CN112257292B - Three-dimensional risk based large coal gasification device space safety layout method - Google Patents

Three-dimensional risk based large coal gasification device space safety layout method Download PDF

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CN112257292B
CN112257292B CN202011244612.7A CN202011244612A CN112257292B CN 112257292 B CN112257292 B CN 112257292B CN 202011244612 A CN202011244612 A CN 202011244612A CN 112257292 B CN112257292 B CN 112257292B
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coal gasification
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王志荣
郭丽萍
郭品坤
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Nanjing Tech University
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Abstract

The invention discloses a three-dimensional risk-based large coal gasification device space safety layout method, which comprises the steps of establishing a three-dimensional risk evaluation model of a large coal gasification device; establishing a target function of multi-series mirror image layout of a large coal gasification device; establishing constraint conditions of multi-series mirror image layout of a large coal gasification device; the model is solved using a DICOPT solver in the GAMS software. According to the method, the target equipment damage degree index is used as an accident consequence to be evaluated, the influence factors of the target equipment damage degree index are quantified by adopting a fuzzy comprehensive evaluation method, the process flow characteristics of the large-scale coal gasification device are analyzed, a new mixed integer nonlinear programming model is provided, some additional constraint conditions are added, and the solving efficiency of the model is effectively improved. The method simultaneously provides solution ideas and method theoretical supports for selecting effective safety protection measures for reducing risks of the large coal gasification device in the production operation stage.

Description

Three-dimensional risk based large coal gasification device space safety layout method
Technical Field
The invention belongs to the technical field of optimization layout problems of chemical process devices, and particularly relates to a three-dimensional risk-based space safety layout method for a large coal gasification device.
Background
The large-scale coal gasification device is internally provided with key dangerous equipment such as a gasification furnace and the like, the internal layout structure of the key dangerous equipment such as the gasification furnace and the like is compact, once an accident occurs when a certain equipment fails, the adjacent device is easily affected and the linkage of the accident is caused, and the key dangerous equipment such as the gasification furnace and the like is internally provided with high-temperature, high-pressure, toxic, inflammable and explosive corrosive mixed gas, so that the possibility of the occurrence of domino accident is greatly increased, and the life and property safety of people is seriously threatened.
Therefore, a set of complete space safety layout method for a large coal gasification device is urgently needed to be established so as to solve some technical difficulties of complexity and comprehensiveness which puzzle the safety of the coal chemical industry in China for a long time, and further reduce the risk level of the newly built or existing coal chemical industry.
Disclosure of Invention
The invention provides a perfect space safety layout method of a large coal gasification device, which is used for the large coal gasification device and more accords with the three-dimensional risk space safety layout method of the actual engineering requirement by integrating various constraint conditions aiming at the technical problems that the internal layout structure of key dangerous equipment such as a gasification furnace and the like is compact and accidents are easily caused in the prior art.
The invention solves the technical problems through the following technical means:
a three-dimensional risk-based large coal gasification device space safety layout method comprises the following steps:
(1) establishing a three-dimensional risk assessment model of the large coal gasification device;
(2) establishing a target function of multi-series mirror image layout of a large coal gasification device;
(3) establishing constraint conditions of multi-series mirror image layout of a large coal gasification device;
(4) the model is solved using a DICOPT solver in the GAMS software.
Specifically, the step (1) specifically includes:
according to the QRA method, the three-dimensional risk of the risk source to the risk receptor in different accident types at a certain point in space can be represented by the following formula:
Figure BDA0002769559180000011
where i denotes the hazard source device, j denotes the affected target device, piProbability of failure, p, indicating different types of accidents occurring at the source of dangerijIndicating the probability of domino failure, EDI, of the target device by the hazard sourcejThe damage degree index of the target equipment is shown, h represents the accident type, and n is the number of the equipment in the evaluation area.
Specifically, the objective function in step (2) is:
Figure BDA0002769559180000021
in the formula, i representsHazard source device, j denotes affected target device, piProbability of failure, p, indicating different types of accidents occurring at the source of dangerijIndicating the probability of domino failure, EDI, of the target device by the hazard sourcejThe damage degree index of the target equipment is shown, h represents the accident type, and n is the number of the equipment in the evaluation area.
The objective function is expressed as a minimization of the initial device three-dimensional risk value, and the safety objective is expressed by the sum of the three-dimensional risks of the hazard source device to the target device at a specific position.
