CHNG 1 M PHNG CNG NGH SN XUT POLYPROPYLENE BNG PHN MM HYSIS

1.1. Nhng thng s ban u: [29] - Cng sut ca nh my - Nh my hot ng : 150.000 (tn/nm); : 8000 (gi / nm); - Di cng sut hot ng ca nh my : (50 100)% cng sut thit k; - Xc tc hiu sut cao, tiu th ti a t (0,033 0,05) kg/tn sn phm; Yu cu c tnh k thut ca nguyn liu Propylen Nguyn liu propylen t phn xng thu hi propylen (PRU) ca Nh my lc du s c chuyn n phn xng PP bng ng ng. Phn propylen nhp s c chuyn n cc b cha t ti khu b cha sn phm ca Nh my . Cc c tnh v iu kin bin ca nguyn liu c ch ra di y: p sut Nhit Trng thi: Bng 1 : : : 26 kg/cm2g Mi trng Lng Thnh phn ca nguyn liu t nh my lc du Tinh khit Propylen, % th tch, ti thiu Hyr, phn triu th tch, ti a Loi Nit, Mtan, phn triu th tch, ti a Etan, phn triu th tch, ti a C4, C5, Hydrocarbon no, phn triu th tch, ti a Etylen, phn triu th tch, ti a Buten, phn triu th tch, ti a Penten, phn triu th tch, ti a
Phan Duy Dng BKN 05h5

99,5 20 0,5 100 200 200 100 100 10

c t: Acetylen, phn triu th tch, ti a Metylacetylen, phn triu th tch, ti a Propadien, phn triu th tch, ti a Butadien, phn triu th tch, ti a C6-C12, phn triu th tch, ti a xy, phn triu th tch, ti a CO, phn triu th tch, ti a COS, phn triu th tch, ti a Lu hunh tng s, phn triu khi lng ti a, Metanol, phn triu th tch, ti a Isopropanol, phn triu th tch, ti a Nc, phn triu khi lng, ti a Asen, phn triu th tch, ti a Phosphin, phn triu th tch, ti a Ammonia, phn triu khi lng, ti a Cyclopentadien, phn triu th tch, ti a 5 3 5 50 20 2 0,03 0,02 1 5 15 2 0,03 0,03 5 0,05

t tnh k thut kh cha Hydrogen:

Kh cha hydro t phn xng Reforming ca Nh my lc du c a n phn xng PP c c tnh k thut nh sau: p sut: Nhit : Trng thi: 50 kg/cm2g Mi trng Kh

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Bng 2 :

Thnh phn ca kh cha hydro Tinh khit

Hyr, % th tch, ti thiu Nit, Metan, , % th tch, ti thiu c t: CO, phn triu th tch, ti a CO2, phn triu th tch, ti a xy, phn triu th tch, ti a Nc, mg/Nm3, ti a Lu hunh tng th, phn triu khi lng, ti a Thu ngn (t in phn), mg/Nm3, ti a Acetylen (t cracking), phn triu th tch, ti a Ammonia (t n/m m), phn triu khi lng, ti a

99,5 ti 0,5

0,5 5 5 2 1 2 10 5

1.2. TNH CC GI TR BAN U CHO QU TRNH M PHNG (Thc t nh my c h thng iu khin lu lng tng dng nhng trong m phng tnh ta phi tnh ton cc s liu ban u a vo m phng) Gi thit : Dng sn phm ra trong mi thit b phn ng hu nh khng cha hydro. Lng tiu th xc tc thp nht trong 1 h chuyn ha Propylen tng : 50 % Bng 3 : chuyn ha ca Propylen v Hydro trong tng thit b phn ng C% H2 TBP preR C% C3H6 C% H2 TBP R1 C% C3H6 C% H2 TBP R2
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C% C3H6
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Lng Propylene nguyn liu thng mi ban u ( make-up) l: F = 150000 ( Tn ) Lu lng khi lng Propylene nguyn liu thng mi ( make-up) l F Propylene make-up =
150000*103 = 18750 ( kg/h ) 8000

Lu lng khi lng Propylene hi lu l F Propylene hi lu = 18750 ( kg/h) ( v hiu sut P t 50% ) Tng lng Propylen a vo u qu trnh l F Propylene = F Propylene make-up + F Propylene hi lu = 37500 ( kg/h ) Tng lng Propylen tinh khit a vo u qu trnh l F Propylene = Gi : X : Tng lng propylene a vo u qu trnh ( propylene make-up v dng propylen hi lu) X1 lng propylene vo thit b ha trn xc tc trc khi vo thit b PreR X2 l lng propylene vo trc tip thit b preR X3 l lng propylene vo trc tip thit b R1 X4 l lng propylene vo trc tip thit b R2 X1 + X2 + X3 + X4 = 37312.5 ( kg / h) Tnh : Xt c qu trnh : Lng propylen phn ng l ; = P : 2500 C3H6 105200 X 18656.25 + H2 2.016 X*2.016/105200 0.358 0.358 = PP 105200.016 X*105200.016/105200 18656.608 (kg/h) (kg/h) (kg/h) (kg/h)
37312.5 * 50 = 18656.25 ( kg/h) 100 37500* 99,5 = 37312.5 ( kg/h ) 100

