Cracking Xuc Tac 3.000.000

n tt nghip Thnh Ho Du 1- K45
Nguyn c
LI M U
Trn th gii, ti bt k mt quc gia no xng du c coi l hng ho c bit quan trng, l mu huyt ca nn kinh t quc dn v quc phng... Ngy nay trong bi cnh Vit Nam ang khng ngng pht i mi v vn ln con ng cng nghip ho v hin i ho t nc, vi cc my mc , thit b v cng ngh mi. Vai tr ca xng du ngy cng c quan tm c bit hn. p ng kp thi khi lng xng tiu th ngy cng ln ,ngi ta a ra phng php cracking xc tc vo cng nghip ch bin du m,v do qu trnh chng ct kh quyn, chng ct chn khng hay cracking nhit, khi lng xng thu c vn khng p ng kp thi c nhu cu ca th trng. tho mn nhu cu nhin liu ngy mt tng. Nghnh cng nghip ch bin du m ra sc ci tin, hon thin quy trnh cng ngh , ng thi p dng nhng phng php ch bin su trong dy chuyn sn xut nhm chuyn ho du th ti mc ti u thnh nhin liu v nhng sn phm quan trng khc. Mt trong nhng phng php hin i c p dng rng ri trong cc nh my ch bin du hin ny trn th gii l qu trnh cracking xc tc. Vi bn n tt nghip thit k phn xng cracking xc tc nng sut 3.000.000 tn nm m em c giao.Em hy vng rng mnh s b xung thm c kin thc gp phn nh b vo cng cuc i mi t nc. Em xin chn thnh cm n TS. L Vn Hiu tn tnh gip em trong thi gian qua em c th hon thnh c bn n ny.
Nguyn c
CHNG I TNG QUAN L THUYT

I.Gii thiu chung v qu trnh cracking xc tc. I.1.S lc v lch s pht trin ca qa trnh cracking xc tc[1,106] Qa trnh cracking xc tc c nghin cu t cui th k XIX, nhng mi n nm 1923, mt k s ngi Php tn l Houdry mi ngh a qa trnh vo p dng trong cng nghip. n nm 1936, nh my cracking xc tc u tin c xy dng M, ca cng ty Houdry Process corporation. Ban u cn tn ti nhiu nhc im nh l hot ng gin on v rt phc tp cho vn hnh, nht l khi chuyn giao gia hai chu k phn ng v ti sinh xc tc trong cng mt thit b.Cho n nay, sau hn 60 nm pht trin, qu trnh ny ngy cng c ci tin v hon thin, nhm mc ch nhn nhiu xng hn vi cht lng xng ngy cng cao t nguyn liu c cht lng ngy cng km hn (t nhng phn cn nng hn). Qu trnh cracking c nghin cu t lu nhng giai on u ch l cc qu trnh bin i di tc dng n thun ca nhit v p sut (qu trnh cracking nhit) vi hiu sut v cht lng thp,tin hnh iu kin khc nghit,ti nhit cao v p sut cao tuy nhin n cng c nhng u im l c th ch bin cc phn cn rt nng ca du m m cracking xc tc khng thc hin c. nng cao hiu sut,cht lng,cho php tin hnh qu trnh nhng iu kin mm mi hn (nhit thp hn, p sut thp hn) ngi ta a vo qu trnh nhng cht m c kh nng lm gim nng lng hot ho,tng tc phn ng, tng tnh cht chn lc( hng phn ng theo hng cn thit) v n khng b bin i trong qu trnh phn ng l cht xc tc v qu trnh c gi l qu trnh cracking xc tc.Cho n nay,qu trnh ny ngy cng c ci tin, hon thin v mi mt ( cng ngh, xc tc, thit b...) cho ph hp hn. 2
Nguyn c
I.2. Mc ch ca qu trnh cracking xc tc.[1,106] Mc ch ca qu trnh cracking xc tc l nhn cc cu t c tr s octan cao cho xng t hay xng my bay t nguyn liu l phn ct nng hn, ch yu l phn ct nng hn t cc qu trnh chng ct trc tip AD (Atmotpheric Distillation) v VD (Vacuum Distillation) ca du th. ng thi ngoi mc ch nhn xng ngi ta cn nhn c c nguyn liu c cht lng cao cho cng ngh tng hp ho du v ho hc. Ngoi ra cn thu thm mt s sn phm ph khc nh gasoil nh , gasoil nng, kh ch yu l cc phn t c nhnh l cc cu t qu cho tng hp ho du. I.3.Vai tr ca qu trnh cracking xc tc so vi cc qu trnh lc du khc v cc iu kin cng ngh ca qu trnh.[1,107] Qu trnh cracking xc tc l qu trnh khng th thiu c trong bt k mt nh my ch bin du no trn th gii, v qu trnh ny l mt trong cc qu trnh chnh sn xut xng c tr s octan cao.Xng thu c t qa trnh ny c dng phi trn vi cc loi xng khc to ra cc mc xng khc nhau. Khi lng xng thu t qu trnh chim t l rt ln khong 7080% so vi tng lng xng thu t cc qu trnh ch bin khc. Lng du m c ch bin bng cracking xc tc chim tng i ln.V d vo nm 1965, lng du m th gii ch bin c 1.500 tn/ngy th trong cracking xc tc chim 800 tn ( tng ng 53%). Qu trnh cracking xc tc c tin hnh iu kin cng ngh l : Nhit Tc khng gian th tch (ty thuc vo dy truyn cng ngh) T l xc tc/nguyn liu bin i: 3 : 4 9/1 Bi s tun hon nguyn liu : C th cn hoc khng tu thuc mc : 4700C 5500C : 1 120 m3/m3. h Ap sut trong vng lng ca l phn ng : 0,27 Mpa
Nguyn c
Nu mc bin i thp hn 60% lng tun hon c th ti a l 30% Khi mc chuyn ho cao trn 70% th phi gim lng tun hon thm ch khng cn tun hon. Xc tc cho qu trnh cracking thng dng l xc tc zeolit mang tnh axt. Sn phm ca qu trnh l mt hn hp phc tp ca hydrocacbon cc loi khc nhau , ch yu l hydrocacbon c s cacbon t 3 tr ln, vi cu trc nhnh. II.Bn cht ho hc ca qu trnh cracking xc tc v c ch ca phn ng. II.1.Bn cht ho hc ca qu trnh cracking xc tc. [2,97] Cracking l qu trnh b gy mch cacbon cacbon (ca hydrocacbon) ca nhng phn t c kch thc ln ( c trng lng phn t ln) thnh nhng phn t c kch thc nh hn( c trng lng phn t nh hn ).Trong cng ngh du m, qu trnh ny c ng dng bin i cc phn on nng thnh cc sn phm nh, tng ng vi khong si ca cc sn phm trng nh xng, kerosen, diezen.Qu trnh ny c th thc hin di tc dng ca nhit (cracking nhit) v xc tc( cracking xc tc) II.2. C ch phn ng cracking xc tc.[3,84] Hin nay vn cha c s nht tr hon ton trong vic gii thch bn cht, c ch ca cc phn ng cracking xc tc nn cn nhiu kin trong vic gii thch c ch xc tc trong qu trnh cracking. Tuy vy, ph bin nht vn l cch gii thch cc phn ng theo c ch ion cacboni. C s ca l thuyt ny da vo cc tm hot tnh l cc ion cacboni. Chng c to ra khi cc phn t hydrocacbon ca nguyn liu tc dng vi tm hot tnh acid ca xc tc loi Bronsted (H+) hay Lewis (L). Theo c ch ny cc phn ng cracking xc tc din ra theo ba giai on sau: Giai on 1 : Giai on to ion cacboni. 4
Nguyn c
Giai on 2 : Cc phn ng ca ion cacboni (giai on bin i ion cacboni to thnh cc sn phm trung gian ). Giai on 3 : Giai on dng phn ng. II.2.1.Giai on to thnh ion cacboni. Ion cacboni to ra do s tc dng ca olefin, hydrocacbon parafin, hydrocacbon naphten , hydrocacbon thm vi tm axt ca xc tc. T olefin Ion cacboni to ra do s tc dng ca olefin vi tm axt Bronsted ca xc tc. R1 CH C R2 + H + (xt) H R1 CH C R2 + (xt) H H
+
Ion cacboni to thnh do s tc dng ca olefin vi tm axit Lewis ca xc tc: RH + olefin hoc l CnH2n + H+ CnH2n+1
+
O Al O Si O R
+
O H Al O Si O
Trong nguyn liu ban u thng khng c hydrocacbon olefin, nhng olefin c th to ra do s phn hu cc hydrocacbon parafin c phn t lng ln. Cc olefin to thnh lp tc tc dng vi tm axit ri to ra ion cacboni. Ion cacboni to thnh trong cc phn ng tun theo quy tc nht nh. Nh khi olefin tc dng vi H+(xt) th xc sut to alkyl bc hai ln hn alkyl bc mt. CH3 CH2 CH CH2 + H + (xt) CH3 CH2 CH CH2 dto th h nh n CH3 CH2 CH2 CH2 5
+ +
Nguyn c
Khi olefin c lin kt i cacbon bc 3 th ion cacboni bc 3 d to thnh hn cacbon bc hai. CH3 CH3 CH C CH3 + H + (xt) CH3 CH2 C CH3 CH3 dto th h nh n CH3 CH CH CH3 CH3
+ +
T hydrocacbon parafin: Bronsted ca xc tc:
Ion cacboni c th c to thnh do s tc dng ca parafin vi tm axt

R cacboni CH2 R th c (xt) R CH ca parafin vi tm XT Ion 1 CH2 cng c 2 + H +to ra do s tc1dng2 CH R2 + H2 + axit
+
Lewis: O Al O Si O O H Al O Si O
RH hoc l:
+ CnH2n+1 + H2
CnH2n+2 + H+
+ CnH2n+3
CmH2m+1 + CnH2n+2 + L T hydrocacbon naphten: CnH2n+1++ LH
+ CnmH2(nm)+2
Khi hydrocacbon naphten tc dng vi tm axit ca xc tc hay cc ion cacboni khc s to ra cc ion cacboni mi tng t nh qu trnh xy ra vi parafin. T hydrocacbon thm ngi ta quan st thy s kt hp trc tip ca H+ vo nhn thm: CH2 CH3 CH2 CH3 H
+ H+ 6
Nguyn c
Cc hydrocacbon thm c mch bn di th s to thnh ion cacboni cng ging nh trng hp parafin. Thi gian sng ca cc ion cacboni c to ra dao ng t phn triu giy n hng pht. Cc ion cacboni ny to ra nm trong lp cc phn t hp ph, chng l nhng hp cht trung gian rt hot ng i vi nhiu phn ng xy ra khi cracking. II.2.2 Giai on bin i ion cacboni.[3,86] Giai on bin i ion cacboni to thnh sn phm trung gian. Ion cacboni c th bin i theo cc phn ng sau: Phn ng ng phn ho: chuyn ri ion hydro(H+) ,nhm metyl (CH3) to cu trc nhnh.
R CH2 CH CH3
+ + +
R CH CH2 CH3
R C CH2 CH3
RCCCC+
C C+ C C R
S chuyn di ion cacboni xc nh c bi n nh ca cc ion . Theo nguyn tc: n nh ion cacboni theo bc gim dn nh sau : C3+ bc 3 > C3+ bc 2 > > C3+ bc 1 bn ca ion cacboni s quyt nh mc tham gia cc phn ng tip theo ca chng. V cc ion cacboni bc 3 c bn cao nht nn s cho php nhn hiu sut cao cc hp cht iso- parafin. ng thi cc ion cacboni nhanh chng li tc dng vi cc phn t trung ho olefin ( CmH2m ) hay parafin (CmH2m +2) to thnh cc ion cacboni mi.
+
CnH2n+1 + CmH2m
CnH2n + CnH2n+2 +
CmH2m+1 CmH2m+1
CnH2n+1 + CmH2m+2
Nguyn c
Phn ng cracking : cc ion cacboni c s nguyn t cacbon ln xy ra s phn hu v t mch v tr b so vi nguyn t cacbon tch in. Sn phm phn hu l mt phn t hydrocacbon trung ho v ion cacboni mi c s nguyn t cacbon nh hn. [A]
+
[B]
R C C C C C C C [C] C Vi ba v tr b( [A] ,[B],[C] ) trn th xc sut t mch v tr [A] ln hn v tr [B] v cui cng l v tr [C] Vi ion cacboni mch thng:
CH3 CH CH2 R CH3 CH CH2 + R i vi ion cacboni l ng ng ca benzen, v d nh :
+ +
C C C Nu p dng quy tc v tr bnh thng th v tr rt bn vng. Ngi ta cho rng proton c kt hp vi mt trong nhng lin kt C trong nhn C thm to thnh nhng hp cht trung gian, sau mi phn hu theo quy tc nu trn. Khi phn hu, in tch ion cacboni s dch chuyn theo s sau:
+
C C C
+
H C C C C
CH C C
Nh vy trong hydrocacbon thm hiu ng tch in nhn thm l nguyn nhn quan trng hn so vi nguyn nhn l s bin i ion cacboni bc hai thnh bc ba. 8
Nguyn c
Cc ion cacboni l ng ng ca benzen, mch bn cng di th tc t mch xy ra cng ln v cng d. Ion cacboni izo-butyl benzen c tc t mch ln hn 10 ln so vi izo-propyl benzen. Cc nhm metyl, etyl kh b t ra khi nhn hydrocacbon thm (v nng lng lin kt ln) v do kh to c CH3 v C2H5. iu ny gii thch c ti sao xng cracking xc tc hm lng hydrocacbon thm c mch bn ngn rt ln v gii thch c ti sao trong kh ca qu trnh cracking xc tc c hm lng ln cc hydrocacbon c cu trc nhnh. II.2.3 Giai on dng phn ng.[3,87] Giai on ny xy ra khi cc ion cacboni kt hp vi nhau, hoc chng nhng hay nhn nguyn t hydro ca xc tc to thnh cc phn t trung ho. III.S bin i ho hc cc hydrocacbon trong qu trnh cracking xc tc. III.1. S bin i cc hydrocacbon parafin.[3,89] Ging nh qu trnh cracking nhit, qu trnh cracking xc tc cc hydrocacbon parafin cng b phn hu to thnh phn t olefin v parafin c trng lng phn t b hn. Phn ng c th biu din bng phng trnh tng qut sau : CnH2n+2 CmH2m+2 + CqH2q (q, m < n)
+ +
Nu mch parafin cng di th s phn hy xy ra ng thi mt s ch trong mch ch khng phi xy ra hai u mt ca mch nh qu trnh cracking nhit. Cc hydrocacbon parafin c trng lng phn t thp th kh nng phn hu km. V d : i vi butan C4H10 ti nhit 5000C , v0 =1 h-1 ch c 1% b phn hu tuy vy tc phn hu ca n vn ln hn 6 ln so vi khi phn hu ch n thun di tc dng ca nhit. Ngoi ra chng cn b kh hydro nhng mc nh. 9
Nguyn c
C4H10
t C, xc tc
CH4 + C3H6 C2H6 + C2H4 C4H6 + H2
(60%) (30%) (10%)
Nng lng hot ho ca phn ng cracking parafin gim dn theo chiu di mch hydrocacbon parafin tng. V d : n-C6H14 E (kcal/mol) 36 n-C7H16 29 n-C8H18 24
V vy khi cracking, mch hydrocacbon parafin cng di , cng d b b gy.V d khi cracking xc tc cc parafin nhit 5500C nh sau: n-C5H12 % cracking 1 n-C7H16 3 n-C12H26 18 n-C12H26 42
S phn nhnh v s lng nhnh ca parafin c vai tr rt quan trng trong qa trnh cracking . N lin quan n kh nng to ion cacboni v do s quyt nh n tc to thnh sn phm. iu ny c chng minh t cc s liu % chuyn ho parafin C6 khi cracking trn xc tc alumilosilicat di y : C6 C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C 10 10 32 25 % chuyn ho 14 25
Nguyn c
Khi cracking n hexan nhit 5500C trn xc tc axit ,s phn b cc sn phm xy ra nh sau : H2 %V 9 CH4 12 C2 19 C3 49 C4 8,5 C5 1,6
S phn b ny khng i xng nhau qua C3. S c mt mt lng ln H2 v metan cho thy rng, cng mt lc xy ra nhiu phn ng, c th c phn ng cracking nhit cng cc phn ng ca ion cacboni nh nu trn. Phn ng chnh to sn phm s ph thuc vo tng quan gia phn ng cracking theo quy tc b v phn ng vn chuyn hydro ca ion cacboni
+
+ R1H
RH
+
+ R1 + olefin
R2
Do cracking xc tc m lm gim kch thc ca ion cacboni +R. Cc ion c kch thc nh nh +CH3 hay +C2H5 s kh to ra ( do ct mch v tr b so vi cacbon mang in tch ).V th trong sn phm u tin to ra C3 hay C4 nhiu hn C1 v C2 so vi qu trnh cracking nhit. III.2. S bin i cc hydrocacbon olefin.[3,90] Tnh hp ph chn lc cao nht ca xc tc l cc hydrocacbon olefin trong qu trnh cracking xc tc cho nn iu kin cracking xc tc cc hydrocacbon olefin chuyn ho vi tc nhanh hn hng nghn n hng chc nghn ln so vi khi cracking nhit. Hydrocacbon olefin c mt trong hn hp phn ng l do phn ng cracking parafin , naphten hay alkyl thm. Hydrocacbon olefin l nhng hp cht hot ng hn, trong giai on u tin ca qu trnh, chng tham gia phn ng to ion cacboni bi v qu trnh hp th mt proton vo lin kt i.Ion cacboni va to ra s b cracking theo quy tc b, khi to thnh mt olefin nh hn v mt ion cacboni bc1, ion ny c th li proton trn b mt ca xc tc hay c th ng phn ho thnh ion cacboni bc 2. V d : 11
Nguyn c
R CH=CH 2 2 1 + H+ CH CH R R 2 CH CH 2 2 1 CH CH R CH3 2 1 CH R
+ +
CH2 CH=CH2 + CH2 CH2 1 R R1 CH=CH2 + H2
Cc hp cht olefin nh C2 C5 va c to thnh t tham gia vo phn ng cracking, chng thng tham gia vo phn ng vn chuyn hydro v phn ng a t, kt qu l dn n to ra parafin hay cc. Khi cracking cc olefin t C5 tr ln, ngoi phn ng ct mch theo quy tc b, ngi ta cn quan st thy phn ng dime ho. V d khi cracking penten th thy c cc phn ng sau : H+ + H2C=CH 2 2 2 CH CH CH CH3 CH=CH2 + 2C5 C7
= =
CH3 + 2 2 3 CH CH CH CH
+
CH2 3 CH
=
C10 C3
=
= =
C3 + C4
+ C7
Chnh v xy ra cc phn ng trn m trong sn phm c t l C 3/C4 bng 2. Phn ng cracking penten l phn ng lng phn t, trong khi phn ng cracking hepten li l phn ng n phn t, ngha l khng c s cnh tranh ca phn ng dime ha. Ngoi phn ng ct mch, olefin cn tham gia phn ng ng phn ha. Tc phn ng ng phn ho tng theo trng lng phn t ca n. CH3 C CH2 CH2 CH CH2 CH3 CH3
CH3 CH CH CH3 Cc hydrocacbon olefin kt hp vi hydro kh c xc tc to thnh parafin
R CH2 CH2 + H2 ln hn:

CH2 CH2 + CH2 CH2
R CH2 CH3
Cc olefin cn tham gia phn ng trng hp to ra phn t c trng lng

CH2 CH CH2 CH3 CH2 CH CH CH2
12
Nguyn c
2CH3 CH2 CH CH2
CH3(CH2)5 CH CH2
Cc olefin trong qu trnh cracking xc tc cn tham gia phn ng ngng t, ng vng to hydrocacbon thm a vng v vng thm a t l cc.
CH2 CH2 + CH2 CH2 + CH2 CH2 CH2 CH CH2 CH2 CH2 CH3
H2
H2
+ 3H2
H2
III.3 S bin i cc hydrocacbon naphten.[3,91]. Cc hydrocacbon naphten tham gia phn ng trong qu trnh cracking xc tc vi tc ln hn 500 4000 ln so vi khi cracking nhit. Trong iu kin cracking xc tc naphten tham gia phn ng kh alkyl, kh hydro v phn b li hydro to hydrocacbon thm, parafin v hydro.
CH2 CH2 CH3 + 3H2
+ C3H8 + 2H2
Phn ng phn hu vng naphten to thnh izo- parafin : CH3 CH3 CH2 CH2 CH2 CH CH3 CH3
Phn ng ng phn ho vng naphten : CH3 Phn ng chuyn v cc nhm bn :

