年产18万吨丙烯-54万吨环氧丙烷项目-物料平衡计算书

年产18万吨丙烯-54万吨环氧丙烷项目-物料平衡计算书第一章物料平衡计算书1.1概述本项目利用进口丙烷为主要原料合成乙烯，最终可制得纯度为99.9%的聚合级丙烯，同时联产纯度为99.9%的环氧丙烷。在确定整个工艺流程后，经AspenPlus的全流程模拟，获得了更为准确的数据，由定型阶段转为定量阶段。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。1.2物料衡算的原理和准则物料衡算是以质量守恒定律为基础，对物料平衡进行的计算。物料平衡是指“在单位时间内进入系统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”。进行物料衡算时，先必须确定衡算的体系。对于已经达到稳定的体系，通常满足以下关系：（进料量之和）-（出料量之和）=（系统累积量）当系统中有化学反应时可表示为：（进料量之和）-（出料量之和）+（反应消耗量）-（反应生成量）=（系统累积量）利用以上两个关系，可以对整个工艺系统或子系统进行物料衡算。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下表所示：表1.1物料衡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质量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由于系统中存在化学反应，我们主要采用总质量衡算的的衡算方法，同时列出每种物料组分的质量流量便于查找和计算。1.3总项目核算从原料入厂到产品输出，其工艺路线可分为如下两个工段：丙烷脱氢工段和丙烯还氧化工段。1.3.1物料衡算任务对于本厂，工艺采取年开工300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：① 确定对丙烯、环氧丙烷以及副产品的实际产量以及质量指标；② 确定丙烷、甲醇、过氧化氢等主要物料的消耗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。

1.3.2丙烷脱氢工段图1.1丙烷脱氢工段（一）图1.2丙烷脱氢工段（二）图1.3丙烷脱氢工段（三） 年产18万吨丙烯-54万吨环氧丙烷项目-物料平衡计算书 表1.2丙烷脱氢工段总物料衡算INOUT流股编号C3H8-FEECO-WATERS125S129H2-OUTS130质量流量kg/hr质量流量kg/hr质量流量kg/hr质量流量kg/hr质量流量kg/hr质量流量kg/hrC3H899692.3761099.086101224.6476488150.51218454.7354192H20046.000849803106.938550C3H600817593696.775669154704.2066C2H60010166.99730.01130325147.2491390.02510131C2H40087.2174602.84565090H2O00.01441222000.013756840CH4003035.4325702518.466060H2O2000000C3H6O000000CH3OH000000C4H10O2000000C3H8O2000000O2000000BENZENE000000温度℃3030-44.2041468.13800273-998.13800273压力bar8197.511.00065147.5气相分率1010.9964164810.99641648总质量流率kg/hr99692.37610.0144122214251.921924658.25256022.8010154758.967199692.3905199691.94251年产18万吨丙烯-54万吨环氧丙烷项目-物料平衡计算书表1.3R101物料衡算INOUT流股编号S102S103质量流量kg/hr质量流量kg/hrC3H8286531.865238174.679H214516.021216520.1594C3H6610.23050844496.2575C2H6687.9504512153.17362C2H413.2948818153.302389H2O1617.950051617.95005CH411766.157112627.9476H2O200C3H6O00CH3OH00C4H10O200C3H8O200O200BENZENE00温度℃600496.791818压力bar21.74气相分率11总质量流率kg/hr315743.469315743.469

表1.4R102物料衡算INOUT流股编号S104S105质量流量kg/hr质量流量kg/hrC3H8238174.679215641.16H216520.159417075.7122C3H644496.257561094.1273C2H62153.173625726.7057C2H4153.30238989.6916669H2O1617.950051617.95005CH412627.947614498.1228H2O200C3H6O00CH3OH00C4H10O200C3H8O200O200BENZENE00温度℃600566.752109压力bar1.741.48气相分率11总质量流率kg/hr315743.469315743.469

表1.5R103物料衡算INOUT流股编号S106S107质量流量kg/hr质量流量kg/hrC3H8215641.16199748.001H217075.712217402.2295C3H661094.127372084.6051C2H65726.70578709.73448C2H489.691666990.7279205H2O1617.950051617.95005CH414498.122816090.2215H2O200C3H6O00CH3OH00C4H10O200C3H8O200O200BENZENE00温度℃600578.927709压力bar1.481.22气相分率11总质量流率kg/hr315743.469315743.469