Specifically, the specific method for establishing the multi-series mirror image layout objective function of the large-scale coal gasification device in the step (2) comprises the following steps:
(21) calculating the probability of an initial accident occurrence, i.e. pi；
(22) Calculating the probability of failure of the target device, i.e. pij(ii) a Adopting a Probit method to simultaneously consider the type of the equipment and the type of the upgrading vector received by the equipment so as to calculate a probability value Y;
after Y is determined, calculating the upgrading probability as follows:
Figure BDA0002769559180000022
in the formula, u is an integral variable.
(23) Calculating target device damage index, EDIj。
Specifically, the specific method for calculating the damage index of the target device in step (23) includes:
(231) selecting four important indexes, U ═ U1,u2,u3,u4The safety barrier effectiveness, equipment criticality and emergency response time are calculated according to the requirements of the equipment;
(232) the evaluation set for damage assessment was three grades, V ═ severe, moderate, mild };
(233) obtaining four first-level index weights by using a chromatographic analysis method;
(234) and performing single-factor fuzzy evaluation according to a single index in the indexes, determining an evaluation fuzzy matrix, and obtaining the damage degree index of each device.
Specifically, the constraint conditions in step (3) specifically include:
(31) multi-series mirrored layout constraints
With the development of modern coal chemical industry, coal gasification devices are continuously developed to large scale, and because of the limitation of the processing capacity of a single device, a mode of parallel operation of a plurality of sets of coal gasification devices is adopted to meet the market demand at present; in order to arrange a plurality of sets of coal gasification devices which run in parallel, a plurality of series of layout constraint conditions are provided, a large coal gasification device adopts a plurality of series of mirror image arrangements, all devices are divided into unit areas with the same size according to functions or actual systems, the number of the units is determined by the number of the actual systems, the dividing direction of the units is determined, and each unit can be transversely distributed in parallel with an x axis or longitudinally distributed in parallel with a y axis;
(32) floor restraint
The arrangement for multi-storey installations must start at a certain storey and occupy a number of floors in succession;
(33) non-overlapping constraints
In order to avoid that two equipment items i and j occupy the same physical location, i.e. N, when assigned to the same floorij1, appropriate constraints should be included in the model to prevent their device footprint projections from overlapping in the x or y direction;
(34) process flow constraints
According to the characteristics of the process flow, the special position relation between equipment is preprocessed, some equipment and other equipment are arranged in an association relation, the relative position of the equipment in the space has two conditions, and the equipment needs to be arranged on the upper layer or the lower layer of the other equipment;
(35) distance constraint
The center-to-center distance of the two devices is calculated using the euclidean distance.
Specifically, in the step (5), a DICOPT solver in the GAMS software is adopted to solve the model, so as to obtain a three-dimensional risk minimum value, coordinates of the center point of each device and a floor distribution condition.
The invention has the beneficial effects that:
the safety layout method based on three-dimensional risk minimization can realize that the large coal gasification device estimates the safety layout of facilities with the minimum risk in the design planning stage, the damage degree index of target equipment is used as the accident consequence for evaluation, and the influence factors influencing the damage degree of the target equipment are quantified by adopting a fuzzy comprehensive evaluation method. The process flow characteristics of the large coal gasification device are analyzed, a new mixed integer nonlinear programming (MINLP) model is provided, and some additional constraint conditions, namely multi-series mirror image layout constraint and process flow constraint, are added, so that the solving efficiency of the model is effectively improved.
According to the invention, the target equipment damage degree index is used as an accident consequence for evaluation, and the influence factors of the target equipment damage degree index are quantified by adopting a fuzzy comprehensive evaluation method, so that risk superposition calculation under a multi-accident scene can be realized. By analyzing the process flow characteristics of the large coal gasification device, a new mixed integer nonlinear programming (MINLP) model is provided, and some additional constraint conditions, namely multi-series mirror image layout constraint and process flow constraint, are added, so that the solving efficiency of the model is effectively improved. The method simultaneously provides solution ideas and method theoretical supports for selecting effective safety protection measures for reducing risks of the large coal gasification device in the production operation stage.
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FIG. 1 is a schematic flow diagram of the process of the present invention.
Fig. 2 is a schematic model of the system elements and equipment.
Fig. 3 is a plan view of the security layout of the embodiment.
