固定床反应器催化剂密相装填过程床层料面监测系统构建与研究

doi:10.16085/j.issn.1000-6613.2020-1559

摘要/Abstract

摘要：

催化剂密相装填过程中反应器内部直观可视性差，无法实时掌握反应器内床层堆积状态，影响布料控制和装填质量。本文以某单位固定床反应器为研究示例，构建了一套催化剂密相装填过程的床层料面监测系统，从机械结构设计、电气控制逻辑、软件窗口架构完成系统设计。使用脉冲微波雷达获取特征点距离，计算空间分布，根据空间分布使用自然条件下三次样条插值法构建料面图像。考察系统对多种形态料面的监测效果，探讨环境光照、催化剂粒径对系统可靠性的影响。结果表明，系统操作维护简单，具有较高的成像分辨率和测量精度，中心位置监测效果优于边缘；生成的三维毯式图像与径向料面分布图极大提高了密相装填过程床层料面信息的可读性；监测系统具有较强的鲁棒性，能适应反应器内多工况下的监测需求。

关键词: 催化剂, 密相装填, 测量, 界面, 雷达, 毯式图

Abstract:

The poor visibility inside fixed bed reactor during the catalyst dense loading process makes it unable to know the accumulation state of the reactor bed in real time, which affects the filling control and bed quality. A bed surface monitoring system for the catalyst dense loading process was constructed, and the system design included the mechanical structure, electrical control, and software system. The pulse microwave radar was used to obtain the distances of a number of characteristic points, then the spatial distribution was calculated, and the surface image was constructed according to the spatial distribution using cubic spline interpolation under natural conditions. The monitoring effect of the system was tested for materials at various levels, and the influences of ambient light and catalyst particle size on system reliability were discussed. The results showed that the system had the advantages of simple operation and maintenance, high imaging resolution and measurement accuracy, and the monitoring effect at center position was better than that at the edge. The generated three-dimensional blanket image and radial material surface distribution map greatly improved the readability of the bed surface information in dense loading process. The monitoring system is of high robustness and can adapt to the monitoring requirements under multiple working conditions.

Key words: catalyst, dense loading process, measurement, interface, radar, blanket map

中图分类号:

TH865

刘梅华, 刘雪东, 徐晓东, 彭涛, 顾宇彤, 蒋威. 固定床反应器催化剂密相装填过程床层料面监测系统构建与研究[J]. 化工进展, 2021, 40(7): 3617-3625.

LIU Meihua, LIU Xuedong, XU Xiaodong, PENG Tao, GU Yutong, JIANG Wei. Bed surface monitoring system for catalyst dense loading process in fixed bed reactor[J]. Chemical Industry and Engineering Progress, 2021, 40(7): 3617-3625.

图/表 14

图1 床层料面监测系统组成框图

图2 床层料面监测设备安装1—料面监测设备；2—固定床反应器；3—反应器内塔板；4—密相装填布料器

图3 床层料面监测系统机械结构1—摆动伺服电机；2—减速机；3—安装板；4—摆动接近开关；5—脉冲雷达；6—转动伺服电机；7—减速机；8—转动接近开关

图4 床层料面监测系统实验装置

图5 控制单元电连接1—摆动组件；2—转动组件；3—密相装填布料器

图6 软件系统主流程

图7 图形用户界面设计效果

图8 建立空间坐标系

图9 平整料面测量结果

图10 单峰料面测量结果

图11 双峰料面测量结果

表1 不同入射角下测量结果

测量点	入射角度θ/（°）	距离L₀/m	垂直距离h₀/m	绝对误差d/m	相对误差 $δ$
1	0	1.44	1.440	—	—
2	5	1.44	1.408	-0.012	0.83%
3	10	1.47	1.448	0.008	0.55%
4	15	1.56	1.507	0.027	1.87%
5	20	1.64	1.541	0.071	4.93%
6	22	1.65	1.530	0.060	4.17%
7	25	1.46	1.323	0.089	6.18%

表1 不同入射角下测量结果

测量点	入射角度θ/（°）	距离L₀/m	垂直距离h₀/m	绝对误差d/m	相对误差 $δ$
1	0	1.44	1.440	—	—
2	5	1.44	1.408	-0.012	0.83%
3	10	1.47	1.448	0.008	0.55%
4	15	1.56	1.507	0.027	1.87%
5	20	1.64	1.541	0.071	4.93%
6	22	1.65	1.530	0.060	4.17%
7	25	1.46	1.323	0.089	6.18%

图12 催化剂粒径对系统影响

图13 环境光照对系统影响

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