表1.6R104物料衡算INOUT流股编号S108S109质量流量kg/hr质量流量kg/hrC3H8199748.001187168.319H217402.229517669.0216C3H672084.605180862.0181C2H68709.7344811002.2529C2H490.7279205103.358418H2O1617.950051617.95005CH416090.221517320.5492H2O200C3H6O00CH3OH00C4H10O200C3H8O200O200BENZENE00温度℃600583.018962压力bar1.220.96气相分率11总质量流率kg/hr315743.469315743.469

表1.7T103物料衡算INOUT流股编号S123S125S126质量流量kg/hr质量流量kg/hr质量流量kg/hrC3H8186314.59199.0861012186215.505H246.000849846.00084980C3H680313.0928179044C2H610167.033710166.99730.03640456C2H487.217460387.217460H2O1617.8928601617.89286CH43035.432573035.432570H2O2000C3H6O000CH3OH000C4H10O2000C3H8O2000O2000BENZENE000温度℃-99-44.20414624.3402582压力bar11.0006514910气相分率010总质量流率kg/hr281581.26114251.9219267329.339281581.261281581.2609

表1.8T104物料衡算INOUT流股编号S126S127S128质量流量kg/hr质量流量kg/hr质量流量kg/hrC3H8186215.50579.3830679186136.122H2000C3H679495.904479337.8002158.104207C2H60.036404560.036404560C2H4000H2O1617.8928601617.89286CH4000H2O2000C3H6O000CH3OH000C4H10O2000C3H8O2000O2000BENZENE000温度℃24.34025828.1788437523.1915153压力bar107.59气相分率010总质量流率kg/hr267329.33979417.2196187912.119267329.339267329.33861.3.3丙烯环氧化工段图1.4丙烯环氧化工段（一）图1.5丙烯环氧化工段（二）图1.6丙烯环氧化工段（三）图1.7丙烯环氧化工段（四）图1.8丙烯环氧化工段（五）图1.9丙烯环氧化工段（六）图1.10丙烯环氧化工段（七） 图1.11丙烯环氧化工段（八）表1.9丙烯环氧化工段总物料衡算INOUT流股编号S201H2O2-FEECH4O-ADDGASFEEDBEN-ADDS206S216S223S233S234S235S236质量流量kg/hr质量流量kg/hr质量流量kg/hr质量流量kg/hr质量流量kg/hr质量流量kg/hr质量流量kg/hr质量流量kg/hr质量流量kg/hr质量流量kg/hr质量流量kg/hr质量流量kg/hrC3H854.7354192000.0320987300.000204554.76791650.000108790000H2000000000000C3H654704.2066000.5630389604.5678814951.971340300000C2H60.0251013100000.0000186470.0250780500000C2H4000000000000H2O083303.69388.0719294200000.056797330.0000030371518.72358105478.7820.000093285CH4000000000000H2O2044855.83520000000000C3H6O000.843473711.1341864400074215.61980000CH3OH00554.7156460.7963149600012.436561500.0065891700C4H10O2000000001414.716730.000354310.00014140C3H8O200000000000.00039402393.95378O200000340.528371000000BENZENE00003.976773220000.000128463.9767830300温度℃4040404080.128675-72.050474-44.725079118.367286120.09446569.14738460.3496367142.059944压力bar44441.0132529.91.01325101.013251.013250.202650.20265气相分率1000.2329773901100000总质量流率kg/hr54758.9671128159.529523.6310492.525639113.97677322345.096476106.76433674228.11331413.716861522.70731105478.783393.953873183488.6296183489.1352表1.10R201物料衡算INOUT流股编号S203S204质量流量kg/hr质量流量kg/hrC3H874.101950874.1019508H200C3H697775.541743127.3132C2H60.049109230.04910923C2H400H2O83311.7695106997.568CH400H2O244855.83520C3H6O62.362986974275.8765CH3OH660245.37659702.38C4H10O201414.71703C3H8O20393.954174O20.00334858340.531721BENZENE00温度℃36.781774636.7817746压力bar5.15.1气相分率00总质量流率kg/hr886325.034886326.491

