1 program development 1.1 Introduction to the device The centrifugal process air compressor driven by MS3002 heavy industrial gas turbine takes gas from the atmosphere. After two-stage filtration and five-stage compression, the process air with a temperature of 140 and a pressure of 4.0~4.2 MPa is sent to the second stage furnace. The anti-surge valve FV02001 is installed at the outlet of the compressor. When the load of the device is not high and the amount of air required for the second stage furnace is not large, FV02001 must maintain a certain amount of venting in order to ensure that the compressor air flow is above the surge flow line. The air compressor air compressor model is 5L-16/50 type, and the structure type is reciprocating piston water-cooled type. It is driven by a motor with a model of TK250-14/1180, power of 250kW and voltage of 6kV. It also takes gas from the atmosphere, after filtration and 3-stage compression, the temperature is 106, the pressure! 3.5 MPa of air is sent to subsequent units to produce high purity nitrogen and oxygen. 1.2 The scheme is that the current equipment load is about 80%, and the process air compressor has about 8000m 3 /h (standard state) air venting. In order to avoid the waste of this part of the pressurized air, consider designing the air supply from the outlet lead to the air separation for the 5L air compressor follow-up device and stopping the 5L air compressor. The process conditions of the two systems are basically the same. Under the condition that the air volume of the process air compressor can meet the operation of air separation, it is completely feasible to introduce the air of the process air compressor into the air separation and reuse. After the implementation of the scheme, the air separation can disable the 5L air compressor, which not only saves a lot of electric energy, improves the control conditions of the circulating water, but also improves the working environment of the air separation post. Therefore, this solution is feasible both economically and technically. 2 operation precautions (1) Before using the process air compressor to release air, confirm that the process air compressor is operating normally: NIP 93%~96%, FV02001>45,000 m3/h (standard), P02025>3.85 MPa, T02100 <543.(2) When the production is full, the gas production of the process air compressor is 45764m3 / h (standard state), and the gas consumption of the second stage furnace is 45750m3 / h (standard state), the system leakage is removed, and the supply and demand are basically balanced. Therefore, when the system is fully loaded, it is necessary to switch the 5L air compressor in time to ensure stable operation of the air separation production. (3) If the process air compressor stops during use, the 1#, 2# valve should be fully closed, and the 4# valve should be opened at the same time, and the 5L air compressor should be started according to the operating procedures. 3 effects after the transformation (1) The energy saving effect is remarkable. Calculated by using the remaining air of the process air compressor for 300 years, the annual electricity saving can be 2.304 million kWh. This alone saves hundreds of thousands of yuan in electricity costs per year. (2) After the 5L air compressor is shut down, the circulating water discharge can be reduced by 40t per hour, so that the concentration ratio of the circulating water system can reach more than 3, and the process index is stable and easy to control. (3) Reducing the maintenance workload and spare parts consumption of the air compressor, saving the air compressor lubricating oil and the piston oil, greatly reducing the consumption of raw materials and machine wear. (4) Reduced the workload of the operator, reduced on-site noise, and improved the working environment. At the same time, since the air of the process air compressor contains oil, the amount of water is small, the quality of the raw material gas entering the fractionation tower is greatly improved, the service life of the molecular sieve is prolonged, the process is formed into a virtuous cycle, and stable production is ensured. (5) Because the process air compressor has high affluent air pressure and stable gas volume, the process operation of the fractionation column of the air separation plant is gradually stable, and basically no substantial adjustment is needed, thereby improving product quality and ensuring product purity. 4 secondary improvement (1) The function of 3# stop valve in the process is to adjust the air pressure of 2.2 ~ 4.1MPa, flow rate 900~1000m3 / h (standard state), on the one hand, because of the small opening, it is not easy to control, on the other hand, high-speed airflow Long-term flushing of the sealing surface will result in poor closure, so a Y43H64 pressure reducing valve is installed in front of the 3# valve. (2) Sometimes the process air compressor air needs to be discharged at the air separation station vent valve. However, in this design, the discharge valve of the air separation station is installed behind the flow meter. When the discharge amount is greater than 1200m3 / h (standard state), the flow meter will be knocked over. Therefore, it is recommended to set up one heat exchanger. E131, use cooling water to reduce the discharge temperature; (2) newly set up two conductivity analyzers to timely analyze the NH3 content in the wastewater, if the over-standard is stopped in time; (3) T09709 measurement point thermocouple is moved to E131 for control The temperature of the liquid. (4) In terms of operation, it is guaranteed that F09702 and F09704 will have sufficient steam. The desorption and decompression load should not be too large. The liquid level of L09701 should not be too high and the liquid should be drained. When flushing and evaporating, try to avoid NH3 in T102 and the urea content is too high. After many equipment modifications and operational improvements, after the overhaul in September 1999, the equipment was in good condition. The NH3 in the discharged wastewater and the urea content were all below 5 & 10-6, and the discharge temperature was controlled between 32 and 38. Recycling. 5 summary Since the production of the process condensate treatment system, with the joint efforts of engineers and operators, after years of exploration and transformation, the entire recycling of waste water has been finally realized, thereby reducing environmental pollution, alleviating the shortage of water supply and reducing Production costs have created good economic and social benefits for the company.
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Analysis on the application of air compressor rich air to air separation source
Our company's ammonia plant with an annual output of 300,000 tons of large-scale ammonia plant was introduced in the late 1980s. One of the features of the device is the low water-to-carbon ratio operation to reduce the load of the first stage and transfer part of the load to the second stage furnace. The excess air supplied by the process air compressor is added to the second stage furnace to meet the requirements of the second stage conversion. Heat and nitrogen required for ammonia synthesis. Due to insufficient supply of natural gas, the device was not fully loaded, resulting in a partial sufficiency (venting) of the process air at the process air compressor. This article describes how to make the most of this remaining resource to achieve energy savings.