Fig. 4 is a three-dimensional view of a security layout of an embodiment.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention are clearly and completely described below, and it is obvious that the described embodiments are a part of the embodiments of the present invention, but not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
As shown in fig. 1, a large coal gasification device safety layout method is characterized in that a three-dimensional risk assessment model is established, a minimized three-dimensional risk value is taken as an objective function, and multiple series of layout constraints and process flow constraint conditions are further added into an optimization model according to actual engineering requirements, so that the obtained equipment layout better meets the engineering requirements. In quantitative risk evaluation, influence factors of target equipment damage degree grades under different accident scenes are quantitatively calculated by adopting a fuzzy comprehensive evaluation method, the model can realize superposition calculation of risk values under multiple accident scenes and obtain an optimal solution by utilizing GAMS software, and the detailed method comprises the following steps:
1. establishing three-dimensional risk assessment model of large coal gasification device
According to the QRA method, the three-dimensional risk of the risk source to the risk receptor in different accident types at a certain point in space can be represented by the following formula:
Figure BDA0002769559180000041
where i denotes the hazard source device, j denotes the affected target device, piProbability of failure, p, indicating different types of accidents occurring at the source of dangerijIndicating domino failure probability, EDI, of the target devicejThe damage degree index of the target equipment is shown, h represents the accident type, and n is the number of the equipment in the evaluation area.
2. Establishing objective function of multi-series mirror image layout of large-scale coal gasification device
In order to obtain a safe layout of chemical equipment in space, an objective function is expressed as the minimization of the three-dimensional risk value of initial equipment, and a safe target is expressed by the sum of the three-dimensional risks of the hazard source equipment at a specific position to target equipment. The objective function is as follows:
Figure BDA0002769559180000051
where i denotes the hazard source device, j denotes the affected target device, piProbability of failure, p, indicating different types of accidents occurring at the source of dangerijIndicating domino failure probability, EDI, of the target devicejThe damage degree index of the target equipment is shown, h represents the accident type, and n is the number of the equipment in the evaluation area.
The following assumptions are made from the actual situation:
(1) the number and size of the devices to be placed in the area are known, and all the devices are approximately cylindrical in shape, and the size and parameters of each device are shown in table 1:
TABLE 1 parameters of a coal water slurry gasification process
Figure BDA0002769559180000052
(2) The framework and the system units are rectangular, the boundaries of the system units are determined, the length and the width of the system units are known, the layout scheme of the coal gasification process equipment takes 3 series (A series, B series and C series) as 1 joint production area, the A series, B series and C series of the equipment layout adopt mirror image layout, and a schematic model of the system units and the equipment is shown in FIG. 2; the rectangular area does not exist actually, only in order to enable each device in the system to be arranged in the area size, each rectangular area is arranged according to a plurality of lines and straight lines, the rectangular area is divided into a plurality of lines, the sizes of the lines are the same, and the size of each unit is determined according to the size of the frame;
(3) the process flow is totally 6 main devices, a gasification furnace, a slag lock hopper and a washing tower are gasification units, a high-pressure flash tank, a vacuum flash tank and a high-pressure flash separation tank are black water units, and for convenient modeling, an A series, a B series and a C series share one frame, the gasification units and the black water units are separated by a firewall, wherein the heights of the gasification furnace, the washing tower and the vacuum flash tank exceed the layer height, the frames are 7 layers in total, the heights of the layers are different, and the building height of the frames is 55.0 m;
(4) for three-dimensional spatial layout, in order to represent the position of each device, a coordinate system is established: the lower left corner of a two-dimensional plane of the layout area is taken as a zero point, the right side is taken as a transverse positive direction (x axis), the upward side is taken as a longitudinal positive direction (y axis), and the upward side perpendicular to the two-dimensional plane is taken as a positive direction (z axis).
Specifically, the step 2 specifically includes:
(1) calculation of initial accident probability
Selecting the equipment number G in the system unit3The scrubber tower (2) is a dangerous source, the accident scene is steam cloud explosion (VCE), the leakage rate of the synthesis gas of the scrubber tower is 0.41kg/s, the leakage time is 10min, the occurrence probability is assumed to be 1, and for the sake of simplicity, the explosion center, the gas cloud center and the scrubber center are assumed to be coincident.
(2) Calculation of target device failure probability
When the physical effect of the initial accident acts on the target device, the target device is damaged at a certain probability, and a domino accident occurs. The Probit method is widely used for estimating the upgrading probability of the equipment due to simplicity and flexibility, and can be applied to various types of equipment. The Probit method may consider both the type of equipment (e.g., atmospheric or pressurized) and the type of upgrade vector received by the equipment (e.g., thermal radiation or explosive overpressure) to calculate the probability value Y, which is given by the equation in table 2.
