乙二醇合成工藝中的物料衡算和熱量衡算計算案例綜述1.1物料衡算1.1.1物料衡算遵循的原則物料衡算是用來研究某一體系內進出物料量及組成的變化。進行物料衡算時，首先必須確定衡算的體系。對一般體系，均可表示為（假設無泄漏）：假設系統無泄漏，有：=FIN-FOUT+GR-CR（3-1）當系統無化學反應發生時，有：=FIN-FOUT（3-2）在穩定狀態下，有：=FIN-FOUT=0（3-3）注:Fin——進入系統的物料流率；Fout——流出系統的物料流率；GR——反應產生物料速率；CR——反應消耗物料速率。1.1.2系統物料衡算本工藝項目的系統總物料衡算結果如下表5-1及表5-2所示。表5-1流入系統物料匯總ITEMIN一氧化碳一氧化氮甲醇氧氣氫氣溫度(℃)2025252525壓力(bar)11555氣相分率11011摩爾流量(kmol/h)1403.9950.00540003602613.766質量流量(kg/h)39322.4610.15128168.6411519.5685269.038總流量(kg/h)184283.857表5-2流出系統物料匯總ITEMOUT甲醇廢水碳酸二甲酯1,2丁二醇乙二醇溫度(℃)6425674060壓力(bar)111.06255氣相分率00000摩爾流量(kmol/h)1282.237719.99731.89212.186598.723質量流量(kg/h)41073.48612970.9553233.1001098.27137161.811總流量(kg/h)95537.623AspenPlus的模擬結果如下：表5-3草酸二甲酯合成工段（一）項目123456溫度℃252051.8454554壓力bar111555氣相分率11100.8281摩爾流量(kmol/h)0.0053607420.08740007780.0926304.336質量流量(kg/h)0.1511519.568225121.452128168.64236641.17234059.417體積流量(cum/h)0.1248767.391199927.793162.73933928.7233820.255焓Gcal/hr0-0.013-50.933-221.958-62.9-51.02質量流量kg/hr草酸二甲酯002.65E-17000亞硝酸甲酯009762.42109762.42197664.513一氧化氮0.15064813.349064813.49921604.536一氧化碳005489.81305489.8135489.927碳酸二甲酯002.49302.4930甲醇0061008.936128168.6461008.93625259.954氧氣011519.5680011519.5680水007.13E-05000.047氮氣0084040.44084040.4484040.44摩爾流量kmol/h草酸二甲酯002.24E-19000亞硝酸甲酯00159.9990159.9991599.999一氧化氮0.00502160.00302160.008720.004一氧化碳00191.9920191.992191.996碳酸二甲酯000.07200.0720甲醇001904.02140001904.021788.335氧氣0360003600水003.96E-06000.003氮氣003000030003000表5-4草酸二甲酯合成工段（二）項目789101112溫度℃114.82081.11301552.7壓力bar51551.022.5氣相分率0110.96601摩爾流量(kmol/h)4391.7651403.9957708.3317024.33215007373.397質量流量(kg/h)130754.68339322.461273381.878273381.71448063.24223540.32體積流量(cum/h)189.22534200.85445024.54945232.99159.72879380.443焓Gcal/hr-248.285-37.116-81.819-110.355-81.845-48.869質量流量kg/hr草酸二甲酯00080772.82400亞硝酸甲酯0.023097664.5139762.45109572.998一氧化氮0021604.53664813.349064808.794一氧化碳039322.46144812.3895489.81305487.298碳酸二甲酯2.493003242.83600甲醇117777.211025259.95425259.95448063.2459657.486水12970.95500.0470.04700氮氣0084040.4484040.44084009.743摩爾流量kmol/h草酸二甲酯00068400亞硝酸甲酯00159.9991600152.896一氧化氮00720.0042160.00302159.851一氧化碳01403.9951599.991191.9920191.902碳酸二甲酯0.072003600甲醇3671.6950788.335788.33515001861.843水719.99700.0030.00300氮氣003000300002998.904表5-5草酸二甲酯合成工段（三）項目1314151617溫度℃77.812174.161.867.1壓力bar2.71.11.36911.062氣相分率00010摩爾流量(kmol/h)1150.935462.899684.03642.69420.209質量流量(kg/h)97908.63417132.56780772.0671581.13215547.436體積流量(cum/h)91.63820.03781.1031283.71319.79焓Gcal/hr-147.328-29.742-111.078-2.064-22.64質量流量kg/hr草酸二甲酯80772.824080772.82400亞硝酸甲酯189.453189.4530189.4220.031一氧化氮4.5554.55504.5550一氧化碳2.5142.51402.5140碳酸二甲酯3242.8363239.5933.2432.4933233.1甲醇13661.70813661.70801351.4512314.259氧氣00000水0.0470.047000.047氮氣30.69730.697030.6970摩爾流量kmol/h草酸二甲酯684068400亞硝酸甲酯3.1043.10403.1030.001一氧化氮0.1520.15200.1520一氧化碳0.090.0900.090碳酸二甲酯3631.9640.0360.07231.892甲醇422.491422.491042.177384.314水0.0030.003000.003氮氣1.0961.09601.0960表5-6草酸二甲酯加氫工段（一）項目123456溫度℃70171.520020060.640.1壓力bar25252525251.1氣相分率101110摩爾流量(kmol/h)2613.766684.03639141.84637840.94835843.3941997.554質量流量(kg/h)5269.03880772.067172052.409172052.5786009.84286042.728體積流量(cum/h)3023.73781.28862239.0460102.12540321.47191.834焓Gcal/hr0.83-111.007-81.8-101.825-12.968-152.741質量流量kg/hr草酸二甲酯080772.82480782.1141611.6429.291602.353亞硝酸甲酯03.48E-220000一氧化氮03.10E-860000一氧化碳02.74E-5600000碳酸二甲酯03.242836163.6583.6580.4153.243甲醇01.94E-0714580.87356264.44214580.71441683.729水00.000142432.295482.28232.294449.987氫氣5269.038076603.4471333.10271333.1020乙醇酸甲酯0031.443621.231.443593.76乙二醇0011.97937599.84211.97937583.864乙醇002.24513.8682.24511.623丁二醇000.3641114.5330.3641114.169氮氣03.44E-560000質量流量(kg/h)草酸二甲酯0684684.07813.6820.07913.603亞硝酸甲酯01.70E-240000一氧化氮01.03E-870000一氧化碳02.41E-570000碳酸二甲酯00.0360.0410.0410.0050.036甲醇02.07E-09451.0531751.95451.0481300.903水07.90E-062.01522.9932.01524.978氫氣2613.76603800035381.5935381.5890乙醇酸甲酯000.34940.2450.34939.896乙二醇000.257601.780.257601.523乙醇000.0490.3010.0490.252丁二醇000.00412.3670.00412.363氮氣01.23E-570000表5-7草酸二甲酯加氫工段（二）項目7891011溫度℃64.264.2177.287.8171.7壓力bar111.0830.40.45氣相分率10000摩爾流量(kmol/h)11.5741282.237699.74381.767617.976質量流量(kg/h)498.95941073.48644474.2835733.39538740.888體積流量(cum/h)430.91151.16942.0821.41239.819焓Gcal/hr-0.741-71.813-73.752-9.823-64.313質量流量kg/hr草酸二甲酯03.99E-051602.3531530.25772.095碳酸二甲酯0.0010.1553.0873.0870甲醇498.77941042.504142.446142.4460水0.09819.979429.91429.910氫氣02.90E-10000乙醇酸甲酯00.0013593.7593588.6481.111乙二醇00.00637583.85732.97637542.881乙醇0.08110.840.7020.7020丁二醇02.93E-111114.1691.3681112.8摩爾流量kmol/h草酸二甲酯03.38E-0713.60312.9590.644碳酸二甲酯00.0020.0340.0340甲醇11.5661280.8914.4464.4460水0.0051.10923.86423.8640氫氣01.44E-10000乙醇酸甲酯01.08E-0539.89639.8390.057乙二醇01.01E-04601.5230.596604.927乙醇0.0020.2350.0150.0150丁二醇03.26E-1312.3630.01512.3482熱量衡算2.1基本原理依據能量平衡方程，見公式6-1至6-2。（6-1）式中：QUOTEQin——表示輸入設備熱量的總和；QUOTEQout——表示輸出設備熱量的總和；——表示損失熱量的總和。對于連續系統：Q+W=（6-2）式中：Q——設備的熱負荷；W——輸入系統的機械能；QUOTEHout——離開設備的各物料焓之和；——進入設備的各物料焓之和。