基于基准假组分的流化催化裂化反应-再生系统建模方法

The reaction-regeneration system (including the main fractionator) is a kernel piece of equipment of a fluidized catalytic cracking unit which is a key unit of a petroleum refining enterprise. The performance of the system decides the safety and effectiveness of the whole unit and to quite an extent, of the enterprise. Although various operational optimization techniques and advanced controls have a long history of application to the system, they have been being accompanied all the way with problems such as difficult initial commissioning and low subsequent availability, due to great difficulties in modeling, tuning and personnel training for controllers and optimizers, which are necessary after changing feedstock oils and product programs. To alleviate these difficulties, this project starting from the preceding work of the applicant and employing measures such as theoretical analysis, process modeling and simulation and optimization, studies: (1) a cracking kinetic model based on special pseudocomponents for petroleum fractions, which possesses a reliable capability of prediction in a wide range of operational conditions and for different feedstock oils and product programs; (2) a phenomenological nonequilibrium model based on the concept of equilibrium stage for distillation trays, which is easy for computation and parameter calibration and has a reliable capability of prediction in a wide range of operational conditions; (3) the correlating relationships of the vapor-liquid equilibrium and other properties with the distribution of special pseudocomponents for petroleum fractions; (4) models for reliably predicting the steady state and dynamic behavior of the reaction-regeneration system based on the foregoing models and models of other predecessors, the corresponding steady state and dynamic prototype simulators, and the applications of the simulators to industrial installations to test their supporting functions in operational optimization and advanced control.

反应-再生系统(含主分馏塔)是炼油企业关键装置流化催化裂化的核心设备，其运行品质对整个装置乃至企业的安全和效益至关重要。各类操作优化与先进控制很早就在该系统上应用，但一直存在初次投用难度大、后续投用率不高等问题，原因是系统原料、生产方案变化后，优化/控制器的建模、调试、人员培训难度过高。为了缓解这些困难，课题基于申请人的前期工作，综合运用理论分析、过程模拟与仿真、最优化等手段，研究：(1) 基于基准假组分的油品裂解动力学模型，该模型对原料和产品方案变化具有全面、可靠的预测能力；(2) 基于平衡级的唯像非平衡级塔板模型，该模型易于计算和参数校正、对不同操作条件具有全面、可靠的预测能力；(3) 基准假组分分布与油品汽液平衡等性质的关联关系；(4) 综合前述和前人研究结果，形成具有可靠预测能力的反应-再生系统稳态/动态机理模型，制作原型仿真系统并在工业装置上验证其对操作优化和先进控制的支撑功能。

课题围绕催化裂化反应-再生系统建模开展研究，主要内容包括：(1) 提出了基于基准假组分的裂解反应机理，并以此构造了提升管反应器模型；(2) 基于基准假组分概念，构建了石油蒸馏建模工具和软件；(3) 基于对精馏塔板上气液相流体运动规律分析，提出了一种唯象的平衡级模型用于描述实际蒸馏塔板；(4) 应用前述提出的模型，结合前人研究结果，构建了反应-再生系统模型和仿真软件；(5)面向反应-再生系统模型在生产操作中的应用，开展了经济型模型预测控制器（RTD-A）研究、不确定性系统控制器研究、基于神经元等经验建模框架的建模研究以及最优化方法研究。用工业生产数据验证了前述的模型、方法和软件的有效性，部分方法在实际工业仿真项目上获得了成功应用。