TABLE 2 probability value calculation formula
Figure BDA0002769559180000061
After Y is determined, the upgrade probability can be calculated as:
Figure BDA0002769559180000062
(3) target device damage index (EDI)j) Is calculated by
Specifically, the step (3) specifically includes:
(31) four important indexes are selected, U is { U ═ U1,u2,u3,u4Device intrinsic hazard, security screenBarrier effectiveness, equipment criticality, emergency response time };
(32) the evaluation set of the damage degree evaluation is three grades, V is { serious, medium and slight }, the final target equipment degree evaluation result is obtained from the evaluation set V, the division standard of each index is shown in table 3, and the division and the grade connotation of different damage degree grades are shown in table 4;
TABLE 3 target Equipment Damage level Table
Figure BDA0002769559180000071
TABLE 4 device Damage level Classification and description
Grade of degree of damage Weighted values Standard score Description of the invention
Severe severity of disease 1.0 (0.7,1.0] Target equipment is completely damaged and the equipment is scrapped
Medium and high grade 0.7 (0.3,0.7] Partial damage of target equipment and maintenance in production halt
Light and slight 0.3 (0,0.3] The target equipment is slightly damaged, and the production can be immediately recovered after the maintenance
(33) The chromatographic analysis method is used to obtain four first-level index weights which are respectively: equipment hazard, safety barrier effectiveness, equipment importance, emergency response time (0.626, 0.146, 0.173, 0.055);
(34) performing single-factor fuzzy evaluation according to a single index in the indexes, determining an evaluation fuzzy matrix, and obtaining the damage degree index results of each device as the following table 5:
TABLE 5 Damage index of each device
Equipment number 1 2 3 4 5 6
IDi 0.984 0.424 0.744 0.700 0.450 0.450
Grade Severe severity of disease Medium and high grade Severe severity of disease Medium and high grade Medium and high grade Medium and high grade
3. Establishing constraint conditions of multi-series mirror image layout of large-scale coal gasification device
Specifically, the step (3) specifically includes:
(31) multi-series mirrored layout constraints
Figure BDA0002769559180000081
Figure BDA0002769559180000082
xi≤[lu-Dw-rad(i)]+(e-1)·lu
xi≥rad(i)+Du+(e-1)·lu
yi≤(wu-Dw-rad(i))+(e-1)·wu
yi≥rad(i)+Dw+(e-1)·wu
(32) Floor restraint
Figure BDA0002769559180000083
Figure BDA0002769559180000084
Figure BDA0002769559180000085
Nij≥Vik+Vjk-1
Figure BDA0002769559180000086
Nij≤1-Vik+Vjk
Figure BDA0002769559180000087
Nij≤1+Vik-Vjk
Figure BDA0002769559180000088
(33) Non-overlapping constraints
Figure BDA0002769559180000089
Figure BDA00027695591800000810
Figure BDA00027695591800000811
Figure BDA00027695591800000812
(34) Process flow constraints
zj-zi+BM(1-UPij)≥(γi+γj)/2
zi-zj+BM(1-DOij)≥(γi+γj)/2
xi-xi＝BM(1-UPij)
yi-yi＝BM(1-UPij)
(35) Distance constraint
And (3) calculating the center distance of the two devices by using the Euclidean distance, wherein the equation is as follows:
Figure BDA0002769559180000091
the parameters of the above constraints are shown in table 6.
TABLE 6 model parameter description
Figure BDA0002769559180000092
Figure BDA0002769559180000101
4. Solving the model by using a DICOPT solver in GAMS software to obtain a three-dimensional risk minimum value of 5.12, wherein Table 7 shows the coordinates of the center point of each device and the distribution condition of floors, the safety layout plan is shown in FIG. 3, and the three-dimensional layout is shown in FIG. 4.
TABLE 7 safe layout parameters of System units
Figure BDA0002769559180000102
Figure BDA0002769559180000111
Through calculation results, the system unit is less risky to be arranged transversely than longitudinally in a limited space. The hazard equipment is placed at the corners and the damage index value (ID) of the scrubber tower is higher, i.e. the consequences for it are more severe in different accident scenarios. The device with the high target device damage index is placed at a distance from the hazard source to reduce the influence of the domino effect on other system elements. The position of the gasification furnace is also worth noting, the damage degree index value (ID) of the gasification furnace is the highest, but the gasification furnace and the washing tower have strong connection in the process, so the gasification furnace is arranged on a frame floor which is closer to the gasification furnace and is lower in the longitudinal direction under the constraint condition of the process flow.
According to the obtained layout result, the model can carry out reasonable layout design on the equipment in the limited space on the basis of accurately estimating the three-dimensional risk value. By adding multi-series mirror image layout constraints and process flow constraints into the constraint conditions, the safety and the reasonability of the obtained layout design can be ensured.

