面向节能降耗的氧化铝蒸发过程优化研究进展

doi:10.11949/0438-1157.20250971

摘要/Abstract

摘要：

蒸发过程作为氧化铝生产工艺中的高能耗单元，已成为制约行业节能降耗、绿色转型的关键环节。本文对其进行系统性研究有助于从多维度统筹能量利用模式与过程调控机制，明确节能优化路径，从而为氧化铝蒸发过程的节能降耗和工艺提升提供科学依据。首先，全面梳理了氧化铝的生产方式、蒸发作业流程及蒸发设备的发展演变，为理解其运行机理和节能潜力奠定了基础。随后，从工艺设备优化、工艺流程优化以及工艺参数优化三个层面构建分层分析框架，系统总结了该领域的优化技术演变规律和发展趋势。在此基础上，归纳总结了液位优化设定与汽水比优化这两类工程优化问题，并通过引入㶲分析理论与智能优化算法，揭示热力学理论与智能优化工具在节能降耗中的融合机制与应用模式。本文可为蒸发系统的节能方案制定、运行策略优化以及工程能效提升提供理论依据和技术借鉴，对推动氧化铝行业实现节能高效运行和绿色低碳转型具有重要意义。

关键词: 氧化铝蒸发过程, 节能降耗, 分层分析, 液位优化设定, 汽水比优化

Abstract:

As a highly energy-intensive unit in the alumina production process, the evaporation process has become a critical bottleneck restricting energy conservation, reducing energy consumption, and achieving the green transformation of the industry. This paper provides a systematic review of optimization efforts on the alumina evaporation process, which helps coordinate energy-utilization patterns and process-control mechanisms from multiple perspectives, clarify the pathways for energy-saving optimization, and thus provide a scientific basis for energy conservation and process improvement in alumina evaporation process. First, the production routes of alumina, the operating procedures of the evaporation section, and the evolution of evaporation equipment are comprehensively reviewed, laying a foundation for understanding the process mechanisms and identifying its energy-saving potential. Subsequently, a hierarchical analytical framework is established from three levels—process equipment optimization, process flow optimization, and process parameter optimization—to systematically summarize the evolution patterns and development trends of optimization technologies in this field. On this basis, two categories of engineering optimization problems, namely liquid level optimization setting and steam-to-water ratio optimization, are summarized. By introducing exergy analysis theory and intelligent optimization algorithms, the integration mechanisms and application modes of thermodynamic theory and intelligent optimization tools in energy conservation are revealed. This study provides a theoretical foundation and technical reference for developing energy-saving schemes, optimizing operational strategies, and improving engineering energy efficiency of evaporation systems, which is of great significance for promoting energy-efficient operation and green, low-carbon transformation in the alumina industry.

Key words: alumina evaporation process, energy conservation and consumption reduction, hierarchical analysis, liquid level optimization setting, steam-to-water ratio optimization

中图分类号:

TB114.1

方双, 李勇刚, 韩洁, 阳春华, 桂卫华. 面向节能降耗的氧化铝蒸发过程优化研究进展[J]. 化工学报, DOI: 10.11949/0438-1157.20250971.

Shuang FANG, Yonggang LI, Jie HAN, Chunhua YANG, Weihua GUI. A review of optimization advances in the alumina evaporation process oriented toward energy conservation and consumption reduction[J]. CIESC Journal, DOI: 10.11949/0438-1157.20250971.