(a)

Lng PP sn xut c trong 1 h : 18656.608 Lng hydro tiu tn trong 1 h : Lng xc tc tiu th trong 1 h :
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18656.608* 0.033 = 0.616 (kg/h) 1000

Lng propylen cn li : = 37312.5 - 18656.25 = 18656.25 (kg/h) Xt trong tng thit b phn ng : chuyn ha ca propylen ti PreR l 5% lng propylen tham gia phn ng ti PreR l : 5% ( X1 + X2 ) chuyn ha ca propylen ti R1 l 50% lng propylen tham gia phn ng ti R1 l : 50%( 95% ( X1 + X2 ) + X3) chuyn ha ca propylen ti R2 l 40% lng propylen tham gia phn ng ti R2 l : 40% (50% (95% ( X1 + X2 ) + X3) + X4 ) Lng propylen cn li l : 60%(50%( 95 %( X1 + X2 ) + X3) + X4) =18656.25 ( b ) Tng lng propylen phn ng l : 5% ( X1 + X2 ) + 50 % ( 95%( X1 + X2 ) + X3) +40% ( 50% (95% ( X1 + X2 ) + X3) + X4 ) = 18656.25 ( c ) Gi s lng propylen vo thit b trn trc khi vo thit b PreR l : X1 = 1000 (kg/h) (d) T ( a ), ( b ), ( c ), ( d ) gii h phng trinh ta c X2 = 4035.043 (kg/h) X3 = 6845.017 (kg/h) X4 = 25437.47 (kg/h) V tinh khit ca Propylen l 99.5 % nn Lu Lng propylene thc vo thit b ha trn xc tc trc khi vo thit b PreR : Fpro1 = Fpro2 = Fpro3 = Fpro4 = 1000 (kg/h) 4035.043 (kg/h) 6845.017 (kg/h) 6845.017 (kg/h) Lu lng propylene thc vo trc tip thit b preR : Lu lng propylene thc vo trc tip thit b R1 : Lu lng propylene thc vo trc tip thit b R2 : Lng propylen tham gia phn ng ti PreR l : 251.752 Lng propylen tham gia phn ng ti R1 l : 5814.154 Lng propylen tham gia phn ng ti R2 l : 12500.638

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Ti thit b PreR: P: 2500 C3H6 105200 X 251.752 Ti thit b R1: P: 2500 C3H6 105200 X 5814.154 Ti thit b R2: P: 2500 C3H6 105200 X 15200.638 + H2 2.016 X*2.016/105200 0.23956 = PP 105200.016 X*105200.016/105200 (kg/h) 12055.877 (kg/h) (kg/h) + H2 2.016 X*2.016/105200 0.11142 = PP 105200.016 X*105200.016/105200 (kg/h) 5814.265 (kg/h) + H2 2.016 X*2.016/105200 0.00482 = PP 105200.016 X*105200.016/105200 251.757 (kg/h) (kg/h)

Lng PP trong thit b PreR : 251.757 (kg/h) Lng PP trong thit b R1: 251.757 + 5814.265 = 6066.022 Lng hydro ( tinh khit )vo thit b preR l : 0.0482 ( kg/h) Lng hydro vo thit b R1 l : 0.11142 ( kg/h) Lng hydro vo thit b R2 l : 0.23956 ( kg/h) V tinh khit ca hydro l 99.5 % nn ta c : Lu lng hydro thc vo thit b preR l : 0.0485 ( kg/h) Lu lng hydro thc vo thit b R1 l : 0.11198( kg/h) Lu lng hydro thcvo thit b R2 l : 0.24076 ( kg/h) Tng Lng hydro a vo l : 0.358 ( kg/h) Bng cn bng vt cht cc dng vo ra ca cc thit b : ( v qua bm v tb trao i nhit thnh phn v lu lng cc dng vt cht xem nh khng i nn ta ch lp bng cho cc thit b PreR, R1, R2, tb tch )
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Lng PP trong thit b R2: 6066.022 + 12055.877 = 18658.606 (kg/h)

Bng 4 :

Bng cn bng vt cht ca thit b PreR Thit b PreR Vo (kg/h) Ra(kg/h) 4758 0 0,62 25,2 1,5.10-5 1.10-5 252 5036

Propylen Hydro Catalyst Propan ln trong Propylen Metan ln trong H2 N2 ln trong H2 PP Tng

5009 0,005 0,62 25,2 1,5.10-5 1.10-5 0 5036

Bng 5 :

Bng cn bng vt cht ca thit b R1 Thit b R1 Vo (kg/h) Ra(kg/h) 5755 0 0,62 59,6 3,5.10-4 2,34.10-4 6066 11881

