Property integration of batch process based on interceptors in semi-continuous operation

doi:10.11949/j.issn.0438-1157.20181074

Abstract

Abstract:

In addition to concentration of contaminant, stream properties such as toxicity, pH, chemical oxygen demand are also important characters indicating water quality. Such situation would make the design of water-using process just according to contaminant concentration fail to meet the increasingly stringent production and environmental requirements, and prompt it to be necessary to consider the simultaneous integration of stream properties in water network synthesis. In this paper, a superstructure involving property interceptors in semi-continuous operation is established for the integration of batch water network with concerning environmental constraints and the minimum total annual cost target. The property interceptors can operate at various treating rates in different time intervals, and a series of tanks are placed before and after the interceptors to satisfy the batch operation of process sources and sinks, in assistance of which the sources in the tanks in front of interceptors are allowed to be reused to sinks directly without treated by interceptors. The calculation results show that the proposed method can effectively reduce the total annual cost and reduce the number of interceptors, which verifies the effectiveness and superiority of the proposed method.

Key words: water network, batch process, integration, system engineering, optimization

摘要：

生产过程对水质的要求不仅体现于杂质浓度，还包括毒性、pH、化学需氧量等流股性质，因此仅以杂质浓度作为水源使用及废水排放依据进行用水过程设计无法满足生产要求，有必要在用水网络综合过程中考虑多种性质的同时集成。针对间歇过程性质集成问题，在考虑环境约束的基础上，以最小年度总费用为目标，建立了包含半连续操作性质截断器的用水网络超结构。其中，截断器在不同时间间隔内可以按不同操作速率运行；在截断器前后分别设置缓冲储罐以满足水源水阱的间歇操作要求，允许前置缓冲储罐中的水源不经过截断器直接回用至水阱。算例计算结果表明，本文方法可以有效降低年度总费用，同时减少截断器数量，验证了本文方法的有效性和优越性。

关键词: 水网络, 间歇过程, 集成, 系统工程, 优化

CLC Number:

TQ 021.8

Xiaozheng GUO, Linlin LIU, Lei ZHANG, Jian DU. Property integration of batch process based on interceptors in semi-continuous operation[J]. CIESC Journal, 2019, 70(2): 516-524.

郭孝正, 刘琳琳, 张磊, 都健. 基于截断器半连续操作的间歇过程性质集成[J]. 化工学报, 2019, 70(2): 516-524.

Figures/Tables 9

Fig.1 Batch water network superstructure of this work

Table 1 Date for process and fresh steams[27]

Sources	Period t	F/(kg·h^-1)	Composition×10⁶	Toxicity/%	pH	COD×10^-3/(kg O₂·m^-3)	$ρ$ /(kg·m^-3)	$μ$ /(mPa·s)
process sources(i)
1	3	8083	0.016	0.3	5.4	0.187	908.00	1.256
2	4	3900	0.024	0.5	4.8	92.10	1002.43	1.220
3	5	3279	0.220	1.5	5.1	48.85	1046.47	1.261
fresh sources(r)
1	—	—	0	0	7.0	0	1000.61	1.002
2	—	—	0.01	0.1	6.8	0.01	1002.88	0.992

Table 1 Date for process and fresh steams[27]

Sources	Period t	F/(kg·h^-1)	Composition×10⁶	Toxicity/%	pH	COD×10^-3/(kg O₂·m^-3)	$ρ$ /(kg·m^-3)	$μ$ /(mPa·s)
process sources(i)
1	3	8083	0.016	0.3	5.4	0.187	908.00	1.256
2	4	3900	0.024	0.5	4.8	92.10	1002.43	1.220
3	5	3279	0.220	1.5	5.1	48.85	1046.47	1.261
fresh sources(r)
1	—	—	0	0	7.0	0	1000.61	1.002
2	—	—	0.01	0.1	6.8	0.01	1002.88	0.992

Table 2 Process sinks data and limits[27]

