CN110442946B - Integration optimization method for coal ash aluminum extraction process system - Google Patents
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- 238000000034 method Methods 0.000 title claims abstract description 59
- 229910052782 aluminium Inorganic materials 0.000 title claims abstract description 37
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title claims abstract description 36
- 238000000605 extraction Methods 0.000 title claims abstract description 31
- 238000005457 optimization Methods 0.000 title claims abstract description 21
- 230000010354 integration Effects 0.000 title description 3
- 239000010883 coal ash Substances 0.000 title description 2
- 239000010881 fly ash Substances 0.000 claims abstract description 53
- 230000008569 process Effects 0.000 claims abstract description 40
- 238000004088 simulation Methods 0.000 claims abstract description 13
- 238000005516 engineering process Methods 0.000 claims abstract description 11
- 238000010206 sensitivity analysis Methods 0.000 claims abstract description 11
- 239000000463 material Substances 0.000 claims abstract description 9
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 8
- 238000004458 analytical method Methods 0.000 claims abstract description 5
- 238000006243 chemical reaction Methods 0.000 claims description 14
- 238000004090 dissolution Methods 0.000 claims description 12
- 238000000926 separation method Methods 0.000 claims description 10
- 241000183024 Populus tremula Species 0.000 claims description 9
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 8
- 238000001816 cooling Methods 0.000 claims description 6
- 230000001131 transforming effect Effects 0.000 claims description 6
- 239000002131 composite material Substances 0.000 claims description 4
- 230000000704 physical effect Effects 0.000 claims description 4
- 239000000377 silicon dioxide Substances 0.000 claims description 4
- 230000029087 digestion Effects 0.000 claims description 2
- 238000001704 evaporation Methods 0.000 claims description 2
- 230000008020 evaporation Effects 0.000 claims description 2
- 238000002156 mixing Methods 0.000 claims description 2
- 238000011160 research Methods 0.000 abstract description 3
- 230000000694 effects Effects 0.000 abstract description 2
- 238000004134 energy conservation Methods 0.000 abstract 1
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 12
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 8
- 239000007787 solid Substances 0.000 description 8
- 238000005984 hydrogenation reaction Methods 0.000 description 5
- 230000004913 activation Effects 0.000 description 4
- 230000008901 benefit Effects 0.000 description 4
- 238000005265 energy consumption Methods 0.000 description 4
- 238000010438 heat treatment Methods 0.000 description 4
- 239000007788 liquid Substances 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 4
- 238000011156 evaluation Methods 0.000 description 3
- 230000009466 transformation Effects 0.000 description 3
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 2
- ANBBXQWFNXMHLD-UHFFFAOYSA-N aluminum;sodium;oxygen(2-) Chemical compound [O-2].[O-2].[Na+].[Al+3] ANBBXQWFNXMHLD-UHFFFAOYSA-N 0.000 description 2
- 238000001354 calcination Methods 0.000 description 2
- 239000013078 crystal Substances 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 239000012065 filter cake Substances 0.000 description 2
- 239000003350 kerosene Substances 0.000 description 2
- 230000035484 reaction time Effects 0.000 description 2
- 229910001388 sodium aluminate Inorganic materials 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 230000003321 amplification Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000004364 calculation method Methods 0.000 description 1
- 238000003889 chemical engineering Methods 0.000 description 1
- 239000003245 coal Substances 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 238000005194 fractionation Methods 0.000 description 1
- 239000002737 fuel gas Substances 0.000 description 1
- 229910003480 inorganic solid Inorganic materials 0.000 description 1
- 238000005272 metallurgy Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000003199 nucleic acid amplification method Methods 0.000 description 1
- 239000003921 oil Substances 0.000 description 1
- 238000013433 optimization analysis Methods 0.000 description 1
- 238000011020 pilot scale process Methods 0.000 description 1
- 238000010248 power generation Methods 0.000 description 1
- 238000011112 process operation Methods 0.000 description 1
- 239000000047 product Substances 0.000 description 1
- 238000007670 refining Methods 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 235000012239 silicon dioxide Nutrition 0.000 description 1
- 239000002910 solid waste Substances 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 238000010977 unit operation Methods 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
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Abstract
The invention provides an integrated optimization method of a fly ash aluminum extraction process system, which comprises the following steps: according to the process flow and the material balance relation in the process of extracting aluminum from fly ash, establishing a process model for extracting aluminum from fly ash by using process simulation software Aspen Plus, and calibrating the process model through the acquired experimental data to enable the simulation output value to be consistent with the experimental data; analyzing and optimizing key operation parameters through sensitivity analysis, respectively investigating the influence of temperature, pressure and feed components on the extraction rate of the alumina, and determining the optimal value of the extraction rate; and a simulation heat exchange network is transformed by using a pinch point technology, and a simulation flow is optimized through energy analysis, so that energy conservation and emission reduction are realized. The invention optimizes the simulation flow by sensitivity analysis and pinch point technology, so that the optimization effect is optimal, and theoretical basis and basis are provided for further research of the fly ash aluminum extraction process.
