MTO装置再生器旋风分离器操作优化模拟研究

摘要/Abstract

摘要： 旋风分离器是甲醇制烯烃（MTO）装置常用的气固两相分离设备，其分离效率对装置的长周期稳定运行非常重要。某0.6 Mt/a MTO装置采用高活性催化剂后，再生器烧焦主风量低于设计值，导致一级旋风分离器入口气速低，20 μm以下细粉催化剂跑损量增大，催化剂消耗量增大。为此，采用计算颗粒流体力学（CPFD）软件模拟再生器四组二级旋风分离器的不同操作工况，调整旋风分离器入口面积与烟气流量改变入口气速，研究入口气速对旋风分离器压降和分离效率的影响规律。结果表明：烟气流量为42 241 m³/h时，封闭一组一级入口，旋风分离器入口气速提高3 m/s，旋风分离器总效率提高0.501百分点。依据模拟结果对旋风分离器提出了优化操作建议，可推广应用于其他MTO装置的操作调整。

关键词: 甲醇制烯烃, 旋风分离器, 再生器, 入口气速, 分离效率, 数值模拟

Abstract: Cyclone separator is a common gas-solid two-phase separation equipment in methanol to olefins (MTO) unit, and its separation efficiency is very important for the long-term stable operation of the unit. Due to the use of a highly active catalyst in a 0.6 Mt/a MTO unit, the main air volume of the regenerator was lower than the design value, which resulted in low gas velocity at the inlet of the first-stage cyclone separator and increased loss of the fine powder catalyst under 20 μm in the unit, and catalyst consumption increased. For this purpose, the commercial computational particle fluid dynamics (CPFD) software was used to simulate the different operating conditions of the four group two-stage cyclones in the regenerator. The inlet gas velocity of the cyclone was changed by adjusting the inlet flow area and main air volume of the cyclone, and the effect of gas speed on the cyclone pressure drop and separation efficiency of the cyclone was studied. The results showed that when the main air volume was 42 241 m³/h, the gas velocity of cyclone separator could be increased by 3 m/s and the total efficiency of cyclone separator could be increased by 0.501 percentage points. Based on the simulation results, the optimal operation suggestions for cyclone separator were put forward, which could be applied to the operation adjustment of other MTO devices.

Key words: MTO, cyclone, regenerator, inlet gas velocity, separation efficiency, numerical simulation

彭威黄新俊詹庆丽刘胜昔马文杰黄立华. MTO装置再生器旋风分离器操作优化模拟研究[J]. 石油炼制与化工, 2024, 55(7): 135-143.

