Simulation Calculation of 1.8 ×106 t/a Methanol Radial Reactor in the Capacity Expansion and Revamping
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摘要: 基于某能源公司的百万吨甲醇生产项目的扩能改造，建立模型并分析计算。针对甲醇径向反应器建立了绝热换热多层交叉一维拟均相数学模型，代入Aspen Plus软件中，实现双径向反应器串并联耦合工艺的模拟。结果表明，增加中心管开孔面积可有效减少较大流量下的穿孔压降；降低进气温度对降低反应器内部热点温度有效，但会增加循环气流量；改变1#反应器和2#反应器的新鲜气配比实际上是改变了反应器连接方式，减小2#反应器入塔气的氢碳体积比能调动装置生产能力。对改造后的工艺进一步优化，得到了最优生产条件，即1#反应器新鲜气体积分数0.800，入塔气温度235.0 ℃，此时产能达到了原工艺的130%。Abstract: For the capacity expansion and revamping of a 1.8×106 t/a Davy methanol production project of an energy company, a multilayer cross one-dimensional, quasi-homogeneous mathematical model was established for the adiabatic heat transfer of methanol radial reactor. The model was used in Aspen Plus to simulate the series-parallel coupling process of the dual radial reactor. We found that an increase in the area of the central pipe hole effectively reduced the pressure drop of the perforation at a large flow rate, and a decrease in the inlet temperature reduced the hot spot temperature but increased the circulating gas flow rate. Variation of the feed gas ratio substantially changed the connection mode of the reactor, and increased the methanol production of the 2# reactor. The optimum production conditions were obtained when the fresh gas ratio was 0.800 and the entry temperature was 235.0 ℃, leading to a production capacity enhancement of 130% with respect to the unoptimized process.
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图 3 Davy甲醇合成工艺流程
C201—Compressor; E101~E104—Heat exchanger; R101,R102—Reactor; V101,V102—Flash tank; 107—Feed stream; 206,214—Crude methanol; 207,217—Cyclic stream; 216—Exhausted gas; 201~205,208~213,215—Gas delivery stream
Figure 3. Davy methanol synthesis process flow chart
图 4 中心管开孔面积变化对反应器内压力的影响
Figure 4. Effect of the change of central tube opening area on the pressure in the reactor
图 5 中心管开孔面积对床层压降和穿孔压降的影响
Figure 5. Effect of central tube opening area on bed pressure drop and perforation pressure drop
图 6 入塔气温度对反应器床层温度的影响
Figure 6. Effect of inlet gas temperature on reactor bed temperature
图 7 入塔气温度对反应器床层反应速率的影响
Figure 7. Effect of inlet gas temperature on reaction rate of reactor bed
图 8 入塔气温度对反应器甲醇产率及循环气量的影响
Figure 8. Effect of inlet gas temperature on methanol yield and circulating gas flow rate in reactor
图 9 新鲜气体积分数对反应器甲醇产率的影响
Figure 9. Effect of fresh gas volume fraction on methanol yield of reactor
图 10 新鲜气体积分数对两台反应器循环比的影响
Figure 10. Effect of fresh gas volume fraction on cycle ratio of two reactors
图 11 新鲜气体积分数对入塔气氢碳比的影响
Figure 11. Effect of fresh gas volume fraction on hydrogen-carbon ratio of tower inlet gas
图 12 新鲜气体积分数对反应器压降的影响
Figure 12. Effect of fresh gas volume fraction on pressure drop of reactor
图 13 反应器不同入塔气温度和新鲜气分配比对出塔气温度和反应器压降的影响
Figure 13. Effect of different inlet gas temperature and fresh gas volume fraction on outlet temperature and pressure drop of reactors
图 14 不同入塔气温度和新鲜气体积分数对甲醇产率的影响
Figure 14. Effect of different inlet gas temperature and fresh gas volume fraction on methanol yield
表 1 改造前后运行参数对比
Table 1. Comparison of operating parameters before and after process modification
Process Reactor Flow rate/(t·h−1) p/MPa T/℃ Yield of 93% crude methanol/(t·h−1) Fresh gas Inlet gas Before modification 1# 197.012 683.307 7.63 250.0 124.8 2# 49.253 608.893 8.05 250.0 116.0 After modification 1# 195.521 910.842 7.59 223.0 133.3 2# 114.290 899.938 7.94 223.0 153.9 
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表 2 改造前后模拟结果对比
Table 2. Comparison of simulation results before and after process modification
Process Stream Flow rate/
(t·h−1)T/℃ p/MPa $ {y}_{{\rm{H}_{2}O}} $ $ {y}_{{\rm{H}}_{2}} $ $ {y}_{\rm{CO}} $ $ {y}_{{\rm{CO}}_{2}} $ $ {y}_{{\rm{N}}_{2}} $ $ {y}_{{\rm{C{H}_{3}OH}}} $ Methanol
yield/(t·h−1)Before modification 204 545.337 286.4 7.59 0.0031 0.8355 0.0452 0.0100 0.0536 0.0525 138.65 212 468.124 278.9 8.02 0.0035 0.8527 0.0278 0.0088 0.0580 0.0490 119.85 After modification 204 910.595 264.2 7.55 0.0020 0.8512 0.0583 0.0163 0.0382 0.0340 158.94 212 875.841 263.3 7.87 0.0019 0.8417 0.0536 0.0162 0.0385 0.0339 158.37
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