Discussion on integrated security control in process industry

doi:10.11949/0438-1157.20240057

Abstract

Abstract:

Process industries such as chemical industry, metallurgy, petrochemicals, steel, papermaking, and electric power are important pillars of the country's economic and social development, and their safe and efficient production is of great strategic significance. The prominent characteristics of the process industry are the complicated long production processes and complex correlation and coupling of various processes. From raw materials to products, it involves various physical and chemical processes, such as mass and heat transfer processes, and interactions occurring in multi-source, multi-scale and multi-temporal and spatial, affecting the production safety, the efficiency of material and energy exchange and ecological environment as well. It has been a long-existing and changing problem for process industry to realize the integrated security. The core concern of integrated safety control of process industry lies in the reflection of mass flow and energy flow to digital flow, the transformation of digital flow to high-quality information flow, and the transformation of information flow to control flow. This paper puts forward a novel idea of integrated safety controls in process industry titled “five flows-three transformations-three controls”, and discusses how to break through the digitalization of the mapping process from mass and energy flows to digital flow, break through the digital intelligence problem of the transformation from digital flow to high-quality information flow, and the decision lag problem of the transformation from information flow to control flow. It is expected to provide a new framework system basis for the integrated safety management and control in processindustry and promote the sustainable development of process industry.

Key words: process industry, production, safety, process control, five flows-three transformations-three controls

摘要：

化工、冶金、石化、钢铁、造纸、电力等流程工业是国家经济社会发展的重要支柱，其安全高效生产具有重要的战略意义。流程工业生产过程工艺繁多、流程长、工序关联耦合，从原料到产品涉及诸多物理化学变化、物质转移转化和能量转换转移等多源、多尺度与多时空因素的交互作用，影响生产安全、物效能效与生态环境。如何实现流程工业一体化安全管控，是一个长期存在又不断变化的问题。一体化安全管控困难的本质在于物质流能量流到数字流的映射、数字流到高质量信息流的转化、信息流到控制流的转换等问题。探讨如何突破物质流、能量流到数字流映射过程的数字化鸿沟，突破数字流到高质量信息流转变的数智化壁垒、信息流到控制流转换的数滞化障碍，保障物质流能量流不失控、数字流信息流不失真、控制流不失误，提出了流程工业一体化安全管控的“五流三化三不”新思路，以期为流程工业一体化安全管控提供新的框架体系基础，促进流程工业的可持续发展。

关键词: 流程工业, 生产, 安全, 过程控制, 五流三化三不

CLC Number:

TK 012

Jianwen ZHANG, Tingsheng ZHAO, Pingyu WAN, Qianlin WANG, Zhan DOU, Bo XU. Discussion on integrated security control in process industry[J]. CIESC Journal, 2024, 75(6): 2375-2384.

张建文, 赵挺生, 万平玉, 王倩琳, 窦站, 徐波. 流程工业一体化安全管控探讨[J]. 化工学报, 2024, 75(6): 2375-2384.

Figures/Tables 12

Fig.1 Single-series 25 million tons per year oil refining process flowchart

Fig.2 Typical steelmaking production process flowchart

Fig.3 Typical structure of “five flows” in process industry

Fig.4 Logic structure of “five flows” in process industry

Fig.5 Transformation logic of “five flows” in chemical process

Fig.6 Barriers of “five flows-three transformations” in process industry

Fig.7 Structure of “five flows-three transformations” for integrated safety control in process industry

Fig.8 Logical structure of “five flows-safety” in process industry

Fig.9 Schematic representation of fixed bed catalytic cracking simulation system architecture

Table 1 Node division of catalytic cracking simulation device

序号	节点名称	节点描述
1	进料流程	来自界区外的氧气和空气经减压后与原料油和预热后的水混合进入气化器
2	进料控制	利用工业控制系统控制气体和液体进料过程
3	气化-反应流程	利用气化器将液态气体和原料加热至气态后通入反应器与催化剂反应
4	气化-反应控制	利用工业控制系统控制气化器、反应器和冷却器的正常运行
5	产品分离流程	初步冷却后的反应物进入冷却分离器进一步冷却，完成液态产品和气态产品的分离
6	产品分离控制	利用工业控制系统控制冷阱和阀门等设备

Fig.10 Risk distribution of “five flows” in device

Fig.11 Classification of risk consequences in catalytic cracking simulation device

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