合成操作手册(外文译本).doc

THE END CUSTOMER 最终用户JOB No. 项目号DOC. NO. 文件号： XINNENG ENERGY LIMITED 6158-006158-00-PBO-001 Sheet No. 页数 1 of 58 PROJECT 项目名称 New Methanol Synloop 2035 MTD with IMC Internals 新甲醇回路2035MTD(带IMC内件) Rev. 版本 A/ This document is the property of METHANOL CASALE who will safeguard its right according to the civil and penal provisions of the law COVER SHEET 首页首页 OPERATING MANUAL 操作手册操作手册 LICENSOR DOC. NO.: 文件号:6158-00-PBO-001 TOTAL PAGES(INCLUDING THIS PAGE): 总页数(包括本页): 58 B A ISSUE FOR BASIC ENGINEERING FSESTGLC04.12.2006 /FIRST ISSUE FOR BASIC ENGINEERING 基础设 计 GF ESTGLC16.10.2006 REV. 版本 DESCRIPTION 描述 PREP 编制. CHK D. 校对 APP RD. 审核 DATE 日期 THE END CUSTOMER 最终用户JOB No. 项目号DOC. NO. 文件号： 6158-006158-00-PBO-001 PLANT LOCATION工 厂地址 Dalate County Erdos City Inner MongoliaChinaSheet No. 页数 2 of 58 PROJECT 项目名称 New Methanol Synloop 2035 MTD with IMC Internals 新甲醇回路2035MTD(带IMC内件) Rev. 版本 /A This document is the property of METHANOL CASALE who will safeguard its right according to the civil and penal provisions of the law REVISION INDEX SHEET 版版 本本 索索 引引 REV . PAG. /ABCD REV . PAG. /ABCD REV . PAG. /ABCD 1XX39X 2XX40X 3X41X 4X42X 5X43X 6X44X 7X45X 8X46X 9X47X 10X48X 11X49X 12X50X 13X51X 14X52X 15X53X 16X54X 17X55X 18X56X 19X57X 20X58X 21X 22X 23X 24X 25X 26X 27X 28X 29X 30X 31X 32X 33X 34X 35X 36X 37X 38X THE END CUSTOMER 最终用户JOB No. 项目号DOC. NO. 文件号： 6158-006158-00-PBO-001 PLANT LOCATION工 厂地址 Dalate County Erdos City Inner MongoliaChinaSheet No. 页数 3 of 58 PROJECT 项目名称 New Methanol Synloop 2035 MTD with IMC Internals 新甲醇回路2035MTD(带IMC内件) Rev. 版本 /A This document is the property of METHANOL CASALE who will safeguard its right according to the civil and penal provisions of the law I N D E X 目录 SECTION 1:GENERAL INFORMATION 综述 SECTION 2:PROCESS DESCRIPTION 工艺描述 SECTION 3:PRE-COMMISSIONING OPERATIONS 预试车操作 SECTION 4:COMMISSIONING AND START-UP 试车和开车 SECTION 5:NORMAL OPERATION 正常操作 SECTION 6:SHUT-DOWN 停车 SECTION 7:STEAM SUPERHEATER 蒸汽过热器 THE END CUSTOMER 最终用户JOB No. 项目号DOC. NO. 文件号： 6158-006158-00-PBO-001 PLANT LOCATION工 厂地址 Dalate County Erdos City Inner MongoliaChinaSheet No. 页数 4 of 58 PROJECT 项目名称 New Methanol Synloop 2035 MTD with IMC Internals 新甲醇回路2035MTD(带IMC内件) Rev. 版本 /A This document is the property of METHANOL CASALE who will safeguard its right according to the civil and penal provisions of the law SECTION 1 第一部分第一部分 GENERAL INFORMATION 综述综述 THE END CUSTOMER 最终用户JOB No. 项目号DOC. NO. 文件号： 6158-006158-00-PBO-001 PLANT LOCATION工 厂地址 Dalate County Erdos City Inner MongoliaChinaSheet No. 页数 5 of 58 PROJECT 项目名称 New Methanol Synloop 2035 MTD with IMC Internals 新甲醇回路2035MTD(带IMC内件) Rev. 版本 /A This document is the property of METHANOL CASALE who will safeguard its right according to the civil and penal provisions of the law I N D E X 目录目录 1. GENERAL INFORMATION 综述综述 1.1Project Description and location项目说明和厂址项目说明和厂址 1.2Basis of Design设计基础设计基础 1.2.1 Make-up gas新鲜合成气新鲜合成气 1.2.2 IMC converter feed gas IMC合成塔原料气合成塔原料气 1.2.3 Boiler Feed Water to Steam Drum去汽包的锅炉给水去汽包的锅炉给水 THE END CUSTOMER 最终用户JOB No. 