Propylen Hydro Catalyst Propan ln trong Propylen Metan ln trong H2 N2 ln trong H2 PP Tng

11569 0,11 0,62 59,6 3,5.10-4 2,34.10-4 251.7 11881

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Bng 6 :

Bng cn bng vt cht ca thit b R2 Thit b R2 Vo (kg/h) Ra(kg/h) 18564 0 0,62 187,4 1,07.10-3 7,15.10-4 18656 37409

Propylen Hydro Catalyst Propan ln trong Propylen Metan ln trong H2 N2 ln trong H2 PP Tng

31065 0,24 0,62 187,4 1,07.10-3 7,15.10-4 6066 37319

Bng 7 : Thit b tch PP

Bng cn bng vt cht ca thit b tch PP

Ra (kg/h) Vo (kg/h) Propylen Hydro Catalyst Propan ln trong Propylen Metan ln trong H2 N2 ln trong H2 PP Tng
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nh( kg/h) 18564 0 0,616 187 7,15.10-4 7,15.10-4 0 18752

y(kg/h) 0 0 0 0 0 0 18656 18656

18564 0 0,616 187 7,15.10-4 7,15.10-4 18656 37409

1.3. TNH TON QU TRNH NH M PHNG BNG PHN MM HYSYS[30] p ng nhu cu ngy cng ln cc sn phm du m c v s lng v cht lng, chng ta phi khng ngng ci tin v cng ngh v phng php sn xut. V vy, cc cng trnh nghin cu khoa hc, cc d n thit k c tin hnh, v cng vi s pht trin vt bc ca ngnh cng ngh thng tin, vi nhng my tnh tc cao, cc h iu hnh siu vit, cc lp trnh vin gp phn to ln cho s ra i ca cc phn mm m phng. Trc y ln k hoch cho mt d n i hi rt nhiu thi gian, v kh nng thc hin d n l kh c th khng th bit trc c. Nhng khi cc phn mm m phng ra i, th cng vic tr nn nh nhng i rt nhiu, chng ta c th m phng hot ng ca cc nh my trong cc ch vn hnh khc nhau, thay i cc thng s lm vic ca bt k n v hot ng no m khng nh hng n qu trnh hot ng chung ca nh my. Ngoi ra, vi nhng tnh nng ca cc phn mm m phng ta c th thit k c cc d n khc nhau, tm c phng n ti u, nhanh, cho kt qu kh quan v t hiu qu kinh t, quan trng hn na l p dng c cho hu ht cc lnh vc ca ngnh du kh v cc ngnh cng ngh ho hc, m bo c tnh kh thi cho nhng k hoch ln s c thc hin trong tng lai. Mt s phn mm m phng: - Simsci (PRO//II). - Hyprotech (HYSIM, HYSYS, HTFS, STX/ACX, BDK). - Bryan research & engineering (PROSIM, TSWEET). - Winsim (DESIGN II for Windows). - IDEAS Simulation. - Simulator 42. - RSI. - Chemstations. 1.3.1. Gii thiu v phn mm Hysys Hysys l phn mm chuyn dng dng tnh ton v m phng cng ngh c dng cho ch bin du v kh, trong cc qu trnh x l v ch bin kh c s dng nhiu nht. Hysys chy trn Windows l phin bn mi ca Hysim, phn mm ny trc y dng trn h iu hnh MS.Dos. Hysys l sn phm ca cng ty Hyprotech - Canada thuc cng ty AEA Technologie Engineering Software - Hyprotech Ltd. L mt phn mm c kh nng tnh ton a dng, cho kt qu c chnh xc cao, ng thi cung cp nhiu thut ton s dng, tr gip trong qu trnh tnh ton cng ngh, kho st cc thng s trong qu trnh thit k nh my ch bin kh. Ngoi th vin c sn, Hysys cho php ngi
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s dng to cc th vin ring rt thun tin cho vic s dng. Ngoi ra Hysys cn c kh nng t ng tnh ton cc thng s cn li nu thit lp thng tin. y chnh l im mnh ca Hysys gip ngi s dng trnh nhng sai st v ng thi c th s dng nhng d liu ban u khc nhau. Hysys c thit k s dng cho hai trng thi m phng: trnh. Dynamic Mode: Trng thi ng, m phng thit b hay quy trnh trng thi ang vn hnh lin tc, kho st s thay i cc p ng ca h thng theo s thay i ca mt vi thng s. 1.3.2. Cc bc m phng s cng ngh sn xut Polypropylene 1.3.2.1. Xy dng m hnh, iu kin phn ng Xy dng mt qu trnh m phng mi bng cch kch chut vo New. Kch chut vo nt Add trong hp thoi Simulation Basis Manager m ra hp thoi Fluid Pacakge chn m hnh nhit ng l: UNIQUAC Peng Robinson Steady Mode: Trng thi tnh, s dng thit k cng ngh cho mt qu

Hnh 1 : Chn m hnh nhit ng cho qu trnh Trong phn Components ta chn cc cu t cho trong qu trnh.

