基于Aspen Plus的Shell气流床工业气化炉模拟

doi:10.16085/j.issn.1000-6613.2020-0946

摘要/Abstract

摘要：

基于Aspen Plus软件的Gibbs自由能最小化法，本文建立了煤粉在Shell气流床中的气化模型。该模型预测气化温度和煤气组成，与文献试验结果吻合良好。利用Aspen Plus的灵敏度分析模块研究了氧煤比、氧气体积分数和氧气预热温度对气化结果的影响，并进行了正交模拟计算，研究了以上3种因素共同作用的结果。结果表明：氧煤比增加使碳转化率升高，冷煤气效率先升高后降低，并在氧煤比为0.9kg/kg时取得最大值77.72%；氧气体积分数增加使煤气热值、碳转化率和冷煤气效率升高，氧煤比为0.8kg/kg且氧气体积分数为50%时，冷煤气效率可达82.6%；氧气预热温度增加使碳转化率、冷煤气效率升高，氧煤比为0.8kg/kg且氧气预热温度为600℃时，冷煤气效率可达82%。通过正交模拟计算综合分析，氧煤比对冷煤气效率和碳转化率的影响作用占首位，氧气体积分数对煤气热值、有效气体积分数、煤气产率的影响作用占首位，氧气预热温度对煤气化指标影响较小。在实验范围内，当氧煤比0.8kg/kg、氧气体积分数100%、氧气预热温度300℃时的煤气热值达到最大值3011kcal/m³；当氧煤比为0.8kg/kg、氧气体积分数60%~100%、氧气预热温度300~500℃时的冷煤气效率达到最大值83.46%。

关键词: Aspen Plus, 气流床, 灵敏度分析, 氧气体积分数, 正交模拟计算

Abstract:

Based on the Gibbs free energy minimization method of Aspen Plus software, the coal gasification model in the Shell entrained flow bed was established. The model predicted the gasification temperature and gas composition, which was in good agreement with experimental results. The sensitivity analysis module of Aspen Plus was used to research the effects of oxygen-to-coal ratio, oxygen concentration and oxygen preheating temperature on the gasification results, and an orthogonal simulation calculation was designed to research the results of the above three factors. The results show that with the increase in the oxygen-to-coal ratio, the carbon conversion rate increases, and the cold gas efficiency increases initially and then decreases, and reaches a maximum value of 77.72% when the oxygen-to-coal ratio is 0.9kg/kg; the increase in oxygen concentration makes the gas calorific value, carbon conversion rate, and cold gas efficiency increase, and when the oxygen-to-coal ratio is 0.8kg/kg and the oxygen volume fraction is 50%, the cold gas efficiency can reach 82.6%; the increase in oxygen preheating temperature increases the carbon conversion rate and the cold gas efficiency, and when the oxygen-to-coal ratio is 0.8kg/kg and the oxygen preheating temperature is 600℃, the cold gas efficiency can reach 82%. The comprehensive analysis of orthogonal simulation calculation shows that the effect of oxygen-to-coal ratio on the efficiency of cold gas and carbon conversion rate takes the first place; the effect of oxygen volume fraction on the gas calorific value, effective gas volume fraction, and gas yield takes the first place; and the oxygen preheat temperature has little effect on coal gasification index. Within the experimental range, when the oxygen-to-coal ratio is 0.8kg/kg, the oxygen volume fraction is 100%, and the oxygen preheating temperature is 300℃, the gas calorific value reaches the maximum value of 3011kcal/m³; when the oxygen-to-coal ratio is 0.8kg/kg, the oxygen volume fraction is 60%—100%, and the oxygen preheating temperature is 300—500℃, the cold gas efficiency reaches the maximum value of 83.46%.

Key words: Aspen Plus, Shell entrained flow bed, sensitivity analysis, oxygen volume fraction, orthogonal simulation calculation

中图分类号:

TQ545

郑志行, 李谦, 张家元, 周浩宇. 基于Aspen Plus的Shell气流床工业气化炉模拟[J]. 化工进展, 2021, 40(4): 2152-2160.

ZHENG Zhihang, LI Qian, ZHANG Jiayuan, ZHOU Haoyu. Simulation of industrial Shell entrained flow bed by Aspen Plus[J]. Chemical Industry and Engineering Progress, 2021, 40(4): 2152-2160.