CH2 CH3 CH3 CH3
CH3 CH3
13
Nguyn c
c trng phn b sn phm khi cracking naphten l to thnh mt lng ln cc hp cht c nhnh v hydrocacbon thm so vi cracking parafin. Nhn chung, sn phm cracking naphten c tnh cht no hn so vi khi cracking parafin.Trong sn phm, do phn ng trn xc tc m hydrocacbon c s nguyn t ln hn 3 chim phn ch yu. V vy khi cracking xc tc cc hp cht naphten s cho nhiu sn phm lng hn,ngha l hiu sut xng s cao hn.Cho nn naphten l thnh phn l tng nht trong nguyn liu cracking xc tc. III.4.S bin i ca cc hydrocacbon thm.[3,93]. Cc hydrocacbon thm khng c cc gc alkyl nh bn ni chung l rt kh b cracking ngay c khi c mt ca xc tc. Tc v hng chuyn ho ca cc hydrocacbon thm ph thuc vo cu trc, vo trng lng phn t ca n. V d : Khi cracking toluen nhit 5000C, v0 =2h-1 th ch c 4% toluen b phn hu. Khi cracking cc hydrocacbon thm c mch alkyl di nh bn, c bit l loi c cu trc mch nhnh th tc phn hu lm t mch bn ln hn nhiu so vi khi cracking iu kin di tc dng n thun ca nhit. Trong qu trnh cracking xc tc, cc hp cht alkyl thm do vng thm c bn cao hn nn trc tin s xy ra qu trnh ct nhnh alkyl. Nhng toluen c bn rt ln. Ta c th gii thch c lun im: mch alkyl cng di, th cng d b b gy v nu mch alkyl li c nhnh th tc ct nhnh cn ln hn khi ta xem xt nng lng hot ha ca cc hydrocacbon thm : Loi hydrocacbon thm C6H5 2H5 C C6H5 4H9 C C6H5 CH 2 3 CH CH CH3 C6H5 CH 3 CH 14 17,5 19 Nng lng hot ho (kcal/mol) 50 34
Nguyn c
CH3 Khi cracking xc tc propylbenzen , th phn ng xy ra nh sau : C6H5 2 2 3 CH CH CH C6H6 + CH3 CH=CH2
Cn khi cracking nhit th li xy ra theo hng khc : C6H5 2 2 3 CH CH CH thm bao gm: Phn ng ng phn ho Cc hydrocabon thm cha nhiu gc metyl d tham gia phn ng ng phn ha do s chuyn v cc nhm metyl theo vng benzen. CH3
t oC, xc tc
C6H5 3 + CH2=CH2 CH
Cc phn ng khc xy ra trong qu trnh cracking xc tc hydrocacbon
CH3
t oC, xc tc
CH3 CH3
CH3
CH3 para-xylen Phn ng khp vng
m eta-xylen
octo-xylen
Cc hydrocacbon thm c nhnh alkyl di, c th khp vng to hydrocacbon thm a vng v cui cng l cc hydrocacbon thm a vng tham gia phn ng ngng t to cc. CH2 CH2 CH2 CH3
t oC, xc tc
+ 5H2
CH2 CH2 CH2 CH3
H2
2H2
15
Nguyn c
Cc hydrocacbon thm a vng ngng t cao to cc d hp ph trn b mt xc tc.V vy chng km hm nh hng n qu trnh cracking cc loi hydrocacbon loi khc. IV. ng hc ca qa trnh cracking xc tc.[1,115] Cracking xc tc l mt v d in hnh v xc tc d th, qu trnh cracking xc tc c th xy ra qua nhng giai on sau : Khuych tn nguyn liu n b mt ca xc tc cn gi l qu trnh khuch tn ngoi Khuch tn hi nguyn liu n cc tm hot tnh trong l xp ca xc tc ( khuych tn trong ) Hp ph nguyn liu trn tm hot tnh xc tc Cc phn ng ho hc trn b mt xc tc Nh hp ph sn phm phn ng ra khi b mt hot tnh ca xc tc Tch cc sn phm cracking v nguyn liu cha tham gia phn ng ra khi vng phn ng Tc chung ca qu trnh s c quyt nh bi giai on no chm nht. Phn ng xy ra trong vng ng hc hay vng khuych tn, hon ton ph thuc vo bn cht ca cht xc tc c s dng, ph thuc vo bn cht ca nguyn liu v vo ch cng ngh ca qa trnh. Cc nghin cu cho thy rng, qu trnh cracking trong lp xc tc gi si, xc tc dng bt nhit t 4800C n 5300C th phn ng xy ra vng ng hc.Cracking trn xc tc ht cu th phn ng xy ra vng khuych tn trong. Nu qu trnh cracking xc tc nguyn liu l gasoil nh trn xc tc dng cu khi kch thc ht xc tc t 3 n 5 mm v nhit l 450 0C- 5500C,th phn ng xy ra vng trung gian gia ng hc v khuych tn. Cn khi cracking lp si (FCC) ca xc tc nhit 480 0C n 5300C th phn ng xy ra vng ng hc. 16
Nguyn c
Tc ca phn ng cracking xc tc, trong a s cc trng hp c m t bng phng trnh bc1 c dng : k = v0.n.ln(1 x) (n 1)x Trong : k : Tc ca phn ng , mol/g.h; v0 : Tc truyn nguyn liu , mol/h; n : S mol sn phm c to thnh t 1 mol nguyn liu; x : Mc chuyn ha, phn mol; i vi phn on du trn xc tc zeolit, phng trnh bc 1 li c dng sau : k=
vo 1 x
vi v0 l tc th tch khng gian truyn nguyn liu, m3/m3.h V.Cc yu t nh hng n phn ng cracking xc tc.[2,115] C rt nhiu yu t nh hng n phn ng cracking xc tc, di y ta ch nu nn vi yu t in hnh. Nguyn liu : Tt nht l phn on kerosen sola gasoil nng thu c t chng ct trc tip ( nhit ca phn on 260 0C 3500C, d = 0,830 0,920). Nhit : Qu trnh cracking xc tc tin hnh khong nhit t
4500C 5200C l thch hp nht cho qu trnh to xng.Khi qa trnh tin hnh nhit tng ln th chuyn ho ca nguyn liu cng tng ln lm cho hiu sut cc sn phm cracking xc tc u tng ln. Nhng nhit ch tng n gii hn cho php nu tng qa cao ( cao hn 5500C ) th hiu sut xng li gim xung, cn hiu sut cc v kh li tng mnh nguyn nhn l do khi nhit tng ln cao qu gii hn cho php th nguyn liu b cracking iu kin cng hn v phn ng xy ra su hn v xng c to ra trong trng hp ny li tip tc b phn hy lm cho hiu sut xng gim xung v hiu sut kh v cc tng ln. 17
Nguyn c
p sut : H thng cracking xc tc thng c tin hnh p sut 1,4 at n 1,8 at, iu kin ny cracking xy ra trong pha hi. Xc tc : Zeolit Y ( l xp ln, Si/Al cao). Tc np liu : Trn mt n v th tch xc tc nm trong vng phn ng thng a vo khong 0,5 2,5 n v th tch nguyn liu trong mt gi. Chn tc th tch np nguyn liu ph thuc vo c tnh ca nguyn liu v xc tc. Bi s tun hon ca xc tc: Khi tng bi s tun hon ca xc tc th thi gian lu ca nguyn liu trong vng phn ng gim, hot tnh trung bnh ca xc tc tng ln, hiu sut xng, kh, cc cng tng . Cn lng cc bm trn b mt xc tc tun hon s gim xung.
18
Nguyn c
CHNG II NGUYN LIU CA QA TRNH CRACKING XC TC, SN PHM THU C T QA TRNH V XC TC CA QU TRNH
I.Nguyn liu dng trong qa trnh cracking xc tc.[4,22] Theo l thuyt th bt k phn on chng ct no ca du m c im si ln hn xng u c th dng lm nguyn liu cho qa trnh cracking xc tc. Nhng gii hn vic s dng cc phn on chng ct du m vo lm nguyn liu cho cracking xc tc c mt tm quan trng rt ln. Nu la chn nguyn liu khng thch hp s khng a n hiu qu kinh t cao hoc s nh hng n hot tnh ca xc tc. Ngy nay ngi ta thng dng cc phn on nng thu c t qu trnh cracking nhit,cc ho chm,cc phn on du nhn trong chng ct chn khng v du mazt tch nha lm nguyn liu cho cracking xc tc. trnh hin tng to cc nhiu trong qu trnh cracking xc tc cng nh trnh nhim c xc tc, nguyn liu cn phi c tinh ch s b trc khi a vo ch bin. Ta c th dng cc phn on sau lm nguyn liu cho cracking xc tc: Phn on kerosen xola ca qu trnh chng ct trc tip Phn on xla c nhit si 3000C 5500C ca qu trnh chng ct chn khng mazt. Phn on gasoil ca qu trnh ch bin th cp khc. Phn on gasoil nng c nhit si 3000C 5500C II.c tnh chi tit du Bch H.[5,101] Cc c tnh Du th T trng. 0API Lu hunh,%tl 19 Du Bch H 38,6 0,03 - 0,05
Nguyn c
im ng c,0C nht, 400C, cSt nht, 500C, cSt nht, 600C, cSt Cn cacbon,%tl Asphanten,%tl Wax, %tl Ap sut, % hi Reid 1000F,psi V/Ni,ppm Nit, %tl Mui Nacl,mg/l axt, mg KOH/g Naphta nh (C5 -950C) Hiu sut trn du th, %tl T trng 150C, Kg/l Lu hunh, %tl Mercaptan,%tl Parafin,%tl Naphten,%tl Thm,%tl N-parafin,%tl NAPHTA NNG (C5 -1490C) Hiu sut trn du th, %tl T trng 150C, Kg/l Lu hunh, %tl Mercaptan,%tl Parafin,%tl Naphten,%tl Thm,%tl N-parafin,%tl KEROSEN (149 -2320C) Hiu sut so vi du th, %kh.l T trng 150C,kg/l Lu hunh, %kh.l axt, mg KOH/g Chiu cao ngn la khng khi,mm Thm,%kh.l GASOIL (232 -4320C) Hiu sut so vi du th, %kh.l T trng 150C,kg/l Lu hunh, %kh.l axt, mg KOH/g 20
33 9,72 6,58 4,73 0,65 -1,08 0,05 27 2.5 2/2 0,067 22 0,05 2,3 0,6825 0,001 0,0002 75,2 18,4 6,4 42,0 10,1 0,7285 0,001 0,0002 60,5 31,3 8,2 34,9 14,35 0,7785 0,001 0,041 35 13,0 23,05 0,818 0,016 0,01
Nguyn c
Tr s xtan CN (342 5500C) Hiu sut trn du th,%V Khi lng ring 150C, Kg/l Lu hunh,%Kh.l Nit,ppm Asphanten,% Kh.l Hp cht no,% Kh.l Hp cht thm,%Kh.l III. Xc tc trong qa trnh cracking xc tc.
47,6 Ti 5500C 14,2 0,811 0,07 1350 0,05 58 15
III.1. Vai tr ca xc tc trong qa trnh cracking.[3,72] Xc tc trong qa trnh cracking c tm quan trng rt ln. N c kh nng lm gim nng lng hot ho ca phn ng do vy m tng c tc phn ng ln rt nhiu. V d khi c mt xc tc 400 0C n 5000C cc olefin chuyn ho nhanh hn 1.000 n 10.000 ln so vi cracking nhit.Dng xc tc cho php qu trnh tin hnh iu kin mm hn v khi c mt ca xc tc th lm tng tc phn ng s y nhanh phn ng n trng thi cn bng lm tng hiu qu ca qu trnh. Ngoi ra, xc tc cn c tnh chn lc , n c kh nng lm tng hay chm khng u cc loi phn ng, c ngha l hng phn ng theo chiu c li. III.2.Nhng yu cu cn thit i vi xc tc cracking III.2.1. Hot tnh xc tc phi cao Trong phng php cracking xc tc, mc chuyn ho ca nguyn liu ph thuc vo hot tnh ca xc tc. S c mt ca xc tc s lm gim nng lng cn thit cho phn ng v thi gian phn ng. Nghin cu v cht xc tc c dng trong cng nghip du m ngi ta nhn thy rng, hot tnh ca xc tc ph thuc vo hot tnh, din tch b mt v ln ca cht xc tc. V vy vic la chn cht xc tc trong qu trnh cracking xc tc l rt quan trng Hot tnh ca xc tc cng cao s cho hiu sut xng cng ln.Khi s dng xc tc c hot tnh cao th th tch vng phn ng yu cu khng cn ln lm 21
Nguyn c
vn c th m bo nng sut yu cu. Hot tnh ca xc tc l yu cu quan trng nht i vi xc tc trong qu trnh cracking III.2.2. chn lc ca xc tc phi cao.[1,121] Kh nng ca xc tc lm tng tc cc phn ng c li, ng thi lm gim tc cc phn ng khng mong mun c gi l chn lc ca xc tc. Trong qa trnh cracking, chn lc ca xc tc quyt nh kh nng to cc sn phm c gi tr ca n. Xc tc c chn lc cao th qa trnh cracking s cho xng c cht lng cao v hiu sut ln v trong kh cracking c nng ln cc hydrocacbon c cu trc nhnh. Ta c th nh gi chn lc bng cch xc nh t l gia hiu sut xng v cc cng mt su bin i.T s gia hiu sut xng/ cc cng cao th chn lc ca xc tc cng cao. Sau mt thi gian lm vic, cng ging nh hot tnh, chn lc ca xc tc cng b gim chnh iu ny gy ra nhng thay i v tnh cht ca xc tc trong iu kin lm vic. III.2.3.Xc tc phi m bo n nh phi ln v bn c nhit. [3,73] Xc tc phi gi c nhng c tnh ch yu ( nh hot tnh, chn lc ) ca n sau thi gian lm vic lu di. Trong qu trnh lm vic xc tc c xt vi nhau v xc tc c xt vo thnh thit b lm cho xc tc d b v, khi xc tc b v lm tn tht p sut qua lp xc tc tng ln, lm mt mt xc tc ln. Do vy m xc tc phi m bo bn c.ng thi, trong qu trnh lm vic nhit c th thay i. Khi nhit cao nu xc tc khng c bn nhit th c th b bin i cu trc dn n lm gim cc tnh cht ca xc tc. III.2.4. Xc tc phi m bo thun nht cao v bn vi cc cht ng c xc tc. [3,73]. Xc tc cn ng nht v thnh phn, cu trc,hnh dng v kch thc. Khi kch thc khng ng u s to ra nhng vng phn lp v c tr lc khc nhau v do s phn lp theo kch thc nn s ph v ch lm vic bnh 22
Nguyn c
thng ca thit b.Mt khc khi kch thc khng ng u s lm tng kh nng v vn dn n tn hao xc tc,khi cu trc l xp khng ng u th s lm gim b mt tip xc dn n lm gim hot tnh xc tc. Xc tc phi c kh nng chng c hiu qu tc dng gy ng c ca nhng hp cht ca nit, lu hunh (NH3, H2S) ,cc kim loi nng ko di thi gian lm vic ca xc tc. III.2.5. Xc tc phi c kh nng ti sinh, phi d sn xut v r tin. [3,73] Xc tc c kh nng ti sinh tt th s nng cao c hiu qu v nng sut ca qu trnh, lng tiu hao xc tc cng gim xung. Xc tc b mt hot tnh trong qu trnh phn ng do nguyn nhn chnh l cc to ra bm trn b mt hot ng ca xc tc.V th ti sinh xc tc , ngi ta cn phi tin hnh t cc bng khng kh nng trong l ti sinh. Cng vi vic ci tin v hon thin v dy truyn cng ngh ca cracking xc tc, ngi ta khng ngng nng cao cht lng xc tc tng hiu sut ch bin ca qu trnh.T ch ch dng xc tc axt Al Si dng v nh hnh, ngi ta nghin cu thnh cng v a vo ng dng loi xc tc dng kt tinh zeolit. Thnh tu ny c th ni l cuc cch mng trong cracking xc tc. Loi xc tc ny cho hiu sut xng v diezel cao, lm gim c t l cc v kh. Trong nm 1969 c gn 90% cc phn xng cracking xc tc M v Canada s dng xc tc loi Zeolit X,Y, chng rt bn vng trong qu trnh ti sinh v c hot tnh cao. III.3.Cc loi xc tc dng trong qu trnh cracking. [2,106] III.3.1. Xc tc triclorua nhm AlCl3. Triclorua nhm cho php tin hnh phn ng nhit thp: 200 3000C, d ch to. Nhc im l xc tc b mt mt do to phc vi hydrocacbon ca nguyn liu, iu kin tip xc gia xc tc v nguyn liu khng tt, cho hiu sut v cht lng xng thp.
23
Nguyn c
III.3.2.Xc tc aluminosilicat v nh hnh. Ban u ngi ta s dng t st bentonit, song hiu sut chuyn ho thp. Sau dng aluminosilicat tng hp, xc tc ny c hot tnh cao hn.Xc tc aluminosilicat l loi khong st t nhin hoc tng hp c thnh phn ch yu nh sau: SiO2 (75 90%) , Al2O3(10 25%), c b mt ring 300 500 m2/g. Ngoi ra cn c H2O, cc tp cht Fe2O3, CaO, MgO. Xc tc aluminosilicat v nh hnh c tnh axt, l cc axt rn. Cc tm hot tnh nm trn b mt xc tc, c chia lm hai loi : tm Lewis v tm Bronsted.Tm Lewis l nhng tm thiu ht electron ca nhm. Nhm lun c xu hng nhn thm cp in t lp y qu o p trng.Cn tm axt Bronsted l nhng tm khi tham gia phn ng c kh nng cho proton hot ng. III.3.3. Xc tc zeolit v xc tc cha zeolit.[1,116]. Zeolit l hp cht ca alumino silic, l cht tinh th c cu trc c bit. Cu trc ca chng c c trng bi cc mng l rng, rnh, rt nh thng vi nhau. Thnh phn ho hc ca zeolit nh sau : M2/n.Al2O3 x.SiO2.yH2O Trong : n l ho tr ca cation kim loi M. V cu to, zeolit c to thnh t cc n v cu trc c bn gi l n v cu trc sodalit. Nu cc n v ny ni vi nhau theo cc mt 4 cnh ta c zeolit loi A cn nu ni vi nhau theo mt 6 cnh th ta c zeolit loi X hay Y.Khi ch to xc tc cracking , hm lng Na cn phi gim ti cc tiu, bi v s c mt ca Na nhit cao v c mt hi nc s lm gim i ng k hot tnh cng nh chn lc ca xc tc cracking. Khi thay th Na bng cc cation kim loi ho tr ln hn hay bng 2 nh Ca, reni hay cc nguyn t t him s lm thay i c trng cu trc ca zeolit ng thi khi li to ra cc tm axt lm hot tnh ca xc tc tng ln.Nu nh zeolit cha oxyt silic cng nhiu, lng oxyt nhm cng t th axit ca n cng tng.
24
Nguyn c
Zeolit c hot tnh cracking ln, v th ngi ta dng n dng hn hp vi xc tc v nh hnh hay aluminosilicat tinh th v c gi l xc tc cha zeolit. Trong lc sn xut xc tc, ngi ta thng trn 10 20% khi lng zeolit, vi hp cht nh vy , xc tc cng c hot tnh mnh, hn hn xc tc aluminosilicat thng thng.Trong cng nghip ngi ta ch to xc tc cha zeolit hai dng chnh : Xc tc dng cu v xc tc dng bt. T xc tc dng bt sau ci tin thnh xc tc dng cu, thng c p dng cho qu trnh cracking xc tc lp si, cn xc tc dng cu vi kch thc ht t 3 mm 5mm th dng cho qu trnh cracking lp xc tc chuyn ng. III.3.4 So snh gia loi xc tc v nh hnh Aluminosilicat v zeolit. [4,24]. Nu em hai loi xc tc s dng trong iu kin (Thit b , nguyn liu...) nh nhau, ngi ta nhn thy cng mt iu kin nh nhau, xc tc zeolit c hot tnh gp 10 ln so vi loi xc tc v nh hnh c %Al2O3 thp v 2 ln so vi cht xc tc v nh hnh c t l %Al2O3 cao. Nu chuyn ho khong 70% th trong trng hp xc tc zeolit cho t l cc bng 1/2 ca cht xc tc v nh hnh c t l %Al 2O3 thp v 2/3 so vi cht xc tc c t l % Al2O3 cao.ng thi hiu sut v xng s tng thm 2,5% th tch so vi cht xc tc v nh hnh c t l %Al2O3 cao khi chuyn ho l 68 -70% v 10% so vi cht xc tc v nh hnh c t l % Al2O3 thp khi chuyn ho l 72%. Ngoi ra khi s dng cht xc tc zeolit ta thu c hiu sut du diezel nh nhiu hn v du diezel nng t hn so vi xc tc v nh hnh.
25
Nguyn c
Cc c tnh
Xc tc v nh hnh Loi c Loi c hm hm lng lng Al2O3 Al2O3 cao thp
Xc tc Zeolit
X 25
XZ 36
TS 36
Thnh phn cu to (%) Al2O3 Na2O SO4 Tnh cht l hc Din tch b mt (m2/g) Th tch ring (cm3/g) T trng (g/cm3) 0,43 0,39 0,52 0,55 0,56 0,77 0,88 0,6 0,55 0,6 580 415 335 270 575 13 0,03 0,3 28 0,04 0,6 31 0,07 0,4 36 0,08 0,4 15 0,08 0,3
III.3.5.Nhng thay i tnh cht ca xc tc khi lm vic.[1,122] Xc tc cracking trong qu trnh lm vic b gim hot tnh v chn lc .Hin tng ny ngi ta gi l qu trnh tr ho xc tc. Qu trnh tr ho cng nhanh, nu ta tin hnh qu trnh iu kin cng ngh kh khn.V d ta tin hnh nhit qu cao, thi gian tip xc qu di, nguyn liu xu;
26
Nguyn c
ngoi ra cn xy ra cc qu trnh khc lm tng tc tr ho. Chng ta c th phn qu trnh tr ho xc tc lm hai qu trinh chnh: Qu trnh tr ho do tc dng ca cc cht lm ng c xc tc S tr ho do tc dng lm thay i cc tnh cht l, ho l ca xc tc Nguyn nhn ca s tr ho xc tc c th l do : Tc dng ca cc c t nh NH3, CO2, ca cc hp cht lu S tch t cc kim lai nng di dng cc oxyt lm thay i S tc ng ca nhit cao v hi nc... Nhm khng tc dng vi xc tc nhit thp hn 6200C nh (CO, CO2, NH3). Nhm lm gim hot tnh ca xc tc nhng khng lm gim chn lc nh hi nc. Nhm lm gim chn lc ca xc tc nh H2S nhit ln hn 4250C, NH3, SO2 , SO3 nhit ln hn 6200C. hot tnh ca xc tc c th c duy tr nu ta thm hi nc vo nguyn liu, hay vic x l trc v sau khi ti sinh xc tc.Thm hi nc khi ch bin nguyn liu c lu hunh s c tc dng m v khi li lm tng qu trnh n mn thit b v sn phm ca qu trnh n mn li lm nhim bn xc tc, dn ti lm gim hot tnh v chn lc ca xc tc.Tc dng ng thi ca nhit cao v hi nc lm gim hot tnh tng cng ca xc tc. Khi p dng qu trnh lp si (FCC), do cn phi duy tr iu kin cc t lng ng trn xc tc v xc tc khng b qu nhit khi ti sinh, ngi ta phi a vo mt lng nh hi nc. ng thi cng cn phi trnh s to cc qu t, v iu dn ti ph v cn bng nhit 27 hunh m c bit l H2S nhit cao. chc nng ca xc tc. Cc hp cht kh khi tc dng ti xc tc c th chia thnh ba nhm:
Nguyn c
lng ca h l phn ng v ti sinh, do nhit to ra trong qu trnh ti sinh khng b nhit thu vo ca cc phn ng cracking trong l phn ng.Hm lng cc trn xc tc khi ra khi l phn ng ph thuc vo lng xc tc tun hon trong h thng. i vi a s cc qu trnh FCC, khi dng xc tc cha zeolit, lng cc to ra thng chim vo khong 1,3 1,8% kh.l xc tc, cn sau khi ti sinh l 0,1 -0,05% kh.l. Cc hp cht c kim v cc hp cht cha nit trong nguyn liu du l cc phn t lm gi ho nhanh xc tc. S c mt ca cc hp cht cha nit trong nguyn liu lm gim hiu sut xng v sn phm trng.Khi tng nhit , tc dng c hi ca cc hp cht nit s gim. S ng c xc tc bi cc kim loi cng c nhiu nghin cu cp ti v ch r c ch tc dng ca chng n hot tnh xc tc. S gim nhanh nht hot tnh ca xc tc xy ra trong lc tip xc ca cc c t vi xc tc. Khi lng ng cc oxyt kim loi nng trn xc tc s dn ti lm gim su cracking v gim hiu sut xng do tng nhanh qu trnh to cc.Khi hm lng cc hp cht lu hunh trong nguyn liu tng, hm lng cc kim loi nng nh niken v vanadi cng tng theo, v a phn chng u tp trung phn cn nng v phn on nha asphan. IV.Sn phm thu c t qa trnh cracking xc tc.[2,102] Hiu sut v c tnh ca cc sn phm trong cracking xc tc ph thuc vo bn cht nguyn liu, cht lng xc tc v ch cng ngh. Sn phm chnh ca qu trnh l xng, ngoi ra cn thu thm mt s sn phm ph nh kh, gasoil nng, gasoil nh. IV.1. Sn phm kh cracking xc tc.[3,66] Hiu sut kh cracking xc tc chim khong 10 - 25% lng nguyn liu em cracking.N c th giao ng ph thuc vo bn cht ca nguyn liu em cracking. Hiu sut ny nhiu hay t ph thuc vo iu kin cracking.Nu cracking xc tc iu kin cng ( nhit cao, tc np liu
28
Nguyn c
nh, bi s tun hon ln) th hiu sut kh s ln,cn nu cracking iu kin mm th hiu sut kh s t. Thnh phn ca kh cracking ph thuc vo bn cht ca nguyn liu, vo bn cht ca xc tc. Nu nguyn liu c hm lng lu hunh cao th kh cracking xc tc cha nhiu H2S. Thnh phn ca kh cracking xc tc: % khi lng C1,C2 C3 C4 C5 10-25 25-30 30-50 10-20
Sn phm kh c a n b phn phn tch kh. Sau khi phn on kh kh c s dng lm nhin liu kh , cn phn on propan propylen v butan butylen c dng lm nguyn liu cho qu trnh alkyl ho nhn cu t c tr s octan cao pha vo xng hay nguyn liu tng hp ha du v ho hc . Phn on C5 c pha vo trong xng. Trong phn on C3, hm lng propylen c th t ti 70- 80%. Trong phn on C4, hm lng buten l 45- 55% , hm lng iso- butan l 40 -60% v hm lng n- butan nh, ch vo khong 10 -20%. IV.2. Xng cracking xc tc.[2,104] y l sn phm chnh ca qu trnh cracking xc tc, hiu sut xng thng dao ng trong khong t 30 -35% lng nguyn liu em vo cracking. Hiu sut v cht lng xng ph thuc vo cht lng nguyn liu, xc tc, ch cng ngh. liu. 29 Nu nguyn liu c nhiu naphten th xng thu c c cht lng cao. Nu nguyn liu c nhiu parafin th xng thu c c tr s octan thp. Nu nguyn liu c nhiu lu hunh th trong xng thu c cng c
nhiu lu hunh (thng chim 15% tng lng lu hunh c trong nguyn
Nguyn c
Xng nhn c t qu trnh cracking xc tc c t trng khong 0,72 0.77, tr s octan 87 - 91 (theo RON). Thnh phn ho hc ca xng cracking xc tc khc vi xng cracking nhit v xng chng ct trc tip, c 30 - 40% olefin, 20- 30% aren, cn li l naphten v iso parafin. Vi cc c trng trn xng cracking xc tc c th dng lm xng t hoc xng my bay. tng tr s octan cho xng cracking xc tc, ngi ta pha thm nc ch (TEL). Xng dng cho my bay thng pha thm 2,5 -3,3 g nc ch cho 1 kg xng v tr s octan s tng ln 10 n 16 n v. Mc tng tr s octan ph thuc vo thnh phn ho hc ca xng v hm lng lu hunh c trong xng.Nu xng c nhiu hydrocacbon thm v nhiu lu hunh th kh nng tip nhn nc ch km. Nu xng c hm lng parafin ln th mc tip nhn nc ch tng. IV.3. Sn phm gasoil nh.[3,69]. Gasoil nh l sn phm ph thu c trong cracking xc tc, c nhit si 175 -3500C. So snh vi nhin liu diezen th n c tr xtan thp v hm lng lu hunh trong sn phm cao.Tuy nhin cht lng ca sn phm ny cn ph thuc vo nguyn liu em cracking. Vi nguyn liu l xla t h du parafinic th gasoil nh cracking xc tc nhn c c tr s xtan tng i cao (45 46) Vi nguyn liu cha nhiu hydrocacbon thm, naphten th tr s xtan thp (25 35). Cht lng ca gasoil nh khng ch ph thuc vo thnh phn nguyn liu m cn ph thuc vo cht lng ca xc tc v ch cng ngh.Nu cracking xc tc iu kin cng th hiu sut v cht lng gasoil nh cng thp v ngc li cracking xc tc iu kin mm th thu c gasoil nh c hiu sut v cht lng cao. Gasoil nh dng lm cu t pha cho nhin liu diezel, lm nguyn liu pha vo mazut lm tng cht lng ca du mazut. 30
Nguyn c
Gasoil nh cracking xc tc c c tnh nh sau : T trng :0,84 -0,94. Thnh phn ho hc: 1,7 -2,4% trng lng lu hunh, 30 -50% hydrocacbon thm, cn li l naphten v parafin. IV.4. Sn phm gasoil nng.[2,105] Sn phm gasoil nng l phn cn cn li ca qu trnh cracking xc tc, c Ts trn 3500C, d420 = 0,890 0,990. Sn phm ny cha mt lng ln tp cht c hc . Hm lng lu hunh cao hn trong nguyn liu ban u khong 1,5 ln. N c s dng lm nguyn liu cho cracking nhit v cc ho, hoc lm nguyn liu t l, lm nguyn liu sn xut b hng, hoc quay tr li qu trnh cracking.
CHNG III CH CNG NGH CA QU TRNH CRACKING XC TC V CC DY CHUYN CNG NGH CRACKING XC TC
I.Ch cng ngh ca qu trnh cracking xc tc.[1,127] Cc thng s cng ngh ca qu trnh nh hng n cc ch tiu lm vic ca qu trnh cracking xc tc.Cc thng s cng ngh bao gm: nhit , p sut, tc np liu khng gian th tch (tc np liu ring), bi s tun hon xc tc v mc bin i hay su chuyn ho. I.1. Mc chuyn ho (C ). i vi hydrocacbon tinh khit, khi tham gia phn ng, mc chuyn ho c o bng lng sn phm to thnh theo thi gian. Nhng i vi phn on phc tp nh phn on du m, trong qu trnh cracking xc tc th ngi ta li o lng xng l sn phm chnh v sn phm ph nh kh v cc.Nu gi y l % th tch ca sn phm vi im si cui cao hn im si cui ca xng th chuyn ho c tnh theo cng thc sau: 31
Nguyn c
C =100 y Tuy nhin cch xc nh ny cha st vi thc t. hiu chnh theo s bin i ho, l trong qu trnh to xng v kh, ngi ta xc nh mc bin i theo cng thc sau: C = 100 y. (100 z). Trong z l % xng c trong nguyn liu. Trong qu trnh cracking xc tc, ngoi mc bin i cn c cc thng s quan trng khc. I.2 Bi s tun hon xc tc.[1,99] Bi s tun hon xc tc l t s gia khi lng xc tc v khi lng nguyn liu (X/RH) a vo thit b phn ng trong mt n v thi gian. Khi dng xc tc cha zeolit cho php gim t l X/RH xung cn 10/1 so vi xc tc v nh hnh l 20/1. Nu khi dng cng ngh xc tc chuyn ng vi kch thc ht xc tc t 3 mm 5 mm th t l X/RH cn thp hn na, ch khong 2 5/1. Khi thay i t l X/RH th s lm thay i nhit ca thit b phn ng, thay i thi gian lu ca xc tc trong thit b phn ng v trong l ti sinh ng thi cng lm thay i c lng cc bm trn xc tc trong mt chu trnh.Bi s tun hon xc tc tng ln th thi gian lu ca xc tc trong vng phn ng gim xung, hot tnh trung bnh ca xc tc tng ln lm cho hiu sut kh, xng, cc u tng ln, nhng lng cc bm trn xc tc sau tun hon li gim xung.iu ny c gii thch l do lng cc c dn ra mt lng xc tc ln hn. Khi gi tc np liu l khng i, nu tng t l X/RH th thi gian tip xc gia xc tc v nguyn liu gim, v nh vy hot tnh trung bnh ca xc tc tng ln.Bng cch thay i bi s tun hon xc tc ta c th iu chnh c hiu sut v cht lng ca sn phm thu. Vic tng bi s tun hon xc tc ch n gii hn cho php. Nu tng cao qu v quan im hiu qu kinh t s khng c li v s dn n tng kch thc ca thit b ti sinh v h thng vn chuyn xc tc, phi tng kh 32
Nguyn c
nn cn thit vn chuyn xc tc v nng lng tiu tn vn chuyn xc tc. I.3.Tc np liu ring. Tc np liu ring l t s gia lng nguyn liu c np vo trong mt n v thi gian trn lng xc tc trong thit b phn ng hay t l v th tch ca chng, c k hiu bng M/H/M hay V/H/V. Nu p l p sut trong thit b phn ng v c tnh bng at th chuyn ho C c mi lin h vi tc np liu theo biu thc: C P.K = 100 C M/H/M Phng trnh ny p dng rt ng vi trng hp xc tc c nh. Trong trng hp cracking xc tc vi lp si ca xc tc, chuyn ho C li ph hp vi cng thc: C C 100 1 100
2
P.K M/H/M
Khi tng tc np liu ring, s lm gim chuyn ho .Cn khi gim tc np liu ring th chuyn ho tng v tc np liu l i lng ngc vi thi gian phn ng. Khi s dng xc tc c hot tnh cao, ta c th tng tc np liu v nh vy s tng c nng sut thit b. Trong thc t nu ta dng xc tc l aluminosilicat v nh hnh, tc np liu th tch ch t t 4 h-1 5h-1. Nhng nu dng xc tc cha zeolit, tc np liu th tch l 80 -120 h-1 khi tnh trong ng ng ca thit b phn ng, v t 20 30 h -1 khi tnh trong lp si ca thit b phn ng. Khi tng tc np liu, nu ta tng nhit phn ng, s tng tr s octan ca xng v tng hiu sut olefin trong khi. I.4. Nhit trong thit b phn ng. Nhit phn ng trong thit b phn ng thng t 480 0C 5500C. Khi tin hnh tng nhit , lc u hiu sut xng tng v sau t n cc i 33
Nguyn c
ri gim xung. iu ny l do qu trnh phn hu tng lm phn hu cc cu t xng va c to thnh. Khi tng nhit , phn ng phn hu tng nhng ng thi cc phn ng bc 2 nh dehydro cng tng, lm tng hiu sut cc hydrocacbon thm v olefin. Khi trong sn phm kh , hm lng C1 C3 tng, cn C4 gim, t trng v tr s octan ca xng tng ln. I.5.nh hng ca p sut. Qu trnh cracking thng c tin hnh p sut 1,4 1,8 at. iu kin ny phn ng xy ra pha hi. Khi tng p sut , hiu sut xng tng ln, hiu sut kh C1 C3 gim, hm lng olefin v hydrocacbon thm gim, hm lng hydrocacbon no tng v do vy cht lng ca xng gim.ng thi qu trnh to cc li tng nn vic tng p sut i vi qu trnh cracking xc tc khng c hiu qu kinh t cao, v vy qu trnh ny ch tin hnh p sut thng. II. Cc dy chuyn cng ngh cracking xc tc. II.1.S lc v s pht trin h thng cracking xc tc. Nm 1936, dy chuyn cracking xc tc u tin c a vo cng nghip ch bin du, hot ng theo phng thc gin on vi lp xc tc c nh do k s ngi php Houdry thit k. Nm 1941, xut hin qu trnh cracking vi lp xc tc chuyn ng thay th cho qu trnh Houdry.Dy chuyn cracking xc tc loi ny Nga c tn l loi 43 -1 v 43 -102, cn cc nc khc c tn l TCC.Cc dy truyn cng v sau cng lin tc c ci tin so vi cc dy chuyn ban u khu vn chuyn xc tc. Nm 1942 dy chuyn cracking xc tc lp si FCC u tin c a vo hot ng vi cng sut 12.000 thng nguyn liu/ngy.Loi dy chuyn ny c tn l (Up Flow).Xc tc c a ra t nh ca l phn ng v ti sinh. Nm 1944 dy chuyn mang tn l Down Flow model II.Dy chuyn c thit b phn ng v thit b ti sinh c ng knh ln hn trc v qu trnh 34
Nguyn c
tch hi sn phm c thc hin ngay trong thit b phn ng, ti sinh xc tc dng tng si v qu trnh thi cng ngy cng c ci tin cho xc tc chuyn ng t pha di v ly ra ngoi y thit b v y ngi ta cng ci tin c hnh dng ca xc tc. Nm 1947, hng UOP thit k loi FCC trong thit b phn ng v thit b ti sinh chng ln nhau trn cng mt trc. Nm 1951, loi Orthor Flow u tin ca M.W. Kellog xut hin. Sau hng Standard oil thit k mt loi FCC mi l ci tin ca model II v n c p dng trong cng nghip vo nm 1952. II.2. Xu hng pht trin ca cracking xc tc.[4,25] K t khi ra i cho n nay, cracking xc tc tri qua mt thi k di gn 40 nm ci tin v hon thin dn cc quy trnh cng ngh cng nh cc loi xc tc s dng t thit b cracking xc tc u tin vi lp xc tc tnh hot ng khng lin tc con ngi khng ngng ci tin thnh kiu cracking xc tc tng si hot ng lin tc vi cht xc tc dng ht hoc dng bt trng thi chuyn ng. Dn dn ngi ta thay th cc loi xc tc dng ht thnh dng bt c ln vo khong 20 -100 micron v thu c hiu sut cao, nng gi tr kinh t ca mt tn du th a vo ch bin. Ngy nay, cracking xc tc lp tng si l mt phng php hin i nht v c p dng rng di trn th gii c bit l M, t l cracking xc tc lp tng si chim vo khong 72% nm 1995 v 10 nm sau tng ln ti 82% so vi ton b cracking xc tc, cn cc nc pht trin khc Ty u, t l ny chim vo khong 79%. Trong 10 nm gn y, xu hng vn tip tc xy dng phn xng cracking xc tc lp si vi cng sut ln t 4,2 n 5,2 triu m 3/nm. Do cng sut ln nn vn u t cng nh chi ph sn xut cho 1 m3 nguyn liu a vo r hn.
35
Nguyn c
II.3. Cc dy chuyn cng ngh cracking. II.3.1.S cracking xc tc dng cu chuyn ng.[3,108]. S gm 2 phn chnh : Phn xy ra qu trnh cracking v ti sinh xc tc. Phn gia nhit v phn chia sn phm. Thuyt minh s cng ngh: Nguyn liu c cho qua bm v cho qua h thng trao i nhit sau c a vo l t. Ti y nguyn liu c t nng n nhit xy ra phn ng v bay hi. Hi nguyn liu t l t i vo vng phn ng ca thit b phn ng. Ti y hi nguyn liu tip xc vi xc tc, trn vi nhau t trn xung di. tch hi sn phm ra khi xc tc ngi ta cho hi nc vo v hi sn phm cho qua thit b c bit, tch ra khi xc tc v cho sang thp chng tch hn hp sn phm. Hi xng, hi nc v kh bo i ra nh thp. Hn hp ny cho qua ngng t v lm lnh ri cho qua thit b phn ly.Ti y tch ring xng, kh bo v nc. Kh nh my nn cho sang phn xng sn xut kh. Xng tch ra khi thit b phn ly mt phn cho hi lu v thp chng tch sn phm. Cn phn ln xng c a v thit b n nh xng. Cn phn gasoil nh ( Ts :1950C 3500C) c ly ra cnh sn thp chng tch sau c cho vo thit b ti bc hi bng hi nc ri ly ra cho qua thit b trao i nhit gia nhit cho nguyn liu sau a qua thit b lm lnh ri a v b cha sn phm. Cn gasoil nng ( c Ts >3500C).ly ra khi y thp chng tch, bm qua thit b trao i nhit v qua thit b lm lnh ri cho v b cha sn phm. Ch cng ngh ca thp chng c gi n nh nh iu chnh cht lng hi lu v tun hon phn on trung gian cho qua thit b trao i nhit v li quay v thp chng. Xc tc t bunke- phn ly ca ng vn chuyn bng kh nn chuyn vo bunke ca thit b phn ng ri cho vo vng phn ng v vo vng tch sn phm ra khi xc tc. Sau xc tc ly ra khi thit b phn ng chuyn 36
Nguyn c
sang ng vn chuyn v nh kh l cho vo bunke- phn ly. Ti y kh l c a ra ngoi , xc tc c cho vo bunke thit b ti sinh. Xc tc i vo qua vng ti sinh t trn xung di. t cc bm trn xc tc ngi ta cho khng kh vo. Xc tc ti sinh chuyn sang ng vn chuyn v vo bunke thit b phn ng. II.3.2.S qu trnh cracking xc tc mt bc trong lp xc tc gi si. [3,113]. Thuyt minh dy chuyn cng ngh: Xc tc ti sinh i t thit b ti sinh theo h thng ng ng cho xc tc i xung im giao nhau. y xc tc c trn vi nguyn liu c t nng i t l ng sang. Hn hp nguyn liu vi xc tc theo h thng ng ng i vo thit b phn ng. Hn hp i vo thit b phn ng li vo theo dng tc tuyn tnh v ri nhanh xung, cc phn nh xc tc to thnh tng si y xy ra qu trnh cracking. Chn chiu cao ca lp xc tc da theo thi gian tip xc cn cho.Kh tch ra khi xc tc trong cc my ht bi tch kh. Sn phm cracking ly cho sang thp chng tch sn phm. Cn bi xc tc c gi li t cyclon c a quay li tng si. Xc tc lm vic c ly ra khi thit b phn ng cho sang thp ti ra hi.Ti y cho hi nc qu nhit vo tch ht hi sn phm ra khi b mt xc tc. Xc tc lm vic t thp ti bc hi cho xung ng ng ri cho xung im trn. Dng xc tc lm vic cho vo ti sinh c iu chnh bng van iu chnh. Thi khng kh t thit b thi khng kh vo im trn, khng kh nn y xc tc theo ng ng i ln thit b ti sinh, ti tng si xy ra qu trnh t cc, tch cc ra khi b mt xc tc. Xc tc c t cc cho qua ging theo ng ng tho xung trn vi nguyn liu. tch ht sn phm chy ra khi xc tc ngi ta cho hi nc vo ging. Xc tc cun theo kh ti sinh qua h thng my ht bi tch kh. Ti y kh ti sinh tch ra khi xc tc i ra nh v cho vo ni hi tn dng v t y 37
Nguyn c
cho i sang h thng lm sch kh. Cn xc tc c gi li v quay tr li tng si. II.3.3 S cng ngh xc tc lp si(FCC) vi thi gian tip xc ngn. [1,147]. Thuyt minh s cng ngh: Dy truyn cng ngh FCC gm cc b phn chnh sau : Thit b phn ng. L ti sinh v khi tn dng nhit ca kh khi. B phn phn chia sn phm.
1.Thit b phn ng. Nguyn liu mi t b cha nguyn liu 1 c cho qua thit b trao i nhit ng chm.Nguyn liu mi c th em trn vi mt phn tun hon (HCO)( phn on du nng ca qu trnh cracking xc tc ) v cn y, sau cho qua l t nng nguyn liu cracking.Nguyn liu cracking c tip xc vi xc tc nng ti sinh y ca ng ng, khi nguyn liu bay hi cng vi hn hp ca hi nng v xc tc c i ln pha trn ti nh ca ng ng, ng thi xy ra cc phn ng cracking xc tc. Hu ht nguyn liu u tham gia phn ng v chuyn ho trong ng ng, cn thit b phn ng c c dng nh mt thit b tch xc tc v hi hydrocacbon. Mt b phn c thit k c bit, b tr gn van chn, dng hi nc thi xc tc v du iu ny s hn ch mc ti a hin tng trn quay tr li ca xc tc v hi kh lm vic.Sau khi tch khi xc tc, hi sn phm nng c chuyn sang ct phn on. Xc tc lm vic c cho qua vung tch hi ( cn gi l b phn ra xc tc ) bng cch thi hi nc vo.B phn ra khng ch lm nhim v ui ht hydrocacbon hp ph trn xc tc m cn lm ti cc ht xc tc chng khng dnh vo nhau trc khi sang l ti sinh.Tc hi cn c iu chnh thch hp v cn 38
Nguyn c
phi kim tra cht ch thi gian lu ca xc tc trong b phn ra trnh phi dng qu nhiu khng kh trong l ti sinh. Ap sut trong thit b phn ng c khng ch bng b phn iu chnh p sut ca ct phn on. 2.L ti sinh v khi tn dng nhit ca khi l. Xc tc c cha cc c chuyn qua van iu khin v khng ch bi kim tra mc xc tc trong l phn ng,sau i vo l ti sinh. Xc tc vo l ti sinh. Xc tc vo l ti sinh theo hng tip tuyn vi thnh l. Mc ch ca ti sinh l t chy cc bm trn xc tc lm vic bng oxy khng kh, sn phm to thnh l CO v CO2, hi nc do vy m tr li b mt hot tnh cho xc tc. Sau khi nn khng kh t c a vo y l ti sinh, qua li phn phi trn c hiu qu gia khng kh v xc tc.S chy cng xy ra trong lp si v t c iu th tc ca khng kh phi ln hn 1 m/s. Xc tc ti sinh c chuyn vo ng ng sau khi ui sch kh qua mt van l m s hot ng ca van ny c khng ch, iu khin t ng nh b phn iu chnh nhit ca thit b phn ng, ri sau xc tc c trn vi nguyn liu cracking v hon thnh mt chu trnh. ng thi ta tin hnh tho xc tc bn gi ho ra v tip tc b xung xc tc mi m bo hot tnh n nh ca xc tc trong qu trnh lm vic. Kh ca qu trnh chy cc v cc ht xc tc chuyn ng t "pha c vo pha long" nh l ti sinh, qua hai cp xyclon gi li cc ht xc tcv kh tch. Sau , kh khi c qua bung lng tch tip bi xc tc, ri qua b phn tn dng nhit, sau kh khi c lm sch bi xc tc bng lc in ri i ra ngoi theo ng khi. 3. B phn phn chia sn phm. Hi sn phm c np vo ct phn on chnh chia thnh cc sn phm khc nhau: Xng v phn nh hn c cho qua b phn ngng t ri vo thit b tch kh. Sau khi tch kh, ta nhn c phn on C1 ,C2. Cc sn phm ny c 39
Nguyn c
th c dng lm kh nhin liu cho dy chuyn. Phn on C3 ,C4 cha nhiu propen v buten c dng lm nguyn liu cho dy chuyn alkyl ho v sn phm tip theo l xng kh butan. T ct phn on chnh ta cn nhn c naphta nng , LCO, HCO. Phn HCO c th cho tun hon li ng ng ca thit b phn ng v sn phm cui cng l phn du cn c lm sch khi bn xc tc. III. Phn tch la chn cng ngh cracking xc tc. Qua lch s pht trin ca qu trnh cracking xc tc, ng thi qua phn tch nh gi cc yu cu khc nh ch lm vic, nguyn liu xc tc... ta thy qu trnh FCC c rt nhiu u im v thun li, h thng ny c s dng ngy cng ph bin trong cng nghip du m, n c cc hng cng nghip hng u trong lnh vc ny nh UOP, Kellogg, Shell, IFP, Exxon... nghin cu hon thin hn nhm mc ich t nng sut hiu qu cao nht, s dng nguyn liu nng hn, tit kim c xc tc... v phi l kinh t nht. Qua thc t dng h thng cracking xc tc lp si s dng xc tc dng bi hay vi cu, ngi ta thy n c nhiu u im hn h thng cracking xc tc trong lp xc tc chuyn ng. Nhng u im l: Cc thit b chnh ca qu trnh l thit b phn ng v thit b ti sinh u c cu to rt n gin, so vi cc dng thit b khc ca qu trnh cracking thc t chng l hnh rng. S tun hon xc tc t thit b phn ng n thit b ti sinh v ngc li l nh s vn chuyn lin tc ca hi v kh trong mt gii hn rng. Do s khuy trn mnh m ca xc tc v hi nguyn liu dn n s ng nht v nhit trong ton b th tch lp xc tc thit b phn ng cng nh thit b ti sinh, khc phc c hin tng qu nhit cc b. H thng ny c kh nng ch bin cc dng nguyn liu khc nhau, nh t nguyn liu l phn on kerosen n nguyn liu nng l mazut, lm tng tnh vn nng ca h thng. 40
Nguyn c
H thng ny c cng sut lm vic ln v c thi gian tip xc ngn (thi gian tip xc gia nguyn liu v xc tc l cc tiu) dn n vic t c hiu sut xng cc i v olefin nh khng xy ra phn ng ngng t bc hai m to xng. ng dng phng php ti sinh (chy hon ton CO trong thit b ti sinh) dn n t hm lng ct cn rt thp trong xc tc. Vi nhng u im n bt nn ta chn s cng ngh xc tc lp si FCC vi thi gian tip xc ngn cho qu trnh cracking xc tc.
41
Nguyn c
CHNG IV TNH TON CN BNG VT CHT V NHIT LNG