Description
Technical Field
The invention relates to the field of chemical industry, in particular to a fly ash aluminum extraction process system integration optimization method.
Background
During the combustion of coal, a large amount of inorganic solid dust with oxides of elements such as Al and Si as main components is generated, i.e. fly ash, which is a main solid waste discharged from thermal power generation. With the rapid development of economy and industry in China, the power demand is increasing day by day. Since 2002, the installed capacity of domestic coal-fired power plants is rapidly increased, and the production amount of fly ash is also increased rapidly. In 2017, the emission of the fly ash reaches 6.8 hundred million tons, the accumulated stacking amount reaches 25 hundred million tons due to huge emission and insufficient effective utilization of the fly ash, the stacking occupies a large amount of land resources, pollutes underground water, influences the ecological environment and causes serious waste of aluminum resources, and the effective and comprehensive utilization of the fly ash becomes an important key technical problem to be solved urgently. In recent years, multiple domestic units develop a high-value utilization technology for extracting alumina from fly ash successively, but most of the technologies stay in a laboratory or a pilot-scale test stage, and no effective support and theoretical basis exists for adjustment and optimization of a production process, risk evaluation of process operation, feasibility evaluation of a process energy-saving scheme and the like.
The Aspen Plus is used as simulation software for strict process calculation, can calculate units and the whole process according to different feeding conditions, process conditions and user models, provides an accurate unit operation model for enterprises, and can perform energy consumption evaluation of existing devices or optimization design of newly-built devices. At present, researchers at home and abroad generally adopt Aspen Plus to research chemical engineering processes, so as to achieve the purpose of improving production benefits by adjusting and optimizing process parameters and modifying the process. In China, some enterprises take the lead to energy-saving transformation through flow simulation and obtain certain results. The simulation software is utilized by the Qingdao petrochemical oil refining chemical industry Limited liability company to carry out fractionation system simulation on a diesel hydrogenation device and an aviation kerosene hydrogenation device, an ideal model which is consistent with the operation of an actual device is obtained, optimization analysis is carried out on the model, the aim of maximizing the energy saving and economic benefits of the device is achieved, the top pressure of a fractionating tower of the diesel hydrogenation device is reduced, the operation temperature of the top of the fractionating tower of the aviation kerosene hydrogenation device is adjusted to be an optimization means, and the consumption of fuel gas of the diesel hydrogenation device is enabled to be 1500m 3 The/h is reduced to 1100m 3 And/h, the economic benefit is improved by 604.8 ten thousand yuan per year.
Although China makes certain progress in process simulation and optimization, the application range is not wide, most of China is concentrated in the field of petrochemical industry, and the application in the aspect of metallurgy is basically zero.
Disclosure of Invention
The invention develops an integrated optimization method of a fly ash aluminum extraction process system, which is based on Aspen Plus to perform material balance and energy balance on a process flow, and achieves the purposes of saving energy, reducing consumption and improving production benefits by adjusting and optimizing process parameters and modifying the process.
The technical scheme for realizing the invention is as follows:
an integrated optimization method for a fly ash aluminum extraction process system comprises the following steps:
(1) selecting a proper unit module by utilizing flow simulation software Aspen Plus according to a process flow and a material balance relation in the fly ash aluminum extraction process, and establishing a fly ash aluminum extraction process model;
(2) calibrating the process model by using the fly ash aluminum extraction process parameters to ensure that the simulation output value is consistent with the experimental data;
(3) analyzing and optimizing the key operation parameters through sensitivity analysis, and determining the optimal value of the key operation parameters;
(4) and transforming the simulated heat exchange network by using a pinch point technology, and optimizing the simulated flow by energy analysis.
The physical property method of the process model for extracting aluminum from fly ash in the step (1) selects ELECTRRLL.
The unit modules in the step (1) comprise a mixing module Mixer, a heat exchange module heater, a digestion reaction module RCSTR, a Flash evaporation cooling module Flash2 and a product separation module Filter.
The sensitivity analysis in the step (3) comprises analysis of dissolution temperature, pressure and feed components.
And (4) transforming the simulated heat exchange network by using a pinch point technology in the step (4) comprises making a composite curve of the simulated heat exchange network by using heat exchange analysis software, obtaining a pinch point position and a pinch point temperature according to the composite curve, and transforming the simulated heat exchange network.
In the step (1), the content of alumina in the fly ash is 40-60%, and the content of silica is 40-50%.
The heat exchange analysis software is Aspen Energy Analyzer.