图/表 17

图1 Shell气流床系统流程示意图

表1 气化过程中发生的主要反应

反应	标准反应热/kJ·mol^-1	反应数
C+O₂ $→$ CO₂	-393.5	R1
C+ $12$ O₂ $→$ CO	-110.5	R2
C+H₂O $→$ CO+H₂	+131.3	R3
C+CO₂ $→$ 2CO	+172.5	R4
C+2H₂ $→$ CH₄	-74.8	R5
H₂+ $12$ O₂ $→$ H₂O	-241.9	R6
CO+ $12$ O₂ $→$ CO₂	-283.0	R7
CO+H₂O $→$ CO₂+H₂	-41.2	R8
CH₄+H₂O $→$ CO+3H₂	+206.1	R9

表1 气化过程中发生的主要反应

反应	标准反应热/kJ·mol^-1	反应数
C+O₂ $→$ CO₂	-393.5	R1
C+ $12$ O₂ $→$ CO	-110.5	R2
C+H₂O $→$ CO+H₂	+131.3	R3
C+CO₂ $→$ 2CO	+172.5	R4
C+2H₂ $→$ CH₄	-74.8	R5
H₂+ $12$ O₂ $→$ H₂O	-241.9	R6
CO+ $12$ O₂ $→$ CO₂	-283.0	R7
CO+H₂O $→$ CO₂+H₂	-41.2	R8
CH₄+H₂O $→$ CO+3H₂	+206.1	R9

表2 神华煤的工业分析和元素分析（干燥基）

工业分析/%				元素分析/%
A_d	V_d	FC_d		C_d	H_d	N_d	S_d	O_d	Cl_d
7	34	59		75.07	4.49	0.96	0.42	12.03	0.01

表3 气化炉操作条件

进料	压力/MPa	温度/℃	质量流率/kg·s^-1
煤	4.00	80	21.59
氮气	4.15	80	1.5
氧气	4.15	180	17.57
水蒸气	5.05	300	2.16

图2 煤气化模型示意图

表4 文献值与模拟值的对比结果

参数	文献值	模拟值
φ（H₂O）/%	1.84	1.69
φ（N₂）/%	4.14	3.04
φ（H₂）/%	28.72	28.42
φ（CO）/%	64.23	65.54
φ（CO₂）/%	1.2	1.12
φ（CH₄）/%		0.05
φ（H₂S）/%	0.124	0.14
出口温度/℃	1450	1458.8

表5 煤种的元素分析和气化炉操作条件

煤种	元素分析（干燥基）/%							煤粉进料速率 /g·s^-1	(H₂O/coal) /g·g^-1	(O₂/coal) /g·g^-1
煤种	C	H	N	S	Cl	O	Ash	煤粉进料速率 /g·s^-1	(H₂O/coal) /g·g^-1	(O₂/coal) /g·g^-1
Illinois No.6	74.05	6.25	0.71	1.77	0.37	1.32	15.53	76.66	0.24	0.87
Wyodak	78.37	5.79	0.92	0.07	0.08	3.7	11.05	86	0.32	0.9
SRC(-Ⅱ)	64.9	3.65	1.25	2.96	—	1.7	25.54	126.11	0.3	0.7
Exxon DSP	70.74	4.67	1.18	2.74	—	3.95	16.72	126.11	0.5	0.79
Western	74.56	5.31	0.99	0.46	—	11.47	7.2	186.78	0.52	0.91
Eastern	72.72	5.03	1.4	2.99	—	9.13	8.73	133	0.79	0.87

图3 模拟值与文献值的煤气组成及碳转化率对比文献值：□CO；▽CO2；○H2；◇CH4；△碳转化率模拟值：■CO；▼CO2；●H2；◆CH4；▲碳转化率

图4 氧煤比对气化温度及气体组成的影响

图5 氧煤比对产气热值、碳转化率及冷煤气效率的影响

图6 氧气浓度对气化温度及气体组成的影响

图7 氧气浓度对产气热值、碳转化率及冷煤气效率的影响

图8 氧气预热温度对气化温度及气体组成的影响

图9 氧气预热温度对产气热值、碳转化率及冷煤气效率的影响

表6 因素水平表

水平	A/kg·kg^-1	B/%	C/℃
1	0.7	21	100
2	0.8	40	200
3	0.9	60	300
4	1.0	80	400
5	1.1	100	500

