Development and Catalytic Cracking Performance of Ultrastable Y Zeolite Rich in Secondary Pores

A novel ultra-stable zeolite, NSZ, rich in secondary pores was developed through the combination of gas-phase andmild hydrothermal methods. This zeolite was successfully tested in an industrial setting for the first time in the world. The porestructure characteristics of the NSZ zeolite prepared for industrial use were analyzed and characterized using BET. The resultsindicate a significant increase in the secondary pore volume of NSZ zeolite compared to the existing ultra-stable zeolite HSZ-5, which is produced through a conventional gas-phase method. The average secondary pore volume to total pore volume ratioin NSZ zeolite was found to be 58.96% higher. The catalytic cracking performance of NSZ zeolite was evaluated. The resultsshowed that the NSC-LTA catalyst, with NSZ as the active component, outperformed the HSC-LTA catalyst with HSZ-5 zeolitein terms of obtaining more high-value products (gasoline and liquefied petroleum gas) during the hydrogenated light cycle oilprocessing. Additionally, the NSC-LTA catalyst showed a significant improvement in coke selectivity.

A Hybrid Algorithm Based on Differential Evolution and Group Search Optimization and Its Application on Ethylene Cracking Furnace

To find the optimal operational condition when the properties of feedstock changes in the cracking furnace online,a hybrid algorithm named differential evolution group search optimization(DEGSO) is proposed,which is based on the differential evolution(DE) and the group search optimization(GSO).The DEGSO combines the advantages of the two algorithms:the high computing speed of DE and the good performance of the GSO for preventing the best particle from converging to local optimum.A cooperative method is also proposed for switching between these two algorithms.If the fitness value of one algorithm keeps invariant in several generations and less than the preset threshold,it is considered to fall into the local optimization and the other algorithm is chosen.Experiments on benchmark functions show that the hybrid algorithm outperforms GSO in accuracy,global searching ability and efficiency.The optimization of ethylene and propylene yields is illustrated as a case by DEGSO.After optimization,the yield of ethylene and propylene is increased remarkably,which provides the proper operational condition of the ethylene cracking furnace.

Estimating the Operation Status of Steam Cracking Furnace Using Numerical Simulation with Combustion Models

An accurate and complete geometric model was constructed to simulate the combustion, flow and temperature environment in the radiant section of the steam cracking furnace. Simulation of flow and radiation status has utilized the standard k-ε model and P1 model. The finite-rate/eddy-dissipation (finite-rate/ED) combustion model and non-premixed combustion model were both used to simulate accurately the combustion and the operation status of the steam cracking furnace. Three different surfaces of the steam cracking furnace were obtained from the simulation, namely:the flue gas temperature field of the entrance surface in long flame burners, the central surface location of tubes, and the crossover section surface. Detailed information on the flue gas temperature and the mass concentration fraction of these different surfaces in the steam cracking furnace can also be obtained by the simulation. This paper analyzed and compared the simulation results with the two combustion models, estimated the operation status of the steam cracking furnace, and reported that the finite-rate/ED model is appropriate to simulate the steam cracking furnace by comparing key simulation data with actual test data. This work has also provided a theoretical basis for simulating and operating the steam cracking furnace.

Coupled simulation of recirculation zonal firebox model and detailed kinetic reactor model in an industrial ethylene cracking furnace

A coupled system simulating both firebox and reactor is established to study the naphtha pyrolysis in an industrial tubular furnace.The firebox model is based on zone method including combustion,radiation,and convection to simulate heat transfer in the furnace.A two-dimensional recirculation model is proposed to estimate the flow field in furnace.The reactor model integrates the feedstock reconstruction model,an auto-generator of detail kinetic schemes,and the reactor simulation model to simulate the reaction process in the tubular coil.The coupled simulation result is compared with industrial process and shows agreement within short computation time.

Multi-objective modeling and optimization for scheduling of cracking furnace systems

Cracking furnace is the core device for ethylene production. In practice, multiple ethylene furnaces are usually run in parallel. The scheduling of the entire cracking furnace system has great significance when multiple feeds are simultaneously processed in multiple cracking furnaces with the changing of operating cost and yield of product. In this paper, given the requirements of both profit and energy saving in actual production process, a multi-objective optimization model contains two objectives, maximizing the average benefits and minimizing the average coking amount was proposed. The model can be abstracted as a multi-objective mixed integer non- linear programming problem. Considering the mixed integer decision variables of this multi-objective problem, an improved hybrid encoding non-dominated sorting genetic algorithm with mixed discrete variables （MDNSGA-II） is used to solve the Pareto optimal front of this model, the algorithm adopted crossover and muta- tion strategy with multi-operators, which overcomes the deficiency that normal genetic algorithm cannot handle the optimization problem with mixed variables. Finally, using an ethylene plant with multiple cracking furnaces as an example to illustrate the effectiveness of the scheduling results by comparing the optimization results of multi-objective and single objective model.