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Hnh 2 : Chn cu t trong th vin Hysys cho qu trnh Ring i vi cu t Polypropylene, trong th vin Hysys khng c, do vy ta phi xy dng mt cu t gi. Cc bc lm nh sau: Chn Hypothetical, click vo Quick Create A Solid Hypov t tn l PP. Double Click vo PP, a vo mt s d liu cn thit nh: Khi lng phn t, khi lng ring, %C, %H, nhit phn ng. Sau Click Estimate Unknown Props Hysys t ng tm nhng d liu cn li

Hnh 3 :

Xy dng cu t gi cho qu trnh

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Hnh 4 : Qu trnh xy dng cu t gi PP Trong phn Rxns, Add cc cu t phn ng v phng trnh phn ng bng cch click chn Simulation Basis Mgr, xut hin phn Reactions (nhng phng trnh phn ng) trong hp thoi Simulation Basis Manager, sau click vo Add comps chn cc cu t tham gia trong phng trnh phn ng ho hc bng cch click chut vo Add This Group of Component, tip tc chn nt Add Rxn xc lp loi phng trnh phn ng xy ra trong thit b, y chn phng trnh phn ng dng chuyn ho (Conversion) v chn Add reaction xut hp thoi Conversion Reaction: Rxn 1, sau chn cc cu t tham gia trong phng trnh phn ng v nhp cc h s t lng (Stoich Coeffs) ca phng trnh phn ng. Trong phn Basis chn cu t Hydrogen ( chuyn ho theo Hydrogen). Xong ng tt c cc hp hi thoi, click vo Enter Simulation Environment (vo mi trng m phng) trong hp hi thoi Simulation Basis Manager.

Hnh 5 : Xy dng phng trnh phn ng cho qu trnh

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Hnh 6 : Xc nh cu t v h s t lng cho phn ng

Hnh 7 :

Xc nh chuyn ha ca phn ng

Trn thanh cng c Case (Main) chn dng vt cht Material Stream (Hnh mi tn mu xanh). Click vo hnh mi tn gi chut v ko t trn nn cn xy dng, Double click vo hnh mi tn va xy dng nhp cc thng s cho dng nh: Tn dng, nhit , p sut, lu lng ca dng trong phn Conditions.

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Hnh 8 : Xc lp nhit , p sut, lu lng cho dng

Hnh 9 : Xc lp thnh phn cho tng cu t trong dng

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Trong phn composition ta nhp thnh phn ( phn mol hoc phn khi lng ) ca cc cu t trong dng nguyn liu. Khi dng chuyn sang mu xanh m l thc hin ng qu trnh. Cc dng vt cht cho Hydrogen v Xc tc cng c xy dng tng t. 1.3.2.2. Xy dng thit b phn ng Trn thanh cng c Case (Main) Click vo Conversion Reaction. Double click vo thit b nhp tn cho dng nguyn liu vo, dng sn phm ra, dng nhit - trong phn Connections Conversion Reaction

Hnh 10 : Xy dng cc dng vo ra v cc thuc tnh cho TBP Trong phn Parameters xc nh cc iu kin, thng s hot ng ca thp nh s pha, tn tht p sut, th tch thit b, cung cp nhit hay lm lnh

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Hnh 11 : Xc lp cc iu kin v thng s cho TBP Tip theo, Click vo Reactions, xc lp loi phn ng v phng trnh phn ng xy ra trong thit b.

Hnh 12 : Xc lp cc iu kin phn ng xy ra trong TBP Trong phn Rating, xc lp thit b loi hnh cu hay tr, kiu ng hay nm ngang (hnh 3.13) n y, v c bn thit lp c cc iu kin cng nh thng s k thut cn thit cho mt thit b phn ng. Trong s cng ngh Spheripol, c ba thit b phn ng v cc bc thc hin tng t nhau.

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Hnh 13 : Chn loi trong TBP chuyn ho 1.3.2.3. Xy dng cc thit b tch loi Trong s cng ngh Hypol II thit b tch dng kh ra khi sn phm Polypropylene (HPS) l thit b lc dng ti. Kh thu c phn nh a i thu hi Propylene tun hon li qu trnh. Sn phm thu c y. Trn thanh cng c Case (Main) Click vo Solid Ops Baghouse Filter. Double click vo thit b nhp tn cho dng nguyn liu vo, dng sn phm ra, trong phn Connections ( hnh 3.14); Trong phn Parameters nhp tn tht p sut cho cc ti ( hnh ) Baghouse Filter

Hnh 14 : Xy dng cc dng vo ra v cc thuc tnh cho thit b tch

Hnh 15 : Xc lp tn tht p sut trong cc ti

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Sau khi thc hin xong cc thao tc xy dng trn, ta c mt s m phng chung cho dy chuyn sn xut ca phn xng Polypropylene nh hnh sau