Claims (6)

1. A three-dimensional risk based large coal gasification device space safety layout method is characterized by comprising the following steps:
(1) establishing a three-dimensional risk assessment model of the large coal gasification device;
(2) establishing a target function of multi-series mirror image layout of a large coal gasification device;
(3) establishing constraint conditions of multi-series mirror image layout of a large coal gasification device; the constraint conditions specifically include:
(31) multi-series mirrored layout constraints
With the development of modern coal chemical industry, coal gasification devices are continuously developed to large scale, and because of the limitation of the processing capacity of a single device, a mode of parallel operation of a plurality of sets of coal gasification devices is adopted to meet the market demand at present; in order to arrange a plurality of sets of coal gasification devices which run in parallel, a plurality of series of layout constraint conditions are provided, a large coal gasification device adopts a plurality of series of mirror image arrangements, all devices are divided into unit areas with the same size according to functions or actual systems, the number of the units is determined by the number of the actual systems, the dividing direction of the units is determined, and each unit is transversely distributed in parallel with an x axis or longitudinally distributed in parallel with a y axis;
(32) floor restraint
The arrangement for multi-storey installations must start at a certain storey and occupy a number of floors in succession;
(33) non-overlapping constraints
In order to avoid that two equipment items i and j occupy the same physical location, i.e. N, when assigned to the same floorij1, appropriate constraints should be included in the model to prevent their device footprint projections from overlapping in the x or y direction;
(34) process flow constraints
According to the characteristics of the process flow, the special position relation between equipment is preprocessed, some equipment and other equipment are arranged in an association relation, the relative position of the equipment in the space has two conditions, and the equipment needs to be arranged on the upper layer or the lower layer of the other equipment;
(35) distance constraint
Calculating the center-to-center distance of the two devices by using the Euclidean distance;
(4) the model is solved using a DICOPT solver in the GAMS software.
2. The three-dimensional risk based large coal gasification device space safety layout method according to claim 1, wherein the step (1) specifically comprises:
according to the QRA method, the three-dimensional risk of the risk source to the risk receptor when different accident types occur at a certain point in space is represented by the following formula:
Figure FDA0003246621880000021
where i denotes the hazard source device, j denotes the affected target device, piProbability of failure, p, indicating different types of accidents occurring at the source of dangerijIndicating the probability of domino failure, EDI, of the target device by the hazard sourcejThe damage degree index of the target equipment is shown, h represents the accident type, and n is the number of the equipment in the evaluation area.
3. The three-dimensional risk based large coal gasification device space safety layout method according to claim 2, wherein the objective function in the step (2) is as follows:
Figure FDA0003246621880000022
where i denotes the hazard source device, j denotes the affected target device, piProbability of failure, p, indicating different types of accidents occurring at the source of dangerijIndicating the probability of domino failure, EDI, of the target device by the hazard sourcejRepresenting the damage degree index of the target equipment, h representing the accident type, and n representing the number of equipment in the evaluation area;
the objective function is expressed as a minimization of the initial device three-dimensional risk value, and the safety objective is expressed by the sum of the three-dimensional risks of the hazard source device to the target device at a specific position.
4. The three-dimensional risk based large coal gasification device space safety layout method according to claim 3, wherein the specific method for establishing the objective function of the multi-series mirror layout of the large coal gasification device in the step (2) comprises the following steps:
(21) calculating the probability of an initial accident occurrence, i.e. pi；
(22) Calculating the probability of failure of the target device, prij(ii) a Adopting a Probit method to simultaneously consider the type of the equipment and the type of the upgrading vector received by the equipment so as to calculate a probability value Y;
after Y is determined, calculating the upgrading probability as follows:
Figure FDA0003246621880000023
(23) calculating target device damage index, EDIj。
5. The three-dimensional risk based large coal gasification device space safety layout method according to claim 4, wherein the specific method for calculating the target equipment damage degree index in the step (23) comprises the following steps:
(231) selecting four important indexes, U ═ U1,u2,u3,u4The safety barrier effectiveness, equipment criticality and emergency response time are calculated according to the requirements of the equipment;
(232) the evaluation set for damage assessment was three grades, V ═ severe, moderate, mild };
(233) obtaining four first-level index weights by using a chromatographic analysis method;
(234) and performing single-factor fuzzy evaluation according to a single index in the indexes, determining an evaluation fuzzy matrix, and obtaining the damage degree index of each device.
6. The three-dimensional risk-based large-scale coal gasification device space safety layout method according to claim 1, wherein in the step (5), a DICOPT solver in GAMS software is adopted to solve the model, so as to obtain a three-dimensional risk minimum value, coordinates of a center point of each device and a floor distribution condition.
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