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| 2024, Vol. 36,No. 2 Published:25 June 2024 |
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Application of 3D Model based on Digital Delivery
Li Lei, Li You, Gao Xueying
2024, 36 (2):
1-5.
This article analyzes the characteristics and current
application status of 3D model based on digital delivery, and proposes the
technical difficulties and challenges faced by the application of 3D models. It
focuses on the research on lightweight technology, post-processing technology
and standardizing technology for 3D models in typical scenarios in refineries, and
explores the best practice route of lightweight model and model transformation
based on digital delivery, which is verified in the intelligent ethylene project
of Zhongke (Guangdong) Refinery and Petrochemical Company Limited. The
application scenarios of 3D models for refineries are further explored, and the
transformation requirements of typical scenarios for 3D models are put forward,
providing a wider application scope for 3D models.
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Optimization of Process Design for Front-end Cold
Box, Demethanizer and Methanation System
Cheng Guangwei
2024, 36 (2):
6-10.
Through
the optimization and improvement of the reflux process of demethanizer and the
selection of methanation catalyst during the process package design of ethylene
plant, the purchase of low-temperature rotary equipment is eliminated, the
steam consumption of hydrogen methanation reaction system is reduced, and the
operation difficulty of operators is lowered, so as to achieve the purposes of
reducing the construction investment and operation energy consumption and
ensuring the long-term stable operation of the ethylene plant.
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Operation of Arsenic
Removal System for Naphtha after Modification for Hidden Danger Treatment
Zhao Xianglong, Zhou Hongbo, Li Xiang, Meng Fei, Zhao Jingjing
2024, 36 (2):
11-14.
PetroChina Dushanzi Petrochemical Company has increased the processing proportion of Mahu crude oil. Due to the high arsenic content of Mahu crude oil, the arsenic content of the naphtha produced exceeded the standard, leading to risks such as the poisoning of catalysts for and gasoline hydrogenation reactors in the ethylene plant, the shortening of catalyst life and the poor quality of hydrogenation products. The arsenic removal system was not allowed to be put into use because there were some non-compliance problems and operational safety risks, so local
modification was required for the existing arsenic removal process and the
environmental non-compliance. After the modified arsenic removal system was put
into use, it was operated in compliance with relevant standards, and good
arsenic removal effect was achieved.
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Influence of Condensating-fractionating Tower Design
on Separation Process of Demethanizer System
Ouyang Yimei
2024, 36 (2):
15-17.
The Low Energy Consumption
Technology (LECT) developed by SEI is studied in detail, the influence of
condensating-fractionating tower design on demethanizer system is analyzed, and
the demethanizer system is simulated and optimized. The results show that properly
reducing the temperature of condensating-fractionating tower can greatly reduce
the ethylene loss while improving the purity of hydrogen product. Maintaining
the overhead temperature of condensating-fractionating tower at about -122 °C can
ensure relatively high ethylene yield and hydrogen purity and keep the
consumption of cooling capacity within a reasonable range.
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Analysis on Abnormal Operation of Spent Caustic Oxidation Unit and the Preventive Measures
Kan Xiaojie, Tian Xiaolan, Wan Xiaoming, Chen Quan, Zhang Lixia
2024, 36 (2):
18-21.
This article elaborates on
the fluctuation of spent caustic oxidation unit
in ethylene plant, and analyzes the operating parameters of caustic wash tower and the sampling of caustic liquor and spent
caustic in each section of the caustic wash tower. Based on the sampling
results, the reasons for the fluctuation of spent caustic oxidation unit were analyzed, and it was determined
that the fluctuation mainly came from the black solid particles in the spent caustic of the 220 kt/a ethylene plant. Based on this, some corresponding
preventive measures were proposed.
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Cause Analysis and Countermeasures for Pressure
Difference Increase in Desulfurization Tank of Methanol Plant
Wang Zhe, Ding Yukui, Zhang Leilei, Luo Chunqing, Li Hong
2024, 36 (2):
22-24.
Methanol plant uses low pressure methane from
the cracking unit of ethylene plant as the raw material. There have been times
when the olefin content of the raw material was high, affecting the safe and
stable operation of the methanol plant. After replacing the desulfurizer in the
desulfurization tank of methanol plant by desulfurizer B with hydrogenation
capacity, the pressure difference gradually increased. Through field
verification and practical operation, low temperature hydrogenation technology
was used to effectively solve the bottleneck problem of pressure difference
increase in the desulfurization tank.
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Application of NMP and ACN in Butadiene
Extraction Unit
Song Shichao
2024, 36 (2):
25-30.
This
article introduces two butadiene extraction units constructed by a Chinese
company using NMP (N-methyl pyrrolidone) method and ACN (acetonitrile) method respectively.
By comparing the two units in terms of process characteristics, product quality
requirements, solvent extraction performance, plant economic benefits and investment,
it is discovered from the actual operating data of the two units that the butadiene
extraction unit using NMP method has the advantages of more reasonable and
shorter process flow, lower operation cost and more environmental-friendly NMP
solvent.
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Cause Analysis and
Countermeasures for Bottlenecks in Long Period Operation of Acetylene
Hydrogenation Reactors
Wang Junbin, Luo Lingli, Huang Bowei, Xiang Yun, Zhang Yun
2024, 36 (2):
31-36.
The acetylene hydrogenation reactor in the 220 kt/a ethylene plant of PetroChina
Dushanzi Petrochemical Company has two parallel reaction beds and adopts the
mode of "one in operation and one standby". The R-401A/B reactor
continued to use the catalyst A from the original manufacturer, and the
operation cycle was less than 10 months, failing to meet the 12 months required.
