催化余热锅炉智能水质分析系统的开发与应用

Development and application of intelligent water quality analysis system in catalytic waste heat boiler

石化催化余热锅炉多依赖人工分析化验提供水汽分析数据作为运行调整支撑,现已无法满足减排降耗对水汽过程监督的高质量要求。针对天津石化2#催化装置产汽单元点位多且相对分散的特点,结合水汽检测需求,按照“机器代人、一机多样、多点多参数”的思路开发智能水质分析系统,采用实验室标准规范的检测方法,实现了在装置现场的自动取样和连续分析,提高了水质化验分析的频次和质量。智能水质分析系统可代替两名实验室人员,解决了分析人员不足与高质量运行对水质分析需求高的矛盾,每年节省100万元以上的水汽分析化验成本。通过同步进行信息化集成、软测量开发和智能化控制,锅炉排污率可从3%~5%降至1%,年减排效益在500万元以上。智能水质分析系统为催化装置实施余热锅炉减排增效、水汽精确调整提供了低成本的水质分析化验数据支撑。

The water vapor analysis data as a support of operational adjustment in petrochemical catalytic waste heat boilers often relies on manual analysis,which can no longer meet the high-quality requirements of water vapor pro⁃cess supervision for emission and consumption reduction.Considering the multiple and relatively dispersed steam production units of 2#catalytic unit in Tianjin Petrochemical Corporation,and combing with the needs of water and steam detection,an intelligent water quality analysis system was developed based on the concept of“machine substi⁃tution,multiple samples in one machine,multiple units and parameters”.The testing methods of this system all ad⁃opted laboratory standards,which realized automatic sampling and continuous analysis in the device site,improved the frequency and quality of water quality analysis.The intelligent water quality analysis system could replace two laboratory technicians,solving the contradiction between the shortage of analysts and the high demand for water qual⁃ity analysis in high-quality operation,and saving more than 1 million yuan in water vapor analysis and testing costs annually.By synchronously integrating information technology,developing soft sensors,and implementing intelligent control,the boiler discharge rate could be reduced from 3%-5%to 1%,with an annual emission reduction benefit of over 5 million yuan.The intelligent water quality analysis system could provide low-cost water quality analysis data as a support of precise adjustment,reducing emissions and increasing efficiency in catalytic waste heat boiler.