The vacuum system is one of the more widely used equipments in the chemical production process. At present, the crude distillation tower and the methanol removal tower in the 200,000 t ethanol production plant of COFCO Bio-Energy (Yidong) Co., Ltd. all require the negative pressure generated by the vacuum system to ensure normal production. The vacuum level of the crude distillation tower is about -60 kPa, except methanol. Tower vacuum is around -45kPa. The vacuum system uses a hydraulic injection system. To achieve the above vacuum conditions, a large amount of primary water is required to perform the hydraulic injection. The energy consumption is high, the efficiency is low, and the operating cost is always high. The vacuum injection system is constructed as shown. The vacuum process is as follows: The vacuum process is completed by the vacuum circulation pump P401 (P401ABCDE) and the water jet (X402AB) and the wash tower T407. Two hydraulic injectors (X402AB) are connected to the rough tower and B tower (except the methanol tower) via the non-condensable gas outlets of the scrubber (T407A, B) and the rough tower (V401) and the B tower (V411), respectively. After circulating water P401 into the water jet (X402AB), the non-condensable gas in the two towers is taken away, the circulating water returns to the water tank, so that the rough tower and the B tower are in a vacuum state, and the required vacuum pressure is adjusted by emptying. The valve regulates the pressure constant. During production, the decantation tower needs to be opened at the same time to the air separation device for the instrument air line as an emergency backup gas source for the methanol plant. The air supply shut-off valve PSV-0104 for the air pressure station will be moved to the new gas source. In the pipeline, a manual shut-off valve is added before and after the PSV-0104 valve for the methanol meter air buffer tank. The instrument air buffer tank inlet pipe (PSV-0104) was replaced with a manual shut-off valve, and a check valve was added to prevent the meter air from falling back. When the instrument air of the air compressor station fails, when the air pressure of the instrument is too low, it is automatically switched to the air separation device to provide air for emergency, ensuring the safe and stable continuous production of the device. The working principle after the transformation is shown in Fig. (2) The air compressor outlet pressure of the air separation unit is 0.52 MPa, which is lower than the normal instrument air 0.7MPa, but it can meet the requirements of the control valve on the air source pressure, in order to prevent the air and space compression of the instrument. The air is connected to each other. After the purification system, a check valve is added to the gas supply pipeline of the meter buffer tank. The hand-cut valve is added before and after the PSV-0104 shut-off valve to facilitate daily inspection, troubleshooting and other unexpected situations. When the instrument buffer tank inlet pressure 0.5MPa, PSV-0104 shut-off valve automatically shuts down to return to normal gas supply. IV. Operation effect after instrument air reformation Shenhua Wuhai Energy Xilaifeng Coal Chemical Company's instrument air reformation at the methanol plant After the transformation of the instrument air fault at the air compressor station occurred, the air source of the air separation unit instrument was automatically put into operation in time. This avoids the accident of methanol plant shutdown, greatly improves the safety and stable operation of the methanol plant, and brings greater economic efficiency to the methanol plant. Technological transformation 1 Equipment management and maintenance 4 circulating water pumps and methanol towers open one Circulating water pumps can reach the vacuum required by the process. In order to achieve the required vacuum level of about -60 kPa for normal production, except for the -45 kPa methanol tank, four 30 kW vacuum circulation pumps need to be turned on at the same time to achieve continuous operation. The efficiency of the system is extremely low, and it takes more than two hours after each startup to reach the desired degree of vacuum. With the increase of the service life, the performance of the vacuum circulating water pump and the hydraulic ejector has been reduced. In order to ensure the continuous and stable operation of the production, five vacuum circulating pumps are required to be turned on at the same time, resulting in a great waste of electrical energy and at the same time, due to the Aging, the degree of vacuum generated by jet pumps has declined, and the impact on production has become increasingly apparent. The initial design idea of ​​the hydraulic injection system in use is to return the water from the hydraulic injector to the circulating