图/表 12

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设备类型	工作原理	优点	缺点	性能表现（相对等级）
标准列管式蒸发器	其加热室由垂直管束组成，利用中央循环管和加热管内料液的密度差可使料液作沿粗管下降、沿细管上升的自然循环运动；	结构简单、制造成本低；	传热面积受限、传热系数低、汽耗高、不适用于处理结晶性物料；	传热系数：低能耗效率：低
自然循环列管式蒸发器	加热室内料液吸收热量之后，造成循环管道两侧料液密度不均匀而产生密度差，进而形成驱动料液循环流动的动力，推动料液的不断循环流动；	单台设备能力强、加热室与分离室独立，便于清晰和更换，适用于大型氧化铝厂；	易结垢、传热系数偏低、汽耗偏高、需较大有效温差且限制多效蒸发的效数；	传热系数：中低能耗效率：中低
强制循环列管式蒸发器	在循环泵的外加动力作用下，料液以较高流速被强制送入加热室，吸收热量后进入分离室，料液因温度升高而发生部分汽化；蒸汽与未汽化液体在分离室中完成汽液分离，未汽化部分在循环泵作用下再次进入加热室；通过循环泵持续驱动，料液在系统中形成稳定的强制对流循环；	减缓结垢、避免堵塞、传热效率高、操作弹性大；	动力消耗高、循环泵检修频繁；	传热系数：中能耗效率：中
板式降膜蒸发器	蒸汽在加热板内侧冷凝，料液沿着加热板外侧形成薄膜流动，热量通过加热板传递使液膜一边流动一边蒸发汽化。二次蒸汽在加热板之间上升，通过液膜分离器进入下一效；	传热强度高、蒸发速率快、汽耗低；	设备价格昂贵、加热板易腐蚀或机械损坏且不易更换；	传热系数：高能耗效率：中高
管式降膜蒸发器	料液从顶部进入加热管，经布膜器作用后均匀流入加热管并形成液膜，液膜吸收管壁传递的热量，一边流动一边蒸发汽化。二次蒸汽随液膜进入分离室，并在分离室实现汽液分离，进入下一效提供热源；	传热系数高、加热管易于更换、造价低、消除了由静压引起的有效温差损失，适用于多效蒸发和大规模连续生产；	结构复杂、对液膜分布要求较高；	传热系数：高能耗效率：高

设备类型	工作原理	优点	缺点	性能表现（相对等级）
标准列管式蒸发器	其加热室由垂直管束组成，利用中央循环管和加热管内料液的密度差可使料液作沿粗管下降、沿细管上升的自然循环运动；	结构简单、制造成本低；	传热面积受限、传热系数低、汽耗高、不适用于处理结晶性物料；	传热系数：低能耗效率：低
自然循环列管式蒸发器	加热室内料液吸收热量之后，造成循环管道两侧料液密度不均匀而产生密度差，进而形成驱动料液循环流动的动力，推动料液的不断循环流动；	单台设备能力强、加热室与分离室独立，便于清晰和更换，适用于大型氧化铝厂；	易结垢、传热系数偏低、汽耗偏高、需较大有效温差且限制多效蒸发的效数；	传热系数：中低能耗效率：中低
强制循环列管式蒸发器	在循环泵的外加动力作用下，料液以较高流速被强制送入加热室，吸收热量后进入分离室，料液因温度升高而发生部分汽化；蒸汽与未汽化液体在分离室中完成汽液分离，未汽化部分在循环泵作用下再次进入加热室；通过循环泵持续驱动，料液在系统中形成稳定的强制对流循环；	减缓结垢、避免堵塞、传热效率高、操作弹性大；	动力消耗高、循环泵检修频繁；	传热系数：中能耗效率：中
板式降膜蒸发器	蒸汽在加热板内侧冷凝，料液沿着加热板外侧形成薄膜流动，热量通过加热板传递使液膜一边流动一边蒸发汽化。二次蒸汽在加热板之间上升，通过液膜分离器进入下一效；	传热强度高、蒸发速率快、汽耗低；	设备价格昂贵、加热板易腐蚀或机械损坏且不易更换；	传热系数：高能耗效率：中高
管式降膜蒸发器	料液从顶部进入加热管，经布膜器作用后均匀流入加热管并形成液膜，液膜吸收管壁传递的热量，一边流动一边蒸发汽化。二次蒸汽随液膜进入分离室，并在分离室实现汽液分离，进入下一效提供热源；	传热系数高、加热管易于更换、造价低、消除了由静压引起的有效温差损失，适用于多效蒸发和大规模连续生产；	结构复杂、对液膜分布要求较高；	传热系数：高能耗效率：高