A New Mathematical Simulation Approach for Thermal Cracking Furnace Studies

Thermal cracking of hydrocarbons for olefin production is normally carried out in long reactor tubes suspended in a large gas fired furnace. In this paper, a coupled furnace-reactor mathematical model based on a computational fluid dynamics (CFD) technique is developed to simulate the complex fluid dynamics phenomena in the thermal cracking furnace. The model includes mass transfer, momentum transfer, and heat transfer, as well as thermal cracking reactions, fuel combustion and radiative heat transfer. The rationality and reliability of the mathematical model is confirmed by the approximate agreement of predicted data and industrial data. The coupled furnace-reactor simulation revealed the details of both the transfer and reaction processes taking place in the thermal cracking furnace. The results indicate highly nonuniform distribution of the flue-gas velocity, concentration and temperature in the furnace, which cause nonuniform distribution of tube skin temperature and heat flux of the reactor tubes. Profiles of oil-gas velocity, pressure, temperature and product yields in the lengthwise direction of the reactor tube are obtained. Furthermore, in the radial direction steep velocity and temperature gradients and relatively slight gradients of species concentration are found. In conclusion, the model can provide more information on the fluid dynamics and reaction behavior in the thermal cracking furnace, and guidance for the design and improvement of thermal cracking furnaces.

U-model Enhanced Dynamic Control of a Heavy Oil Pyrolysis/Cracking Furnace

This paper proposes a case study in the control of a heavy oil pyrolysis/cracking furnace with a newly extended U-model based pole placement controller(U-PPC). The major work of the paper includes: 1) establishing a control oriented nonlinear dynamic model with Naphtha cracking and thermal dynamics; 2) analysing a U-model(i.e., control oriented prototype) representation of various popular process model sets; 3)designing the new U-PPC to enhance the control performance in pole placement and stabilisation; 4) taking computational bench tests to demonstrate the control system design and performance with a user-friendly step by step procedure.

Strategy of changing cracking furnace feedstock based on improved group search optimization

The scheduling process of cracking furnace feedstock is important in an ethylene plant. In this paper it is described as a constraint optimization problem. The constraints consist of the cycle of operation, maximum tube metal temperature, process time of each feedstock, and flow rate. A modified group search optimizer is proposed to deal with the optimization problem. Double fitness values are defined for every group. First, the factor of penalty function should be changed adaptively by the ratio of feasible and general solutions. Second, the "excellent" infeasible solution should be retained to guide the search. Some benchmark functions are used to evaluate the new algorithm. Finally, the proposed algorithm is used to optimize the scheduling process of cracking furnace feedstock. And the optimizing result is obtained.

FAILURES AND THE LIFE OF FURNACE TUBES

It is showed after the furnace tubes serviced for 8-10 years that the density of damage in the HAZ (heat affected zone) of the weld has higher than in parent metals, though the depth of damage is not equal to. By the test of creep crack growth, it is also acquired that under same mechanic parameter C* (t), the rate of creep crack growth in the HAZ is more than twice as fast as in parent metals. Two mechanisms (overheating and thermal shock) of failure occurred in an accident are presented. The stress of thermal shock is analyzed, in which the change of the elasticity modulus with the radius ET = /(r) is considered. Based on it, the safety region of the thermal shock is obtained. Finally, two sets of curves for the safe life are suggested which can facilitate to estimate the remaining life of HK-40 or HP-Nb tubes by their creep rupture data.

Progress of Modern Pyrolysis Furnace Technology

This paper presents the fundamentals of thermal pyrolysis and discusses the modern ethylene furnace technology and its design trends. Technip’s proprietary SPYRO? program is discussed for prediction of hydrocarbon cracking.

乙烯绿色低碳生产技术进展

科技与产业的有效结合推动乙烯工业的绿色低碳发展。从装置结构、涂层材料、动力供应、原材料等方面综述了乙烯绿色低碳生产技术进展。提出通过炉管强化传热技术、炉管涂层技术与新型炉管材料的应用优化裂解炉热效率;有机框架材料等新型分离材料具有优化乙烯分离过程的潜力;可再生能源装机和消纳能力的提高,为乙烯装置的电气化提供了绿色基础;采用生物质、废塑料、二氧化碳等原料替代化石原料将从原料端实现乙烯生产的绿色化。此外,生产过程智能化以及用能清洁化等也将在减碳方面发挥重要作用。

裂解炉五开模式对急冷系统的运行影响及优化措施

独山子石化公司为降低220 kt/a乙烯装置能耗,根据乙烯装置用能分析,结合裂解炉和裂解气压缩机的现行工况,提出将裂解炉运行模式由“6开1备”改为“5开1停1备”。为选择出裂解炉“5开1备1停”的最优运行模式,分5个阶段进行工况测试。并在乙烯装置短停开工后进行测试验证,通过对比2号汽油分馏塔(C-103)的设计参数,优化调整并固化该塔的裂解气负荷与塔中部回流、汽油回流量的关系,确保了急冷油黏度和急冷水品质稳定受控。通过裂解炉运行模式攻关,快速实现了乙烯装置节能降耗的目标。

