Simulation of industrial Shell entrained flow bed by Aspen Plus

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

Abstract

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

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

CLC Number:

TQ545

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.

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.

Figures/Tables 17

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

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

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

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

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

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

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

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

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

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