Hua Ze's high-performance packing technology has been widely used in a large number of industrial devices, especially the atmospheric and vacuum distillation unit of crude oil with high difficulty and the hydrogenation unit of lubricating oil. Other typical applications include catalytic cracking, base oil hydrogenation, sulfur recovery, styrene and cyclohexylamine, and dozens of other devices. These projects have successfully achieved the expected goals of capacity expansion, production increase, quality improvement, consumption reduction, pollution reduction, tower diameter reduction and benefit increase, among which the transformation project has received "immediate" results.
So far, packing technology in Hua Ze has been used in thousands of tower reconstruction or new construction projects. China's customers have expanded to more than 20 provinces (regions). Packed tower equipment has been exported to the United States, South Korea, Spain, Australia, Denmark, Taiwan Province Province and other countries (or regions), with an export value exceeding tens of millions of dollars.
(1) SepakTM series high performance structured packing
SepakTM series structured packing developed by Hua Ze Company has special surface structure, so it has better separation efficiency and operational performance than conventional structured packing. The main features of SepakTM series structured packing include:
1. The special surface structure makes the packing soak more completely, and improves the mass transfer area and separation efficiency of the packing;
2. The strength of the filler is increased, which improves the compressive performance of the filler;
3. The minimum specific surface area is 64m2/m3, and the maximum specific surface area is 500m2/m3; ;
4. The amplification effect is very small;
5. The scope of application is wider;
6. Materials can be metal plate, wire mesh, plastic and ceramics.
(2) SepakTM series high performance random packing
MSR-2 multistage ring bulk packing (patent name: a multistage ring bulk packing), its main features are:
(1) The diameter-height ratio of this filler is 2. 1-3.75, and the filler tends to be placed horizontally when filling, so the windward surface is small, the resistance is small and the flux is large;
(2) The filler adopts a central supporting structure with good rigidity;
(3) The specific surface area of the packing is larger than that of the annular packing, the inner and outer surfaces of the packing are completely open, the inner ribs evenly divide the inner space of the ring, the packing has more spray points than the annular packing, and the liquid dispersion effect is good, which is beneficial to mass transfer;
(4) The filler has no flanging, which prevents the droplets from agglomerating during liquid-liquid extraction and is beneficial to liquid-liquid mass transfer;
MSR-2 multistage annular packing has the advantages of good mass transfer performance, small resistance, large production capacity, simple structure and high mechanical strength. In the process of distillation, absorption and extraction, it can greatly improve the production capacity and mass transfer efficiency of distillation tower, absorption tower, washing tower and extraction tower, improve product quality, reduce energy consumption and improve process efficiency.
(3) High performance liquid distributor
The design of liquid distributor is the key and core of packed tower design. Any packed bed must have a matching liquid distributor. Because of the great operating elasticity of packing itself, the operating elasticity of packed bed often depends on the operating elasticity of its liquid distributor. If the liquid distributor is not designed properly, the efficiency of the whole packed bed may be greatly affected.
Hua Ze Company introduced a high-performance liquid distributor, which has obtained the national patent (patent number: 98207 197.3). Its main features are as follows:
1. The liquid distributor has great operation flexibility and wide application range;
2. Uniform liquid distribution with point-by-point error
3. The free cross-sectional area is large, the airflow resistance is small, and the entrainment of liquid foam is small; The gradient of liquid flow in the main tank is small;
4. Good anti-blocking performance;
5. Easy installation, easy level adjustment and convenient maintenance.
(4) High-performance liquid collector (oil collecting tank)
The main functions of the liquid collector are liquid collection and gas redistribution. Hua Ze's high-performance liquid collector has the following characteristics:
1. High porosity, uniform gas distribution and low gas resistance;
2. Short liquid retention time can avoid local liquid retention and effectively prevent liquid coking;
3. Reasonable structure, high strength, gas impact resistance and thermal expansion and cold contraction resistance;
4. The welding quantity on site is small, which is convenient for installation.
(5) High-performance streamlined feed gas distributor
When structured packing or random packing is used in large distillation column, the uniform distribution of gas in the column, especially the initial distribution of gas flow at the inlet (or the reflux port of vapor-liquid mixture in reboiler), has great influence on the separation efficiency and product quality of the column, because the resistance drop of packing is very small, and the gas distribution is difficult to correct itself. Therefore, the design of gas feed distributor is very important for large packed tower.