项目号DOC. NO. 文件号： 6158-006158-00-PBO-001 PLANT LOCATION工 厂地址 Dalate County Erdos City Inner MongoliaChinaSheet No. 页数 6 of 58 PROJECT 项目名称 New Methanol Synloop 2035 MTD with IMC Internals 新甲醇回路2035MTD(带IMC内件) Rev. 版本 /A This document is the property of METHANOL CASALE who will safeguard its right according to the civil and penal provisions of the law PROJECT GENERAL DATA 项目基本信息项目基本信息 1.GENERAL INFORMATION 基本信息基本信息 1.1Process Description and location 工艺说明和厂址工艺说明和厂址 - Owner业主: Xinneng Energy Limited新能能源有限公司新能能源有限公司 - Plant location : Erdos City Inner Mongolia of P.R. China 装置所在地 中国内蒙古鄂尔多斯市 - Definition of the project: New Methanol Synloop 2035 MTD with IMC Internals 项目 采用IMC内件的新建2035MTD甲醇合成回路 - Engineering/Licensor: METHANOL CASALE S.A. 6900 LUGANO (SWITZERLAND) 1.2Basis of Design 设计基础 1.2.1 Make-up gas 新鲜合成气 The specified flow rate and composition is referred to the total fresh make-up gas entering into the C-7001/1 synthesis gas compressor. 特指的流速和组分是指进入C-7001/1 合成气压缩机的总新鲜气。 EOR末期SOR初期 - Flow rate流量 kmol/h 85838583 - Analysis 分析(wet basis):（湿基） COmol %30.4830.48 CO2 mol %2.722.72 H2 mol %66.1466.14 N2 mol %0.390.39 CH4 mol %0.120.12 Ar mol %0.150.15 - Conditions (at syngas compressor C-7001/1 suction): 合成气压缩机C-7001/1入口条件： . pressure压力MPa a5.4 . temperature温度C30 THE END CUSTOMER 最终用户JOB No. 项目号DOC. NO. 文件号： 6158-006158-00-PBO-001 PLANT LOCATION工 厂地址 Dalate County Erdos City Inner MongoliaChinaSheet No. 页数 7 of 58 PROJECT 项目名称 New Methanol Synloop 2035 MTD with IMC Internals 新甲醇回路2035MTD(带IMC内件) Rev. 版本 /A This document is the property of METHANOL CASALE who will safeguard its right according to the civil and penal provisions of the law 1.2.2 IMC converter feed gas IMC合成塔进料气 The IMC converter is fed by different gas composition during the SOR/EOR catalyst life. 在SOR/EOR催化剂寿命期间， IMC合成塔原料气的组分是不同的。 Here below the SOR and EOR expected gas flow rate and composition fed to the IMC converter R-7001. 以下是预计的初末期工况时入塔气的流量和组成。 SOR condition 初期工况 - Flow rate流量kmol/h25376 - Analysis (dry basis):分析（干基） COmol %16.25 CO2 mol %5.47 H2 mol %69.21 N2 mol %5.43 CH4 mol %1.28 Armol %1.89 H2Omol %0.06 MeOHmol %0.41 EOR condition 末期工况 - Flow rate流量kmol/h26260 - Analysis (dry basis):分析（干基） COmol %17.02 CO2 mol %5.24 H2 mol %72.63 N2 mol %2.89 CH4 mol %0.75 Armol %1.02 H2Omol %0.06 MeOHmol %0.39 1.2.3 Boiler Feed Water to the Steam Drum 汽包锅炉给水 The heat and material balance around the steam drum has been performed considering the BFW discharged from the BFW pumps at the following conditions: 考虑了如下的泵出口锅炉给水条件，进行了汽包的物料和热量衡算。 222 C and about 4.58 MPa abs.(SOR初期) 226 C and about 4.79 MPa abs.(EOR末期) THE END CUSTOMER 最终用户JOB No. 项目号DOC. NO. 文件号： 6158-006158-00-PBO-001 PLANT LOCATION工 厂地址 Dalate County Erdos City Inner MongoliaChinaSheet No. 页数 8 of 58 PROJECT 项目名称 New Methanol Synloop 2035 MTD with IMC Internals 新甲醇回路2035MTD(带IMC内件) Rev. 