Sinks n	Period t	G/(kg·h^-1)	Comp^Max×10⁶	pH^Min	pH^Max	$ρ M i n$ /(kg·m^-3)	$ρ M a x / (k g · m - 3)$	$μ M i n$ /(mPa·s)	$μ M a x$ /(mPa·s)
1	10	6000	0.013	5.3	8.0	817.20	1271.2	0.900	1.202
2	15	4400	0.011	5.4	7.8	771.80	1135.0	0.905	2.230
3	21	2490	0.100	5.2	8.2	819.47	1316.6	0.903	1.260

Table 2 Process sinks data and limits[27]

Sinks n	Period t	G/(kg·h^-1)	Comp^Max×10⁶	pH^Min	pH^Max	$ρ M i n$ /(kg·m^-3)	$ρ M a x / (k g · m - 3)$	$μ M i n$ /(mPa·s)	$μ M a x$ /(mPa·s)
1	10	6000	0.013	5.3	8.0	817.20	1271.2	0.900	1.202
2	15	4400	0.011	5.4	7.8	771.80	1135.0	0.905	2.230
3	21	2490	0.100	5.2	8.2	819.47	1316.6	0.903	1.260

Table 3 Data of property interceptors[27]

Property	Interceptor	Processing time/h	Conversion factor	Operating cost/(USD·kg^-1)	Fixed cost/USD	Variable cost/(USD·period^-1)
composition	REC¹	2	0.02	0.0065	8000	25
	REC²	2	0.15	0.0033	7000	18
toxicity	TOX¹	1	0	0.0075	9000	15
	TOX²	1	0.1	0.0063	8200	12
COD	AER¹	1	0.2	0.0055	6800	13
	AER²	1	0.3	0.0043	5200	11
pH	NEU¹	1	0.5	0.0085	5200	16
	NEU²	1	0.7	0.0093	4800	14
	NEU³	1	1.5	0.0055	3700	13
	NEU⁴	1	1.3	0.0065	2900	12

Table 4 Environmental constraints[27]

Property	Minimum	Maximum
composition×10⁶	0.005	0.05
toxicity/%	0	0.05
pH	5.5	9
COD $×$ 10^-3/(kg O₂·m^-3)	0	75

Table 4 Environmental constraints[27]

Property	Minimum	Maximum
composition×10⁶	0.005	0.05
toxicity/%	0	0.05
pH	5.5	9
COD $×$ 10^-3/(kg O₂·m^-3)	0	75

Fig.2 Optimal result of this work

Fig.3 Result using method of Ref.[27]

Table 5 Comparison of results

Item	Method of literature^[27]	Method of this paper
fresh resources/(kg·batch^-1)	1545	4259
fresh cost/(USD·a^-1)	4628.9	10333.4
number of interceptors	6	3
operating cost of interceptor/(USD·a^-1)	38795.6	38672.8
fixed cost of interceptor/(USD·a^-1)	11100.0	6420.0
variable cost of interceptor/(USD·a^-1)	77640.6	29054.4
total cost of interceptor/(USD·a^-1)	127536.2	74147.2
number of storage tanks	7	5
cost of storage tanks/(USD·a^-1)	45237.2	61090.4
total annual cost/(USD·a^-1)	177402.3	145571.0