I.Tnh cn bng vt cht. Tng lng vt cht vo l phn ng bng tng lng vt cht ra khi l phn ng :Gvo = Gra.
Gk
Gx GNL Gc Ggnh
Ggn
Cn bng vt cht ca l phn ng Phng trnh cn bng vt liu ca l phn ng c dng: GNL =Gk +Gc+G x +Ggnh +Ggn+ Gmm Trong : GNL : Lng nguyn liu mi vo trong l phn ng( nng sut ca phn xng ) ,T/h. Gk : Lng sn phm kh to thnh, T/h. Gc : Lng cc to ra , T/h. Gx : Lng sn phm xng to thnh, T/h. Ggnh : Lng gasoil nh ,T/h. Ggn : Lng gasoil nng, T/h. Gmm : Lng mt mt ,T/h. Phn xng cracking xc tc c nng sut 3.000.000 tn/nm vi nguyn liu l ly t phn cn ca du th Bch H. Ta coi thi gian lm vic ca phn xng trong 1 nm l 8000 h 42
Gm m
Nguyn c
3.106 Nng sut ca phn xng tnh theo gi s l : GNL= = 375 T / h. 8000
Chn hiu sut xng ( tnh theo % trng lng nguyn liu mi ) l X = 45,1% trng lng nguyn liu mi Chn hiu sut cc Xc = 1,7% trng lng nguyn liu mi. Chn hiu sut kh khi cracking l Xk = 17,7% trng lng nguyn liu mi. Hiu sut gasoil nh l : Xgnh = 22% trng lng nguyn liu mi Hiu sut gasoil nng l : Xgn = 12,5% trng lng nguyn liu mi Coi lng mt mt l 1%. Tng lng vt cht vo l phn ng Gvo = GNL = 375 Lng sn phm ra khi thit b phn ng : Lng kh cracking l: Gk = GNL .17,7 Lng xng l : ,T/h , T/h ,T/h ,T/h ,T/h = 375. 0,177 = 66,375 ,T/h ,T/h
Gx = GNL . 0,451 = 375 . 0,451 = 169,125 Lng gazoil nh l : Ggnh = GNL . 0,22 Lng gazoil nng l : Ggn = GNL . 0,125 = 375. 0,125 = 46,875 Lng cc l Lng mt mt l : = 6,375 = 3,75 : Gc = GNL 0,017 = 375. 0,017 Gm = GNL 0,01 = 375. 0,01 Vy tng lng sn phm v mt mt l: Gra = Gk + Gx + Ggnh + Ggn + Gc + Gm = 375. 0,22 = 82,5
= 66,375 + 169,125 + 82,5+ 46,875 + 6,375 + 3,75 = 375 , T/h kt qu tnh ton cn bng vt cht cho thit b phn ng nh sau : Bng 1: Kt qu tnh ton cn bng vt cht cho thit b phn Cc thnh phn Trng lng , T/h % Trng lng theo nguyn liu mi
43
Nguyn c
u vo Nguyn liu mi u ra Sn phm Kh Sn phm Xng Sn phm Gasoil nh Sn phm Gasoil nng Cc Lng mt mt Tng 66,375 169,125 82,5 46,875 6,375 3,75 375 17,7 45,1 22 12,5 1,7 1 100 375 100
Xc nh lng xc tc tun hon v tiu hao hi nc. Vi h thng xc tc dng ht cu th bi s tun hon xc tc N = 4 9/1 Ta chn N = 6/1 nh vy lng xc tc s l : GCatalyst = N. Gc = 6.375 = 2250 ,T/h Xc nh lng tiu hao hi nc. Hi nc s dng trong qu trnh l hi qu nhit iu chnh mt ca hn hp hi nguyn liu v xc tc trong ng vn chuyn ta dng hi nc v n tiu tn khong 0,4 -2,0% trng lng tnh theo ti trng ca l phn ng. Ta chn tiu tn hi nc iu chnh mt hn hp l 1,6% trng lng theo nguyn liu. Vy lng hi nc tiu hao trong trng hp ny l : Gn1 = 0,016 .375 = 6 ,T/h. Hi nc dng tch hi sn phm cracking ra khi xc tc trc khi a vo l ti sinh trong vng tch. Tiu tn trong trng hp ny vo khong 5 -10 kg tch c 1 tn xc tc c dnh cc. Ta chn gi tr l 7 kg /1tn xc tc. Nh vy lng hi nc tiu tn s l : Gn2 = 7.2250 =15750 , Kg/h. Vy lng hi nc tiu tn tng cng l: 44
Nguyn c
GH2Ohv = Gn1 + Gn2 = 6 +15,75 = 21,75

