Safety evaluation system and application of VOCs treatment engineering in industrial coating industry based on process simulation

doi:10.16085/j.issn.1000-6613.2025-0440

Abstract

Abstract:

In recent years, the frequent occurrence of safety accidents in VOCs treatment projects is due to the lack of targeted safety theory and method guidance, and the safety evaluation of related industries need to build. The industrial coating industry is one of the main emission sources of industrial VOCs. Therefore, according to the characteristics of VOCs treatment and emission in industrial coating industry, a VOCs treatment engineering safety evaluation system based on process simulation was proposed, including safety check list, HAZOP/risk matrix/LOPA analysis, shock wave overpressure calculation, and post-leakage analysis (Gaussian model +MATLAB). On the one hand, the introduction of Aspen process simulation reduced the evaluator's dependence on experience through "actual + simulation" HAZOP analysis, and also provided simulated data of risk boundary values and standard specified values to support quantitative analysis. On the other hand, the instantaneous response value of Aspen dynamic simulation parameter fluctuation to key indicators and the dynamic change rate over time could quantify the risk deviation and determine the reasonable range of system operation, which provided a basis for formulating emergency response plan and accident prevention measures. The proposed safety evaluation system was used to evaluate and apply typical process cases, and the results showed that the safety evaluation system could effectively identify potential safety hazards in VOCs treatment projects of industrial coating industry, and provide improvement suggestions to reduce the need for the number of evaluation personnel and experience. With the help of simulation results, the influence range of explosion and leakage accidents could be visually presented, which provided a basis for setting alarm value and determining reasonable operating range.

Key words: volatile organic compounds (VOCs), industrial coating industry, safety evaluation system, Aspen simulate, dynamic simulation

摘要：

近年来挥发性有机物（VOCs）治理工程的安全事故频发，原因在于缺乏针对性的安全理论和方法指导，需要构建相关行业的安全评价，工业涂装行业又是工业源VOCs的主要排放源之一。为此，根据工业涂装行业VOCs治理及排放特点，提出一种基于流程模拟的VOCs治理工程安全评价体系，体系包括安全检查表、HAZOP/风险矩阵/LOPA分析、冲击波超压计算、泄漏后果分析（高斯模型+MATLAB）。引入Aspen流程模拟，一方面通过“实际+模拟”进行HAZOP分析降低了评价人员对经验的依赖，也提供危险边界值、标准规定值的模拟数据支撑定量分析；另一方面Aspen动态模拟参数波动对关键指标的瞬时响应值以及随时间变化的动态变化率，使得风险偏差定量化，也确定了系统运行的合理范围，为制定应急响应计划和预防事故的措施提供依据。采用提出的安全评价体系对典型工艺案例进行了评价应用，结果表明该安全评价体系能有效识别工业涂装行业VOCs治理工程中的潜在安全隐患，并提供改进建议，降低安全评价方法对评价人员数量和经验的需求，并且借助模拟结果能直观呈现爆炸及泄漏事故的影响范围，为报警值的设定和确定合理的运行范围提供依据。

关键词: 挥发性有机物, 工业涂装行业, 安全评价体系, Aspen模拟, 动态仿真

CLC Number:

CHE Xinghao, LUO Chenhui, DUAN Dongquan, FENG Yajuan, CAO Junya, ZHANG Xianglan, XIE Qiang. Safety evaluation system and application of VOCs treatment engineering in industrial coating industry based on process simulation[J]. Chemical Industry and Engineering Progress, 2025, 44(8): 4741-4753.

车兴灏, 罗晨辉, 段东全, 冯雅娟, 曹俊雅, 张香兰, 解强. 基于流程模拟的工业涂装行业VOCs治理工程安全评价体系及应用[J]. 化工进展, 2025, 44(8): 4741-4753.

Figures/Tables 17

References 48

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序号	VOCs治理设施选址、布局、消防	是否符合	存在问题
1	设计单位是否具备相应行业专业甲级设计资质或环境工程（大气污染防治工程）专项乙级以上设计资质。
2	VOCs治理设备选址是否符合GB501870的地质条件、水文条件
3	VOCs治理设备选址是否位于最小频率风向的上风侧（GB501870）
4	VOCs治理区域是否按照GB50016进行厂房火灾分级
5	甲、乙类厂房和甲、乙、丙类仓库内的防火墙是否按照GB50016进行设计
6	VOCs治理区域厂房设置自动灭火系统时是否按照GB50016、GB55037、GB50160进行
7	VOCs治理区域与厂区内建筑的间距是否符合GB50016
8	需要采用防腐蚀材质的设备、管道和管件等的施工和验收应符合HG/T20229的相关规定。
	……

序号	VOCs治理设施选址、布局、消防	是否符合	存在问题
1	设计单位是否具备相应行业专业甲级设计资质或环境工程（大气污染防治工程）专项乙级以上设计资质。
2	VOCs治理设备选址是否符合GB501870的地质条件、水文条件
3	VOCs治理设备选址是否位于最小频率风向的上风侧（GB501870）
4	VOCs治理区域是否按照GB50016进行厂房火灾分级
5	甲、乙类厂房和甲、乙、丙类仓库内的防火墙是否按照GB50016进行设计
6	VOCs治理区域厂房设置自动灭火系统时是否按照GB50016、GB55037、GB50160进行
7	VOCs治理区域与厂区内建筑的间距是否符合GB50016
8	需要采用防腐蚀材质的设备、管道和管件等的施工和验收应符合HG/T20229的相关规定。
	……