2.2各工段能量衡算2.2.1草酸二甲酯制取工段MN再生反應精餾塔表6-1MN再生反應精餾塔負荷計算表冷凝器再沸器熱負荷/Gcal/hr-167.009152.561Q=-10.448Gcal/hr表6-2MN再生反應精餾塔焓變計算表流進塔頂流出塔底流出溫度℃454554114.8壓力bar5555氣相分率00.82810摩爾流量(kmol/h)40007780.0926304.3364391.765質量流量(kg/h)128168.64236641.17234059.417130754.683體積流量(cum/h)162.73933928.7233820.255189.225焓Gcal/hr-221.958-62.9-51.02-248.285ΣH/Gcal/hr-288.858-299.305表6-3MN再生反應精餾塔能量平衡表Q總/Gcal/hrW總/Gcal/hrΣHin/Gcal/hrΣHout/Gcal/hr誤差-10.4480-288.858-299.3050CO偶聯反應器表6-4CO偶聯反應器負荷計算表熱負荷熱負荷/Gcal/hrQ=-24.536Gcal/hr-24.536表6-5CO偶聯反應器焓變計算表流進流出溫度℃81.1130壓力bar55氣相分率10.966摩爾流量(kmol/h)7708.3317024.332質量流量(kg/h)273381.878273381.714體積流量(cum/h)45024.54945232.991焓Gcal/hr-81.819-110.355ΣH/Gcal/hr-81.819-110.355表6-6CO偶聯反應器能量平衡表Q總/Gcal/hrW總/Gcal/hrΣHin/Gcal/hrΣHout/Gcal/hr誤差-24.5360-81.819-110.3550甲醇吸收塔表6-7甲醇吸收塔負荷計算表冷凝器再沸器熱負荷/Gcal/hr無無Q=0Gcal/hr表6-8甲醇吸收塔焓變計算表塔底物流流入塔頂物流流入塔頂物流流出塔底物流流出溫度℃1301552.777.8壓力bar51.022.52.7氣相分率0.996010摩爾流量(kmol/h)7024.33215007373.3971150.935質量流量(kg/h)273381.71448063.24223540.3297908.634體積流量(cum/h)45232.99159.72879380.44391.638焓Gcal/hr-110.355-81.845-48.869-147.328ΣH/Gcal/hr-192.2-192.2表6-9甲醇吸收塔能量平衡表Q總/Gcal/hrW總/Gcal/hrΣHin/Gcal/hrΣHout/Gcal/hr誤差00-192.2-192.20DMO精餾塔表6-10DMO精餾塔負荷計算表冷凝器再沸器熱負荷/Gcal/hr-1.0638.737Q=3.674Gcal/hr表6-11DMO精餾塔焓變計算表物流流入塔頂物流流出塔底物流流出溫度℃5012174.1壓力bar2.71.11.369氣相分率000摩爾流量(kmol/h)1150.935462.899684.036質量流量(kg/h)97908.63417132.56780772.067體積流量(cum/h)92.44020.03781.103焓Gcal/hr-148.494-29.742-111.078ΣH/Gcal/hr-148.494-144.82表6-12DMO精餾塔能量平衡表Q總/Gcal/hrW總/Gcal/hrΣHin/Gcal/hrΣHout/Gcal/hr誤差3.6740-148.494-144.820DMC精餾塔表6-13DMC精餾塔負荷計算表冷凝器再沸器熱負荷/Gcal/hr-0.7891.826Q=1.037Gcal/hr表6-14DMC精餾塔焓變計算表物流流入塔頂物流流出塔底物流流出溫度℃1261.867.1壓力bar1.111.062氣相分率010摩爾流量(kmol/h)462.89942.69420.209質量流量(kg/h)17132.5671581.13215547.436體積流量(cum/h)20.0371283.71319.79焓Gcal/hr-29.742-2.064-22.64ΣH/Gcal/hr-29.742-28.704表6-15DMC精餾塔能量平衡表Q總/Gcal/hrW總/Gcal/hrΣHin/Gcal/hrΣHout/Gcal/hrError1.0370-29.742-28.70402.2.2草酸二甲酯加氫工段加氫反應器表6-16加氫反應器負荷計算表供熱負荷熱負荷/Gcal/hr-20.025Q=-20.025Gcal/hr表6-17加氫反應器焓變計算表流進流出溫度℃200200壓力bar2525氣相分率11摩爾流量(kmol/h)39141.84637840.948質量流量(kg/h)172052.409172052.57體積流量(cum/h)62239.0460102.125焓Gcal/hr-81.8-101.825ΣH/Gcal/hr-81.8-101.825表6-18CO偶聯反應器能量平衡表Q總/Gcal/hrW總/Gcal/hrΣHin/Gcal/hrΣHout/Gcal/hrError-20.0250-81.8-101.8250氣液分離器表6-19氣液分離器負荷計算表供熱負荷熱負荷/Gcal/hr-73.084Q=-73.084Gcal/hr表6-20氣液分離器焓變計算表物流流入塔頂物流流出塔底物流流出溫度℃2004040壓力bar252020氣相分率110摩爾流量(kmol/h)37840.94835843.3941997.554質量流量(kg/h)172052.5786009.84286042.728體積流量(cum/h)60102.12547182.73791.834焓Gcal/hr-101.825-18.168-152.741ΣH/Gcal/hr-101.825-174.909表6-21CO氣液分離器能量平衡表Q總/Gcal/hrW總/Gcal/hrΣHin/Gca