环己烷精馏装置仿真培训系统的开发

The development of an emulation training system for the cyclohexane rectification equipment

化学工业的生产特点及其在安全环保方面的特别要求决定了企业员工培训和学校学生的实习都不允许在真实的生产装置上动手操作,解决这一难题的途径之一是开发具有真实工业场景、工艺过程和操作参数与实际装置高度接近的仿真培训系统。按照工艺和设备具有典型代表性的思路,选择以环己烷氧化制环己酮生产装置中的环己烷精馏为对象开发仿真培训系统,针对三效精馏和组分多的复杂工艺,采用序贯模块法开发了整个系统的仿真模型,将各个独立的模型设计成独立的模块,模块之间通过变量进行连通,模块的连接关系按工艺连接关系搭接,仿真对象的有关数据来源于实际生产装置的运行参数,保证仿真速度的实时性和外部特性的逼真。整个系统包括了环己烷精馏装置生产工艺仿真软件,计算机控制系统(DCS)的实时仿真和仿真操作评价系统,是对环己烷精馏装置的全系统仿真。系统中开发平台的各项功能,提供了一套完整的开放式仿真平台。通过使用证明该系统能够有效模拟环己烷精馏的工艺现象和工艺操作步骤,真实地反映装置的开停车、生产及事故状态的动态效果,同时对工艺装置的安全分析和应急处理训练提供了一个良好的平台,可满足培训操作工和学生的需要,也可用于生产工艺的优化、诊断和控制方案方面的研究。

The production characteristics,safety and environmental protection of chemical engineering have some special requirements.It usually forbids the practical operations on the real equipments for staff training and students＇ practice.One of the pathways to solve this difficulty is to develop an emulation training system which is similar to the real equipment in industrial scene,technical process and operation parameters.It is also necessary to choose a typical technology and equipment to develop.As a result,an emulation training system was developed for the cyclohexane rectification equipment in the cyclohexanone production process of cyclohexane oxidation.The emulation model of the whole system was developed using sequential modular method for triple-effect rectification and complicated techniques of components.The separate models were designed to be separate modules.The modules were connected with variables.The connection relations were built up according to the technical relations.The relative data of the emulation objects arose from the operation parameters of the real equipments.The real time and the external characteristics of realistic of emulation speed were assured by the effective calculation approach. The system contains the emulation software of cyclohexane rectification technology,real time emulation of DCS and emulation operation judgment system.It is whole-system emulation for the cyclohexane rectification equipment.Every function in the platform has been developed and provides a perfect open emulation platform.The system was proved to simulate cyclohexane rectification phenomena and operation steps effectively.A dynamic effect was applied in the emulation system to reflect the start up and shut down of the equipment,production and accident state faithfully.A good platform for safety analysis of technical equipment and emergency treatment training has been provided.The system can not only satisfy the needs of training operators and students,but also apply in the optimization and diagnosis of processing techniques,the study of controlling schemes.