Hnh 16 : TNG QUAN S M PHNG DY CHUYN SN XUT POLYPROPYLENE THEO CNG NGH Hypol II 1.3.3. Kt qu thu c t qu trnh m phng Sau khi chy m phng, thu c kt qu cn bng vt cht ca qu trnh nh sau:
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Bng 8 :

Cn bng vt cht ca cc thit b Thit b PreR Vo (kg/h) Ra(kg/h) 4778 0 0,77 25,28 1,44.10-4 9,6.10-5 251,6 5056

Propylen Hydro Catalyst Propan ln trong Propylen Metan ln trong H2 N2 ln trong H2 PP Tng

5029 0,05 0,77 25,28 1,44.10-4 9,6.10-5 0 5056 Thit b R1 Vo (kg/h)

Ra (kg/h) 5799 0 0,77 59.68 3,44.10-4 2,26.10-4 6066 11926

Propylen Hydro Catalyst Propan ln trong Propylen Metan ln trong H2 N2 ln trong H2 PP Tng

11614 0.066 0,77 59,68 3,44.10-4 2,26.10-4 252 11926

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Thit b R2 Vo (kg/h) Propylen Hydro Catalyst Propan ln trong Propylen Metan ln trong H2 N2 ln trong H2 PP Tng 31237 0,24373 0,77 187,5 1,074.10-3 7,16.10-4 6066 37491 Ra(kg/h) 18647 0 0,77 187,5 1,074.10-3 7,16.10-4 18656 37491

Thit b tch PP Ra(kg/h) Vo (kg/h) Propylen Hydro Catalyst Propan ln trong Propylen Metan ln trong H2 N2 ln trong H2 PP Tng 18647 0 0,77 187,5 7,16.10-4 7,16.10-4 18656 37491 nh( kg/h) 18647 0 0,77 187,5 7,16.10-4 7,16.10-4 0 18835 y(kg/h) 0 0 0 0 0 0 18656 18656

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Bng 9 :

Bng tng kt cc dng vo ra ca qu trnh m phng Nhit (oC) p sut (bar) 25 49,03 25 34,28 34,28 1,5 1,5 1,5 1 2,7 2,7 2,7 Lu lng (kg/h) 18750 0,359 0,778 1866 1884 1,959.106 8,275.104 3,176.105 2200 293 730 2400 Nhit lng (kJ/h) Phn hi

Propylene Hydrogen Xc tc Polypropylene Propylene hi lu Nc lm mt thit b preRvo Nc lm mt thit b R1 vo Nc lm mt thit b R2 vo H2O lm lnh Pro vo tb trn Hi H2O gia nhit Pro vo R1 Hi H2O gia nhit Pro vo R2 Hi nc ha hi Pro

26 26 10 84,35 84,35 13,33 26 26 6 151 151 151

3,931.106 4,318 -3307 -1,225.108 8793.106 -3,108.1010 -3,127.108 -5,021.109 -3,497.107 -3,849.106 9,598.106 -3,155.107

0 1 0 0 1 0 0 0 0 1 1 1

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CHNG 2 TNH TON CC THIT B CHNH

2.1. TNH TON KCH THC CHO THIT B CHNH 2.1.1. Cc thit b phn ng Trong Hysys khng h tr vic t ng tnh ton th tch thit b phn ng khi m phng trng thi tnh (vi thp chng ct th c) m ch h tr vic tnh ton cc gi tr cn li nh ng knh, b dy v thit b,khi xc lp mt gi tr th tch no . Theo tnh cht ca qu trnh nh: Phn ng pha lng, xc tc c ho trn trong dng vt cht, cho nn khi tnh ton gi tr kch thc cc thit b phn ng phi thng qua cc gi tr nh: Lu lng th tch thc (F v) v thi gian lu (TR) ca lu cht trong thit b phn ng. Cc gi tr t Hysys nh sau: TBP Fv (m3/h) preR 9,75 R1 2299 R2 75,97

Theo yu cu cng ngh, cc thit b phn ng PreR, R1, R2 c thi gian lu ln lt l 6, 1.25h, 0.75h. Vy th tch hot ng ca cc thit b phn ng l: V (m3) = Fv* TR TBP V (m3) 2.1.2. Thit b tch loi i vi thit b loi kh Propylen v rn Polypropylen vi lu lng 246.4 (m3/h) th Hysic c th tnh ton c tt c cc thng s v kch thc thit b. 2.1.3. Kt qu thu c t m phng Sau khi ta tnh ton c cc gi tr th tch ca cc thit b ni trn. Tin hnh chy Hysys hiu chnh cc kch thc trn mang tnh kinh t hn v cc kch thc v bm, thit b trao i nhit cng c xc lp. Ta c kt qu sau: preR 0,975 74 R1 28, 76 R2 56,9

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TBP V (m3) ng knh (m) Chiu cao (m)

p reR 0 ,975 0 ,939 1 ,408 ,35 ,9 8,74

1

R
2

R 5 6,976 3 ,643 5 ,465

2 2 4

i vi thit b tch loi vi lu lng 246.4 (m3/h) ta c kt qu nh sau:

Thit b tch PP Thi gian lu (h) S ngn Din tch 1 ngn (m2) Tng din tch (m2) ng kch ht (mm) Din tch ti (m2 ) ng knh ti (m) S ti / ngn Tc dng kh(m/s) Bc ti(m) 2.2. CC THIT B PH KHC Cc my bm C 3 my bm k hiu ln lt P-100, P-101, dng bm dng Propylene nguyn liu, v xc tc.Vi tng p qua cc bm l 11 bar. Khi chy Hysic ta thu c cc thng s k thut ca bm nh sau. Thit b
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25.74 1 14,2 14,2 1 1,48 0,3 78 0,005 0,02

P-100

P-101

Nng sut (m3/s) p sut ton phn (m) Cng sut ton phn (kcal/h) Hiu sut bm ( %) Tc quay ca bm(rpm) NPSH

73,4 219,8 2573 75 1800 279

38,5.10-5 55,56 0,135 75 1800 126

Thit b trao i nhit Thit b trao i nhit E-01 lm lnh dng propylene trc khi vo thit b trn xc tc trc khi vo thit b tin phn ng (PreR); Thit b trao i nhit E-02, gia nht dng propylen trc khi i vo thit b phn ng th nht ( R1 ); Thit b trao i nhit E-03, gia nhit dng propylene trc khi vo thit b phn ng th hai ( R2 ) Thit b trao i nhit E-04, ha hi propylene lng cha phn ng trc khi vo thit b tch; Khi tin hnh m phng ta bit c lu lng ca dng nc lm lnh v lm nng dng propylene qua cc thit b trao i nhit E-01, E-02, E-03, E-04 ln lt l 2200 (kg/h), 292.7(kg/h), 730(kg/h), 134720(kg/h). Ta tin hnh thit k tnh ton cc thng s thit b trao i nhit nh sau: Trn thanh cng c Case (Main) Click vo Heat exchanger. Double click vo thit b nhp tn cho dng nguyn liu vo, dng sn phm ra, dng nhit - trong phn Connections. Dng vt cht i trong ng l dng Propylen, dng i ngoi ng l dng nc gia nhit (Chn dng vt cht i trong ng hay ngoi ng ph thuc nhiu yu t: nhit , loi lu cht Nhng thng thng dng i trong ng l dng lnh, dng i ngoi ng l dng nng).

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Hnh 17 : Xy dng thit b trao i nhit Trong phn Parameters chn cch thc trao i nhit (Heat Exchanger Model )l trong phm vi m phng tnh (Steady state rating). Nhp tn tht p sut cho dng i trong ng v ngoi ng.

Hnh 18 : Xc lp tn tht p sut trong thit b trao i nhit Trong phn Worksheet nhp lu lng hi thp p trao i nhit.

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Hnh 19 : Xc lp lu lng hi thp p Ta hon tt vic nhp thng s cho thit b trao i nhit. Hysic t tnh cc thng s kch thc thit b. Tng t ta thit k cc thit b trao i nhit cn li. Bng 10 : Thit b Loi ( TEMA) ng knh v thit b, mm S ng B tr ng ng knh ngoi ng, mm ng knh trong ca ng, mm Chiu di ng, m B mt trao i nhit (m2) S pass ng Bc ng, mm
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Thng s kch thc thit b. E - 01 E - 02 E - 03 AES 197 30 796 160 2554 480 Kiu tam gic 18 14 2 10 2 20 20 16 3 60 2 50 24 18 6 217 2 100 20 16 4 80 2 50 1091 320 E- 04

Tn tht p ngoi ng, KPa Tn tht p trong ng

200 300

200 400

500 2000

500 3000

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CHNG 3 XY DNG H THNG IU KHIN CA QU TRNH[31]

