基于稳定性的循环物流系统流程模拟——以催化裂化反应-再生系统为例

doi:10.11949/0438-1157.20211472

摘要/Abstract

摘要：

过程流程模拟中广泛应用的序贯模块法处理循环物流系统存在很多困难，如断裂流股的选择、迭代方程的收敛性等。基于稳定性理论解决循环物流系统的流程模拟问题，首先根据化工单元装置的模型方程将其分为正向模型和反向模型，并将循环物流中的变量定义为迭代变量和收敛变量；然后在收敛变量处将循环物流的流股断裂，迭代变量分别通过正向模型和反向模型计算收敛变量，二者的偏差通过增益系数对迭代变量进行修正，进而得到迭代方程；最后，利用控制理论中的稳定性理论来确定迭代方程的增益系数，将迭代方程线性化，采用劳斯判据确定增益系数的稳定范围，当增益系数位于稳定范围以内时，迭代方程必然收敛。催化裂化装置反应-再生系统因催化剂循环的存在而成为典型的循环物流系统，本文将反应器作为正向模型，再生器作为反向模型，以再生温度和再生催化剂含碳量作为迭代变量，构造了催化裂化装置反应-再生系统流程模拟的迭代方程，利用稳定性理论找到增益系数的稳定范围，保证流程模拟计算必定达到收敛，验证了该方法的可行性和有效性。

关键词: 循环物流, 过程系统, 流程模拟, 催化裂化装置, 稳定性

Abstract:

The sequential modular method, which is widely used in process simulation, has many difficulties in dealing with stream circulation system, such as the selection of tearing stream and the convergence of iterative equations. Based on the stability theory, this paper solves the process simulation problem of stream circulation system. First, according to the model equation, chemical plants are identified as forward model and backward model, and the variables in stream circulation are defined as iterative variables and convergence variables respectively. Then, the stream circulation is broken at the convergence variables, and the convergence variables are calculated from the iterative variables by the forward model and the backward model respectively; the convergence errors are used for the correction of iterative variables through the gain coefficients, and then the iterative equation is obtained. Finally, the stability theory in control theory is used to determine the gain coefficient of the iterative equation, the iterative equation is linearized, and the Routh criterion is used to determine the stable range of the gain coefficient; when the gain coefficients is within the stable range, the iterative equation must converge. The reaction and regeneration system of FCCU is a typical stream circulation system because of catalyst circulation. The reactor is treated as the forward model and the regenerator is treated as the backward model. The temperature and carbon content of regenerator are treated as iteration variables to build the iterative equation of process simulation for FCCU reaction and regeneration system. The stability range of the gain coefficients is found by using the stability theory to ensure the convergence of the simulation calculation, and the feasibility and effectiveness of this method are verified.

Key words: stream circulation, process system, process simulation, FCCU, stability

中图分类号:

TQ 021.8

曹森山, 许锋, 罗雄麟. 基于稳定性的循环物流系统流程模拟——以催化裂化反应-再生系统为例[J]. 化工学报, 2022, 73(3): 1256-1269.

Senshan CAO, Feng XU, Xionglin LUO. Process simulation of stream circulation system based on stability:[J]. CIESC Journal, 2022, 73(3): 1256-1269.

图/表 16

图1 正向模型

Fig.1 Forward model

图2 反向模型

Fig.2 Backward model

图3 含循环物流的信息流图

Fig.3 Information flow diagram with stream circulation

图4 断裂后的含循环物流的信息流图

Fig.4 Information flow diagram of stream circulation system after tearing stream

图5 求取收敛模块的流程图

Fig.5 The flow chart for obtaining convergence module

表1 劳斯表

Table 1 Rolls table

$w n$	$a n$	$a n - 2$	$a n - 4$	$a n - 6$	…
$w n - 1$	$a n - 1$	$a n - 3$	$a n - 5$	$a n - 7$	…
$w n - 2$	$b 1$	$b 2$	$b 3$	$b 4$	…
$w n - 3$	$c 1$	$c 2$	$c 3$	$c 4$	…
$w n - 4$	$d 1$	$d 2$	$d 3$	$d 4$	…
$?$	$?$	$?$	$?$	$?$	$?$
$w 2$	$e 1$	$e 2$
$w 1$	$f 1$	0
$w 0$	$g 1$	0

表1 劳斯表

Table 1 Rolls table

$w n$	$a n$	$a n - 2$	$a n - 4$	$a n - 6$	…
$w n - 1$	$a n - 1$	$a n - 3$	$a n - 5$	$a n - 7$	…
$w n - 2$	$b 1$	$b 2$	$b 3$	$b 4$	…
$w n - 3$	$c 1$	$c 2$	$c 3$	$c 4$	…
$w n - 4$	$d 1$	$d 2$	$d 3$	$d 4$	…
$?$	$?$	$?$	$?$	$?$	$?$
$w 2$	$e 1$	$e 2$
$w 1$	$f 1$	0
$w 0$	$g 1$	0

图6 甲苯氧化制苯甲酸反应-分离系统流程图

Fig.6 Schematic diagram of the reaction-separation cycle for the oxidation of toluene to benzoic acid

图7 反应-分离的信息流图

Fig.7 Information flow diagram for reaction-separation

图8 甲苯氧化反应-分离系统四种模拟计算结果对比— 正向/反向模型迭代法; ---- 直接迭代法; -·- 加权迭代法; … 牛顿迭代法

Fig.8 Comparison simulation of four iterative methods for reaction-separation cycle of the toluene oxidation

图9 催化裂化装置结构示意图

Fig.9 Schematic diagram of FCCU

表2 催化裂化装置过程数据

Table 2 Process data of FCCU

压力/kPa		温度/℃
反应器顶	再生器顶	提升管出口	再生器密相床
244.95	274.38	500	700
催化剂藏量/ kg	主风流量/ (m³/h)	新鲜原料量/ (kg/h)	催化剂循环量/ (kg/h)
27000	45500	75000	410000

图10 催化裂化装置反应-再生系统的信息流X1——提升管出口变量; X2——再生器入口变量; X3——再生器第一个CSTR出口变量; X4——再生器第二个CSTR入口变量; X5——再生器第二个CSTR出口变量

Fig.10 Information flow diagram of the FCCU reaction-regeneration system

图11 断裂后催化裂化装置反应-再生系统的信息流

Fig.11 Information flow diagram of the FCCU reaction-regeneration system after tearing stream

图12 提升管与汽提段主要变量迭代收敛曲线

Fig.12 Iterative convergence curves for the main variables in riser and strip section

图13 再生器主要变量迭代收敛曲线

Fig.13 Iterative convergence curves for the main variables in regenerator

表3 本文模拟计算的稳态值和生产数据对比

Table 3 Comparison of simulated steady-state values and production data from this paper

各单元出口变量	模拟结果稳态值	生产数据	误差/%
再生剂含碳量/%(mass)	0.18	0.1875	4.00
再生温度/℃	699.85	700	0.02
再生烟气氧含量/%(mol)	2.66	2.77	3.97
反应温度/℃	503.39	500.0855	0.66
待生催化剂活性	0.2071	0.2030	0.02
汽提段出口焦炭含量/%(mass)	1.03	1	3.00
回炼油生成量/(t/h)	14.756	14.9500	1.30
回炼油油浆生成量/(t/h)	8.3908	8.5500	1.86
焦炭产率/%(mass)	4.7696	5.0104	4.81
柴油产率/%(mass)	39.9028	38.6386	3.27
汽油产率/%(mass)	39.5864	41.2439	4.02
气体产率/%(mass)	11.5450	12.1089	4.66

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