表1.11T201物料衡算INOUT流股编号S205S206S207质量流量kg/hr质量流量kg/hr质量流量kg/hrC3H874.10195080.000204574.1017463H2000C3H643127.31324.5678814943122.7454C2H60.049109230.0000186470.04909058C2H4000H2O106997.5680106997.568CH4000H2O2000C3H6O74275.8765074275.8765CH3OH659702.380659702.38C4H10O21414.7170301414.71703C3H8O2393.9541740393.954174O2340.531721340.5283710.00334992BENZENE000温度℃37.3525568-72.050474177.292396压力bar29.929.929.9气相分率010总质量流率kg/hr886326.491345.096476885981.395886326.491886326.4915

表1.12T202物料衡算INOUT流股编号S207S208S209质量流量kg/hr质量流量kg/hr质量流量kg/hrC3H874.101746319.334439454.7673069H2000C3H643122.745443070.774151.9712667C2H60.049090580.024012530.02507805C2H4000H2O106997.5680106997.568CH4000H2O2000C3H6O74275.876560.384056574215.4924CH3OH659702.3881.6706092659620.709C4H10O21414.7170301414.71703C3H8O2393.9541740393.954174O20.003349920.003349920BENZENE000温度℃177.29239641.5100526160.031696压力bar29.91717气相分率010总质量流率kg/hr885981.39543232.1906842749.204885981.395885981.3946

表1.13T203物料衡算INOUT流股编号S215S216S217S218质量流量kg/hr质量流量kg/hr质量流量kg/hr质量流量kg/hrC3H8109.2657354.767916554.49781370H20000C3H653.009406451.97134031.03806610C2H60.025119040.025078050.0000409930C2H40000H2O106997.56800.05697756106997.511CH40000H2O20000C3H6O84325.9927084325.99270CH3OH660769.6901161.48852659608.202C4H10O21414.71703001414.71703C3H8O2393.95417400393.954174O20000BENZENE0000温度℃62.9387391-44.72507934.280320568.137395压力bar1.013251.013251.013251.01325气相分率0100总质量流率kg/hr854064.222106.76433685543.0741768414.384854064.222854064.2224

表1.14T204物料衡算INOUT流股编号S220S221S223质量流量kg/hr质量流量kg/hr质量流量kg/hrC3H854.497813754.49770490.00010879H2000C3H61.03806611.03806610C2H60.0000409930.0000409930C2H4000H2O0.056977560.000180220.05679733CH4000H2O2000C3H6O84325.992710110.372974215.6198CH3OH1161.488521149.0519612.4365615C4H10O2000C3H8O2000O2000BENZENE000温度℃117.210749115.085452118.367286压力bar101010气相分率000总质量流率kg/hr85543.074111314.960874228.113385543.074185543.0741

表1.15T205物料衡算INOUT流股编号S224S225S226质量流量kg/hr质量流量kg/hr质量流量kg/hrC3H8000H2000C3H6000C2H6000C2H4000H2O106997.5110.00370476106997.507CH4000H2O2000C3H6O000CH3OH659608.202659608.1950.00658933C4H10O21414.7170301414.71703C3H8O2393.9541740393.954174O2000BENZENE000温度℃68.13739564.534760499.9023184压力bar1.013251.013251.01325气相分率000总质量流率kg/hr768414.384659608.199108806.185768414.384768414.384

表1.16T206物料衡算INOUT流股编号S226S227S228质量流量kg/hr质量流量kg/hr质量流量kg/hrC3H8000H2000C3H6000C2H6000C2H4000H2O106997.5071518.72471105478.782CH4000H2O2000C3H6O000CH3OH0.006589330.006589330C4H10O21414.717031414.716890.0001414C3H8O2393.9541740393.954174O2000BENZENE000温度℃99.902318496.9578688100.042013压力bar1.013251.013251.01325气相分率000总质量流率kg/hr108806.1852933.44819105872.737108806.185108806.1852