water tank on the first floor, and then recycle it through the pump to save water. However, in the actual production process, the temperature of the water passing through the hydraulic ejector and returning to the circulating water tank has undergone great changes, and the water temperature in the circulating water tank has continuously increased, causing the system vacuum degree to gradually deviate from the normal parameters until it cannot be satisfied. Production requirements. In order to achieve a good spray effect, it is necessary to continuously discharge the high-temperature water in the circulating water tank and then replenish a large amount of primary water, resulting in a waste of water. After measuring the entire vacuum system, the amount of water discharged once per hour amounts to 15 m 3 per hour. External drainage 1.26 million m3. In the production process, there are many impurities in the production equipment. These impurities are in direct contact with the circulating water in the hydraulic injector, so that these impurities are entrained by the ejector water back into the circulating water tank. This part contains impurities. The circulating water has a certain corrosion effect on the circulating water tank, vacuum circulating water pump and carbon steel pipe with Q235 material. The existing spray tank has been corroded with multiple leaks, and repairs are required every year for overhaul. Some of the vacuum circulating water pumps have been used. Flow components are also damaged from time to time, and operation and maintenance costs are high. Because these equipments are located in the Class A explosion-proof zone of the rectification section, it brings great difficulty and safety hazards to the hot work of overhaul. The principle of transformation is to make the vacuum level of the crude distillation tower reach -60 kPa without changing the original process flow, except for the vacuum degree of the methanol tower reaching -45 kPa. Meanwhile, the time required from the start of the entire system to achieve the above process index, from The 2h before the transformation was shortened to within 40min. Reducing production costs, realizing the goal of tapping potential, reducing consumption, and saving energy and reducing emissions. Based on the above requirements, after investigation and analysis, it was decided to adopt a water ring vacuum pump instead of a hydraulic injector for the vacuum system transformation. The water ring vacuum pump is a new series of energy-saving products developed by Siemens in Germany in the late 1970s. It features simple structure, reliable work, safety and convenience, and high durability. It can pump corrosive and explosive gases and sodas containing particles. The mixture, which has a small footprint and energy saving, is more advantageous for the recovery of active ingredients in the extraction and concentration process. The water ring vacuum pump was selected based on the performance parameters of the original hydraulic injector and the working conditions of the crude distillation tower and the methanol tower in operation. According to the amount of gas and non-condensable gas flashed from the two towers and from the establishment of the vacuum to the required vacuum time, a water ring vacuum pump with 2BV6161-0HE 15kW is used in addition to the methanol tower, and the crude distillation tower is selected from 2BE1 203- 0HE22KW two vacuum pumps, each type of vacuum pump are added as a standby machine. After the reformation of the vacuum system, the water ring vacuum pump directly extracts the non-condensable gas after washing by the scrubber (T407AB), and the non-condensable gas is discharged to the outside through the pump outlet drain line to form a vacuum between the two towers. The vacuum degree is constant or passes. The pneumatic valve connected to the atmosphere of the system regulates. The vacuum pump is equipped with a cavitation protection device to ensure stable operation under high vacuum, avoiding the generation of cavitation and its damage to the pump body; simple design features to maximize the technical transformation of equipment management and maintenance 1 ç± mixed-flow pump impeller optimization Li An Yue Honghao flow pump impeller, extend the reboiler operation cycle. Guangxi COFCO Biomass Energy Co., Ltd. is a company that produces fuel ethanol from cassava. The production of cassava contained impurities (grit, woven fabrics, etc.), and it was clogged and severely worn on the subsequent distillation equipment. Especially for the reboiler heat transfer tubes of each tower, the heat exchange tubes were easy to clog and restrict production. . For this purpose, by optimizing the impeller of the mixed-flow pump, the output efficiency of the pump is increased, and the operating cycle of the reboiler is prolonged. In