基于化工机理与工业数据孪生建模的甲醇精馏过程优化

doi:10.16085/j.issn.1000-6613.2023-1286

摘要/Abstract

摘要：

在化学工业生产中，分布式控制系统（distributed control system，DCS）数据作为反映过程生产状况的关键信息，通常由于测量误差影响而不能满足过程精准建模与优化的要求。常规过程建模与优化研究一般无法充分考虑工业实际生产与设计数据产生的偏差。为此，本工作在结合化工机理、DCS工业数据及工业经验的基础上，从底层逻辑出发，提出一种基于甲醇精馏工业生产数据与化工机理孪生建模框架来指导工业过程更精准的优化。将仪表的测量范围作为权重赋予测量变量，使用非线性规划算法基于化工机理约束对测量变量进行校正并求解校正值。结合校正值和工业经验提出过程变量的置信分数模型，实现对测量变量的置信评价。基于校正后的测量变量构建更贴近工业实际的甲醇双效精馏过程模型并实现对其更精准的过程工艺优化。该工作提出的化工机理与工业数据孪生建模思想，对构建数字化工孪生系统和智能化工厂的数据甄别、工艺优化等过程具有重要的科学意义和实际应用价值。

关键词: 数据驱动, 置信分析, 数据协同, 过程优化, 甲醇精馏, 数字孪生

Abstract:

In the production of the chemical industry, the data from the distributed control system (DCS) is crucial for reflecting the production status of the process. However, due to measurement errors, it often fails to meet the requirements for accurate process modeling and optimization. Conventional process modeling and optimization studies do not fully consider the deviations caused by industrial production and design data. In this work, we proposed a twin modeling framework based on industrial production data of methanol distillation and chemical mechanisms, combined with industrial experience, to guide more accurate optimization of industrial processes. We established material and energy conservation constraints and assigned weights to measurement variables based on the measurement range of instruments. Using nonlinear programming algorithms and chemical mechanism constraints, we calibrated and solved for the calibrated values of the measurement variables. We also proposed a confidence score model for process variables based on the calibrated values and industrial experience to evaluate the confidence of the measurement variables. By constructing a methanol distillation process model which was closer to industrial reality based on the calibrated measurement variables, we achieved more accurate process optimization. The twin modeling approach combining chemical mechanisms and industrial data proposed in this work has significant scientific and practical value for the construction of digital twin systems and intelligent chemical plants.

Key words: data-driven, confidence analysis, data reconciliation, process optimization, methanol distillation, digital twin

中图分类号:

TQ021.8

王雄, 杨振宁, 李越, 申威峰. 基于化工机理与工业数据孪生建模的甲醇精馏过程优化[J]. 化工进展, 2024, 43(1): 310-319.

WANG Xiong, YANG Zhenning, LI Yue, SHEN Weifeng. Optimization of methanol distillation process based on chemical mechanism and industrial digital twinning modeling[J]. Chemical Industry and Engineering Progress, 2024, 43(1): 310-319.

图/表 11

图1 某工厂甲醇双效精馏工艺流程

表1 加压塔进料的主要组成及含量

组成	质量分数/%
CH₃OH	90.54
H₂O	9.334
C₂H₅OH	0.081
C₄H₁₀O	0.045

表2 甲醇双效精馏三塔的操作参数

参数	加压塔	常压塔	回收塔
进料流量/kg·h^-1	12640.99	7458.99	1647.99
进料压力/kPa	900	561	500
进料温度/℃	82.87	120.12	90.11
塔顶压力/kPa	560	57	120
塔顶温度/℃	115.42	41	68.84
塔底压力/kPa	581	132	150
塔底温度/℃	121.35	90.497	111.4
理论板数	72	70	78
进料位置	65	55	47
塔顶回流量/kg·h^-1	13473.3	10846	3536

表3 重要物流设计数据与模拟数据对比表

组分	f₄质量分率		组分	f₅质量分率
组分	设计数据	模拟数据	组分	设计数据	模拟数据
CH₃OH	0.99999	0.999966	CH₃OH	0.99998	0.99992
H₂O	0.000003	0.000002	H₂O	0	0.00001
C₂H₅OH	0.000007	0.000032	C₂H₅OH	0.00002	0.00007

表4 低压蒸汽的热力学参数(焓值)

变量	DCS仪表	描述	汽化潜热/kJ·kg^-1
H₁	FI_4007.PV	至E0405低压蒸汽流量	2752.88
H₂	FI_4012.PV	至E0409低压蒸汽流量	2752.88

表5 流股的热力学参数(质量等压热容)

变量	DCS仪表	描述	质量等压热容/kJ·kg^-1·K^-1
$c p 3$	FI_4005.PV	T0402甲醇液流量	3.111
$c p 4$	FI_4018.PV	E0407甲醇液流量	2.918
$c p 5$	FI_4011.PV	T0403精甲醇产品流量	2.474
$c p 6$	FI_4023.PV	E0411甲醇液流量	2.627
$c p 7$	FI_4014.PV	P0407A/B含醇水流量	4.147
$c p 8$	FI_4025.PV	T0404采出杂醇油流量	5.658
$c p 9$	FI_4006.PV	T0402回流量	3.018
$c p 10$	FI_4008.PV	T0403回流量	2.396
$c p 11$	FI_4013.PV	T0404回流量	3.012