表1.17T207物料衡算INOUT流股编号S227S231S232-INS233质量流量kg/hr质量流量kg/hr质量流量kg/hr质量流量kg/hrC3H80000H20000C3H60000C2H60000C2H40000H2O1518.7247151.67045471570.395160.000003037CH40000H2O20000C3H6O0000CH3OH0.006589330.003276630.009865970C4H10O21414.716890.006508710.006672121414.71673C3H8O20000O20000BENZENE019542.634219542.63410.00012846温度℃96.957868869.149926670.7714313120.094465压力bar1.013251.013251.013251.01325气相分率0010总质量流率kg/hr2933.4481919594.314421113.04581414.7168622527.7625922527.76266 表1.18T208物料衡算INOUT流股编号S230S235S236质量流量kg/hr质量流量kg/hr质量流量kg/hrC3H8000H2000C3H6000C2H6000C2H4000H2O105478.782105478.7820.000093285CH4000H2O2000C3H6O000CH3OH000C4H10O20.00014140.00014140C3H8O2393.9541740.00039402393.95378O2000BENZENE000温度℃60.368541560.3496367142.059944压力bar0.202650.202650.20265气相分率000总质量流率kg/hr105872.737105478.783393.953873105872.737105872.73691.3.4物料衡算表1.19全流程总物料衡算INOUT流股编号C3H8-FEECO-WATERH2O2-FEECH4O-ADDGASFEEDBEN-ADDH2-OUTS125S129S206S216S223S233S234S235S236质量流量kg/hr质量流量kg/hr质量流量kg/hr质量流量kg/hr质量流量kg/hr质量流量kg/hr质量流量kg/hr质量流量kg/hr质量流量kg/hr质量流量kg/hr质量流量kg/hr质量流量kg/hr质量流量kg/hr质量流量kg/hr质量流量kg/hr质量流量kg/hrC3H899692.37610000.032098730150.51218499.086101224.64764880.000204554.76791650.000108790000H20000003106.9385546.000849800000000C3H600000.56303896096.775669181759364.5678814951.971340300000C2H6000000147.24913910166.99730.011303250.0000186470.0250780500000C2H40000002.845650987.2174600000000H2O00.0144122283303.69388.07192942000.0137568400000.056797330.0000030371518.72358105478.7820.000093285CH40000002518.466063035.4325700000000H2O20044855.83520000000000000C3H6O0000.843473711.1341864400000074215.61980000CH3OH000554.7156460.7963149600000012.436561500.0065891700C4H10O20000000000001414.716730.000354310.00014140C3H8O2000000000000000.00039402393.95378O2000000000340.528371000000BENZENE000003.976773220000000.000128463.9767830300温度℃303040404080.128675-99-44.2041468.13800273-72.050474-44.725079118.367286120.09446569.14738460.3496367142.059944压力bar814441.0132511.000651497.529.91.01325101.013251.013250.202650.20265气相分率10000.232977390110.996416481100000总质量流率kg/hr99692.37610.01441222128159.529563.6310492.525639113.976773226022.8010114251.921924658.2525345.096476106.76433674228.11331414.716861522.70731105478.783393.953873228422.053228423.10671.4总结通过对工段以及单个单元操作的物料平衡计算，我们得到了原料、产品、三废处理量，具体数据如下所示：表1.20原料消耗量序号名称消耗量1主要原料丙烷71.79万t/a2过氧化氢9.27万t/a3甲醇0.37万t/a4苯48.22t/a5辅助原料TS-1分子筛103.2t/a6Pt-Sn/Al2O3催化剂326.07t/a表1.21环氧丙烷及副产品的产量和质量指标产品产量万吨/年质量指标%丙烯17.8>99.9环氧丙烷53.4>99.9丙烯17.74>99.9丙二醇（副产物）0.28>99.9丙二醇单甲醚（副产物）1.02>99.9表1.22三废处理量排放物处理量万t/年废气10.3废水77废渣429.27第二章能量平衡计算书2.1总述本项目计划建设一套以丙烷脱氢制丙烯联合丙烯环氧化装置。