The invention has the beneficial effects that: the invention optimizes the simulation flow through sensitivity analysis and pinch point technology, so that the optimization effect is optimal, the energy consumption is reduced by 20-30%, and a theoretical basis and a basis are provided for further research of the fly ash aluminum extraction process.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the drawings without creative efforts.
FIG. 1 shows a flow chart of a fly ash aluminum extraction process;
fig. 2 shows a simulated flow chart of a fly ash aluminum extraction process.
Detailed Description
The technical solutions of the present invention will be described clearly and completely with reference to the following embodiments of the present invention, and it should be understood that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be obtained by a person skilled in the art without inventive effort based on the embodiments of the present invention, are within the scope of the present invention.
Example 1
An integrated optimization method of a fly ash aluminum extraction process system comprises the following steps:
(1) introduction of a fly ash aluminum extraction process flow: the fly ash aluminum extraction process mainly comprises the working sections of activation, pre-desiliconization, dissolution, seed separation, calcination and the like, and the process flow is shown in figure 1;
(2) the content of alumina in the fly ash is 55 percent, and the content of silicon dioxide is 40 percent;
(2) the process conditions of the activation section are as follows: the treatment capacity of the fly ash is 150 kg/h; the liquid-solid ratio of the hydrochloric acid to the fly ash is 4: 1; the concentration of hydrochloric acid is 10 percent; the reaction temperature is 70 ℃;
(3) the process conditions of the pre-desilication section are as follows: the mass ratio of NaOH to fly ash is 0.5; the concentration of NaOH is 15%; the reaction temperature is 130 ℃; the reaction time is 2 h; 15% of filter cake attached liquid;
(4) the process conditions of the dissolution section are as follows: the treatment capacity of the desiliconized fly ash is 120 kg/h; the liquid-solid ratio of the sodium aluminate adjusting liquid to the fly ash is 6: 1; the reaction temperature is 260 ℃; the reaction pressure is 7 Mpa;
(5) the process conditions of the separation section are as follows: the adding amount of the aluminum hydroxide seed crystal is 800 g/L; the seed separating time is 48 h; the initial seed separation temperature is 60 ℃; the final seed separation temperature is 48 ℃;
(6) the technological conditions of the roasting section are as follows: the roasting temperature is 1100 ℃;
(7) selecting a proper unit module by utilizing process simulation software Aspen Plus, establishing a process model for extracting aluminum from fly ash, selecting ELECTRTL by a physical property method, and simulating a flow chart as shown in figure 2; in the figure, B1-B31 are modules such as a reactor, a heat exchanger, a filter and the like, and S1-S53 are material flow numbers;
(8) calibrating the process model through the acquired experimental data to enable the simulation output value to be consistent with the experimental data;
(9) and (3) sensitivity analysis: under the condition of keeping other parameters unchanged, comparing the influences of different temperatures on the dissolution rate of the alumina, wherein the dissolution rate is gradually increased along with the rise of the temperature, and the increase is stable after 270 ℃, so that the dissolution temperature is 270 ℃;
(10) similarly, sensitivity analysis is carried out on the liquid-solid ratio and the reaction pressure, the optimal liquid-solid ratio is 7:1, and the reaction pressure is 8 Mpa;
(11) optimizing a heat exchange network: extracting cold and hot logistics data, inputting the extracted cold and hot logistics data into Aspen Energy Analyzer software, and drawing a heat exchange network diagram according to the cold and hot logistics matching condition of the current working condition of the device. At the moment, the total of the cooling utility is 14520kW, and the total of the heating utility is 33670 kW;
(12) optimizing a heat exchange network by Aspen Energy Analyzer software, taking the minimum heat exchange temperature difference as 10 ℃, and visually seeing the position of a pinch point in a simulated heat exchange network curve chart, wherein the hot material flow temperature at the pinch point is 210 ℃, the cold material flow temperature is 200 ℃, at the moment, the total amount of a cooling utility is 9812kW, and the heating utility is 26550 kW;
(13) the process heat exchange network is transformed by the pinch point technology, so that 11828kW of energy can be saved after transformation, and the energy consumption is reduced by 24.54%.