3.1. TNG QUAN V H THNG IU KHIN Trong ngnh iu khin t ng c hai loi chnh l iu khin c kh nng ng hoc m (discrete control) v iu khin qu trnh (process control). 3.1.1. Cc nguyn tc c bn ca qu trnh iu khin 3.1.1.1. iu khin ng m iu khin ng m l h thng iu khin t ng thng c s dng cho cc nh my lp rp. Trong ngnh cng nghip ho hc ni chung cng nh trong ngnh cng ngh lc du v ch bin kh ni ring, iu khin ng m tuy khng ph bin nhng cng l khng th thiu v c vai tr quan trng, c bit trong cc ng dng start up, shutdown, an ton nh my. Nhng u vo, u ra ca loi iu khin ny ch mt trong hai trng thi ng hay m (on hay off). Phng php iu khin ca loi ny l logic, vi cng OR, AND, NAND vv....Cch y 40 nm b iu khin ca loi ny l mt h thng rle v rle thi gian t trong t bng. Vi s pht trin ca ngnh in t, b iu khin c kh nng lp trnh PLC (Programmable Logic Control) ra i lm cho h thng rle tr nn li thi. 3.1.1.2. iu khin qu trnh Trong cc nh my lc du, ho du, ch bin kh, ngi ta s dng ch yu loi iu khin ny. Qu trnh sn xut l lin tc, cc thng s iu khin bao gm nhit , p sut, mc cht lng, lu lng, pH, nng vv... Thit b u vo thng l t cc b chuyn i tn hiu cho ra tn hiu tng t dng chun nh 4-20 mA hoc 3-15 psig. Thit b u ra thng thng l cc van iu khin. Phng php iu khin thng l thut ton iu khin t l (Proportional), tch phn (Integral) v vi phn (Differential) vit tt l PID. [3] 3.1.2. H thng iu khin phn tn DCS trong cc nh my hin i Do t th c nhiu phn xng nm phn tn trong mt din tch ln v c rt nhiu u vo v u ra ng vi tng phn xng nn hu ht cc nh my lc du hin nay u s dng h thng iu khin phn tn DCS (Distributed Control System). H thng c cu thnh bi nhiu h thng nh hn nm phn tn mi phn xng, mi h thng nh ny c nhim v m bo qu trnh iu khin phn xng m n m nhim, n chu s qun l ca cc h thng ch bn trn, c th nhn hoc cung cp tn hiu vi cc h thng ch. Bn thn cc h thng phn tn ny s qun l trc tip cc thit b ti hin trng nh van, cm bin, m t... Tp hp tt c cc d liu t cc h thng phn tn tng phn xng s c gi ln cc h thng cp cao hn, cc h thng ny thng c tp trung phng
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iu khin trung tm ca nh my, ni m cc k s vn hnh v nh qun l trc tip a ra nhng quyt nh v ch hot ng ca nh my. Ra i t gia nhng nm 70, h thng iu khin phn tn DCS mang n mt cuc cch mng thc s cho phng iu khin trung tm ca cc nh my lc du bng cch s ho nhng vng iu khin v biu din thng tin ca qu trnh ln mn hnh iu khin.

Hnh 20 : M hnh h thng iu khin DCS Nhng li th m DCS mang li c th k ra nh

m bo an ton cao trong qu trnh hot ng.

Lu tr cc thng tin trong qu trnh hot ng phc v cho cng tc thng k, nghin cu, hoch nh chin lc.

Cung cp ci nhn tng qut nht v hot ng ca nh my.

Cc module tnh ton cho php trin khai cc chin lc iu khin nhm mc ch ti u hiu qu cng ngh v hiu qu kinh t. Giao din thn thin vi ngi vn hnh bng ngn ng v hnh nh... Vai tr ca b iu khin PID 3.1.3. B IU KHIN PID 3.1.3.1. Tn gi PID l ch vit tt ca ba thnh phn gm khu khuych i P (Proportional), khu tch phn I (Integral) v khu vi phn D (Differential). S hot ng ca khu PID nh sau:

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Hnh 21 : S hot ng ca khu PID B iu khin PID c s dng kh rng ri iu khin i tng theo nguyn l hi tip, c bit l trong ngnh cng nghip qu trnh, trong ni bt nht l lnh vc du kh. L do b iu khin ny c s dng rng ri l tnh n gin v cu trc ca n ln nguyn l lm vic. B iu khin PID c nhim v a sai lch e(t) gia gi tr t SP v gi tr thc t PV v khng sao cho qu trnh qu tho mn cc yu cu c bn v cht lng. B iu kin PID c m t bng m hnh vo ra theo phng trnh sau

1 u(t) = kp[ e(t) + Ti

Trong

e(t )dt + Td
0

de(t ) ] dt

Kp l h s khuych i, t trng cho khu t l. Ti l hng s tch phn, t trng cho khu tch phn. Td l hng s vi phn, t trng cho khu vi phn. y l ba thng s t trng cho b iu khin PID. Cht lng h thng ph thuc vo ba thng s ny. Mun c h thng c cht lng nh mong mun th phi phn tch i tng ri trn c s chn cc thng s Kp, Ti, Td cho ph hp 3.1.4. La chn khu tc ng v cc thng s t trng cho PID Nhim v ca vic thit k b iu khin PID cho mt qu trnh c th l La chn khu tc ng Tnh ton cc thng s t trng cho tng khu

Khng phi bao gi cng dng c ba khu ny trong mt vng iu khin. Thng thng tc ng P + I c dng iu khin cc thng s thay i nhanh nh iu khin mc, iu khin p sut, iu khin lu lng. Tc ng P+I +D c dng iu khin cc thng s thay i chm nh iu khin nhit , iu khin pH, iu khin nng . Vic la chn cc thng s t trng cho mi khu thng thng c cn c vo hm truyn ca qu trnh.