表7 正交模拟方案及结果表

组数	A	B	C	气化温度/℃	煤气热值/kcal·m^-3	有效气体积分数/%	煤气产率/m³·kg^-1	冷煤气效率/%	碳转化率/%
1	1	1	1	954.55	1279.87	40.58	3.45	61.73	87.20
2	1	2	2	1091.42	2042.50	65.89	2.52	72.11	91.99
3	1	3	3	1177.28	2476.34	80.41	2.18	75.60	93.57
4	1	4	4	1236.75	2743.57	89.39	2.01	77.13	94.26
5	1	5	5	1281.11	2926.55	95.55	1.90	77.96	94.62
...	...	...	...	...	...	...	...	...	...
21	5	1	5	1516.96	995.72	32.92	4.73	65.87	100
22	5	2	1	1795.27	1586.50	52.46	2.97	65.86	100
23	5	3	2	2171.62	2040.07	67.47	2.31	65.89	100
24	5	4	3	2425.56	2380.17	78.72	1.98	65.94	100
25	5	5	4	2609.84	2645.10	87.48	1.78	65.99	100

表8 极差分析表

气化指标	A	B	C
煤气热值/kcal·m^-3
极差	364.25	1614.53	69.73
主次顺序	B>A>C
最优水平	A₂	B₅	C₃
有效气体积分数/%
极差	11.35	53.69	2.22
主次顺序	B>A>C
最优水平	A₂	B₅	C₃、C₄
煤气产率/m³·kg^-1
极差	0.26	2.29	0.27
主次顺序	B>C>A
最优水平	A₅	B₁	C₅
冷煤气效率/%
极差	14.98	5.62	3.50
主次顺序	A>B>C
最优水平	A₂	B₃、B₄、B₅	C₃、C₄、C₅
碳转化率/%
极差	7.67	2.53	1.57
主次顺序	A>B=C
最优水平	A₃、A₄、A₅	B₃、B₄、B₅	C₃、C₄、C₅