$ψ n, p m a x$	——水阱n性质p的性质算子的最大值
$ψ n, p m i n$	——水阱n性质p的性质算子的最小值
$ψ n, t, p i n, S K$	——水阱n在t时刻进口性质p的性质算子
$ψ p m a x, W W$	——废水性质p的性质算子的最大值
$ψ p m i n, W W$	——废水性质p的性质算子的最小值
$ψ p W W$	——废水性质p的性质算子
A _f	——年度因子，A _f=0.3
$C k, m f i x, I N T$	——性质截断器INT _k 的固定费用，USD
$C k, m o p e r, I N T$	——性质截断器INT _k 的操作费用，USD·kg^-1
$C k, m v a r, I N T$	——性质截断器INT _k 的可变费用，USD·kg^-1
$C k, s f i x, S$	——前置储罐S _k,s 的固定费用，USD
$C k, s v a r, S$	——前置储罐S _k,s 的可变费用，USD·kg^-1
$C k, u f i x, U$	——后置储罐U _k,u 的固定费用，USD
$C k, u v a r, U$	——后置储罐U _k,u 的可变费用，USD·kg^-1
C_r	——新鲜水源的单位成本，USD·kg^-1
$F I i, t o u t$	——水源i在t时刻排出的水量，kg
$F I N i, n, t$	——水源i在t时刻直接回用至水阱n的水量，kg
$F I S i, k, s, t$	——水源i在t时刻进入前置储罐S _k,s 的水量，kg
$F N n, t i n$	——在t时刻进入水阱n的水量，kg
$F R N r, n, t$	——在t时刻新鲜水源r供给水阱n的水量，kg
$F S k, s m a x$	——前置储罐S _k,s 的最大存水量，kg
$F S k, s, t$	——前置储罐S _k,s 在t时刻的水量，kg
$F S k, s, t i n$	——前置储罐S _k,s 在t时刻的进水量，kg
$F S N k, s, n, t$	——前置储罐S _k,s 在t时刻回用至水阱n的水量，kg
$F U k, u m a x$	——后置储罐U _k,u 的最大存水量，kg
$F U k, u, t$	——后置储罐U _k,u 在t时刻的水量，kg
$F U N k, u, n, t$	——后置储罐U _k,u 在t时刻回用至水阱n的水量，kg
$F W r$	——一个周期内需要消耗新鲜水源r的总量，kg
$F W W i, t$	——水源i在t时刻直接排废的水量，kg
$f R k i n, m a x$	——流入截断器INT _k 的最大流率，kg·h^-1
$f R k, h i n$	——截断器INT _k 在时间间隔h内的进口流率，kg·h^-1
$f R k, h o u t$	——截断器INT _k 在时间间隔h内的出口流率，kg·h^-1
$f R R k, k', h$	——截断器INT _k 在时间间隔h内流入其他截断器INT _k’ 的流率，kg·h^-1
$f R U k, u, h$	——截断器INT _k 在时间间隔h内流入后置缓冲储罐U _k,u 的流率，kg·h^-1
$f S R k, s, h$	——前置储罐S _k,s 在时间间隔h内进入性质截断器INT _k 的流率，kg·h^-1
$f w w k . h$	——截断器INT _k 在时间间隔h内排废的流率，kg·h^-1
N _B	——每年操作的周期数，N _B=333
Δt_h	——时间间隔h的时长，h
WW	——一个周期内排放废水的总量，kg
y_k _, _m	——表示性质截断器INT _k 候选设备m是否存在的二元变量
$y k, s S$	——表示前置储罐S _k,s 是否存在的二元变量
$y k, u U$	——表示后置储罐U _k,u 是否存在的二元变量
$α k, m$	——性质截断器INT _k 候选设备m的转化因子
$ψ i, p$	——过程水源i的性质p的性质算子
$ψ k, h, p i n, I N T$	——截断器INT _k 在时间间隔h内进口性质p的性质算子
$ψ k, h, p o u t, I N T$	——截断器INT _k 在时间间隔h内出口性质p的性质算子
$ψ k, s, t, p i n, S$	——前置储罐S _k,s 在t时刻进口性质p的性质算子
$ψ k, s, t, p o u t, S$	——前置储罐S _k,s 在t时刻出口性质p的性质算子
$ψ k, u, t, p o u t, U$	——后置储罐U _k,u 在t时刻出口性质p的性质算子