版本 /A This document is the property of METHANOL CASALE who will safeguard its right according to the civil and penal provisions of the law SECTION 2 第二部分第二部分 PROCESS DESCRIPTION 工艺描述工艺描述 THE END CUSTOMER 最终用户JOB No. 项目号DOC. NO. 文件号： 6158-006158-00-PBO-001 PLANT LOCATION工 厂地址 Dalate County Erdos City Inner MongoliaChinaSheet No. 页数 9 of 58 PROJECT 项目名称 New Methanol Synloop 2035 MTD with IMC Internals 新甲醇回路2035MTD(带IMC内件) Rev. 版本 /A This document is the property of METHANOL CASALE who will safeguard its right according to the civil and penal provisions of the law I N D E X 2.PROCESS DESCRIPTION 工艺描述工艺描述 2.1SynLoop Process Description合成回路工艺描述合成回路工艺描述 2.2IMC Converter Process Description IMC合成塔工艺描述合成塔工艺描述 THE END CUSTOMER 最终用户JOB No. 项目号DOC. NO. 文件号： 6158-006158-00-PBO-001 PLANT LOCATION工 厂地址 Dalate County Erdos City Inner MongoliaChinaSheet No. 页数 10 of 58 PROJECT 项目名称 New Methanol Synloop 2035 MTD with IMC Internals 新甲醇回路2035MTD(带IMC内件) Rev. 版本 /A This document is the property of METHANOL CASALE who will safeguard its right according to the civil and penal provisions of the law 2.PROCESS DESCRIPTION 工艺描述 2.1Synloop Process Description合成回路工艺描述合成回路工艺描述 (Ref. drawing No. 6158-00-PDI-101 108) The methanol synthesis loop imply the installation of a synthesis section, having a Isothermal methanol converter (R-7001) developed with the new METHANOL CASALE features, and a complete methanol recovery system, including a feed- product exchanger, a methanol water cooler and a methanol H.P. separator. 甲醇合成回路即指合成工段，包括用到了卡萨利甲醇公司新技术的等温甲醇合成塔(R- 7001)，一套完整的甲醇冷却回收系统，一个进出口换热器以及一个甲醇水冷器和一个甲醇 高压分离器。 A steam drum and a couple of boiler feed water circulation pumps are installed too, in order to achieve the methanol converter isothermocity. 为了使合成塔达到均温，会设置一个汽包和几个锅炉给水循环泵。 A steam superheater will heat-up a share of the stream produced in the steam drum, then fed to the ammonia steam turbine (outside B.L.) and to the methanol syngas compressor. 一部分由蒸汽包生成的蒸汽被蒸汽过热器加热，然后被送至氨蒸汽轮机（位于界区外）以 及甲醇合成气压缩机。 Resuming, the main synloop equipment installed are here below listed: 重复一遍，添置的主要回路设备包括以下这些： * R-7001: IMC Methanol Converter, with METHANOL CASALE Internals 使用卡萨利内件的IMC合成塔 * R-7002A/B: Guard Bed保护床 * E-7001: Feed-Product Exchanger进出口换热器 * E-7002:Water Cooler水冷器 * E-7003:Kick Back Cooler防喘振水冷器 * E-7005:Desalted Water Preheater脱盐水预热器 * V-7001:Steam Drum汽包 * V-7002:Methanol H.P. Separator甲醇高压分离器 * V-7003:Methanol Flash Drum甲醇闪蒸槽 * V-7006:Blow Down Drum排污罐 * P-7001 A/B:Boiler Feed Water Pumps锅炉给水泵 * M-7001:HRU氢回收装置 * M-7002 A/B:Crude Methanol Filters粗甲醇过滤器 * F-7001:Steam Superheater蒸汽过热器 THE END CUSTOMER 最终用户JOB No. 项目号DOC. NO. 文件号： 6158-006158-00-PBO-001 PLANT LOCATION工 厂地址 Dalate County Erdos City Inner MongoliaChinaSheet No. 页数 11 of 58 PROJECT 项目名称 New Methanol Synloop 2035 MTD with IMC Internals 新甲醇回路2035MTD(带IMC内件) Rev. 版本 /A This document is the property of METHANOL CASALE who will safeguard its right according to the civil and penal provisions of the law Fresh make-up gas coming from the MUG compressor (C-7001/1) is fed to the Guard Bed R-7002A/B , then mixed with the recirculating gas from circulator (C-7001/2), which from the Methanol H.P. separator (V2002), and then to the methanol synthesis loop. 