PSE for feedstock consumption reduction in reaction system of HPPO plant

doi:10.16085/j.issn.1000-6613.2023-1044

Abstract

Abstract:

The process systems engineering(PSE) study to reaction system of preparing propylene oxide by hydrogen peroxide method, which meets the requirements of environmental friendliness, atomic economy and sustainable development, can achieve good technical and economic results. The technological process PSE study in the 100—400kt/a HPPO plant can reduce the feedstock consumption of 149—720t/a hydrogen peroxide and 184—889t/a propylene. Under the conditions of reaction pressure 1.5—4.5MPa and reaction temperature 39—95℃, the automatic control PSE study in the 400kt/a HPPO plant can reduce the feedstock consumption of 509—757t/a hydrogen peroxide and 629—935t/a propylene. The PSE study in reaction system of HPPO plant with different process parameters and different production scale can increase the total heat transfer coefficient of the reactor to 2400—2800 W/(m²·K) and prolong the service life of the catalyst to 4.8—5.0a. Thus Sinopec completed Chinese first 100kt/a industrial-scale HPPO plant in 2014, with 100% high-grade product rate, becoming the world's third industrial-scale HPPO full-set technology licensor, with feedstock consumption in HPPO plant at international leading level. The part of PSE study results are being or will be applied to 4 HPPO industrial-scale production plants, with the total production capacity of 1.00 Mt/a and the number of HPPO plants and PO production scale ranking first in the world.

Key words: propylene oxide, propylene, hydrogen peroxide, feedstock consumption, process systems engineering

摘要：

符合环境友好、原子经济和可持续发展要求的过氧化氢法制环氧丙烷工艺技术反应系统的过程系统工程（PSE）研究能够取得良好的技术与经济效果。本文介绍了100～400kt/a的HPPO装置工艺流程PSE研究，降低149～720t/a过氧化氢原料消耗和184～889t/a丙烯原料消耗；在反应压力1.5～4.5MPa和反应温度39～95℃条件下，400kt/a的HPPO装置自动控制PSE研究，降低509～757t/a过氧化氢原料消耗和629～935t/a丙烯原料消耗；不同工艺参数，不同生产规模HPPO装置反应系统PSE研究，增加反应器总传热系数至2400～2800W/(m²·K)、延长催化剂使用寿命至4.8～5.0a。由此2014年中石化建成我国第一套100kt/a工业规模HPPO装置，产品优级品率100%，成为世界上第三个拥有工业规模HPPO全套技术专利商，物耗国际领先。截止2022年底，过程系统工程部分研究结果正在或即将应用在4套HPPO工业生产装置中，总产能1.00Mt/a，装置数量和生产规模居世界首位。

关键词: 环氧丙烷, 丙烯, 过氧化氢, 原料消耗, 过程系统工程

CLC Number:

TQ223.26

YANG Jianping. PSE for feedstock consumption reduction in reaction system of HPPO plant[J]. Chemical Industry and Engineering Progress, 2023, 42(S1): 21-32.

杨建平. 降低HPPO装置反应系统原料消耗的PSE[J]. 化工进展, 2023, 42(S1): 21-32.

Figures/Tables 21

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工艺参数	数值
工艺参数	100kt∙a^-1	200kt∙a^-1	300kt∙a^-1	400kt∙a^-1
催化反应器数量范围/台	2～6	2～8	4～10	6～12
设计催化反应器数量	4	4	6	8
第1反应器反应温度/℃	78	79	78	77
第2反应器反应温度/℃	65	70	73	73
第3反应器反应温度/℃	58	59	69	68
第4反应器反应温度/℃	50	50	63	64
第5反应器反应温度/℃	—	—	59	61
第6反应器反应温度/℃	—	—	53	57
第7反应器反应温度/℃	—	—	—	52
第8反应器反应温度/℃	—	—	—	49
催化反应器反应压力/ MPa	2.8	3.2	3.6	4.0
循环水/新鲜水流量比/ t∙t^-1	8.0	10.0	12.0	16.0

工艺参数	数值
工艺参数	100kt∙a^-1	200kt∙a^-1	300kt∙a^-1	400kt∙a^-1
催化反应器数量范围/台	2～6	2～8	4～10	6～12
设计催化反应器数量	4	4	6	8
第1反应器反应温度/℃	78	79	78	77
第2反应器反应温度/℃	65	70	73	73
第3反应器反应温度/℃	58	59	69	68
第4反应器反应温度/℃	50	50	63	64
第5反应器反应温度/℃	—	—	59	61
第6反应器反应温度/℃	—	—	53	57
第7反应器反应温度/℃	—	—	—	52
第8反应器反应温度/℃	—	—	—	49
催化反应器反应压力/ MPa	2.8	3.2	3.6	4.0
循环水/新鲜水流量比/ t∙t^-1	8.0	10.0	12.0	16.0

项目	数值
项目	100kt∙a^-1	200kt∙a^-1	300kt∙a^-1	400kt∙a^-1
过氧化氢原料消耗/kt∙a^-1	60.254	120.496	180.708	240.894
丙烯原料消耗/kt∙a^-1	74.432	148.849	223.227	297.575
节省过氧化氢原料/t∙a^-1	149	311	502	720
节省丙烯原料/t∙a^-1	184	384	621	889
常规总传热系数/W∙m^-2∙K^-1	1000~2000	1000~2000	1000~2000	1000~2000
常规催化剂寿命/a	3.9~4.1	3.9~4.1	3.9~4.1	3.9~4.1
改进后总传热系数/W∙m^-2∙K^-1	2490	2600	2710	2750
改进后催化剂寿命/a	4.9	4.9	4.9	5.0

项目	数值
项目	100kt∙a^-1	200kt∙a^-1	300kt∙a^-1	400kt∙a^-1
过氧化氢原料消耗/kt∙a^-1	60.254	120.496	180.708	240.894
丙烯原料消耗/kt∙a^-1	74.432	148.849	223.227	297.575
节省过氧化氢原料/t∙a^-1	149	311	502	720
节省丙烯原料/t∙a^-1	184	384	621	889
常规总传热系数/W∙m^-2∙K^-1	1000~2000	1000~2000	1000~2000	1000~2000
常规催化剂寿命/a	3.9~4.1	3.9~4.1	3.9~4.1	3.9~4.1
改进后总传热系数/W∙m^-2∙K^-1	2490	2600	2710	2750
改进后催化剂寿命/a	4.9	4.9	4.9	5.0

项目	数值
项目	400kt∙a^-1	400kt∙a^-1	400kt∙a^-1	400kt∙a^-1
过氧化氢原料消耗/kt∙a^-1	241.105	240.978	240.894	240.857
丙烯原料消耗/kt∙a^-1	297.835	297.678	297.575	297.529
节省过氧化氢原料/t∙a^-1	509	636	720	757
节省丙烯原料/t∙a^-1	629	786	889	935
常规总传热系数/W∙m^-2∙K^-1	1000~2000	1000~2000	1000~2000	1000~2000
常规催化剂寿命/a	3.9~4.1	3.9~4.1	3.9~4.1	3.9~4.1
改进后总传热系数/W∙m^-2∙K^-1	2400	2600	2750	2800
改进后催化剂寿命/a	4.8	4.9	5.0	5.0