球团配加钒钛磁铁精矿试验研究

为充分利用哈密地区钒钛磁铁精矿,进行了配加钒钛磁铁精矿球团试验及球团矿冶金性能试验。试验结果表明:钒钛精矿球团生球爆裂温度均大于600℃,可满足竖炉生产要求;与普通精矿相比,钒钛磁铁精矿需要更高的焙烧温度,本次试验将焙烧温度提高了50℃左右,但球团矿抗压强度仍略偏低;成品球团矿还原膨胀率在8.19%~12.09%;成品球团矿900℃还原度在54.50%~63.20%。

关于美国西方化学技术EDC裂解炉炉管结焦问题的探讨

针对某个采用美国西方化学技术的EDC裂解装置,分析了在高负荷运行条件下影响EDC裂解炉炉管结焦形成的主要7个相关因素,并总结了相应的控制措施。通过合理的控制,达到了延长裂解炉良性运行周期、控制氯乙烯产品品质及相关单耗的目的。

大型乙烯裂解炉用低NO_(x)燃烧器的结构优选

随着大能力大型化裂解炉的不断发展,国内首台单炉膛20万吨/年产能乙烯裂解炉对燃烧器提出了更高的设计要求,在稳定燃烧的同时还要满足特定的工艺要求和严苛的环保要求。采用CFD技术和热态试验方法优选新型乙烯裂解炉用低NO_(x)燃烧器,通过数值分析方法研究不同底部与侧壁供热比(底侧比)下裂解炉内的燃烧状态(火焰形状、火焰长度、炉内温度分布及NO_(x)排放量等),结果表明:在底侧比为70:30时燃烧状态最优,炉膛内温度分布均匀且满足工艺要求和环保要求。在热态试验炉上对最终设计工况(底侧比72:28)进行热态试验,结果显示:炉内燃烧状态良好,温度分布均匀且满足热通量曲线,NO_(x)排放量也较低。

关于EDC裂解装置TLE结焦及换热控制问题的探讨

针对采用美国西方化学技术的EDC裂解装置,分析了在高负荷(设计负荷的105%~110%)运行条件下,影响TLE管侧内壁结焦及换热的主要因素,并总结了对应的控制措施,实施后达到了延长EDC裂解装置良性运行周期的目的。

制氢转化炉上尾管加强接头频繁开裂原因分析及对策

某炼化企业制氢转化炉2010年升级改造后,不同炉管的加强接头与上尾管焊口位置先后出现了5次开裂,造成制氢装置非计划停工。通过对运行环境、高温氢腐蚀、热膨胀应力、结构应力、异种钢焊接、弹簧支吊架等多方面开展深入分析,发现泄漏的原因主要是加强接头与上尾管连接焊缝局部高应力区发生了应力松弛开裂,同时,工艺参数控制不严格加遽了开裂速度。2021年通过实施炉管材质升级、稳定工艺运行环境、严控施工质量等措施,没有再出现过开裂的情况,彻底消除了炉管运行过程中的安全隐患,保障了设备的本质安全和装置的长周期运行。

合成氨单元开工加热炉炉管开裂失效分析

为了查明合成氨单元开工加热炉炉管发生开裂失效的原因,采用多种检测方法对失效炉管进行了分析。根据裂纹形貌分析、材质化学成分分析、金相组织分析和裂纹填充物能谱分析等结果可以得出,失效炉管两处开裂的原因分别是湿硫化氢破坏和异种金属混入,炉管上部外壁的密集蚀坑则是由烟气硫酸露点腐蚀所致,基于炉管失效原因分析,提出了针对性的预防措施。

基于双向多步预测的炉管温度场重构方法

针对高温封闭的乙烯裂解环境下裂解炉炉管温度感知难的问题,提出一种融合机理和长短记忆神经网络(Long Short-Term Memory,LSTM)的裂解炉炉管表面温度场重构方法。该方法首先基于计算流体力学仿真平台fluent构建乙烯裂解反应机理模型,用来描述裂解反应与炉管温度的数学关系,然后利用工业现场数据对机理模型进行数值矫正和过程参数求解,进一步基于皮尔逊相关系数确定适用性强的主要过程参数,在此基础上,设计卷积块注意力模块(Convolu tional Block Attention Module,CBAM)对反映裂解反应与炉管温度关系的主要过程参数的特征进行提取,最后基于遗传算法和LSTM网络设计双向多步预测模型(GA-BMLSTM)对炉管温度分布进行预测。实验结果表明该方法对炉管温度场的重构有较高的准确率和较强的适用性。

粒化高炉矿渣粉沥青混合料路用性能研究

为了拓宽废弃粒化高炉矿渣的利用途径,文中采用不同比例的粒化高炉矿渣粉代替矿粉后,进行AC-13C沥青混合料配合比设计,并对其高温稳定性、水稳定性和低温抗裂性等路用性能进行对比分析。结果表明,将粒化高炉矿渣粉作为填料应用于沥青混合料中,提高了沥青混合料的高温稳定性和高温水稳定性,但降低了其低温水稳定性。当粒化高炉矿渣粉替代率不超过50%时,沥青混合料的低温抗裂性可以得到提高,而当粒化高炉矿渣粉替代率超过75%时,沥青混合料的低温抗裂性降低。综合分析结论得出,AC-13C沥青混合料的粒化高炉矿渣粉替代率不超过50%。