Abstract:

For the catalytic reaction system, the reactor acts as the core of material conversion, and its key lies in selecting highly active catalysts. During production, catalyst activity decreases with the passage of operating time, affecting the reactor performance and the operation of subsequent devices. Clarifying system parameters' changing rules and making corresponding deactivation compensation measures is of great significance in strengthening system performance and reducing production costs. Based on separable reaction kinetics and mass/energy balance, correlation models targeting the relation between the reaction performance, reactor operating parameters, and running time are established. According to the topology analysis, pinch analysis, and cascade effect analysis, the time-varying law of each device's and system's energy requirement is revealed. On this basis, an economic evaluation index considering system integration is constructed to guide catalyst regeneration and system parameter optimization. A benzene selective hydrogenation to cyclohexene process is taken as an example, with the system performance/operating parameters' time-varying characteristics visually displayed. The catalyst's optimal regeneration cycle is determined as 1.92 a. Compared with the literature results, the optimized service life is closer to the engineering value, with the average production cost per unit product reduced by 5.2%.

Key words: system integration, catalyst activity, regeneration cycle, cost, optimization

摘要：

对于催化反应系统，反应器作为物料转化的核心，其关键在于高活性催化剂的选用。生产过程中，催化剂活性随运行时间推移不断降低，影响反应器性能和后续装置的操作。明确系统参数动态变化规律及相应催化剂失活补偿措施，对于强化系统性能，降低生产成本具有重要意义。从可分离反应动力学和物料/能量平衡出发，建立了针对反应器的性能，操作参数及运行时间关联模型；基于拓扑结构分析，夹点分析和级联效应分析，揭示了各装置及系统能耗的时变规律。在此基础上，构建基于系统集成的经济评价指标，用于指导催化剂再生和系统参数调优。以苯选择加氢制环己烯为例，直观展示系统性能/操作参数时变特性。该生产过程催化剂最佳再生周期为1.92年，相较文献结果，优化后的使用周期更贴近工程值，单位产品平均生产成本可降低5.2%。

关键词: 系统集成, 催化剂活性, 再生周期, 成本, 优化