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Ngy nay c mt s b iu khin hin i c th t ng la chn cc khu iu khin v k c vic thit t cc thng s t trng cho tng khu. Bng sau trnh by kinh nghim la chn khu iu kin v cc thng s c trng cho mi khu ng vi tng qu trnh c th ng dng trong m phng ng ca phn mm HysysDynamic Bng 11 : Qa trnh iu khin nhit iu khin p sut iu khin mc (khu P) iu khin mc (khu PI) iu khin lu lng Khong kinh nghim cc khu ca PID[32] Kp 2-10 2-10 2 2-10 0.4-0.65 Ti (pht) 2-10 2-10 Khng s dng 1-5 0.05-0.25 Td (pht) 0-5 Khng s dng Khng s dng Khng s dng Khng s dng

Trn y l bn qu trnh iu khin c bn, tt c cc vng iu khin trong thc t u l s cu thnh ca cc thnh phn trn. Khu PID rt t c s dng trong thc t iu khin qu trnh, hu ht tt c cc qu trnh u c th iu khin c bng khu PI nu la chn ng cc thng s t trng. 3.1.5. H thng iu khin trong nh my sn xut POLYPROPYLEN H thng iu khin ca nh my rt phc tp. Gm c cc b iu khin nhit , p sut, nng , khi lng ring, lu lngC th biu din theo s sau.

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Hnh 22 : S h thng iu khin trong nh my sn xut PP 3.1.5.1. B iu khin lu lng : Gm cc thit b iu khin lu lng : Dng nguyn liu Propylen Dng nguyn liu hydro Dng Xc tc Cc dng Propylen vo cc thit b trao i nhit. Dng nc lm lnh, nc gia nhit. 3.1.5.2. B iu khin nhit Gm cc thit b iu khin : Nhit cc dng Propylen ra khi thit b trao i nhit. Nhit cc thit b phn ng Nhit dng Polypropylen Propylen ra khi thit b ha hi Propylen. 3.1.5.3. B iu khin nng Thit b iu khin nng hydro trong dng Propylen.

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iu khin nng Propylen trong thit b phn ng thng qua iu khin chuyn ha ca phn ng ( thc t iu khin khi lng ring ca h nh tng ca cc thit b phn ng ) 3.1.5.4. B iu khin mc Thit b iu khin mc PP trong thit b tch. Thit b iu khin tc dng kh Propylen ra khi thit b 3.2. PHNG PHP IU KHIN MT S THNG S DNG VT CHT BNG HYSIS ( y ta ch ly mt v d v cch iu khin cc thng s dng vt cht qua thit b trao i nhit ) C th ta xt qu trnh v phng php iu khin nhit dng Propylen ra khi thit b trao i nhit trc khi vo thit b phn ng th hai ( R2 ) Gm c cc bc sau : 3.2.1. Tin hnh v hon tt m phng tnh qu trnh trao i nhit ca dng Propylen :

Hnh 23 : Thit b trao i nhit 3.2.2. Xy dng h thng iu khin PID cho thit b : Gm c cc thit b iu khin nh sau : FIC-100 : Thit b iu khin lu lng hi thp p vo thit b trao i nhit thng qua m van VLV-101. FIC-101 : Thit b iu khin lu lng dng Propylen vo thit b trao i nhit thng qua iu khin m van VLV-100.
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 TIC-100 : Thit b iu khin nhit dng Propylen ra khi thit b trao i nhit thng qua iu khin m van VLV-101.

Hnh 24 : H thng iu khin thit b trao i nhit Cch thc thit lp mt thit b iu khin: Trn thanh cng c Case (Main) Click vo Control Ops PID Controller. Double click vo thit b nhp cc thng s iu khin.

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Hnh 25 : Xy dng h thng iu khin Trong phn Connections ti mc Process Variable Source chn bin iu khin l nhit dng PRO11 nh sau

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Hnh 26 : Xc lp bin iu khin Ti mc Output Target Object chn i tng thay i (l m van VLV102). Trong phn Parameters in cc thng s Kc, Ti, Td, khong gi tr nhit ti thiu, ti a. Tng t ta thit lp cc thit b iu khin cn li FIC-100, FIC-101. Sau khi xy dng h thng cc thit b iu khin ta kch chut vo nt Dynamics Assistant trn thanh cng c v chn Make Change Finish. Sau vo Tool Chn Databook (hoc Ctrl D), Ti mc Variables insert cc dng vt cht nh sau :

Hnh 27 : Qu trnh iu khin Ti mc Strip Chats ta nh du tick vo cc mc chn v kch vo Strip Charts hin th ng biu din s thay i nhit , lu lng khi cc bin cn li thay i. Cui cng kch vo nt Intergrator active trn thanh cng c (hoc vo Simulation Intergrator) chuyn qua trng thi m phng ng. Ta xem nh hon tt vic m phng ng ca mt thit b. Tng t ta c th m phng ng s thay i cc thng s ca tt c cc thit b cn li.

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Hnh 28 : H thng iu khin thit b trao i nhit Tng t ta c th tin hnh m phng ng xy dng h thng iu khin cc thit b cn li. V s liu cn cha chnh xc so vi thc t nn cha th m phng ng ton b nh my cng mt lc m ch c th xy dng h thng iu khin ca tng thit b v tng khu vc trong nh my.

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