参考文献 22

1	汪寿建. 现代煤气化技术发展趋势及应用综述[J]. 化工进展, 2016, 35(3): 653-664.
	WANG Shoujian. Development and application of modern coal gasification technology[J]. Chemical Industry and Engineering Progress, 2016, 35(3): 653-664.
2	岑建孟, 方梦祥, 王勤辉, 等. 煤分级利用多联产技术及其发展前景[J]. 化工进展, 2011, 30(1): 88-94.
	CEN Jianmeng, FANG Mengxiang, WANG Qinhui, et al. Development and prospect of coal staged conversion poly-generation technology[J]. Chemical Industry and Engineering Progress, 2011, 30(1): 88-94.
3	刘永健, 何畅, 冯霄, 等. 煤制合成天然气装置能耗分析与节能途径探讨[J]. 化工进展, 2013, 32(1): 48-53, 103.
	LIU Yongjian, HE Chang, FENG Xiao, et al. Analysis of energy consumption and energy saving approach in a coal to SNG plant[J]. Chemical Industry and Engineering Progress, 2013, 32(1): 48-53, 103.
4	NI Qizhi, WILLIAMS Alan. A simulation study on the performance of an entrained-flow coal gasifier[J]. Fuel, 1995, 74(1): 102-110.
5	LI X, GRACE J R, WATKINSON A P, et al. Equilibrium modeling of gasification: a free energy minimization approach and its application to a circulating fluidized bed coal gasifier[J]. Fuel, 2001, 80(2): 195-207.
6	KONG Xiangdong, ZHONG Weimin, DU Wenli, et al. Three stage equilibrium model for coal gasification in entrained flow gasifiers based on Aspen Plus[J]. Chinese Journal of Chemical Engineering, 2013, 21(1): 79-84.
7	SANCHEZ Cristian, ARENAS Erika, CHEJNE Farid, et al. A new model for coal gasification on pressurized bubbling fluidized bed gasifiers[J]. Energy Conversion and Management, 2016, 126: 717-723.
8	王辅臣, 于广锁, 龚欣, 等. 大型煤气化技术的研究与发展[J]. 化工进展, 2009, 28(2): 173-180.
	WANG Fuchen, YU Guangsuo, GONG Xin, et al. Research and development of large-scale coal gasification technology[J]. Chemical Industry and Engineering Progress, 2009, 28(2): 173-180.
9	KUNZE Christian, SPLIETHOFF Hartmut. Modelling, comparison and operation experiences of entrained flow gasifier[J]. Energy Conversion & Management, 2011, 52(5): 2135-2141.
10	KONG Xiangdong, ZHONG Weimin, DU Wenli, et al. Compartment modeling of coal gasification in an entrained flow gasifier: a study on the influence of operating conditions[J]. Energy Conversion and Management, 2014, 82: 202-211.
11	JANG D H, YOON S P, KIM H T, et al. Simulation analysis of hybrid coal gasification according to various conditions in entrained-flow gasifier[J]. International Journal of Hydrogen Energy, 2015, 40(5): 2162-2172.
12	赵先国, 常杰, 吕鹏梅, 等. 生物质流化床富氧气化的实验研究[J]. 燃料化学学报, 2005, 33(2):199-204.
	ZHAO Xianguo, CHANG Jie, Pengmei LYU, et al. Biomass gasification under O₂-rich gas in a fluidized bed reactor[J]. Journal of Fuel Chemistry and Technology, 2005, 33(2):199-204.
13	刘霞, 田原宇, 乔英云. 国内外气流床煤气化技术发展概述[J]. 化工进展, 2010, 29(S2): 120-124.
	LIU Xia, TIAN Yuanyu, QIAO Yingyun. Progress of entrained-bed coal gasification technology[J]. Chemical Industry and Engineering Progress, 2010, 29(S2): 120-124.
14	盛新, 韩启元, 汪永庆, 等. Shell煤气化装置模拟计算和操作优化软件的开发与应用[J].化工进展, 2009, 28(11): 2076-2082.
	SHENG Xin, HAN Qiyuan, WANG Yongqing, et al. Development and application of simulation and optimization software for Shell coal gasification plant[J]. Chemical Industry and Engineering Progress, 2009, 28(11): 2076-2082.
15	谭富桃. 用化学平衡常数证明影响化学平衡的因素[J]. 化学教育, 2014, 35(9):37-39.
	TAN Futao. Proving the factors influencing chemical equilibrium with chemical equilibrium constant[J]. Chinese Journal of Chemical Education, 2014, 35 (9): 37-39.
16	刘建峰, 邓蜀平, 蒋云峰,等. Shell干煤粉气化的模拟与分析[J]. 化工进展, 2014, 33(S1): 145-149.
	LIU Jianfeng, DENG Shuping, JIANG Yunfeng, et al. Simulation and analysis of dry pulverized coal gasification in Shell gasifier[J]. Chemical Industry and Engineering Progress, 2014, 33(S1): 145-149.
17	张宗飞, 汤连英, 吕庆元,等. 基于Aspen Plus的粉煤气化模拟[J]. 化肥设计, 2008(3): 14-18, 26.
	ZHANG Zongfei, TANG Lianying, Qingyuan LYU, et al. Pulverized coal gasification simulation based on Aspen Plus software[J]. Chemical Fertilizer Design, 2008(3): 14-18, 26.
18	东赫, 刘金昌, 解强, 等. 典型气流床煤气化炉气化过程的建模[J]. 化工进展, 2016, 35(8): 2426-2431.
	DONG He, LIU Jinchang, XIE Qiang, et al. Modeling of coal gasification reaction in typical entrained-flow coal gasifiers[J]. Chemical Industry and Engineering Progress, 2016, 35(8): 2426-2431.
19	GOVIND Rakesh, SHAH Jogen. Modeling and simulation of an entrained flow gasifier[J]. AIChE Journal, 1984, 30(1): 79-92.
20	YU K S, LIU W W, ZHANG H X, et al. Research on gasification of shenhua coal and blended coal in industrial circulating fluidized bed gasifier[J]. Proceedings of the CSEE, 2017, 37(20): 5980-5986.
21	朱有健, 王定标, 周俊杰. 固定床煤气化炉的模拟与优化[J]. 化工学报, 2011, 62(6): 1606-1611.
	ZHU Youjian, WANG Dingbiao, ZHOU Junjie. Simulation and optimization of fixed bed gasifier[J]. CIESC Journal, 2011, 62(6): 1606-1611.
22	刘忠慧, 于旷世, 张海霞, 等. 基于Aspen Plus的循环流化床工业气化炉模拟[J]. 化工进展, 2018, 37(5): 1709-1717.
	LIU Zhonghui, YU Kuangshi, ZHANG Haixia, et al. Simulation of industrial circulating fluidized bed gasifier by Aspen Plus[J]. Chemical Industry and Engineering Progress, 2018, 37(5): 1709-1717.