$ψ n, p m a x$	——水阱n性质p的性质算子的最大值
$ψ n, p m i n$	——水阱n性质p的性质算子的最小值
$ψ n, t, p i n, S K$	——水阱n在t时刻进口性质p的性质算子
$ψ p m a x, W W$	——废水性质p的性质算子的最大值
$ψ p m i n, W W$	——废水性质p的性质算子的最小值
$ψ p W W$	——废水性质p的性质算子
A _f	——年度因子，A _f=0.3
$C k, m f i x, I N T$	——性质截断器INT _k 的固定费用，USD
$C k, m o p e r, I N T$	——性质截断器INT _k 的操作费用，USD·kg^-1
$C k, m v a r, I N T$	——性质截断器INT _k 的可变费用，USD·kg^-1
$C k, s f i x, S$	——前置储罐S _k,s 的固定费用，USD
$C k, s v a r, S$	——前置储罐S _k,s 的可变费用，USD·kg^-1
$C k, u f i x, U$	——后置储罐U _k,u 的固定费用，USD
$C k, u v a r, U$	——后置储罐U _k,u 的可变费用，USD·kg^-1
C_r	——新鲜水源的单位成本，USD·kg^-1
$F I i, t o u t$	——水源i在t时刻排出的水量，kg
$F I N i, n, t$	——水源i在t时刻直接回用至水阱n的水量，kg
$F I S i, k, s, t$	——水源i在t时刻进入前置储罐S _k,s 的水量，kg
$F N n, t i n$	——在t时刻进入水阱n的水量，kg
$F R N r, n, t$	——在t时刻新鲜水源r供给水阱n的水量，kg
$F S k, s m a x$	——前置储罐S _k,s 的最大存水量，kg
$F S k, s, t$	——前置储罐S _k,s 在t时刻的水量，kg
$F S k, s, t i n$	——前置储罐S _k,s 在t时刻的进水量，kg
$F S N k, s, n, t$	——前置储罐S _k,s 在t时刻回用至水阱n的水量，kg
$F U k, u m a x$	——后置储罐U _k,u 的最大存水量，kg
$F U k, u, t$	——后置储罐U _k,u 在t时刻的水量，kg
$F U N k, u, n, t$	——后置储罐U _k,u 在t时刻回用至水阱n的水量，kg
$F W r$	——一个周期内需要消耗新鲜水源r的总量，kg
$F W W i, t$	——水源i在t时刻直接排废的水量，kg
$f R k i n, m a x$	——流入截断器INT _k 的最大流率，kg·h^-1
$f R k, h i n$	——截断器INT _k 在时间间隔h内的进口流率，kg·h^-1
$f R k, h o u t$	——截断器INT _k 在时间间隔h内的出口流率，kg·h^-1
$f R R k, k', h$	——截断器INT _k 在时间间隔h内流入其他截断器INT _k’ 的流率，kg·h^-1
$f R U k, u, h$	——截断器INT _k 在时间间隔h内流入后置缓冲储罐U _k,u 的流率，kg·h^-1
$f S R k, s, h$	——前置储罐S _k,s 在时间间隔h内进入性质截断器INT _k 的流率，kg·h^-1
$f w w k . h$	——截断器INT _k 在时间间隔h内排废的流率，kg·h^-1
N _B	——每年操作的周期数，N _B=333
Δt_h	——时间间隔h的时长，h
WW	——一个周期内排放废水的总量，kg
y_k _, _m	——表示性质截断器INT _k 候选设备m是否存在的二元变量
$y k, s S$	——表示前置储罐S _k,s 是否存在的二元变量
$y k, u U$	——表示后置储罐U _k,u 是否存在的二元变量
$α k, m$	——性质截断器INT _k 候选设备m的转化因子
$ψ i, p$	——过程水源i的性质p的性质算子
$ψ k, h, p i n, I N T$	——截断器INT _k 在时间间隔h内进口性质p的性质算子
$ψ k, h, p o u t, I N T$	——截断器INT _k 在时间间隔h内出口性质p的性质算子
$ψ k, s, t, p i n, S$	——前置储罐S _k,s 在t时刻进口性质p的性质算子
$ψ k, s, t, p o u t, S$	——前置储罐S _k,s 在t时刻出口性质p的性质算子
$ψ k, u, t, p o u t, U$	——后置储罐U _k,u 在t时刻出口性质p的性质算子

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