参考文献

[1]苟荣恒, 潘海涛, 尉秀峰, 等.装置再生立管内催化剂输送不畅的流态特性分析[J].石油炼制与化工, 2022, 53(10):16-20; [2]卢春喜, 王祝安.催化裂化流态化技术 [M]. 中国石化出版社, 2002.; [3]陈俊武, 许友好.催化裂化工艺与工程 [M]. 中国石化出版社, 2017.; [4]金涌, 祝京旭, 汪展文.流态化工程原理[M]. 清华大学出版社, 2001.; [5]高助威, 王娟, 姜龙骏, 等.沉降器内不同结构旋风分离系统的模拟分析[J].石油学报石油加工, 2017, 33(6):1120-7 [6] 时铭显.PV型旋风分离器的性能及工业应用[J]. 石油炼制与化工, 1990(1): 37-42.; [7]谭争国, 高雄厚, 李荻, 等.催化裂化装置中旋风分离器和烟气轮机催化剂粘连结垢原因分析[J].石油炼制与化工, 2010, 41(4):40-3 [8]HOFFMANN A.C.,STEIN LE.,BRADSHAW P. Gas cyclones and swirl tubes: principles,design and operation[J].Appl Mech Rev, 2003, 56(2):B28-B9 [9]SONG J, WANG D, HE Y, et al.A Stepwise Diagnosis Method for the Catalyst Loss Fault of the Cyclone Separator in FCC Units[J].Separations, 2023, 10(1):28- [10]YAN C-Y, SUN G-G, CHEN J-Y, et al.Experimental study on the particle flow patterns in a cyclone dipleg with a trickle valve[J].Petroleum Science, 2020, 17(3):822-37 [11]葛坡, 袁惠新, 付双成.对称多入口型旋风分离器的数值模拟[J].化工进展, 2012, 31(02):296-9 [12]于洲，马春元.动态旋风分离器数值模拟及实验研究[J].化工进展, 2014, 33(07):1684-90 [13]蔡香丽, 杨智勇, 魏耀东, 等.旋风分离器气相旋转流流场动态特性的研究进展[J].化工进展, 2019, 38(11):4805-14 [14]解明, 宋健斐, 魏耀东, 等.旋风分离器内气相旋转流动态特性分析与表征[J].化工进展, 2022, 41(7):3455-64 [15]陈俊冬, 宋金仓, 曾川, 等.旋风分离器分离性能的数值模拟与分析[J].化工进展, 2016, 35(05):1360-5 [16]杜振国, 汪显盼, 白士玉, 等.工业流化床反应器一级旋风分离器入口颗粒物性-模拟[J].洁净煤技术, 2023, 29(S2):566-73 [17]BARAHMAND Z, JAYARATHNA C, RATNAYAKE C.CPFD Simulations on a Chlorination Fluidized Bed Reactor for Aluminum Production: an Optimization Study [Z]. Proceedings of The First SIMS EUROSIM Conference on Modelling and Simulation, SIMS EUROSIM 2021, and 62nd International Conference of Scandinavian Simulation Society, SIMS 2021, September 21-23, Virtual Conference, Finland. 2022: 341-9.10.3384/ecp21185341; [18]BANDARA J C, JAYARATHNA C, THAPA R, et al.Loop seals in circulating fluidized beds – Review and parametric studies using CPFD simulation [J]. Chemical Engineering Science, 2020, 227.; [19]CHEN C, WERTHER J, HEINRICH S, et al.CPFD simulation of circulating fluidized bed risers [J]. Powder Technology, 2013, 235: 238-47.; [20]LIANG Y, ZHANG Y, LU C.CPFD simulation on wear mechanisms in disk–donut FCC strippers [J]. Powder Technology, 2015, 279: 269-81.; [21]LU H, GUO X, JIN Y, et al.Powder discharge from a hopper-standpipe system modelled with CPFD[J].Advanced Powder Technology, 2017, 28(2):481-90 [22]WEBER J M, LAYFIELD K J, VAN ESSENDELFT D T, et al.Fluid bed characterization using Electrical Capacitance Volume Tomography (ECVT), compared to CPFD Software' s Barracuda [J]. Powder Technology, 2013, 250: 138-46.; [23]YANG S, WU H, LIN W, et al.An exploratory study of three-dimensional MP-PIC-based simulation of bubbling fluidized beds with and without baffles [J]. Particuology, 2018, 39: 68-77.; [24]YANG Z, ZHANG Y, LIU T, et al.MP-PIC simulation of the effects of spent catalyst distribution and horizontal baffle in an industrial FCC regenerator. Part II: Effects on regenerator performance [J]. Chemical Engineering Journal, 2021, 421: 129694.; [25]SNIDER D M, CLARK S M, O' ROURKE P J.Eulerian–Lagrangian method for three-dimensional thermal reacting flow with application to coal gasifiers[J].Chemical engineering science, 2011, 66(6):1285-95 [26]WANG S, LUO K, HU C, et al.Impact of operating parameters on biomass gasification in a fluidized bed reactor: An Eulerian-Lagrangian approach [J]. Powder Technology, 2018, 333: 304-16.; [27]LIN W, WANG K, YANG Y, et al.Characterization of flow pattern of cohesive particles in gas-solid fluidized bed via axial distribution of particle motions [J]. International Journal of Multiphase Flow, 2020, 130: 103355.; [28]XIE Y, CHEN Y, FANG Z, et al.The research of gas-solid fluidized bed bubbling behavior based on CFD-DEM coupled simulation [J]. Chemical Engineering Research and Design, 2023, 195: 166-80.; [29]YANG T-Y, LEU L-P.Multi-resolution analysis of wavelet transform on pressure fluctuations in an L-valve[J].International Journal of Multiphase Flow, 2008, 34(6):567-79 [30]祁海鹰, 戴群特, 陈程.大型流态化多相流数值模拟的关键科学问题——曳力模型的理论分析[J].力学与实践, 2014, 36(3):269-277 [31]Adam Zanker.Determining air inlet-velocity for cyclones[J].Chemical Engineering, 1984, 91(6):159- [32]闫思博, 单学军, 刘芳芳.旋风分离器分离效率影响因素分析[J].水泥工程, 2022, 35(4):12-16