从MUG压缩机出来的新鲜合成气进入R-7002A/B保护床与来自循环机的循环气体混合， 随后进入到甲醇合成回路中。 The gas mixture is firstly preheated in the Feed Product Exchanger E-7001, then enters into and reacts in the R-7001, IMC converter, and the heat of reaction is partly recovered in the feed-product exchanger E-7001. The methanol starts to condense in the E-7001. 该混合气体首先在进出口换热器E-7001中预热，然后进入IMC合成塔R-7001中进行反 应，部分反应热在进出口换热器E-7001中回收。甲醇在E-7001处开始发生冷凝。 The gas is further cooled down in the Desalted Water Preheater E-7005 to recover heat by heating demineral water. The crude methanol is then condensed by mean of water cooler E-7002 and separated in the V-7002 methanol H.P. separator. 气体在脱盐水预热器E-7005中加热脱盐水回收热量。粗甲醇通过E-7002水冷器冷凝下来 并在V-7002甲醇高压分离器中分离。 The recovered crude methanol is sent to the methanol flash drum V-7003. After flashing, the crude methanol is then sent to B.L. for further processing facilities. 冷凝下来的粗甲醇送到甲醇闪蒸槽V-7003。闪蒸之后，粗甲醇被送出界区用于下游工艺。 The V-7002 overhead gas is sent again to the Circulator C-7001/2 suction, as recycle gas. V-7002顶部的气体作为循环气体返回到C-7001/2 段循环机入口处。 2.2IMC Converter Process Description IMC合成塔工艺说明 The catalytic mass loaded in the R-7001 is cooled-down during the methanol conversion reaction by means of plate exchangers immersed in the catalyst itself. 装载在R-7001中的催化剂在甲醇转化反应期间通过浸没在催化剂中的板式换热器来冷却。 The heat exchange is performed counter-current respect to the process gas flowing through the catalyst and the BFW inside the plates. 换热是通过流经催化剂的工艺其和板内的锅炉给水的逆向流动来实现的。 The process side path is from the top to the bottom of the converter, while the BFW from the bottom to the top of the plate exchangers. 工艺气侧的流向是从合成塔的顶部至合成塔的底部的，而锅炉给水则是从板式换热器的底 部到顶部的。 The BFW during the path inside the plate changes phase and the steam is then generated and released in the steam drum V-7001. 锅炉给水在换热板内流动时发生相变化，产生蒸汽且在汽包中得到分离。 The boiler feed water / steam system is a forced circulation one, by means of the P-7001 A/B (two electrical driven pumps). 锅炉给水/蒸汽系统通过泵P-7001A/B（两台电机驱动泵）来维持强制循环。 The process side gas path is very simple. The gas enters in the vessel from the nozzle “A“, then after the inlet distributors reaches the catalyst and after having passed all the catalytic mass flows to the external feed-product exchanger E- 7001 through the nozzle “B“. THE END CUSTOMER 最终用户JOB No. 项目号DOC. NO. 文件号： 6158-006158-00-PBO-001 PLANT LOCATION工 厂地址 Dalate County Erdos City Inner MongoliaChinaSheet No. 页数 12 of 58 PROJECT 项目名称 New Methanol Synloop 2035 MTD with IMC Internals 新甲醇回路2035MTD(带IMC内件) Rev. 版本 /A This document is the property of METHANOL CASALE who will safeguard its right according to the civil and penal provisions of the law 工艺气侧的流向非常简单，气体从管口”A”进入合成塔，经入口分布器后接触催化剂，经过 全部催化剂之后通过管口”B”进入进出口换热器E-7001。 The boiler feed water coming from the pump P-7001 A/B enters the converter in the bottom part. Then by-means of an internal collector, is sent properly divided plates by plates, at the bottom collector of each plate. 