Qk
,T/h.
II. Cn bng nhit lng ca l phn ng. Cn bng nhit ca l phn ng Phng trnh cn bng nhit lng ca l phn ng c dng: QNL + QH2Ohv1 + QH2Ohv2 + QXtv =
QNL QH O
2 hv
Qmm
Qx
tr
Qx
(QH O QH O )
2 hv1, 2 hv2,
Qc QH O
2 hr
Qxtv
Qgnh
Qp
u
QXtr + Qk + Qx + Qgnh + Qgn +Qcc + QH2Ohr1 + QH2Ohr2 + Qmm + Qp. Trong :
Qgn
V tri ca biu thc biu din tng nhit lng mang vo thit b tnh bng , Kcal/h. QNL : Nhit lng do nguyn liu mi mang vo QH2Ohv1 : Nhit lng do hi nc a vo ng vn chuyn QH2Ohv2 : Nhit lng do hi nc mang vo vng tch QXtv : Nhit lng do xc tc mang vo V phi ca phng trnh biu din tng nhit lng mang ra khi thit b phn ng tnh bng (Kcal/h). QXtr Qk Qx Qgnh Qgn : Nhit lng do xc tc mang ra : Nhit lng do sn phm kh mang ra : Nhit lng do hi xng mang ra : Nhit lng do hi gasoil nh mang ra : Nhit lng do phn gasoil nng mang ra
QH2Ohr1 : Nhit lng do hi nc mang ra khi ng vn chuyn QH2Ohr2 : Nhit lng do hi nc mang ra khi vng tch Qmm Qp : Mt mt nhit vo mi trng : Nhit lng tiu hao cho phn ng cracking. 45
Nguyn c
Da vo cc ti liu v thc t cng nghip ta chn nhit ca cc thnh phn lc i vo thit b phn ng nh sau: Nhit ca xc tc vo thit b phn ng l : txtv = 6000C Nhit ca hi nc a vo ng vn chuyn l: tH2Ov1 = 6000C ( p sut 40 at) Nhit ca hi nc a vo vng tch: tH2Ov2 = 2300C ( p sut 2 at) II.1. Nhit lng do kh sn phm mang ra. Trong bng 2 di y theo ti liu [6,118] s ch ra thnh phn ca kh cracking ( Ngi ta xc nh c bng cch phn tch sc k kh ca sn phm kh nhn c khi cracking). Vi gi thit l p sut trong thit b phn ng l tng i nh, v vy nh hng ca p sut ln hm nhit l khng ng k. Khi bit thnh phn ca kh cracking ta c th tm c hm nhit ca ring tng cu t sau ta c th tnh c hm nhit ca hn hp cc cu t. Tng hm nhit ring phn ca cc cu t s l hm nhit ca kh cracking nhit cho. Nh ni suy ta c th xc nh c hm nhit ca kh cc nhit trung gian. Bng 2: Thnh phn ca kh cracking Cu t H2S H2 CH4 C2H4 C2H6 C3H6 C3H8 Hiu sut % trng lng theo nguyn liu 0,85 0,2 2,31 0,57 1,25 3,22 2,43 46 Kg/h 3187,5 750 8662,5 2137, 5 4687,5 12075 9112,5 S lng Kmol/h 93,75 375 541,4 76,34 156,25 287,5 207,1
Nguyn c
C4H8 C4H10
3,95 2,92
14812,5 10950
264,5 188,79
Bng 3: Hm nhit ca cc cu t kh trong khong nhit 3000C 5000C. Cu t Thnh phn % trng H2S H2 CH4 C2H4 C2H6 C3H6 C3H8 C4H8 C4H10 Tng lng 4,802 1,13 13,05 3,22 7,062 18,192 13,729 22,316 16,499 100 Ring 75,3 1035,0 188,8 142,9 162,6 141,4 159,1 148,9 159,5 300 C Ring phn 3,616 11,67 24,64 4,60 11,48 25,72 21,84 33,23 26,31 163,10 103,2 1383,0 269,0 205,0 236,0 204,0 231,0 214,0 231,0
0
Hm nhit 4000C Ring Ring phn 4,96 15,62 35,10 6,601 16,67 37,11 31,71 47,76 38,11 233,64
5000C Ring Ring phn 131 1733 357 273 316 272 309 285 308 6,29 19,58 46,59 8,79 22,32 49,48 42,42 63,60 50,82 309,89
T bng trn ta xc nh c hm nhit ca kh cracking khi ra khi l phn ng 5000C. Hm nhit ca kh cracking 5000C c gi tr bng : qk = 309,89, Kcal/Kg. Nh vy nhit lng do kh sn phm mang ra l : 47
Nguyn c
Qk = 66,375.103 . 309,89 = 2,057 .107 ,Kcal/h II.2 Nhit lng do hi cc sn phm nng hn mang ra. Hm nhit ca hi hydrocacbon c xc nh theo cng thc : qh = ( 50,2 + 0,109. t + 0,00014.t2 )*( 4 - 1515 ) -73,8 Trong : qh t : Hm nhit ca phn on trng thi hi , Kcal/Kg : nhit phn on , 0C 1515 : T trng ca phn on lng Hm nhit ca hi sn phm ra khi thit b phn ng 5000C l : qh = ( 50,2 + 0,109.500 + 0,00014.5002 )*( 4 -0,76 ) -73,8 =378,83 Kcal/Kg. Nhit lng do hi xng mang ra khi thit b phn ng Qx = 169,125 .103 . 378,83 =6,4069.107 Kcal/h Nhit hm ca cc hydrocacbon lng c tnh theo cng thc :
1
[6,120]
ql =
15, 6 15, 6
( 0,403. t + 0,000405 .t2 )
[6,120]
Trong : ql t : l hm nhit ca phn on hydrocacbon lng nhit t, Kcal/Kg : Nhit ca phn on .0C
1 0,933
d15,615,6 : T trng ca phn on Hm nhit ca gasoil nh 5000 C l : qgnh=

.(0,403.500 + 0.000405 .500 2 ) =313,43 ,Kcal/kg
( do t trng ca gasoil nh l : 1515 = 0,933 ) Lng nhit do phn gasoil nh mang ra : Qgnh = 82,5.103 . 313,43 = 2,5856 .107 ,Kcal/h Hm nhit ca phn gasoil nng mang ra : qgn =
1 0,9429 .(0,403.500 + 0,000405 .500 2 ) = 311,78 ,Kcal/kg
( t trng ca gasoil nng l : 1515 = 0,9429 ) 48
Nguyn c
Lng nhit do phn gasoil nng mang ra l : Qgn =46,875. 103. 311,78 = 1,4615 .107 ,Kcal/h Hm nhit ca cc v xc tc c tnh theo cng thc : qcc = C.t q cc : hm nhit ca cc hoc xc tc , Kcal/kg C t : l nhit dung ring ca cc hay nhit dung ring ca xc tc v tng : Nhit ca xc tc hay cc. ng bng 0,6 v 0,27 ,Kcal/ Kg.. Hm nhit ca xc tc i vo ng phn ng : qxtv =0,27. 600 = 162 ,Kcal/Kg Nhit lng ca xc tc mang vo ng phn ng QXtv = 2250. 103 .162 = 36,45 .107 ,Kcal/h Hm nhit ca xc tc ra khi thit b phn ng : qxtr =0,27 .500 = 135 ,Kcal/kg Lng nhit do xc tc mang ra khi thit b phn ng : QXtr = 2250. 103 .135 = 30,375. 107 Kcal/h Hm nhit ca cc mang ra khi thit b phn ng : qcc = 0,6.500 =300 Kcal/kg Lng nhit do cc mang ra l : Qcc = 6,375 . 103 .300 =0,19125.107 Kcal/h Hm nhit ca hi nc c xc nh theo 40 at ,2300C l : 0,293 Kcal/ Kg. 2 at ,5000C l :0,509 Kcal/Kg. Hm nhit ca hi nc mang vo ng phn ng : qH2Ov1 = 0,5285 .600 = 317,1 Kcal/ Kg Lng nhit do hi nc mang vo ng phn ng l : QH2Ovl = 6.103. 317,1 = 0,19026.107 , Kcal/h Hm nhit do hi nc mang vo vng tch l : 49 [7,196] Nhit dung ring ca hi nc 40 at , 6000C l : 0,5285 Kcal/Kg. [6,120]
Nguyn c
qH2Ov2 = 0,293.230 = 67,39 Kcal/kg Nhit lng do hi nc mang vo vng tch l : qH2Ov2 = 15,75.103 . 67,39 = 0,1061.107 Kcal/h Tng lng nhit do hi nc mang vo l : QH2Ot = (0,19026 +0,1061 ) .107 = 0,29636 .107 Kcal/h Hm nhit ca hi nc khi ra khi thit b phn ng : qH2Or = 0,590 .500 = 254,5 ,Kcal/ Kg Lng nhit do hi nc mang ra : QH2Ohr = 21,75.103 .254,5 =0,5535. 107 ,Kcal/h su bin i c xc nh: 100-22-12,5= 65,5% trng lng tra th hnh 59 (ti liu[ 6,120]) ta c hiu ng nhit ca phn ng: H=62, Kcal/kg Lng nhit tiu hao cho phn ng cracking:
Qp= 375.103.62= 2,325.107 , Kcal/h Lng nhit mt mt ta coi nh tnh bng 5% lng nhit cn bng ( Qmm = 0,05 Qvo ) Tng lng nhit vo thit b phn ng :
Qvo = QNL + 0,29636.107 + 36,45 .107 =QNL + 36,74636.107 ,Kcal/h Tng lng nhit mang ra khi thit b :
Qr = 2,057 .107 + 6,4069.107 + 2,5856.107 + 1,4615 .107 + 30,375. 107 + 0,19125.107 +0,5535 . 107 + 2,325.107 + Qmm Qr = 45,96 . 107 +0,05. Qvo ,Kcal/h Qvo = Qr = 48,379 .107 , Kcal/h Qmm = 0,05 . 48,379. 107 = 2,61351.107 ,Kcal/h 50
Nguyn c
Lng nhit do nguyn liu mi mang vo l : QNL = (48,379 36,74636 ). 107 =11,63264.107 ,Kcal/h Hm nhit ca nguyn liu :
qNL = QNL 11,63264.107 = = 310, 2 GNL 375.103
,Kcal/ Kg.
Ta c bng cn bng nhit nh sau :
Bng 4: Bng Cn bng nhit lng ca thit b phn ng Tn Nhit

0
S lng T/h 51
Hm nhit Kcal/Kg
Tng cng, 107 Kcal/h
Nguyn c
Vo QNL QXtv QH2Ov1 QH2Ov2 Cng Ra Qx Qk Qgnh Qgn Qxtr Qcc QH2Ohr Qp Qmm Cng 500 500 500 500 500 500 500 500 169,125 66,375 82,5 46,875 2250 6,375 21,75 378,83 309,89 313,43 311,78 135 300 254,5 62 6,4069 2,057 2,5856 1,4615 30,375 0,19125 0,5535 2,325 2,61351 48,56926 600 600 230 375 2250 6 15,75 394,125 310,2 162 317,1 67,39 11,63264 36,45 0,19026 0,29636 48,56926
III. Tnh ton thit b phn ng. III.1. Tnh ng knh l phn ng ng knh l phn ng c xc nh theo cng thc sau : D=1,128. S 52 [6,122]
Nguyn c
Trong : S : l din tch tit din ngang ca l phn ng , m2 S c tnh bng : Trong : V : Th tch hi i qua mt ct ngang ca l phn ng, m3/h Vn tc cho php ca hi trong tit din t do ca l phn ng , m/s. i vi thit b cracking xc tc th vn tc trung bnh ca hi trong tit din t do ca l phn ng l 0,63 m/s. Khi V c xc nh theo cng thc :
22,4. Gi (273 + t p ) Mi 273.
S=
V 3600.
V =
[ 6,123]
Gi : L lng hn hp hi trong l phn ng , Kmol/h , Mi
tp
: L nhit trong l phn ng ,0C : p sut tuyt i bn trn lp gi si ca l phn ng , ta ly bng 2 at
Trng lng phn t trung bnh ca kh cracking:

66,375.103 = 30, 2995 , Kg/kmol 2190, 63
Ta tnh c:
Gi Mi 66,375.103 = 30, 2995
169,125.103 105
82,5.103 200
46,875.103 340
21,75.103 = 18
5560 , Kmol/h Vy rt ra V l :
V= 22, 4.5560 .(273 + 500) = 176324, 7 , m3 /h 273.2
Tit din ngang ca l phn ng l : 53
n tt nghip Thnh Ho Du 1- K45 S= 176324, 7 = 77, 74 , m2 3600.0, 63
Nguyn c
ng knh ca l phn ng l : D=1,128. S =1,128 . 77, 74 = 9,946 , m
Trong cng nghip ngi ta thng s dng l c ng knh nm trong khong 2,5 m 12 m . Ta chn l c ng knh l D = 10 , m. III.2. Tnh chiu cao ca l phn ng. Chiu cao ton b l phn ng c xc nh theo cng thc sau : Htl = H1 + H2 + H3 +H4 Trong : H1 : Chiu cao vng tch, thng chn H1 = 6 , m H2 : Chiu cao vng t cyclon, n ph thuc vo kch thc ca cyclon v thng chn l H2 = 6,m H3 : Chiu cao nh l phn ng. Do nh l phn ng c dng bn cu nn ta thng ly H3 = 0,5 .D = 0,5 . 10 = 5 ,m Ta c: HN : H4 = HN + HT Chiu cao phn hnh nn ca vng chuyn tip [6,124]
HT : Chiu cao phn hnh tr ca vng chuyn tip. Thng chn HT = 5 , m. Cho ng knh vng tch D1 = 5 m v gc to bi phn hnh nn v thit b l 450, ta tnh c: HN = Vy: H4 = 2 + 5 = 7
D D1 9 5 = =2 ,m 2 2
,m H = 6 + 6 + 5 +7 = 24 ,m 54
Nh vy chiu cao ca l phn ng l :
Nguyn c
III.3. Tnh ton ng ng. Theo vic la chn cng ngh FCC thi gian tip xc ngn , ta chn thi gian lu ca nguyn liu v sn phm trong ng ng l : =2, s. Tc ca hi nguyn liu v sn phm ta chn gi tr v =15 ,m/s chiu di ng ng l : Hng = .v = 30 ,m Th tch ca ng ng l : V = Hng. S Trong : S : L din tch tit din ngang ca ng ng.
Hng : Chiu cao ca ng ng. Ta c S = Trong : d : l ng knh ng ng , m Nh vy c :

.d 2 .V V = Hng . 4 .d 2 4
d= Ta c thi gian lu : Trong : Vng : Th tch ng ng , m3 V

=
Vong V
4.Vong
.H
,s
: Th tch hi i qua mt ct ngang ca l phn ng ,m3/s
Suy ra Vng = .V Nh vy ng knh ca ng ng l : 55
Nguyn c
d=
4.2.176324, 7 4. .V = = 2,04 , m 3,14.30.3600 .H
Chn ng knh ng phn ng l d = 2 , m V.Cyclon ca l phn ng Ta t cyclon trong l phn ng nhm mc ch thu hi bi xc tc b cun theo hi sn phm phn ng. Mc lm sch c th dao ng trong khong 65 98% .Trong trng hp cn lm sch mc cao hn ta c th dng cyclon hai hay ba bc. Trong n ny ta ch gii hn vic tnh s lng v tr lc thu lc ca cyclon. tnh ton ta phi da vo tc quy c ca dng hi sn phm i trong tit din t do ca cyclon v tc quy c c xc nh theo cng thc : y = Trong : V : l th tch ca dng hi sn phm , m3/s S : tit din chung ca cc cyclon, m2 Mc gim p sut trong cyclon c xc nh nh mt tr lc cc b :
2 y p == . . sp 2.g
V ,m/s S
[6,129]
= .
2 y .sp 2
, N/m2
D1
[6,129]
Trong : : L h s tr lc sp : Trng lng ring ca hi sn phm,

h'3 h'1 h'2
N/m
g : L gia tc trng trng , m/s2 sp : T trng ca hi sn phm , Kg/m3 56

d h'4

p Ta chn =65 ,m ta tnh c y theo cng thc : sp
Nguyn c
y =
2.g . . sp
,m/s
Ta chn loi cyclon theo [6,130] c : ng knh ng ra D1 = 0,6 Chiu rng ng vo B =0,26 Chiu cao ng vo h1 =0,66 Chiu cao ng ra : h2 =1,74 Chiu cao phn hnh tr : h3 = 2,26
Chiu cao phn hnh nn : h4 = 2,00 Chiu cao chung ca cyclon : H =4,56 ng knh y hnh nn H s tr lc thu lc : d =0,25 : = 105
2.9,81.65 105
Thay cc ga tr trn vo ta tnh c y = Tit din chung ca cc cyclon l : S = 3600.3, 485 = 14,054, m2
176324,7
=3,485 ,m/s
Nu ta dng cyclon c D =0,8 ,m th tit din ca mt cyclon s l :

.D 2 3,14.0,82 s= = = 0,5 ,m2 4 4
S cyclon cn dng l : n =
14, 054 S = 0,5 =28,109 s
57
Nguyn c
Ta ly chn s cyclon l n = 28 khi tit din chung thc t ca cc cyclon l : S = 0,5 .28 = 14 ,m2 .
58
Nguyn c
CHNG V XY DNG
I. Mc ch v ngha. Vic xc nh a im xy dng nh my l vn quan trng, then cht gip t nc ngy cng pht trin. Bi vy, xc nh c a im xy dng hp l s to iu kin tt cho giai on chun b u t, l c s cho vic pht trin sn xut ca nh my, n to iu kin lm gim vn u t cng nh gi thnh ca sn phm ca nh my v trc mt cng nh lu di. V tr ca nh my s quyt nh n s nh hng trc tip n mi trng. ng thi v tr ca nh my cn c lin quan n s pht trin kinh t v chnh tr ca t nc. II. Cc yu cu chung i vi a im xy dng nh my. II.1.V quy hoch. a im xy dng la chn phi ph hp vi quy hoch lnh th, quy hoch vng, quy hoch cm kinh t cng nghip c cc cp c thm quyn ph duyt.To iu kin pht huy ti a cng sut ca nh my v kh nng hp tc sn xut ca nh my vi cc nh my ln cn. II.2. V iu kin t chc sn xut. a im la chn xy dng phi tha mn cc iu kin sau : Phi gn vi cc ngun cung cp nguyn liu cho sn xut v gn ni tiu th sn phm ca nh my. Gn cc ngun cung cp nng lng, nguyn liu nh : in, nc, hi, kh nn, than, du... nh vy s hn ch ti a cc chi ph cho vn chuyn, h gi thnh sn phm, gp phn thc y s pht trin ca nh my. II.3. iu kin h tng k thut. a im xy dng phi m bo c s hot ng lin tc ca nh my. Do cn ch ti cc yu t sau : 59
Nguyn c
Ph hp v tn dng ti a h thng giao thng quc gia bao gm : ng b, ng st, ng sng, ng bin, ng hng khng. Ph hp v tn dng ti a h thng mng li cung cp in, thng tin lin lc v cc mng li k thut khc. Nu a phng cha c sn cc iu kin h tng k thut trn th phi xt n kh nng xy dng cc c s h tng k thut trc mt cng nh trong tng li. II.4. iu kin xy lp v vn hnh nh my. a im xy dng c la chn phi ch cc iu kin sau : Kh nng ngun cung cp vt liu, vt t xy dng gim chi ph gi thnh u t xy dng c bn ca nh my, gim chi ph vn chuyn vt liu v vt t xy dng t xa n. Kh nng cung ng cng nhn trong qu trnh xy dng nh my cng nh vn hnh nh my sau ny. Do vy trong qa trnh thit k cn ch xc nh cc cng nhn ca nh my v kh nng cung ng cng nhn a phng ngoi ra cn phi tnh n kh nng cung ng cng nhn cc a phng ln cn. III.Cc yu cu v k thut xy dng. III.1. V a hnh. Khu t phi c kch thc v hnh dng thun li cho vic xy dng trc mt cng nh trong vic m rng nh my trong tng lai. Kch thc, hnh dng v quy m ca khu t khng hp l s gy rt nhiu kh khn trong qu trnh thit k, b tr dy truyn cng ngh cng nh vic b tr cc hng mc cng trnh trn mt bng khu t do vy khu t la chn cn phi p ng cc yu cu sau : Khu t phi cao ro trnh ngp lt trong ma ma l, khu t phi c mc nc ngm thp, to iu kin tt cho vic thot nc thi v nc mt d dng. 60
Nguyn c
Khu t phi tng i bng phng v c dc t nhin tt nht l 0,5 -1% hn ch ti a kinh ph cho vic san lp mt bng III.2.V a cht. Khu t c la chn phi p ng c cc yu cu sau : Khng c nm trn cc vng c m khong sn hoc a cht khng n nh nh l ng t, si mn t, hay hin tng ct chy. Cng khu t xy dng l 1,5 - 2,5 KG/cm 2.Nn xy dng trn nn t st, st pha ct, t ong, t i... gim ti a chi ph gia c nn mng ca cc hng mc cng trnh, nht l hng mc cng trnh c ti trng bn thn v ti trng ng ln. III.3. Yu cu v mi trng v sinh cng nghip. Khi chn a im xy dng cn xt n mi quan h mt thit gia khu dn c th v khu cng nghip. y l iu cn thit v trong qu trnh sn xut cc nh my ho cht thng thi cc ho cht c hi nh : Kh c, nc bn, khi bi, ting n... hoc cc yu t bt li khc nh d chy n, nhim mi trng ... hn ch ti a nh hng ca mi trng cng nghip ti khu dn c, cc khu vc c di tch lch s v danh lam thng cnh ca a phng cn phi m bo cc iu kin sau : m bo khong cch bo v, v sinh cng nghip thch hp, a im xy dng phi m bo yu cu quy phm, quy nh v mt bo v mi trng v sinh cng nghip. Phi trng cy xanh hn ch tc hi ca khu cng nghip gy ra. V tr xy dng nh my thng cui hng gi ch o, ngun nc thi ca nh my c x l h lu v cch bn nc dng ca khu dn c ti thiu l 500 m. Tm li, la chn a im xy dng nh my hp l, phi cn c vo cc yu t trn nhng trong thc t rt kh khn khi la chn c a im tho mn cc yu cu trn. Do vy cc chuyn gia cn nghin cu, cn nhc 61
Nguyn c
v u tin n c im sn xut ring ca nh my quyt nh a im la chn nh my l ti u. T nhng yu cu trn, ta chn a im xy dng nh my lc du ti Dung Qut Qung ngi. Ni c chnh ph ph duyt xy dng nh my. IV. c im ca a im xy dng. Nh my lc du l nh my hin i v mt dy chuyn, sn xut vi quy m ln. N c vai tr quan trng trong nn kinh t quc dn ng thi y l mt d n mang tnh chin lc ca Chnh Ph. V vy vic chn a im xy dng cn phi thn trng. y ta chn a im xy dng nh my lc du ti Dung Qut Qung ngi. Phn xng cracking xc tc c xy dng trong nh my lc du. i vi a im ny, mang nhiu yu t thun li cho vic xy dng nh my lc ha du nh : Mng li giao thng, do nm trong vng trng im pht trin kinh t ca chnh ph vi d n pht trin khu cng ngh cao.Thun tin c v giao thng ng b v ng thy v hng khng. Hng ng cch bin khong 6 Km. Bin c su ln v rng to iu kin thun li cho cc tu c ti trng ln vo cp bn. Hng Bc gip khu kinh t m Qung Nam. V vy v mt giao thng s rt thun li cho vic vn chuyn nguyn liu, nhin liu v nh my cng nh vn chuyn sn phm ca nh my i tiu th. Vt liu , vt t xy dng ly ngay trong ni tnh. Ngun cng nhn di do, y l yu t quan trng trong qu trnh y mnh xy dng nh my cng nh vic vn hnh nh my sau ny. Kch thc v hnh dng ca khu t rt thun lij cho vic xy dng trc mt cng nh m rng nh my sau ny . Khu t rt cao ro, khng b ngp lt , dc t nhin ca khu t khong 1%, khng nm trn cc m khong sn, c chu nn tt. 62
Nguyn c
Hng gi ch o l gi ng Nam v vy cc cht kh, bi ca nh my s t nh hng n khu dn c. Tuy nhin vn cn mt hn ch l : Xa ngun nguyn liu do vy m chi ph vn chuyn nguyn liu cao. Nn kinh t y nhn chung cha pht trin cc ngnh thng mi, dch v cha mnh. Kh hu khc nghit, thng c bo, l.
CHNG VI THIT K TNG MT BNG CA PHN XNG V TNH TON KINH T