production, the reboiler material is forced to circulate the kettle liquid through the tower tank circulation pump on the tube course, and exchange heat with the medium in the shell side to achieve the purpose of heating the medium of the reboiler. Because there are many sediments and weaving materials in the raw material, the raw material in the distillation (mature mortar) contains more impurities, and the knit fabric enters the reboiler heat exchange tubes and is easily coked and hinders the advancement of the kettle liquid. Less than 20 days, each heat exchange tube is blocked by debris, which directly affects the amount of feed and heat exchange effect, and restricts the output. The analysis believes that by increasing the head of the circulating pump in the heat exchange unit, the condition of the reboiler clogging caused by insufficient pump output can be improved. This method is feasible after testing. Speed ​​730r/min, impeller diameter 570mm. The impeller is the core component of the centrifugal pump, directly determines the performance and efficiency of the pump. When the rotation speed is constant, the pump head, flow rate and shaft power will change after the impeller outer diameter is cut or enlarged. The components are reduced and the maintenance and maintenance are simple; the bearing is a grease-lubricated roller bearing with an imported heavy-load structure, and its B-10 design class has a service life of more than 100,000 hrs. There is no need to replace grease and maintenance within two years of operation. Centrifugally cast special stainless steel bushings are especially resistant to wear, protect the shaft from wear and corrosion, and are easy to replace. After the transformation, the normal operation of the vacuum system at the same time open two 22kW vacuum pumps and a 15kW vacuum pump, the total power consumption of 59kW/h, compared to the need to open five circulating water pumps before the transformation, total power consumption of 150kW/h to save 91kW /h; The vacuum system water consumption has been reduced from 15m3/h to 5.4m3/h, saving 9.6m3/h. The annual cost savings totals about 650,000 yuan. In addition to saving water and electricity costs, equipment maintenance costs and maintenance personnel's workload have been correspondingly reduced. The reduction of effluent discharge has also greatly eased the pressure of sewage treatment. The operating cost of energy consumption and maintenance costs for the hydro-jet vacuum system used in alcohol distillation has been high, and after replacing the water jet with a water ring vacuum pump, it can meet the production requirements and realize the purpose of tapping potential, reducing consumption, and saving energy and reducing emissions. The energy-saving effect is obvious, and the investment cost can be recovered in a short period of time. 1箢Equipment management and maintenance By measuring and optimizing the gap between the front impeller and the pump casing, it is determined that the diameter of the impeller wheel is increased from the original 570mm to 608mm, and the lift can be increased by 4m. After the impeller is optimized, the calculation is recalculated. The existing motor can satisfy the cycle. Pump operation requirements, circulation pump put into use, on-site monitoring of motor operation data is stable. Through the optimization of the impeller, the lift of the circulation pump is increased, the number of shutdowns caused by blockage of the reboiler due to lack of pump output is reduced, and the period of operation of the reboiler is prolonged, from the original cleaning of 20 to 30 days to 50 to 60 days of cleaning. , Reduce the labor intensity of employees and extend the equipment operation cycle. Reducing the steam consumption for restarting the reboiler after shutting down the machine: It will be cleaned once in the first 25 days of the renovation, and it will take 14.6 times per year; it will be cleaned once in 55 days after the renovation, and only 6.6 times per year. After the renovation, the reboiler can be reduced by 8 times. After each shutdown, the reboiler is restarted and then turned on. It consumes 185 tons of steam. According to 130 yuan per ton of steam, the annual savings can be 192,400 yuan. Improve pump output efficiency and reduce lost work. [Editor Wang Qi]
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Reformation of alcohol distillation vacuum system
Core Tip: The vacuum system is one of the more widely used equipments in the chemical production process. At present, the crude distillation tower and the methanol removal tower in the 200,000 t ethanol production plant of COFCO Bio-Energy (Qiandong) Co., Ltd. all require the negative pressure generated by the vacuum system to ensure normal production. The vacuum level of the crude distillation tower is about -60 kPa, except methanol.