来自泵P-7001A/B的锅炉给水进入合成塔的底部。随后，通过内部分布管，通过每块板的 底部收集管分别送至各块换热板。 The heat of reaction is then absorbed by the boiler feed water and the medium pressure steam generated. 反应热接着被锅炉给水所吸收并且产生中压蒸汽。 Through the upper plate collector the two-phase mixture (liquid BFW plus generated steam) is then collected to the outlet nozzles and sent to the Steam Drum V-7001 where the steam is released and sent to Steam Superheater F- 7001 and let down to Battery Limits. 通过上部换热板的收集管收集的两相混合物（液态锅炉给水和产生的蒸汽）被收集至出口 管且被送到汽包V-7001处，在该处蒸汽被分离并送至F-7001蒸汽过热器最终减压送出界 区。 The medium pressure steam generated is partially sent to the LP steam heater and partially superheated in the fired heater F-2001. 生成的中压蒸汽部分被送至低压蒸汽过热器并且在加热炉F-2001中被部分过热加热。 The super heated steam is fed to the synthesis compressor steam turbine and sent outside the battery limits. 过热蒸汽被送至合成压缩机蒸汽锅炉然后被送至界区外。 THE END CUSTOMER 最终用户JOB No. 项目号DOC. NO. 文件号： 6158-006158-00-PBO-001 PLANT LOCATION工 厂地址 Dalate County Erdos City Inner MongoliaChinaSheet No. 页数 13 of 58 PROJECT 项目名称 New Methanol Synloop 2035 MTD with IMC Internals 新甲醇回路2035MTD(带IMC内件) Rev. 版本 /A This document is the property of METHANOL CASALE who will safeguard its right according to the civil and penal provisions of the law SECTION 3 第三部分第三部分 PRE-COMMISSIONING OPERATIONS 预试车预试车 THE END CUSTOMER 最终用户JOB No. 项目号DOC. NO. 文件号： 6158-006158-00-PBO-001 PLANT LOCATION工 厂地址 Dalate County Erdos City Inner MongoliaChinaSheet No. 页数 14 of 58 PROJECT 项目名称 New Methanol Synloop 2035 MTD with IMC Internals 新甲醇回路2035MTD(带IMC内件) Rev. 版本 /A This document is the property of METHANOL CASALE who will safeguard its right according to the civil and penal provisions of the law I N D E X 目录目录 3.PRE-COMMISSIONING OPERATIONS 预试车预试车 3.1General概述概述 3.2Converter Internals Erection合成塔内件安装合成塔内件安装 3.3Plant Inspection and Testing装置的检测装置的检测 3.4Plant Cleaning装置的清洗装置的清洗 3.5 Pressure Testing压力测试压力测试 3.6 Plant Purging装置吹扫装置吹扫 THE END CUSTOMER 最终用户JOB No. 项目号DOC. NO. 文件号： 6158-006158-00-PBO-001 PLANT LOCATION工 厂地址 Dalate County Erdos City Inner MongoliaChinaSheet No. 页数 15 of 58 PROJECT 项目名称 New Methanol Synloop 2035 MTD with IMC Internals 新甲醇回路2035MTD(带IMC内件) Rev. 版本 /A This document is the property of METHANOL CASALE who will safeguard its right according to the civil and penal provisions of the law 3.PRE-COMMISSIONING OPERATIONS 预试车预试车 3.1General 概述概述 In this section we will give general guidelines of the step normally executed during pre-commissioning phase and refers only to equipments, piping and instrumentations inside the synloop. 在这一节中我们将给出预试车阶段的正常操作步骤和总体方针，范围仅限于合成回路中的 设备，管道及仪器。 The detailed description and the operation to be performed shall be in accordance with Xinneng Chemical Co., Ltd. standard procedure and rules with special attention to safety precautions. 详细的描述和要采取的操作应当符合新能化工有限公司的标准流程和规范，特别是安全预 防措施。 