I. Yu cu thit k tng mt bng ca phn xng cracking xc tc. [ 8,131] c c phng n ti u khi la chn v thit k quy hoch tng mt bng nh cng nghip phi tho mn cc yu cu c th sau : 1. Gii php thit k tng mt bng nh my phi p ng c yu cu cao nht ca dy truyn cng ngh sao cho chiu di dy truyn sn xut ngn nht, khng trng lp v ln xn, hn ch ti a s giao nhau.Bo m mi lin h mt thit gia cc hng mc cng trnh vi h thng giao thng v cc mng li cung cp k thut khc bn trong cng nh bn ngoi nh my. 2.Trn khu t xy dng nh my phi c phn chia thnh cc khu vc chc nng theo c im sn xut, yu cu v sinh, c im s c, khi lng, phng tin vn chuyn, mt cng nhn... to iu kin tt nht cho vic qun l vn hnh cc khu vc chc nng. 63
Nguyn c
3.
Din tch khu t xy dng c tnh ton tho mn mi yu cu i hi
ca dy chuyn cng ngh trn c s b tr hp l cc hng mc cng trnh, tng cng kh nng hp khi nng tng, s dng ti a cc din tch khng xy dng trng cy xanh, t chc mi trng cng nghip v nh hng pht trin m rng nh my trong tng lai. 4. T chc h thng giao thng vn chuyn hp l ph hp vi dy truyn cng ngh , c tnh hng ha p ng mi yu cu sn xut v qun l. Lung ngi v lung hng ho phi khng trng lp hoc ct nhau. Ngoi ra cn phi ch khai thc v tn dng mng li giao thng quc gia v ca cc cm nh my ln cn. 5.Phi tho mn cc yu cu v sinh cng nghip, hn ch ti a s c sn xut, m bo v sinh mi trng bng cc gii php phn khu chc nng, b tr hng nh hp l theo hng go ch o ca khu t. Khong cch ca cc hng mc cng trnh phi tun theo quy phm thit k, to mi iu kin cho vic thng thong t nhin, hn ch bc x nhit ca mt tri truyn vo nh. 6. Khai thc trit cc c im a hnh t nhin, c im kh hu a phng nhm gim ti thiu cc chi ph san nn, x l nn t, tiu thu v x l cc cng trnh ngm khi b tr cc hng mc cng trnh. 7. Phi m bo tt cc mi quan h hp tc mt thit vi cc nh my ln cn trong khu cng nghip vi vic s dng chung cc cng trnh m bo k thut, x l cht thi, chng nhim mi trng cng nh cc cng trnh hnh chnh phc v cng cng... nhm mang li hiu qu kinh t, hn ch vn u t xy dng nh my v tit kim t xy dng. 8. Phn chia thi k xy dng hp l, to iu kin thi cng nhanh,sm a nh my vo hot ng sn xut, nhanh chng hon vn u t xy dng. 9. m bo cc yu cu k thut thm m ca tng cng trinh, tng th nh my. Ho nhp, ng gp cnh quan xung quanh, to thnh khung cnh kin trc cng nghip th. 64
Nguyn c
II.B tr mt bng. II.1. c im ca phn xng. Phn xng cracking xc tc thng t lin hp vi cc dy chuyn chng ct du th, alkyl ho, isome ho, phn xng polime...v n l phn xng rt quan trng ca nh my lc du sn xut ra xng. Vn chuyn nguyn liu v sn phm trong phn xng ch yu bng ng ng.Trong qu trnh sn xut phn xng sinh ra kh CO, SOx , NOx , H2S gy nh hng xu ti mi trng v cc cht d bay hi ,d gy chy n nn t cui hng gi. Ton b dy truyn u l thin II.2. B tr mt bng phn xng. Thit k mt bng ca phn xng tun theo quy tc phn vng gm c cc vng sau : 1. Vng pha trc phn xng: Bao gm nh hnh chnh, nh xe, nh n, hi trng, phng bo v... 2. Vng sn xut : y l vng quan trng nht trong nh my.V vy khi b tr mt bng th n c u tin v mi mt nh a cht , a hnh v v hng. y cng l ni gy ra ting n ln,lng bi to ra nhiu, cc cht gy tc ng xu n mi trng, lng nhit to ra ln, rt d gy chy n nn t pha cui hng gi v phi tun th nghim ngt cc quy nh ca v sinh cng nghip. Gm c thit b phn ng, thit b ti sinh, thit b tch phn on chnh, t hp x l kh cracking , ng khi, sn xut hi nc, phng iu khin trung tm. 3. Vng cng trnh ph : L ni t cc cng trnh ph tr nh cc trm cung cp in, my bm, my nn, phn xng c kh, nh phng chy cha chy v cc h thng cung cp k thut khc ( h thng ng 65
Nguyn c
ng dn nguyn liu, sn phm, h thng ng ng phng chy cha chy...). i vi cc h thng k thut th cn phi lp t ti u khng chng cho khng gy nh hng ti giao thng trong nh my. 4. Vng kho tng h thng giao thng : L vng b tr h thng kho tng bn bi nhp nguyn liu v xut sn phm. Do nguyn liu v sn phm ca nghnh ha du d chy n. Nn khi b tr n th phi t cui hng gi, ti mi b cha th cn phi lp t h thng cc ng ng cha chy khi c s c th ngay lp tc hot ng. Vng ny bao gm b cha nguyn liu v sn phm. Ta b tr khong cch gia hai b l 50m, ng chnh trong phn xng thit k rng 5m. u im ca vic b tr mt bng nh trn l : D qun l theo ngnh, theo cc phn xng, theo cc cng on ca dy chuyn sn xut ca nh my. Thch hp vi cc nh my c nhng xng, nhng cng on c cc c im v iu kin sn xut khc nhau . m bo cc yu cu v v sinh cng nghip, d dng x l cc b phn pht sinh cc iu kin bt li trong qu trnh sn xut nh kh c, bi, chy, n ... D dng b tr h thng giao thng v sp xp cc thit b trong nh my. Thun li trong qu trnh pht trin m rng nh my. Gim c ti trng cng trnh nh kt cu bao che, ti trng gi ngang, cu trc trong nh...Do vy, gim c khi lng xy dng, tit kim c vt liu xy dng t gim c chi ph cho xy dng. Gim thi gian xy dng, tit kim c mt bng. Tuy nhin cn c nhng nhc im l : 66
Nguyn c
Dy chuyn sn xut ko di. H thng ng ng k thut v mng li giao thng tng. H s xy dng v s dng thp. II.3. Cc hng mc cng trnh. Cc cng trnh trong phn xng c th hin bng di y : Bng 5: Cc hng mc cng trnh trong phn xng cracking S TT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Tng Tn cng trnh Phng bo v Nh xe Nh hnh chnh Nh n Hi trng Trm y t B cha nc sch Trm in Xng c kh Phng th nghim B x l nc thi Phng iu khin trung tm Thit b phn ng Thit b ti sinh Thp phn tch chnh T hp x l kh cracking Sn xut hi nc ng khi B cha nguyn liu u B cha xng B cha LCO B cha LPG B cha kh nh B cha HCO B cha du cn Kho cha xc tc mi Nh my bm v my nn Nh phng chy cha chy. S lng 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 4 2 2 2 2 2 2 1 1 Kch thc 64 30 18 30 12 20 12 30 12 12 6 20 20 12 6 12 9 12 6 20 20 12 6 12 12 12 12 12 12 24 12 24 12 12 12 30 30 24 24 24 24 24 24 24 24 24 24 24 24 50 30 12 6 12 6 Din tch, m2 72 540 360 240 360 72 400 72 108 72 400 72 144 144 144 288 288 144 3600 2304 1152 1152 1152 1152 1152 3000 72 72 18152
67
Nguyn c
II.4.Tnh ton cc ch tiu k thut c bn. Chiu di phn xng: Chiu rng phn xng: Tng din tch phn xng F: Din tch kho bi l thin B 350 ,m 220 ,m F = 77000,m2 : B = 4500 ,m2
Din tch chim t ca nh v cng trnh A : A = 18152 , m2 Din tch chim t ca ng giao thng, ca h thng ng ng vn chuyn vt cht, rnh thot nc, va h v t d tr C = 30000, m2 Xc nh h s xy dng Kxd: Kxd = Kxd = 77000 A+B 100 F 100 = 29,42% [8,141] [8 ,141]
18152 + 4500
Xc nh h s s dng Ksd: Ksd = Ksd =
A + B+ C 100 F 100 = 68,38%
18152 + 4500 + 30000
77000
Theo tiu chun Vit Nam th cc ch tiu kinh t k thut xy dng Kxd v Ksd ca phn xng cracking xc tc hon ton tho mn v m bo yu cu quy nh. Do qu trnh sn xut hu ht c tin hnh trong cc thit b kn, kch thc thit b rt cao v to, vn chuyn bng ng ng, cc qu trnh c c kh ho t ng ho ton b, vic iu khin c tin hnh trong phng iu khin trung tm. Do thit k nh sn xut l thin - bn l thin. Nh sn xut l thin - bn l thin c thit k bng khung thp. Bn trong c nh iu khin trung tm v t cc thit b ph tr cho qu trnh sn xut nh thit b lm lnh ni hi, bm, cc thit b chnh nh thit b phn ng, thit b ti sinh, thit b tch sn phm c t ngoi tri. Nhp nh L1 = 6 m, L2 = 6 m. Bc ct B = 6 m. Chiu cao nh H = 6 m. 68
Nguyn c
Nh c hai mi dc hai pha thng gi t nhin trong nh do i lu khng kh. Nn nh l loi nn xi mng v b tng, loi nn ny chu c khong cht, hp cht v c v kim yu. Ct nh bng thp dng mng n di ct. Loi mng ny c t trn mt lp lt mng dy 100 mm. Nu t kh cng c th dng lp lt bng dm, nu t t dng b tng gch v hoc b tng mc 50. Ct c kch thc 400 mm, dm chnh chy dc theo chiu dc nh kch thc 300 mm, c 3 m s c mt dm ph theo chiu ngang dy 200 mm. Hai bn thit b s c dm ph chu lc v gi thit b ng vng. Dm chnh c gn vo ct nh bt bulng qua gi ta, dm ph gn vo dm chnh bng bulng. Mi nh dng loi mi 30% v gc nghing va h l 150. ng giao thng trong phn xng ch yu l ng b, ng t. ng t c bng b tng nha c hai ln xe, mi ln 3 m mt u ni vi ng chnh trong khu lin hp mt u ni vi ng ph xung quanh phn xng. ng giao thng l loi ng cp 3, va h i b c chiu rng 1,5 m. Trong phn xng c ng ni lin cc khu vi nhau bo m mt giao thng vn chuyn cc vt t nguyn liu c d dng v thun tin. Hai bn ng trng cy cnh v cc vn hoa m bo cnh quan cho mi trng phn xng. Cc ng ng chnh trong phn xng nh ng ng cp nc phc v sn xut, sinh hot, ng ng nc thi, cc ng ng dn nguyn liu lng, kh t trn mt t v ngm di mt t. III.Tnh ton kinh t. III.1.Tnh ton chi ph vt liu u vo. Ta cn quy i gia tn v thng, ta coi mt thng c th cha c 160 lt.
69
Nguyn c
i vi sn phm kh ta coi tt c l LPG thng mi .Da theo sn phm gas ang lu hnh ngoi th trng , 1 bnh gas 20 lt cha c 12 Kg gas nh vy t trng ca kh l d =0,6. Nh vy 1 thng 160 lt s cha c : 160. 0,6 = 96 ,Kg. Suy ra 1000 Kg kh th s c cha trong :
1000 =10,42 thng. 96
i vi sn phm xng c t trng ca xng 200 C l d = 0,76 ,Kg/l 1 thng 160 lt s cha c : 0,76. 160 = 121,6 ,Kg 1000 Kg xng th s cha c trong : 121,6 = 8,22 thng. i vi sn phm gasoil nh c t trng l 0,933, Kg/l 1 thng 160 lt s cha c : 0,933 .160 = 149,28, Kg 1000 Kg nh th s cha c trong : 148,28 = 6,7 thng. i vi sn phm gasoil nng c t trng l 0,9429 Kg/l 1 thng 160 lt s cha c : 0,9429.160 =150,864 , Kg. 1000 Kg gasoil nng s cha c trong : 150,864 = 6,63 thng Da vo lng sn phm thu c ta c bng chuyn i gia tn sang thng nh sau : Bng 6: Bng chuyn i gia tn sang thng Tn sn phm Sn phm Kh Sn phm Xng Sn phm Gasoil nh Sn phm Gasoil nng Cc Lng mt mt Tng Trng lng , T/h 66,375 169,125 82,5 46,875 6,375 3,75 375 70 2945,36 23562880 Thng/h 691,63 1390,2 552,75 310,78 Thng/ nm 5533040 11121600 4422000 2486240
1000 1000 1000
Nguyn c
III.1.1. Chi ph nguyn liu.(CNL) Nguyn liu i t phn cn du Bch H, c khi lng ring l : 0,811, Kg/l. 1 thng 160 lt s cha c : 160 .0,811 = 129,76 ,Kg. 1000 Kg s cha c trong : 129,76 = 7,7 thng. Do vy 3000000 tn s cha c trng : 3000000 .7,7 = 23100000 thng Gi ca nguyn liu : 20 USD /thng. Nh vy chi ph cho nguyn liu l : 23100000 .20 = 462000000 , USD/nm III.1.2. Chi ph in.(C) nh mc tiu hao l 0,8 KWh/thng sn phm, trong mt nm s tiu th ht l : 0,8. 23562880 =18850304 , KWh/ nm. Gi ca 1 KWh in l : 0,15 USD Nh vy chi ph in nng trong 1 nm l : 18850304 .0,15 =2827545,6, USD/nm III.1.3. Chi ph cho nhin liu t.(CNL) nh mc tiu hao l 0,01 tn/thng sn phm.Trong 1 nm s tiu tn l : 0,01. 23562880 = 235628,8 Tn/ nm. n gi ca nguyn liu t l : 10 USD/tn Vy chi ph nhin liu t trong 1 nm l : 10. 235628,8 =2356288 ,USD/nm III.1.4. Chi ph hi nc.(CHN) nh mc tiu hao l 4 m3/thng sn phm tng ng vi : 4. 23562880 = 94251520 m3/nm. n gi : 0,35 USD/m3. Vy chi ph hi nc trong 1 nm l : 0,4. 23562880 = 9425152 USD/nm. 71
1000
Nguyn c
III.1.5. Chi ph cho nc cng nghip.(CN) nh mc tiu hao l 0,9 m3/thng sn phm tng ng vi : 0,9. 23562880 = 21206592 m3/nm n gi : 0,1 USD/nm. Vy chi ph nc cng nghip trong 1 nm l : 0,1. 21206592 =2120659,2 USD/nm. III.1.6.Chi ph cho xc tc.(CXT) nh mc tiu hao l 0,0025 Kg/thng sn phm hay l 25.10-7 tn/ thng sn phm. n gi 10 USD/Kg =10000 USD/tn. Vy chi ph xc tc cho 1 nm l : 10000.25.10-7. 23562880 =589072 USD/nm. Nh vy tng chi ph cho vt liu u vo l : CPv = CNL +C +CNL + CHN +CN +CXT = 462000000 + 2827545,6 + 2356288 + 9425152 + 589072 = 479318716,8 USD/nm. Chi ph cho nguyn liu, hi nc, nng lng cho mt thng sn phm l :
479318716, 8 =20,34 USD/thng sn phm 23562880
2120659,2 +
IV. Chi ph vn hnh phn xng. iu khin phn xng hot ng c lin tc th cn phi c ngi vn hnh phn xng v mi ngy lm vic c chia lm 3 ca. Cng nhn phc v phn xng : Qun c Ph qun c K s cng ngh Cn b th nghim : 1 : 1 : 4 : 3
Cng nhn vn hnh : 25 72
Nguyn c
Th c kh Th in
:3 :3
Tng s cng nhn lao ng trong phn xng : 40 Chi ph cho cng nhn lao ng trong phn xng c th hin bng di y: Bng 7: B tr cng nhn lao ng trong phn xng. S TT 1 2 3 4 5 6 7 8 Chc v Qun c Ph qun c K s cng ngh Cn b th nghim Cng nhn vn hnh Th c kh Th in Tng S lng 1 1 4 3 25 3 3 40 Lng thng USD/ngi 270 250 230 180 200 180 180 USD/nm 3240 3000 11040 6480 60000 6480 6480 96720
Nh my thc hin vic tr cc loi bo him cho cng nhn chim 20% lng: 0,2. 96720 =19344 ,USD/nm. Chi ph lng cho cn b cng nhn vin lm vic trong phn xng l : 96720 + 19344 = 116064 USD/nm. Chi ph tin lng cho cng nhn trn 1 thng sn phm( CTL ): CTL =
116064 = 0,0049 USD/thng sn phm. 23562880
V. Chi ph khu hao cho phn xng. Vn u t cho xy dng : Vxd = 35.000.000 ,USD. Vn u t cho thit b Vt = Vxd + Vtb + 0,05Vt Nh vy ta tnh c Vt =
35.000.000 + 85.000.000 =126315789,5 ,USD. 0,95
: Vtb = 85.000.000 ,USD.
Cc chi ph khc ly bng 5% tng vn u t:
73
Nguyn c
Nh sn xut c thi gian khu hao l 20 nm, do mc khu hao theo ti sn l :

35.000.000 =1750000 ,USD/nm. 20
Thit b c thi gian lm vic chung l 20 nm, do mc khu hao trong 1 nm l :

85.000.000 =4250000 ,USD/nm. 20
Khu hao sa cha ly 5% khu hao thit b v khu hao nh xng : 0,05 .( 1750000 + 4250000 ) = 300000 USD/nm. Tng mc khu hao trong 1 nm l : 1750000 + 4250000+300000 =6300000 ,USD/nm. Mc khu hao trn 1 thng sn phm l : phm. VI. Cc chi ph khc cho mt thng sn phm Chi ph khc cho phn xng ly 2% chi ph sn xut(CPSX) CPSX = 0,02. CPSX + KH +TL +NL KH : Chi ph khu hao. NL : Chi ph cho nguyn liu, nc, hi nc,nng lng. TL : Chi ph tin lng. CPSX = 0,02 CPSX +0,2 +0,0049 + 20,34 CPSX = 20,96 USD/thng sn phm. Vy cc chi ph khc l : 0,02 .20,96 =0,4192 USD/thng sn phm Chi ph cho qun l doanh nghip v chi ph bn hng 2% gi thnh ca mt thng(GT) : GT = 0,02.GT + CPSX GT = 21,39 USD/thng sn phm Nh vy chi ph cho qun l doanh nghip v bn hng: CPQB = 0,02. 21,39=0,4278 USD/thng sn phm Bng di y ch ra tng chi ph cho sn xut 1 thng sn phm: 74
6300000 =0,267 USD/thng sn 23562880
Nguyn c
Bng 8: Chi ph cho sn xut ca mt thng sn phm S TT Cc khon mc 1 2 3 4 5 6 Chi ph cho vt liu u vo Chi ph tin lng Khu hao Cc chi ph khc cho phn xng Chi ph qun l va bn hng Tng USD/thng sn phm 20,34 0,0049 0,267 0,4192 0,4278 21,4589
Tng chi ph ca phn xng trong mt nm sn sut l: 21,4589. 23562880 = 505633485,6 VI. Tnh hiu qu kinh t. Bng di y a ra gi bn cc sn phm ca phn xng. , USD/nm.
Bng 9 : Quy nh gi bn ca cc sn phm n gi cho 1 STT 1 2 3 4 5 Tn sn phm Kh Xng Gasoil nh , USD 24 30 25 Lng sn hm nm, Thng 5533040 11121600 4422000 Doanh thu trong 1 nm USD 132792960 333648000 110550000 59669760 637,5 636661357,5 thng sn phm thu c trong 1
Gasoil nng 24 2486240 Cc 100 USD/tn Tng doanh thu phn xng trong 1 nm
Tnh li nhun Li nhun = Doanh thu - Tng chi ph - thu. Coi thu ly bng 10% doanh thu 75
Nguyn c
Vy : Li nhun = 636661357,5- 505633485,6 -0,1. 636661357,5 = 67361735,7 ,USD/nm Thi gian thu hi vn. VSX : l vn sn xut. VSX = Tng chi ph + Vn u t = 505633485,6+126315789,5 = 631949275,1 USD/nm. T=
631949275, 1 VSX = 124661258, 3 + 6300000 LN + KH
= 8,6 ,nm
Nh vy thi gian thu hi vn 8 nm 8 thng. Nh vy phng n xy dng ny c hiu qu kinh t tt cho php thi gian thu hi vn l 8 nm 8 thng v kh nng sinh li cao
CHNG VII AN TON LAO NG