Example 2
An integrated optimization method of a fly ash aluminum extraction process system comprises the following steps:
(1) introduction of a fly ash aluminum extraction process flow: the fly ash aluminum extraction process mainly comprises the working sections of activation, pre-desiliconization, dissolution, seed separation, calcination and the like, and the process flow is shown in figure 1;
(2) the content of alumina in the fly ash is 52 percent, and the content of silica is 43 percent;
(3) the process conditions of the activation section are as follows: the treatment capacity of the fly ash is 1000 kg/h; the liquid-solid ratio of the hydrochloric acid to the fly ash is 5: 1; the concentration of hydrochloric acid is 10 percent; the reaction temperature is 70 ℃;
(4) the process conditions of the pre-desilication section are as follows: the mass ratio of NaOH to fly ash is 0.5; the concentration of NaOH is 15 percent; the reaction temperature is 130 ℃; the reaction time is 2 h; 15% of filter cake attached liquid;
(5) the process conditions of the dissolution section are as follows: the treatment capacity of the desiliconized fly ash is 1200 kg/h; the liquid-solid ratio of the sodium aluminate adjusting liquid to the fly ash is 7: 1; the reaction temperature is 250 ℃; the reaction pressure is 8 Mpa;
(6) the process conditions of the separation section are as follows: the adding amount of the aluminum hydroxide seed crystal is 800 g/L; the seed separating time is 48 h; the initial seed separation temperature is 60 ℃; the final seed separation temperature is 48 ℃;
(7) the technological conditions of the roasting section are as follows: the roasting temperature is 1100 ℃;
(8) selecting a proper unit module by utilizing process simulation software Aspen Plus, establishing a process model for extracting aluminum from fly ash, selecting ELECNTL by a physical property method, and showing a simulation flow chart in figure 2;
(9) calibrating the process model through the acquired experimental data to enable the simulation output value to be consistent with the experimental data;
(10) and (3) sensitivity analysis: and comparing the influence of different temperatures on the dissolution rate of the alumina under the condition of keeping other parameters unchanged. The dissolution rate is gradually increased along with the rise of the temperature, and after the temperature is 280 ℃, the amplification tends to be stable, so the dissolution temperature is 280 ℃;
(11) similarly, sensitivity analysis is carried out on the liquid-solid ratio and the reaction pressure, the optimal liquid-solid ratio is 7:1, and the reaction pressure is 7.5 Mpa;
(12) optimizing a heat exchange network: extracting cold and hot logistics data, inputting the extracted cold and hot logistics data into Aspen Energy Analyzer software, and drawing a heat exchange network diagram according to the cold and hot logistics matching condition of the current working condition of the device; at the moment, the total amount of cooling utilities is 95832kW, and the total amount of heating utilities is 225589 kW;
(13) optimizing a heat exchange network by Aspen Energy Analyzer software, and taking the minimum heat exchange temperature difference as 10 ℃; the position of a pinch point can be visually seen from a simulated heat exchange network curve chart, the hot material flow temperature at the pinch point is 210 ℃, the cold material flow temperature is 200 ℃, at the moment, the total amount of a cooling utility is 64760kW, and the total amount of a heating utility is 180540 kW;
(14) the process heat exchange network is transformed by the pinch point technology, so that 76121kW of energy can be saved after transformation, and the energy consumption is reduced by 23.68%.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents, improvements and the like that fall within the spirit and principle of the present invention are intended to be included therein.
Claims (7)
1. An integrated optimization method for a fly ash aluminum extraction process system is characterized by comprising the following steps:
(1) selecting a proper unit module by utilizing flow simulation software Aspen Plus according to a process flow and a material balance relation in the fly ash aluminum extraction process, and establishing a fly ash aluminum extraction process model;
(2) calibrating the process model by using the fly ash aluminum extraction process parameters to ensure that the simulation output value is consistent with the experimental data;
(3) analyzing and optimizing the key operation parameters through sensitivity analysis, and determining the optimal value of the key operation parameters;
(4) and transforming the simulated heat exchange network by using a pinch point technology, and optimizing the simulated flow by energy analysis.
2. The integrated optimization method for the fly ash aluminum extraction process system according to claim 1, characterized in that: the physical property method of the process model for extracting aluminum from fly ash in the step (1) selects ELECTRRLL.
3. The integrated optimization method for the fly ash aluminum extraction process system according to claim 1, characterized in that: the unit modules in the step (1) comprise a mixing module Mixer, a heat exchange module heater, a digestion reaction module RCSTR, a Flash evaporation cooling module Flash2 and a product separation module Filter.
4. The integrated optimization method for the fly ash aluminum extraction process system according to claim 1, characterized in that: the sensitivity analysis in the step (3) comprises analysis of dissolution temperature, pressure and feed components.
5. The integrated optimization method for the fly ash aluminum extraction process system according to claim 1, characterized in that: and (4) transforming the simulated heat exchange network by using a pinch point technology in the step (4) comprises making a composite curve of the simulated heat exchange network by using heat exchange analysis software, obtaining a pinch point position and a pinch point temperature according to the composite curve, and transforming the simulated heat exchange network.
6. The integrated optimization method for the fly ash aluminum extraction process system according to claim 1, characterized in that: in the step (1), the content of alumina in the fly ash is 40-60%, and the content of silica is 40-50%.
7. The integrated optimization method for the fly ash aluminum extraction process system according to claim 5, characterized in that: the heat exchange analysis software is Aspen Energy Analyzer.
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| CN104765926A (en) * | 2015-04-14 | 2015-07-08 | 北京中润零碳节能技术有限公司 | Energy optimization analysis method for chemical engineering device |
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