序号	参数	引导词	偏差	原因	后果	已有安全措施	后果等级	现有频率	现有风险等级
1.1	风量	无	无风量	催化床层温度传感器误报警	系统停止，生产停止	床层设有两个温度传感器	S1	F1	1
1.2		无	无风量	PLC断电	系统停止，生产停止	配有备用发电机	S1	F4	4
1.3		低	低风量	催化床层堵塞	堵塞导致废气与催化剂床层接触不充分，VOCs排放不达标	尾气排放设有VOCs浓度检测仪	S3	F2	6
1.4		低	低风量	管路泄漏	VOCs泄漏，排放不达标甚至引发人员中毒	VOCs浓度检测设备	S4	F2	8
1.5		高	高风量	脱附风量过高	脱附风量过高，超过处理能力排放超标	风机故障报警装置	S3	F2	6
2.1	温度	高	催化床层温度过高	电加热故障	电加热异常升温，导致催化剂床层过热融化、着火，甚至爆炸	催化装置装有两枚热电偶,配有高低位温度警报	S5	F1	5
2.2		高	催化床层温度过高	VOCs脱附浓度过高	浓度过高导致床层过热高温融化、着火，甚至爆炸	脱附出气管道安装有 VOCs 浓度检测仪	S5	F1	5
2.3		低	催化床层温度过低	电加热故障	电加热故障，加热温度低，VOCs排放不达标	催化装置装有两枚热电偶,并配有高低位温度警报	S2	F1	2
2.4	温度	低	循环气温度低	补冷风机故障C0301，补冷过多	脱附温度不足，脱附不达标，导致VOCs超标排放	风机安装有故障报警；废气排放口配有浓度监测	S3	F2	6
3.1	压力	高	管路压力高	阀门误关	阀门受损，甚至管路破损泄漏	流量监测器	S4	F2	8
4.1	浓度	高	VOCs浓度过高	活性炭床层脱附，浓度波动	浓度过高导致床气体可能达到爆炸下限	催化装置装有两枚热电偶,并配有高低位温度警报，入口配有浓度检测装置	S5	F1	5
4.2	浓度	高	VOCs浓度过高	风机流量过低	浓度过高导致床气体可能达到爆炸下限，产生爆炸	风机安有故障报警，入口配有浓度检测装置	S5	F1	5

序号	参数	引导词	偏差	原因	后果	已有安全措施	后果等级	现有频率	现有风险等级
1.1	风量	无	无风量	催化床层温度传感器误报警	系统停止，生产停止	床层设有两个温度传感器	S1	F1	1
1.2		无	无风量	PLC断电	系统停止，生产停止	配有备用发电机	S1	F4	4
1.3		低	低风量	催化床层堵塞	堵塞导致废气与催化剂床层接触不充分，VOCs排放不达标	尾气排放设有VOCs浓度检测仪	S3	F2	6
1.4		低	低风量	管路泄漏	VOCs泄漏，排放不达标甚至引发人员中毒	VOCs浓度检测设备	S4	F2	8
1.5		高	高风量	脱附风量过高	脱附风量过高，超过处理能力排放超标	风机故障报警装置	S3	F2	6
2.1	温度	高	催化床层温度过高	电加热故障	电加热异常升温，导致催化剂床层过热融化、着火，甚至爆炸	催化装置装有两枚热电偶,配有高低位温度警报	S5	F1	5
2.2		高	催化床层温度过高	VOCs脱附浓度过高	浓度过高导致床层过热高温融化、着火，甚至爆炸	脱附出气管道安装有 VOCs 浓度检测仪	S5	F1	5
2.3		低	催化床层温度过低	电加热故障	电加热故障，加热温度低，VOCs排放不达标	催化装置装有两枚热电偶,并配有高低位温度警报	S2	F1	2
2.4	温度	低	循环气温度低	补冷风机故障C0301，补冷过多	脱附温度不足，脱附不达标，导致VOCs超标排放	风机安装有故障报警；废气排放口配有浓度监测	S3	F2	6
3.1	压力	高	管路压力高	阀门误关	阀门受损，甚至管路破损泄漏	流量监测器	S4	F2	8
4.1	浓度	高	VOCs浓度过高	活性炭床层脱附，浓度波动	浓度过高导致床气体可能达到爆炸下限	催化装置装有两枚热电偶,并配有高低位温度警报，入口配有浓度检测装置	S5	F1	5
4.2	浓度	高	VOCs浓度过高	风机流量过低	浓度过高导致床气体可能达到爆炸下限，产生爆炸	风机安有故障报警，入口配有浓度检测装置	S5	F1	5

参数	数值
进口风量/m³·h^-1	100000
进口温度/℃	25
VOCs（甲苯）浓度/mg·m^-3	400
单一吸附床层工作风量/m³·h^-1	25000
单一吸附床层结束吸附时出口废气浓度/mg·m^-3	4.36
脱附气流量/m³·h^-1	2500
脱附气温度/℃	80
脱附最高浓度/mg·m^-3	1985