After replacing the catalysts in R-401C/D with new catalysts, it was found that
the green oil production increased significantly during operation, and the
initial operation cycle was only 3 months, failing to meet the 6 months required. The short operation cycle
of the reactor affects the ethylene increment. Also, when the reactor is switched
at the end of operation, the materials need to be discharged to the flare
system, resulting in material loss. Therefore, long operation cycle of reactor is
significant for improving the quality and efficiency of the unit and reducing
energy consumption.
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Key
Points of Maintenance for Cracking Gas Double Gate Valve and the Problem
Improvement
Chen Yakuan
2024, 36 (2):
37-40.
The operating environment
and strict process requirements of cracking gas switching valve make its
maintenance a key and difficult point in the industry. This paper elaborates on
the process characteristics of cracking gas switching valve and the selection
and use of switching valve, introduces the
structural characteristics and sealing principle of cracking gas double gate
valve, analyzes the key points of maintenance for cracking gas double gate
valve, lists the cases of faults caused by improper maintenance, and presents
some improvement measures for the maintenance problems.
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Coking in Cracking Gas
Compressor and the Countermeasures
Zhang Jiangping, Xie Ming
2024, 36 (2):
41-46.
Due to the special characteristics of the medium in cracking gas
compressor, coking and fouling will occur inside the compressor, so that the
compressor cannot be operated with design conditions, the compressor load will
decrease, and the ethylene plant will shut down in case of severe fouling. This paper presents
the phenomenon, causes and mechanism of coking, illustrates the hazards of
fouling in cracking gas compressor with examples, introduces the monitoring and
evaluation methods for coking during the operation of compressor, and analyzes a
series of physical and chemical countermeasures for coking and fouling in
cracking gas compressor.
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Analysis and Optimization of Anti-surge Valve Opening for Propylene
Refrigeration Compressors
Huang Xinyuan, Liu Houtao
2024, 36 (2):
47-53.
After the revamping and expansion of a 1
100 kt/a ethylene plant of SINOPEC, the energy consumption of propylene
refrigeration compressor unit exceeded the design value, and the heat loads of
each stage were mismatched. High liquid level was observed on the ethylene side
of ethylene product vaporizer. In order to lower the liquid level, an
appropriate opening was set for the anti-surge valve on the pipeline from the 4th stage to the 3rd stage of propylene refrigeration compressor to
increase the flow rate and temperature on the refrigerant side. However, this
method further increased the load of the propylene refrigeration compressor
unit, limited the further capacity expansion of the plant, and reduced the
margin of the anti-surge valve, bringing hidden danger of tripping. ASPEN PLUS
was used to build a propylene refrigeration compressor unit model from the process
point of view, and the process parameters of each stage and the heat loads
of each user were simulated and compared with design values. HTRI was used to
build an ethylene product vaporizer model from the equipment point of view. The
reasons for high liquid level were analyzed, and some optimization measures
were proposed based on the actual situations for reducing the opening of
anti-surge valve and the power consumption of propylene refrigeration
compressor unit.
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Cause Analysis and
Countermeasures for Oil Seal Coking in Cracking Gas Compressor Turbine
Xu Baoan, Song Zechen, Sun Yonghang
2024, 36 (2):
54-56.
During
normal operation, the shaft vibration at the high and low pressure ends of
cracking gas compressor turbine in the ethylene plant at PetroChina Liaoyang Petrochemical
Company fluctuated abnormally. By checking the process equipment and other
factors, it was determined that the abnormal vibration was caused by oil seal
coking. During unit maintenance, the oil seal structure at the high and low
pressure ends was analyzed, and isolation nitrogen was introduced into the oil
seal, thus fundamentally solving the problem of oil seal coking.
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Cause Analysis and Countermeasures for High
Liquid Level in
First Stage Suction Tank of Propylene Refrigeration Compressor
Yang Pan, Long Xianhuang, Liang Duo, Bai Zhonghui, Yang Zhinan
2024, 36 (2):
57-59.
This paper takes the propylene
refrigeration compressor system of an ethylene plant as an example, and
analyzes the problem that the liquid level in the first stage suction tank
continues to be high during actual operation. After field investigation and
discussion, it is concluded that the root cause of the difference between
design and actual operation is the internal leakage of the temperature control
valve on top of the first stage suction tank. During
the operation of the ethylene plant, such measures as making process
adjustment and installing a new pipeline for transporting hot propylene gas were taken to effectively solve this problem, thus ensuring
the safe, stable and long-term operation of the propylene refrigeration
compressor.
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Problems in Long-term Operation of Cracking Gas Compressor and the Countermeasures
Tian Xiaolan, Kan Xiaojie, Wan Xiaoming, Li Zhaolong, Wang Youheng
2024, 36 (2):
60-64.
The cracking gas compressor
in the 1.1 Mt/a ethylene plant of PetroChina Dushanzi Petrochemical Company is
a large unit with three cylinders and five stages. This article studies the
problems in the long-term operation of this compressor including liquid
entrainment in suction line, increased interstage pressure difference, interstage
corrosion and increased displacement of high-pressure cylinder. By analyzing
the insufficient capacity of the demister for interstage suction tank, the
accumulation of coke particles inside the tube bundle of interstage heat
exchanger, the high sulfur content of cracking raw materials and the severe
coking in the fifth stage, some countermeasures are taken. By taking
technological transformation measures, optimizing daily operation and adjusting
the injection amount of polymerization inhibitors, the operating efficiency of
the compressor is improved, thus ensuring the stable, long-term and efficient
operation of the compressor.
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Supervisor: China petrochemical corporation