Trong qu trnh sn xut th khu an ton lao ng l khu c vai tr rt quan trng nhm ci thin c iu kin lm vic ca cng nhn, m bo sc kho an ton cho cng nhn lm vic trong nh my cng nh bo v ti sn ca nh my. V vy ngay t u thit k xy dng phn xng cn phi c nhng gii php b tr hp l v phi ra c cc gii php tt nht v an ton. Nh vy hon thin tt nht v an ton cn phi m bo cc yu cu sau: I. Yu cu phng cha chy. Thng xuyn thc hin cc cng tc gio dc an ton lao ng n ton th cng nhn lao ng trong phn xng, thc hin quy nh chung ca nh my, tin hnh kim tra nh k thc hin thao tc an ton lao ng trong sn xut. Khi thit k b tr mt bng phn xng cn phi hp l, thc hin cc bin php an ton. 76
Nguyn c
Cc thit b phi m bo an ton chy n tuyt i khng cho c hin tng r r hi sn phm ra ngoi, khi thit k cn chn nhng vt liu c kh nng chng chy n cao thay th cc vt liu nhng ni c th xy ra chy n. Phi c h thng t ng ho an ton lao ng v bo ng kp thi khi c hin tng chy n xy ra. B tr cc my mc thit b phi thong, cc ng ng dn trong nh my phi m bo hn ch ti a hin tng cc ng chng cho ln nhau, nhng ng bt qua ng giao thng chnh khng c ni ln, cc ng ng trong khu sn xut phi b tr trn cao m bo cho cng nhn qua. Khu cha nguyn liu v sn phm phi c tng bao che phng khi c s c du b r r ra ngoi , phi tnh cc kh nng pht sinh ngun la bt chy.Khong cch gia cc b cha nguyn liu cng nh l sn phm phi m bo l cch nhau 50m chng chy n. Cn i vi nhng kho bi c h thng phng chy cha chy tt, hin i th c th b tr h thng bn b cch nhau khong 30m v cc bn b cha phi nm cui hng gi. B tr h thng t ng ho cho cc thit b d sinh ra hin tng chy n m bo an ton, cc h thng cung cp in cho cc thit b t ng phi tuyt i an ton khng hin tng chp mch lm pht sinh tia la in xy ra. Vn hnh cc thit b phi theo ng thao tc k thut, ng quy trnh cng ngh khi khi ng cng nh khi tc hot ng, lm vic theo cc quy nh cht ch. Trong trng hp phi cha cc thit b c cha hi sn phm d gy chy n th cn phi dng kh tr thi vo thit b ui ht hi sn phm ra ngoi , lu nu sa cha bng hn th phi khng nh trong thit b an ton khng cn kh gy chy n.
77
Nguyn c
Gim thp nht nng cc cht chy n trong khu sn xut, i vi chy n trong xng du y l mt vn c quan tm nht hin nay bo v tnh mng cn ngi v ti sn ca nh my. Trong phn xng phi c i ng phng chy cha chy thng trc 24/24h vi y trang thit b hin i thun tin. Cc tiu lnh v phng chy cha chy phi tun theo y phng khi c cc s c xy ra x l kp thi. B tr dng c thit b cha chy linh ng ti ch cc thit b d gy chy n ( nh thit b phn ng, thit b phn tch, t hp kh, kho b cha ) kp thi khi c hin tng. Tm li, trong nh my lc du ni chung v phn xng cracking xc tc ni ring cn phi trang b y cc trang thit b phng , cha chy hin i, phi c i ng phng cha chy thng trc,ti ch cc thit b d xy ra chy n cn b tr cc thit b cha chy linh ng. Xung quanh cc b cha sn phm hoc nguyn liu cn b tr h thng ng dn kh tr, hi nc v bt cha chy kp thi x l khi c s c. ng i li trong khu sn xut phi thun tin d dng cho cc xe cu ho i li. Cc thit b phi c bo dng ng nh k, theo di cht ch ng ch cng ngh ca nh my cc b cha cn phi ni t phng khi xng du bm chuyn b tch in, st nh. Trong qa trnh sn xut phi m bo an ton cc thit b p lc, h thng in phi c thit k an ton, hn ch ti a cc nguy c gy ra s c, thit b phi c h thng bo him, phi c che chn. Trang thit b phng h lao ng cho cng nhn lao ng trong phn xng. II. Trang thit b phng h lao ng. Nhng cng nhn lm vic trong nh my phi c hc tp cc thao tc v ni quy phng chy cha chy ca nh my, phi c kin thc bo v thn th v mi trng khng gy c hi cho mi trng xung quanh.
78
Nguyn c
Trong nh my tuyt i khng dng la, trnh cc va chm cn thit gy ra cc tia la in , trong sa cha hn ch vic s dng ngun in cao p. Trong cng tc bo qun cc b cha, nu phi lm vic trong b cha phi m bo ht ht cc hi c ca kh sn phm trong b, cng nhn lm vic trc tip phi c trang b cc thit b phng h lao ng : Qun o, mt l , gng tay, ng ... trnh cc hi c bm vo ngi qua da, cc trang thit b phng h lao ng phi c ct gi ti ni lm vic khng c mang ra ngoi. i vi cc qu trnh c pht sinh hi c ln cn b tr h thng t ng ho trong sn xut gim bt lng cng nhn cn thit, bo v sc kho cho cng nhn ng thi nng cao hiu qu kinh t, cn lp t h thng o lng t ng hm lng cc cht gy c hi cho con ngi cng nh mi trng a ra cc cnh bo. Kim tra sc kho nh k cho cng nhn, pht hin nhng bnh ngh nghip phng chng m bo ch lao ng cho mi ngi theo quy nh ca nh nc. Nghim cm vic s dng xng du ra chn tay, c qun o v chng c tc hi ln i vi sc kho ca con ngi. Xng du l cc hydrocacbon d bay hi, hi xng du d gy nhim mi trng do vic x l hi xng du cng l nhim v rt quan trng ca nh my. III. Yu cu i vi vn v sinh mi trng. i vi mt bng phn xng phi chn tng i bng phng, c dc tiu thot nc tt, vng quy hoch nht thit phi c nghin cu, phi c cc cp Chnh Ph ph duyt, m bo v sinh mi trng ng thi phng nga chy n. V tr nh my phi c khong cch an ton vi khu dn c , cc phn xng thot hi ,bi c hi ra ngoi cn b tr cui hng gi ch o ng thi cn lu n cng go. Nc thi sinh hot cng rt nguy him do vy cn phi x l lm sch nc trc khi thi ra ngoi sng h. Nc thi sn xut sau khi lm ngui 79
Nguyn c
cc thit b trao i nhit, lng nc ngng mc d tip xc trc tip hay khng trc tip vi cc hi c cng phi tin hnh x l.
CHNG VIII T NG HA
I. Mc ch v vai tr ca t ng ha. Qa trnh iu khin t ng l qu trnh ng dng cc dng c, cc thit b v cc my mc t ng iu khin vo qu trnh cng ngh.Nhng phng tin ny cho php thc hin cc qa trnh cng ngh theo mt phng trnh tiu chun c to dng ph hp vi cng ngh, m bo cho my mc thit b hot ng theo ch ti u nht, vic t ng ho khng ch lm n gin cc thao tc trong sn xut, trnh c nhm ln, tng nng sut lao ng v cho php gim s lng cng nhn v cn l bin php hu hiu trong an ton lao ng. Trong phn xng cracking xc tc th cc thit b lm vic iu kin nhit cao, hm lng hi cc hydrocacbon ln chng l nhng cht rt d gy chy n. Ngoi cc hi sn phm ca qu trnh cn c cc kh c hi cho sc kho v c hi cho mi trng : H2S , NH3 , SO2, CO2, CO... do cn phi nghim ngt v an ton trong sn xut v m bo sc kho cho cng nhn v mi trng xung quanh nh my. m bo cc yu cu va nu th vic s dng h thng t ng o lng v cc bin php t ng ho trong sn xut khng ch l mt vn cn thit m cn c tnh cht bt buc vi cng ngh cracking xc tc ni ring v trong nh my lc du ni chung. Trong khi hot ng ch mt thit b khng n nh th ch n nh ca dy chuyn cng ngh b ph v, trong nhiu trng hp phi dng hot ng ca c dy chuyn sa cha cho d ch do mt thit b. Nh vy t cc c im cho thy o lng t ng ho v t ng ha trong dy chuyn cng ngh l mt vn ht sc quan trng. N khng ch tng nng xut ca cng ngh, cng sut ca thit b m l c s vn hnh cng ngh ti u nht 80
Nguyn c
tng hiu qu thu hi sn phm ng thi lm gim ng k cc chi ph khc m bo an ton cho nh my sn xut. Nh c iu khin t ng m cho ta bit c nhng ni xy ra hn tng r r khng an ton cng nh cc s c trong thit b. Qu trnh ny gip cho ngi lao ng trong phn xng trnh phi tip xc vi cc iu kin c hi n cn thay th cho con ngi lm vic trong cc iu kin khc nghit nhng khu vc con ngi khng th vo c. T ng ho m bo cc thao tc iu khin cc thit b cng ngh mt cch chnh xc v trnh c cc s c xy ra trong thao tc iu khin, t ng bo ng khi c s c xy ra. II. H thng iu khin t ng. H thng t ng iu chnh bao gm i tng iu chnh (T) v b iu chnh ( BC ). B iu chnh c th bao gm b cm bin v b khuych i. B cm bin dng phn nh s sai lch cc thng s iu chnh so vi gi tr cho trc v bin i thnh tn hiu. B khuych i lm nhim v khuych i tn hiu ca b cm bin gi tr c th iu khin (CQK), c quan ny tc ng nn i lng nhm xo i sai lch ca cc thng s iu chnh. Mch iu chnh c khp kn nh quan h ngc. Quan h ny c gi l quan h hi tip chnh. III. Cc dng iu khin t ng. T ng kim tra cc thng s cng ngh ( nhit , p sut, lu lng, nng ...) kim tra cc thng s cng ngh c thay i hay khng. Nu c th cnh bo ch th ghi li gi tr thay i , truyn tn hiu tc ng iu chnh n i tng. S t ng kim tra v t ng iu chnh
81
Nguyn c
5.a
5.b 1 2 3 5.c 4 5.d
1: i tng iu chnh. 2: Cm bin i tng. 3: B khuych i. 4: Yu t nhiu.
5.a : Cnh bo. 5.b : Ch th bng kim hoc bng s. 5.c : Ghi li s thay i. 5.d : Phn loi.
82
Nguyn c
S t ng iu khin
4 Trong : i tng iu khin. Cm bin i tng B khuych i Yu t nhiu B c S cu trc ca h iu khin t ng
Trong : 1: i tng iu chnh. 2: Cm bin i tng. 3: B khuych i. 4: Yu t nhiu.
3 5: B c. 6: B so snh N 7: C cu chp hnh
i lng ra Y Trong tticc dngtng iu khin thng c s dng nht l kiu c lng t X h thng t ng iu khin c tn hiu phn hi ( mch iu khin khp kn ).Gi tr thng tin u ra ca thit b da trn s khc nhau gia cc gi tr Phn h o c ca bin iu khin vi gi tr tiu chun. S c m t nhi sau: XCB X T X CB S mch iu khin phn hi. XPH 83 O
Nguyn c
Trong : Y : l i lng t T: Phn t t tr X : i lng ra C : phn t iu chnh N : Tc nhn nhiu XCB : Ga tr cm bin. O : i tng iu chnh XT : Gi tr t tr XPH : Tn hiu phn hi X = XT - XCB CB : cm bin SS : phn t so snh
Phn t cm bin : L phn t lm nhim v nhn tn hiu iu chnh X v dch chuyn n ra mt rng thng s khc ph hp vi thit b iu chnh Phn t t tr : L b phn n nh cc thng s cn duy tr hoc gi tr phm vi cc thng s cn iu chnh ( XT ). Khi thng s vn hnh lch ra khi gi tr th thit b iu chnh t ng phi iu chnh li cc thng s cho ph hp. Phn t so snh : L c cu tip nhn ga tr ca phn t nh tr quy nh ( XT) so snh vi gi tr thng s nhn c t phn t cm bin X C, xc nh sai lch ca hai thng s X = XT - XCB a tn hiu vo c cu iu chnh.
84
Nguyn c
C cu iu chnh : C nhim v bin cc tn hiu nhn v sai lch X gy ra tc ng iu chnh trc tip. Gi tr iu chnh c thay i lin tc tng ng vi s thay i lin tc ca c cu iu chnh.
IV. H iu khin t ng phn hi. S iu khin nng . Dng c o Thit b

LC
B iu khin Van iu chnh
Dng ra Trong s ny bin c iu khin l nng , tc dng chy l bin thao tc. Tn hiu c iu khin sinh ra bng cch so snh cc gi tr ca bin c iu khin vi gi tr mong mun ( gi tr ci t ) S sai khc gia hai tn hiu ny c gi l tn hiu sai khc, h thng iu khin thng tin lun l hm ca cc tn hiu sai khc. Tn hiu iu khin c dng bng hi nc hoc dng bng in. Tn hiu iu khin c truyn qua van iu khin bng van iu khin n cc v tr c bit hoc ng , m . Khi thay i mt trong cc tn hiu iu khin th dn n cc thay i c th tnh trc trong tc dng chy ca cht lng khi ra khi thit b. Nh vy v nguyn tc th nguyn l iu khin ca h thng nh trn hu nh l ging nhau trong tt c cc h thng.
85
Nguyn c
V. Cc k hiu thng dng trong t ng ho.

t
0
:Dng c o nhit . : Dng c o p sut.
:Dng c o lu lng.
TI TT
:Dng c o nhit hin th ti trung tm iu khin :Dng c o nhit truyn xa t ti trung tm iu khin. : :
P cz
LRA
Thit b o p sut t ng iu chnh ( van an ton ). B iu chnh mc cht lng t ghi c bo ng, kh c lp tai trung
tm iu khin. :
PIR
B iu chnh p sut t ghi v hin th, kh c lp ti trung tm iu
chnh : C cu iu chnh. : C cu chp hnh. :T ng m khi mt tn hiu. :T ng ng khi mt tn hiu. :Gi nguyn VI. Cu to ca mt s thit b t ng cm bin. VI.1. B cm bin p sut.
P
Z
86
Nguyn c
B cm ng kiu mng B cm ng kiu piston ng kiu B cm piston Trong cc b iu chnh thng s dng b cm ng p sut kiu mng, hp xp piston, ng cong n hi...vic chn b cm ng p sut ph thuc vo vic camr ng v chnh xc theo yu cu. VI.2. B cm ng nhit .
Cm ng nhit kiu mng hp xp
Cm ng nhit kiu
Cm ng nhit kiu thanh kiu lng kim gin n
Cm ng nhit in tr
87
Nguyn c
Hot ng ca cm ng nhit da trn nguyn l gin n nhit, mi quan h gia nhit ca cht kh v p sut hi bo ho ca n trong h kn, da trn nguyn l nhit in tr.
VI.3 B cm ng mc o cht lng. Mc cc cht lng c th o bng nhiu cch khc nhau nhng cch n gin v c chnh xc cao l o bng phao.
Z
Kiu phao
Kiu Mng
VI.4. B cm bin lu lng. B cm bin lu lng c xy dng trn s ph thuc Q = f.V Trong : f : l din tch ca ng ng dn. V : l tc cht lng chy trong ng dn theo nh lut Becnuli. V =
2 P
P: chnh lch p sut cht lng. 88
Nguyn c
: t trng ca cht lng. Nu t trng khng i th lu lng th tch ph thuc vo 2 thng s l tit din S v s chnh lch p sut P. Ta c hai cch o lu lng: Khi tit din khng i o lu lng bng chnh lch p sut trc v sau thit b c ng hp. Khi chnh lch p sut khng i o din tch tit din ca ng dn xc nh c lu lng ca dng chy. C h n h p bi n i C h n h p k h n g bi n
Z
89
Nguyn c
KT LUN
Cracking xc tc l mt phng php ch bin su v c mt tm quan trng rt ln trong cng nghip ch bin du m hin nay v n gp phn gii quyt v p ng kp thi nhu cu tiu th nhin liu ca th trng v c s lng v cht lng. Sau hn 3 thng nghin cu v tm hiu, em hon thnh ti thit k phn xng cracking xc tc c nng xut 3.000.000 tn/nm. Qua bn n ny gip em hiu c c bn cc bc v qu trnh Thit k mt phn xng sn xut. Bn n ny gip em hiu c vic a mt thnh qu ca vic p dng nghin cu vo sn xut l mt qu trnh ht sc phc tp, n i hi phi c s lin quan n qu trnh sn xut. Bn n ny c hon thnh nhng v iu kin cng nh ti liu tham kho cn hn ch, hn na v bc u lm quen vi vic thit k phn xng sn xut cho nn chc chn khng trnh khi sai st. Vy em rt mong c s ch bo cng nhng kin ng gp ca cc thy c v cc bn ng nghip bn n c hon thin hn. Cui cng em xin chn thnh by t lng bit n ti cc thy c gio trong B mn Cng ngh Ho du - Hu c v cc bn. c bit l thy gio TS. L Vn Hiu tn tnh gip em hon thnh bn n ny. Em xin chn thnh cm n! H Ni, thng 6 nm 2005 Sinh vin thc hin Nguyn c Thnh 90
Nguyn c
Mc lc
Trang
CHNG I................................................................................2 TNG QUAN L THUYT............................................................2 CHNG II..............................................................................19 NGUYN LIU CA QA TRNH CRACKING XC TC, SN PHM THU C T QA TRNH V XC TC CA QU TRNH............19 CHNG III.............................................................................31 CH CNG NGH CA QU TRNH CRACKING XC TC V CC DY CHUYN CNG NGH CRACKING XC TC.........................31 CHNG IV............................................................................42 TNH TON CN BNG VT CHT V NHIT LNG...................42 CHNG V.............................................................................59 XY DNG..............................................................................59 CHNG VI............................................................................63 THIT K TNG MT BNG CA PHN XNG V TNH TON KINH T..................................................................................63 CHNG VII...........................................................................76 AN TON LAO NG............................................................76 CHNG VIII...........................................................................80 T NG HA........................................................................80 KT LUN...............................................................................90
91

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n tt nghip Thnh Ho Du 1- K45

n tt nghip Thnh Ho Du 1- K45

CHNG I TNG QUAN L THUYT

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T hydrocacbon parafin: Bronsted ca xc tc:

Ion cacboni c th c to thnh do s tc dng ca parafin vi tm axt

CmH2m+1 + CnH2n+2 + L T hydrocacbon naphten: CnH2n+1++ LH

n tt nghip Thnh Ho Du 1- K45

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CH4 + C3H6 C2H6 + C2H4 C4H6 + H2

(60%) (30%) (10%)

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CH2 CH=CH2 + CH2 CH2 1 R R1 CH=CH2 + H2

R CH2 CH2 + H2 ln hn:

Cc olefin cn tham gia phn ng trng hp to ra phn t c trng lng

n tt nghip Thnh Ho Du 1- K45

2CH3 CH2 CH CH2

CH2 CH2 CH3 + 3H2

Phn ng ng phn ho vng naphten : CH3 Phn ng chuyn v cc nhm bn :

n tt nghip Thnh Ho Du 1- K45

n tt nghip Thnh Ho Du 1- K45

Cc phn ng khc xy ra trong qu trnh cracking xc tc hydrocacbon

CH3 para-xylen Phn ng khp vng

CH2 CH2 CH2 CH3

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47,6 Ti 5500C 14,2 0,811 0,07 1350 0,05 58 15

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Xc tc v nh hnh Loi c Loi c hm hm lng lng Al2O3 Al2O3 cao thp

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CHNG IV TNH TON CN BNG VT CHT V NHIT LNG

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GH2Ohv = Gn1 + Gn2 = 6 +15,75 = 21,75