工艺设备优化问题	主要研究方向	优点	缺点	适用场景
蒸发设备热利用率低、能耗偏高	新型设备研发	显著提升传热效率、延长运行周期	投资高、改造周期长	新建装置或大规模改造
	现有结构改造	成本低、见效周期短	改造幅度有限、提升效果受现有设备制约	现有装置的节能改造
	能量回收利用	充分利用余热、大幅提高能源利用率并降低汽耗	系统集成、改造复杂，运维成本较高	大型装置系统的整体能效改造
结垢引起的传热衰减与频繁清洗导致系统运行不稳定	结垢机理解析	揭示影响因素，为防垢提供理论依据	属于理论研究，需与工程技术结合方能转化为可见节能成效	放垢机制研究与防垢方案设计
	传热强化	显著提升传热系数和蒸发效率、延长清洗周期	强化效果依赖物料性质与操作条件，对工况敏感且需配套改造	设备换热性能快速提升
	药剂防垢	治垢效果显著、回报周期短	前期实验与试错成本较高、药剂研发周期较长、适用工况有限	管道结垢情况复杂、高负荷工况下设备传热性能提升
浮游物富集引发的管路堵塞、汽耗增加及有效碱浓度下降	分离过滤提效	显著降低浮游物含量、提高运行稳定性	对系统传热和能耗水平的直接改善作用有限	系统运行优化、周期延长、维护成本降低
浮游物富集引发的管路堵塞、汽耗增加及有效碱浓度下降	高效回收利用	提高氧化铝回收率，改善产品质量	设备投资较高，运行维护要求提升	资源回收与品质提升

工艺设备优化问题	主要研究方向	优点	缺点	适用场景
蒸发设备热利用率低、能耗偏高	新型设备研发	显著提升传热效率、延长运行周期	投资高、改造周期长	新建装置或大规模改造
	现有结构改造	成本低、见效周期短	改造幅度有限、提升效果受现有设备制约	现有装置的节能改造
	能量回收利用	充分利用余热、大幅提高能源利用率并降低汽耗	系统集成、改造复杂，运维成本较高	大型装置系统的整体能效改造
结垢引起的传热衰减与频繁清洗导致系统运行不稳定	结垢机理解析	揭示影响因素，为防垢提供理论依据	属于理论研究，需与工程技术结合方能转化为可见节能成效	放垢机制研究与防垢方案设计
	传热强化	显著提升传热系数和蒸发效率、延长清洗周期	强化效果依赖物料性质与操作条件，对工况敏感且需配套改造	设备换热性能快速提升
	药剂防垢	治垢效果显著、回报周期短	前期实验与试错成本较高、药剂研发周期较长、适用工况有限	管道结垢情况复杂、高负荷工况下设备传热性能提升
浮游物富集引发的管路堵塞、汽耗增加及有效碱浓度下降	分离过滤提效	显著降低浮游物含量、提高运行稳定性	对系统传热和能耗水平的直接改善作用有限	系统运行优化、周期延长、维护成本降低
浮游物富集引发的管路堵塞、汽耗增加及有效碱浓度下降	高效回收利用	提高氧化铝回收率，改善产品质量	设备投资较高，运行维护要求提升	资源回收与品质提升

算法	适应度函数	F₀	P₀	P_m	T₀	D	CPU time
算法	适应度函数	m³/h	MPa	MPa	℃	t/h	s
粒子群优化算法	0.3603	0.64	4.91	0.18	69.92	51.97	39.28
遗传算法^[54]	0.362	0.56	5.20	0.13	70.00	52.35	57.55