[1]	郑志行, 张家元, 李谦, 周浩宇. 气流床煤气化的Aspen Plus建模：平衡模型和动力学模型[J]. 化工进展, 2021, 40(8): 4165-4172.
[2]	曹学文, 杨健, 边江, 刘杨, 郭丹, 李琦瑰. 新型双压Linde-Hampson氢液化工艺设计与分析[J]. 化工进展, 2021, 40(12): 6663-6669.
[3]	陈延贵, 张纹齐, 王银峰, 廖传华, 朱跃钊. 基于Aspen Plus的煤-炼化污泥高温气化特性分析[J]. 化工进展, 2021, 40(10): 5786-5793.
[4]	邵缨迪, 胡建杭, 刘慧利, 蔡正达. 异丁烯提纯装置换热网络的能效分析[J]. 化工进展, 2020, 39(S2): 57-65.
[5]	李恋,陈志,杨进飞,王计辉,李建明. 气隙式膜蒸馏在溴化锂吸收式制冷系统中的应用[J]. 化工进展, 2020, 39(1): 80-88.
[6]	程相龙,郭晋菊,张海永,孙加亮,张延兵,宋成建. 褐煤氧化和气化反应协同作用下夹带流反应器的建模[J]. 化工进展, 2020, 39(1): 119-128.
[7]	程相龙, 郭晋菊, 王永刚, 申恬, 孙加亮, 张海永. 不同反应器中氧化反应与水蒸气气化反应协同作用差异性[J]. 化工进展, 2019, 38(05): 2179-2188.
[8]	岳小洋, 李舒宏, 徐梦凯, 李彦军, 杜垲, 杨柳. 基于膜分离器的NH₃-H₂O-LiBr吸收式制冷系统的研究分析[J]. 化工进展, 2019, 38(02): 813-818.
[9]	王浩鹏, 陈智超, 张晓研, 曾令艳, 李争起, 方能, 刘晓英. 水冷壁气流床气化炉渣层热应力数值模拟方法的改进[J]. 化工进展, 2018, 37(09): 3288-3293.
[10]	刘忠慧, 于旷世, 张海霞, 朱治平. 基于Aspen Plus的循环流化床工业气化炉模拟[J]. 化工进展, 2018, 37(05): 1709-1717.
[11]	于点, 仲兆平, 李全新. 生物油裂解气费托合成-烯烃齐聚耦合制取航煤组分的过程模拟及(火用)分析[J]. 化工进展, 2018, 37(05): 1767-1773.
[12]	柏静儒, 王林涛, 张庆燕, 白章, 王擎. 桦甸式油页岩气体热载体综合利用系统改造建模及分析[J]. 化工进展, 2017, 36(04): 1258-1264.
[13]	李春启. 基于动力学模型的合成气完全甲烷化回路系统模拟分析[J]. 化工进展, 2017, 36(01): 146-155.
[14]	柏静儒, 李启凡, 吴海涛, 白章, 王擎. 基于Aspen Plus抚顺式油页岩干馏过程模拟方法研究[J]. 化工进展, 2017, 36(01): 121-128.
[15]	吕奇铮, 徐起翔, 张长森, 张瑞芹, 岳辉, 张莉红. Aspen Plus在生物质快速热解制取燃料油中的应用进展[J]. 化工进展, 2016, 35(S1): 116-121.