4.1管廊運(yùn)輸........................................................140

12.4.2裝載區(qū)設(shè)計(jì)....................................................141

12.4.3廠區(qū)內(nèi)運(yùn)輸路線設(shè)計(jì)............................................141

第13章車間布置...........................................................142

13.1設(shè)計(jì)依據(jù).............................................................142

13.2基本資料............................................................142

13.3車間布置原則........................................................143

13.4車間組成.............................................................143

7

13.5車間布置方案...........................................................143

13.5.1平面結(jié)構(gòu)形式....................................................143

13.5.2柱網(wǎng)布置和跨度...................................................144

13.5.3廠房的寬度.......................................................144

13.6設(shè)備的布置.............................................................144

13.6.1塔的布置........................................................144

13.6.2換熱器的布置...................................................145

13.6.3容器的布置....................................................145

13.6.4泵和壓縮機(jī)的布置...............................................146

13.6.5爐類設(shè)備的布置.................................................146

13.6.6固定床反應(yīng)器的布置..............................................147

13.6.7安全、衛(wèi)生和防腐蝕問(wèn)題..........................................147

第14章公用工程...........................................................149

14.1企業(yè)集成方案.........................................................149

14.2設(shè)計(jì)依據(jù)..............................................................149

14.3公用工程站...........................................................150

14.3.1氮?dú)庹?.........................................................150

14.3.2富氧空氣站.......................................................150

14.3.3液氨站..........................................................150

14.3.4冷卻水站........................................................150

14.4供電系統(tǒng)...............................................................151

14.4.1供電電源........................................................151

14.4.2變配電站........................................................151

14.4.3保安電源系統(tǒng)..................................................151

14.4.4通訊系統(tǒng)......................................................152

14.5給排水系統(tǒng).............................................................152

14.5.1設(shè)計(jì)依據(jù)........................................................152

14.5.2本廠氣候........................................................152

14.5.3工藝用水........................................................152

8

14.6維修系統(tǒng)...............................................................153

14.6.1設(shè)備維護(hù)內(nèi)容...................................................153

14.6.2壓力容器、管道的定期檢修.......................................154

14.6.3泵的維修......................................................154

14.7消防系統(tǒng)...............................................................155

14.7.1設(shè)計(jì)依據(jù)........................................................155

14.7.2基礎(chǔ)消防措施.....................................................155

14.7.3廠區(qū)消防布置.....................................................156

14.7.4穩(wěn)高壓消防給水系統(tǒng)...............................................156

14.7.5滅火器.........................................................156

14.7.6消防管網(wǎng)的布置...................................................157

14.7.7消防水炮和消火栓.................................................157

14.7.8火災(zāi)系統(tǒng)監(jiān)測(cè)和火災(zāi)報(bào)警系統(tǒng).......................................157

第15章分析檢驗(yàn)...........................................................158

15.1設(shè)計(jì)依據(jù)..............................................................158

15.2設(shè)計(jì)原則..............................................................158

15.3硫磺的分析化驗(yàn).......................................................158

15.4二氧化碳的分析化驗(yàn)...................................................160

第16章重大危險(xiǎn)源分析及安全措施.........................................161

16.1概述.................................................................161

16.2重大危險(xiǎn)源分析.......................................................161

16.2.1潛在危險(xiǎn)場(chǎng)所.....................................................161

16.3重大危險(xiǎn)源物質(zhì)分析...................................................161

16.4HAZ0P分析..........................................................162

16.4.1概述............................................................162

16.4.2節(jié)點(diǎn)圖及具體分析.................................................163

16.4.3HAZOP分析的作用和意義...........................................166

16.5安全措施...............................................................166

9

16.5.1概述............................................................166

16.5.2總圖布置和建筑方面的安全措施....................................166

16.5.3工藝及設(shè)備等方面的對(duì)策措施.......................................167

16.5.4罐區(qū)安全措施....................................................168

16.5.5建（構(gòu)）筑物.....................................................172

16.5.6職業(yè)安全衛(wèi)生與常規(guī)防護(hù)安全對(duì)策措施..............................174

16.5.7事故及應(yīng)急管理...................................................174

第17章環(huán)境保護(hù)...........................................................175

17.1執(zhí)行法規(guī)與標(biāo)準(zhǔn)........................................................175