在生产过程中，伴随着物料从一个单元进入另一个单元，发生质量传递的同时也进行能量传递。我们通过对整个流程中的能量进行衡算，从而进一步定量的描述，便于我们根据设备的热负荷选型，确定在流程中的能量输入位置、整体的公用工程耗量、能量利用效率等。通过能量衡算，我们可以进一步发现过程中能量利用不合理的环节，从而有助于我们进行换热网络设计，在当前能源危机的背景下进行能量的最大化回收。2.2热量衡算的原理和准则工程依据化工设计中关于热量衡算的基本思想和要求，遵循基本规范与实际工艺相结合的原则，进行热量衡算书的编制。其中一个主要依据是能量平衡方程：其中，——表示输入设备热量的总和；——表示输出设备热量的总和；——表示损失热量的总和。对于连续系统：Q+W=∑Hout-∑Hin其中，Q——设备的热负荷。W——输入系统的机械能。∑Hout——离开设备的各物料焓之和。∑Hin——进入设备的各物料焓之和。在进行全厂热量衡算时，是以单元设备为基本单位，考虑由机械能转换、化学反应释放和单纯的物理变化带来的热量变化。最终对全工艺段进行系统级的热量平衡计算，进而用于指导节能降耗设计工作。2.3热量衡算任务在进行丙烯环氧化装置的热量衡算中，主要通过定量计算完成下述基本任务：确定精馏等单元操作中所需要的热量或冷量以及传递速率，计算换热设备的尺寸，确定加热剂和冷却剂的消耗量，为后续设计中比如供汽、供冷、供水等专业提供设备条件；确定为保持一定反应温度所需移除或者加入的热传递速率，指导反应器的设计和选型；提高热量内部集成度，充分利用余热，提高能量利用率，降低能耗；最终计算出总需求能量和能量的费用，并由此确定工艺过程在经济上的可行性。2.4热量衡算我们对于各个工段的主要能量设备进行能量衡算（流股名为PFD上所标物流号）2.4.1丙烷脱氢工段表2.1R101热量衡算表热负荷Gcal/hr0物流焓变流股名S102S103焓值Gcal/hr-35.726949-35.726949∑HinGcal/hr-35.726949∑HoutGcal/hr-35.726949热量平衡QINOUTERROR0-35.726949-35.7269490表2.2R102热量衡算表热负荷Gcal/hr0物流焓变流股名S104S105焓值Gcal/hr-3.8844911-3.8844911∑HinGcal/hr-3.8844911∑HoutGcal/hr-3.8844911热量平衡QINOUTERROR0-3.8844911-3.88449110表2.3R103热量衡算表热负荷Gcal/hr0物流焓变流股名S106S107焓值Gcal/hr6.578736576.57873657∑HinGcal/hr6.57873657∑HoutGcal/hr6.57873657热量平衡QINOUTERROR06.578736576.578736570表2.4R104热量衡算表热负荷Gcal/hr0物流焓变流股名S108S109焓值Gcal/hr13.230227913.2302279∑HinGcal/hr13.2302279∑HoutGcal/hr13.2302279热量平衡QINOUTERROR013.230227913.23022790表2.5T103热量衡算表位置冷凝器再沸器Q热负荷Gcal/hr-13.395103233.872004520.4769013物流焓变流股名S123S125S126焓值Gcal/hr-157.12469-10.55613-126.09166∑HinGcal/hr-157.12469∑HoutGcal/hr-136.64779热量平衡QINOUTERROR20.4769013-157.12469-136.647790表2.6T104热量衡算表位置冷凝器再沸器Q热负荷Gcal/hr-151.781003157.7635355.982532物流焓变流股名S126S127S128焓值Gcal/hr-126.091668.18216605-128.29128∑HinGcal/hr-126.09166∑HoutGcal/hr-120.109114热量平衡QINOUTERROR5.982532-126.09166-120.10911402.4.2丙烯环氧化工段表2.7R201热量衡算表热负荷Gcal/hr-71.7312663物流焓变流股名S203S204焓值Gcal/hr-1539.1981-1610.9294∑HinGcal/hr-1539.1981∑HoutGcal/hr-1610.9294热量平衡QINOUTERROR-71.7312663-1539.1981-1610.92940表2.8T201热量衡算表位置冷凝器再沸器Q热负荷Gcal/hr-0.0187303555112.465169112.4464386物流焓变流股名S205S206S207焓值Gcal/hr-1610.1518-0.0082023-1497.6971∑HinGcal/hr-1610.1518∑HoutGcal/hr-1497.705302热量平衡QINOUTERROR112.4464386-1610.1518-1497.7053020表2.9T202热量衡算表位置冷凝器再沸器Q热负荷Gcal/hr-52.38623235.5758301-16.810402物流焓变流股名S207S208S209焓值Gcal/hr-1497.69714.62472783-1519.1281∑HinGcal/hr-1497.6971∑HoutGcal/hr-1514.5