表5 流股的热力学参数(质量等压热容)

变量	DCS仪表	描述	质量等压热容/kJ·kg^-1·K^-1
$c p 3$	FI_4005.PV	T0402甲醇液流量	3.111
$c p 4$	FI_4018.PV	E0407甲醇液流量	2.918
$c p 5$	FI_4011.PV	T0403精甲醇产品流量	2.474
$c p 6$	FI_4023.PV	E0411甲醇液流量	2.627
$c p 7$	FI_4014.PV	P0407A/B含醇水流量	4.147
$c p 8$	FI_4025.PV	T0404采出杂醇油流量	5.658
$c p 9$	FI_4006.PV	T0402回流量	3.018
$c p 10$	FI_4008.PV	T0403回流量	2.396
$c p 11$	FI_4013.PV	T0404回流量	3.012

表6 DCS流量仪表数据校正结果及相对误差

变量	描述	DCS测量值/kg·h^-1	校正值/kg·h^-1	相对误差/%
f₁	至E0405低压蒸汽流量	10038.199	9862.606	1.75
f₂	至E0409低压蒸汽流量	2134.483	1705.557	20.10
f₃	至T0402甲醇液流量	12939.601	11486.436	11.23
f₄	自E0407甲醇液流量	4961.233	5049.447	-1.78
f₅	自T0403精甲醇产品流量	5712.498	5275.642	7.65
f₆	自E0411甲醇液流量	66.816	64.845	2.95
f₇	自P0407A/B含醇水流量	465.631	833.960	-79.10^①
f₈	T0404侧线采出杂醇油流	48.562	48.655	0.19
f₉	T0402回流量	13334.351	13193.590	1.06
f₁₀	T0403回流量	13087.428	13062.239	0.19
f₁₁	T0404回流量	3889.730	4285.911	-10.19
f₁₂	至V0407A/B甲醇液流量	10014.640	9917.230	0.97

表7 DCS温度仪表数据校正结果及相对误差

变量	描述	DCS测量值/℃	校正值/℃	相对误差/%
t₁	自V0402甲醇液温度	104.311	106.718	-2.31
t₂	T0403回流液温度	33.986	34.039	-0.16
t₃	T0404回流液温度	66.158	66.023	0.20
t₄	T0404塔釜温度	109.540	110.570	-0.94
t₅	自V0408杂醇油温度	39.284	39.196	0.22
t₆	至V0402甲醇液温度	97.365	110.971	-13.97^①
t₇	T040塔顶气温度	64.564	64.741	0.27
t₈	自E0408甲醇液温度	38.533	38.531	0.01
t₉	T0404塔顶气温度	67.805	66.557	1.84
t₁₀	自E0410温度	63.558	63.800	-0.38

图2 DCS测量变量的置信分数评价

图3 基于化工机理与工业数据孪生建模优化后的甲醇双效精馏过程

表8 甲醇双效精馏过程优化前后对比

参数	优化前	优化后
加压塔塔顶CH₃OH质量分率	0.999996	0.999978
常压塔塔顶CH₃OH质量分率	0.99995	0.999975
低压蒸汽流量f₁/kg·h^-1	10038.20	9862.61
低压蒸汽的潜热H₁/kJ·kg^-1	2752.88	2752.88
加压塔精甲醇流量f₄/kg·h^-1	4868.35	4935.5
常压塔精甲醇流量f₅/kg·h^-1	5042.71	5027.87
精甲醇价格 $C C H 3 O H$ /CNY·kg^-1	2.7
水电价格C_水电/CNY·kg^-1	0.27
运行时间/d	300
经济收益/10⁴CNY·a^-1	19267.1	19368.8
加压塔塔釜的热负荷/kW	7676.10	7541.83
换热器E0406热负荷/kW	4742.99	4453.62
公用工程费用/10⁴CNY·a^-1	1951.43	1917.29

表8 甲醇双效精馏过程优化前后对比

参数	优化前	优化后
加压塔塔顶CH₃OH质量分率	0.999996	0.999978
常压塔塔顶CH₃OH质量分率	0.99995	0.999975
低压蒸汽流量f₁/kg·h^-1	10038.20	9862.61
低压蒸汽的潜热H₁/kJ·kg^-1	2752.88	2752.88
加压塔精甲醇流量f₄/kg·h^-1	4868.35	4935.5
常压塔精甲醇流量f₅/kg·h^-1	5042.71	5027.87
精甲醇价格 $C C H 3 O H$ /CNY·kg^-1	2.7
水电价格C_水电/CNY·kg^-1	0.27
运行时间/d	300
经济收益/10⁴CNY·a^-1	19267.1	19368.8
加压塔塔釜的热负荷/kW	7676.10	7541.83
换热器E0406热负荷/kW	4742.99	4453.62
公用工程费用/10⁴CNY·a^-1	1951.43	1917.29

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