17.1.1項(xiàng)目編制原則.....................................................175

17.1.2環(huán)境質(zhì)量標(biāo)準(zhǔn).....................................................176

17.2廢氣處理.............................................................176

17.2.1工藝廢氣處理：.................................................177

17.2.2無(wú)組織排放氣處理...............................................177

17.3廢水處理...............................................................177

17.3.1脫硫廢水處理..................................................178

17.3.2含油污水處理..................................................180

17.4廢渣處理...............................................................181

17.4.1制硫催化劑和抗氧保護(hù)制硫催化劑.................................182

17.4.2加氫催化劑廢固處理..............................................182

17.4.3廢活性炭廢固處理................................................185

第18章概算...............................................................188

18.1工程概況.............................................................188

18.2設(shè)計(jì)依據(jù)..............................................................188

18.3項(xiàng)目總概算...........................................................188

第19章參考文獻(xiàn)...........................................................189

10

第1章項(xiàng)目總論

1.1項(xiàng)目概況

目前煤焦制氫是煉廠氫氣來(lái)源的新興選擇。近年來(lái)中國(guó)的茂名、淄博、九江、南京、

安慶等地?zé)拸S建設(shè)了一系列大規(guī)模煤制氫裝置。在煤化工領(lǐng)域，直接液化、合成氨等也

需要使用大規(guī)模氫氣。此外，在石化/化工園區(qū)建設(shè)氣化裝置，為園區(qū)用戶供應(yīng)氫氣、

蒸汽和工業(yè)氣體正在成為發(fā)展趨勢(shì)。因此，保證經(jīng)濟(jì)可行的大規(guī)模氫氣來(lái)源勢(shì)在必行，

所以提升針對(duì)煤制氫尾氣的脫硫處理也勢(shì)在必行。

GB31570-2015《石油煉制工業(yè)污染物排放標(biāo)準(zhǔn)》己頒布實(shí)施，GB31570-2015明

確規(guī)定，煉油行業(yè)新建企業(yè)自2015年7月1日起，現(xiàn)有企業(yè)自2017年7月1日起，酸

性氣硫磺回收裝置煙氣中SOz排放質(zhì)量濃度小于100mg/m3（0℃,101.325kPa,下同），

部分環(huán)境敏感地區(qū)小于50mg/m3。同時(shí)對(duì)硫化物排放總量也作了規(guī)定，這就要求裝置

硫回收率只有高于99.5%,才能達(dá)到此規(guī)定要求。尾氣處理工藝的開(kāi)發(fā)和實(shí)施勢(shì)在必行

并日趨重要。因此，煤制氫廢氣脫硫及資源化利用對(duì)于國(guó)家有著很大的戰(zhàn)略意義。

該項(xiàng)目是采用組合工藝，處理50000Nm3/h煤制氫廢氣脫硫及資源化利用的一體化

化工項(xiàng)目，為中國(guó)石油化工股份有限公司茂名分公司設(shè)計(jì)。

該項(xiàng)目選址于廣東茂名石化工業(yè)園區(qū)，利用煤制氫含硫廢氣作為原料，經(jīng)過(guò)脫硫脫

碳并進(jìn)行資源化利用，最大限度滿足工藝簡(jiǎn)單、低能耗、脫硫效率高、高品質(zhì)副產(chǎn)品和

環(huán)保的設(shè)計(jì)要求。

項(xiàng)目設(shè)計(jì)研究分析了市場(chǎng)及經(jīng)濟(jì)評(píng)價(jià)，不僅經(jīng)濟(jì)效益高，還制定了抵抗風(fēng)險(xiǎn)的措施,

增強(qiáng)了降低風(fēng)險(xiǎn)能力。嚴(yán)格三廢排放要求和控制處理措施，最大化的減少生產(chǎn)給環(huán)境造

成的污染。此外，詳細(xì)的安全評(píng)估