3.2Converter Internals Erection 合成塔内件安装 3.3Plant Inspection and Testing 设备的检查与测试 The plant must be systematically checked against the P 所有设备，管道，阀门和仪表都要正确放置； correct connections to instruments on site and on control panel and ESD(Emergency Shut Down System). 正确连接现场，控制板和ESD（紧急停车系统）仪表。 3.4Plant Cleaning 装置清洗 The purpose is to remove all rust with scale and grease or other contaminants on the surfaces as well as any foreign material left during construction to prevent the possibility of damaging rotating equipment or blocking instrument connections. 目的是移除表面上的所有铁锈，污垢和油脂或其他污染物以及在施工期间遗留下来的异 物，从而防止动设备受损或者堵塞仪表接口。 3.5Pressure Testing 压力测试 Prior to completion of construction any equipment/piping will have been subjected to hydrostatic, or possibly pneumatic tests, as required by the applicable design Codes and Statutory Regulations. The purpose of the above testing is to prove the mechanical strength and integrity of the individual plant items and pipe works. THE END CUSTOMER 最终用户JOB No. 项目号DOC. NO. 文件号： 6158-006158-00-PBO-001 PLANT LOCATION工 厂地址 Dalate County Erdos City Inner MongoliaChinaSheet No. 页数 16 of 58 PROJECT 项目名称 New Methanol Synloop 2035 MTD with IMC Internals 新甲醇回路2035MTD(带IMC内件) Rev. 版本 /A This document is the property of METHANOL CASALE who will safeguard its right according to the civil and penal provisions of the law 在完成安装之前，任何设备/管道都要进行水压或根据相关的设计规范和法令规定，可能进 行气密测试，该测试的目的是验证单个装置设备和管道工程的机械强度和完整性。 In addition after completion of construction all parts of the plant subjected to pressure shall undergo a pneumatic test at or near their normal operating pressure to determine whether there are any leaks in the system which could lead to escape of toxic/inflammable substances. 此外，在完成安装后，装置所有的承压部件都必须在达到或者接近正常操作压力下进行气 压测试以测定该系统中是否有导致毒物/易燃物泄漏等的任何漏洞。 Pressurizations gas can be air or preferably nitrogen (if available at such pressure) in order to perform at a same time pressure test and preliminary plant purging. 加压气体可以是空气，最好是氮气（如果有此压力等级氮气），这样可以同时进行压力测 试和装置的初步吹扫。 Pressure test is normally considered successful if no leaks have been detected on flanges or instruments and pressure decrease is not higher than 2% of test pressure over a period of 24 hours. 若在24小时中法兰或仪器处未发现泄漏并且在压力测试中压力下降不超过2%的情况下，我 们一般认为该压力测试是成功的。 When pressure testing is performed with catalyst or packing installed rate of pressure decrease shall be not higher than 0.20.3 MPa/10 min. 当在有催化剂或填料的情况下进行压力测试，则压力下降速率不能快过0.20.3 MPa/10 min。 The pressure difference between the process side of the plates (catalyst side) and the steam side (internal of the plates) shall not exceed the value of 6.6 MPa. At this value the interlock system (PDSHH7001) will be activated preventing damages to the equipment. 换热板的工艺侧（催化剂侧）和蒸汽侧（设备内件处）之间的压差不得超过换热板的工艺侧（催化剂侧）和蒸汽侧（设备内件处）之间的压差不得超过6.6MPa。在这。在这 个压力值上连锁装置系统（个压力值上连锁装置系统（PDSHH7043）会自动启动保护设备不受伤害。）会自动启动保护设备不受伤害。 The interlock system linked to the pressure difference calculation shall be kept in operation during every operating phase of the IMC methanol synthesis loop. (Refer also to Loop Operation, and to Interlock Description E- 101) 在IMC甲醇合成回路系统的每个运行阶段，必须保持连锁装置系统与压差计算之间的关 联。（参考