The streamlined feed gas distributor developed by Hua Ze Company was developed on the basis of summarizing the advantages and disadvantages of various gas distributors, and has obtained national patents. The gas distributor has been used in many domestic oil refining units with remarkable results. Its main features are as follows:
1. The flow channel is streamlined, with small airflow resistance and less energy loss;
2. The airflow turns smoothly and can be well separated from the liquid with little entrainment;
3. The ascending airflow is symmetrical around and further homogenized in the ascending process, so that the uniformity of airflow distribution is better;
4. If grid packing is installed, the separation efficiency of packed tower can be further improved.
In the experimental tower, its performance was measured and compared with several common gas distributors. The results show that the streamlined feed gas distributor of Hua Ze Company has the best comprehensive performance. The main test data are shown in the following table: name: streamline of perforated straight pipe tangential horn type single tangential circulation type double-row blades
(Hua Ze patent) Uneven rate 2.01.97 0.521.80.37 Liquid entrainment rate,% 5.3 0 0.6 0. 1 distributor resistance drop △P, PA 274010 49 301
The design features of Hua Ze's high-performance packing bracket are as follows:
1. The tower has low cross-sectional area occupancy, low gas passing resistance and low pressure;
2. Gas can circulate freely on both sides, which is beneficial to the uniform distribution of gas;
3. The height of the tower can be reduced, which is especially suitable for occasions where the height of the tower is limited. ADV (Advanced Dispersion Valve) is a new type of high-performance tray technology independently developed by Hua Ze Company. In the past seven years, adv & amp； Reg technology has been successfully applied to crude oil atmospheric and vacuum distillation, catalytic cracking, gas fractionation, hydrocracking, delayed coking, aromatics, p-xylene and p-xylene at home and abroad. 200,000 tons/year of acrylonitrile, ethylene, butadiene and more than 900 large industrial towers, and played a key role in more than 20 provincial and ministerial key projects.
ADV & amp； Reg differential float valve tray was developed on the basis of F 1 float valve tray. Inheriting its advantages, overcoming its disadvantages, the structure of float valve and tray was innovated. ADV & amp； Reg through comprehensive optimization, the tray not only improves the production capacity, but also improves the efficiency, reduces the resistance and increases the operation flexibility, which makes it have excellent comprehensive performance and comprehensively improves the technical level of the tray. ADV & amp； The main technical innovations of reg pallet are:
⑴ Optimization of float valve structure
There are two main aspects to optimize the structure of floating valve. One is to add three notches on the valve surface, which has the functions of (1) making the air flow finer, eliminating the mass transfer dead zone at the top of the traditional F 1 float valve and improving the efficiency; ⑵ It is beneficial to reduce entrainment and improve production capacity; ⑶ It is beneficial to reduce leakage and increase operation flexibility. Secondly, the special valve leg design makes adv & reg；; The floating valve has a guiding function, which is: (1) to reduce the liquid level gradient on the tray, reduce the entrainment and improve the production capacity; ⑵ Eliminate the stagnant area of liquid on the tray, make the liquid flow distribute evenly and improve the efficiency; ⑶ Reduce backmixing and improve efficiency.
⑵ Optimization of valve hole structure
The new valve hole structure makes the floating valve unable to rotate and can only float up and down to ensure that adv & reg；; The guiding characteristics of the float valve prolong the service life of the float valve.
⑶ Optimization of tray connection structure
Articulated tray connection structure is adopted, and floating valve can be set at the tray connection to eliminate the mass transfer dead zone at the tray connection. Its functions are as follows: (1) increase the tray opening rate and improve the production capacity; ⑵ Make the floating valves of the whole tray evenly arranged, improve the gas-liquid contact state and improve the separation efficiency; (3) The installation is convenient and the installation time is shortened.
⑷ Structure optimization of liquid inlet area
A bubble promoter is installed in the liquid inlet area. The principle of bubble accelerator is to make the liquid layer thinner, reduce the static pressure of the liquid at the liquid inlet, and make bubbles easier to form. A liquid baffle is arranged, and an opening is made in the negative pressure area at the back, so that the air flow can pass through more easily. The role of bubble promoter: (1) The gas flow will loosen the liquid flowing out of the downcomer, which is beneficial to the formation of bubbles; (2) Prevent leakage in the entrance area; (3) make the air distribution more uniform; (4) It is beneficial to improve efficiency, productivity and flexibility of operation.
5. Optimization of downcomer structure
The optimization of downcomer structure has the following functions: (1) the optimization of downcomer outlet section shape reduces the area of liquid receiving tray and increases the bubbling area of tray; ⑵ Improve the liquid passing capacity of downcomer, and make adv &；; Reg has improved the production capacity of pallets.
[6] Overall structural optimization
The optimization of the whole structure includes three aspects: (1) optimizing the structure of the whole tray to make the whole tray in the best operation state; ⑵ Carefully design other tower structures such as feeding and reflux; ⑶ According to the different gas-liquid loads in each section of the tower, design by sections and optimize the structural design of the internals of the whole tower, so as to make the whole tower run in the best state.
Through the above measures, adv & amp； Reg this tray can improve the treatment capacity while maintaining high separation efficiency, and the treatment capacity is greater than that of F 1 float valve tray; This also makes adv & amp； Reg under low load, the tray maintains high efficiency and has a lower operating limit than F 1 float valve tray.
In a word, adv & amp； Reg differential floating valve tray has the characteristics of low pressure, strong anti-clogging ability, high efficiency and great operational flexibility, and has been successfully applied to the renovation or new design of more than 4000 towers in more than 80 devices.
All the above technologies involving equipment have been patented. By taking the above measures, adv & amp； Compared with F 1 valve tray, reg differential valve tray has the following advantages: the production capacity is increased by more than 40%, the separation efficiency is more than 10%, the operation flexibility is more than 40%, and the pressure drop is about 10%.