减压转油线气液两相流动特性模拟及结构优化研究
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摘要
减压转油线作为原油蒸馏中减压单元的重要组成部分,对于减压装置的稳定操作、减压深拔、改善油品质量和节能意义重大。本文在采集大量工业数据的基础上,针对转油线内伴随相变的气液两相流动过程,建立了相应的数学模型,对各种参数在转油线内的分布规律进行了深入系统的研究。
基于多级闪蒸模型和压降模型建立了转油线的一维两相流模型。模型求解可以得到转油线内压力、温度、流速和汽化率沿转油线轴向的变化情况,结果表明,各参数的变化主要发生在过渡段和合流段,低速段变化不大。对七套工业转油线的计算结果表明,A型直插式转油线合流处压力陡降,压降最大;B型渐扩式转油线合流处压力缓慢下降,压降最小;C型二次扩径式结构压力出现两处陡降,压降较小。
利用计算流体力学(CFD)方法建立了变质量可压缩三维拟单相流数学模型,用于描述可压缩气体各物理量在转油线内分布情况。模拟结果表明,合流段克服流动阻力损失的能量最多,其次是过渡段。过渡段弯管会产生二次流动现象,合流处有旋涡区存在,这些局部损失是过渡段与合流段压降较大的主要原因。对七套工业减压转油线的流场变化规律综合分析表明:过渡段中弯头、高差、管径以及合流段的连接方式对转油线的压降影响很大;在合流段采用裤形三通连接以及二次扩径均有利于减小转油线的压降。
利用多级闪蒸模型和VOF两相流模型建立了多级闪蒸与两相流耦合三维数学模型,分段考察了转油线内气液两相流动过程中的压降和流型。研究发现,过渡段最后管段及合流段第一段管段压降最大;液相在转油线内以大液滴的形式存在,呈现出环状流与雾状流之间的一种过渡流型,而且,不同的转油线结构合流处液体分布情况不同。另外,对所建立的三种模型进行了综合对比分析。
在以上研究的基础上,为减小转油线压降、以提高常压渣油拔出率或降低减压炉出口温度,利用单相流模型对转油线的过渡段、合流段和低速段直径分别进行了优化,并提出了改进结构。利用已建立的多级闪蒸与两相流动耦合模型对改进结构进行了准确计算,结果表明改进结构比原结构压降减小36.8%。利用一维两相流模型考察了改进结构对减压蒸馏单元的影响,研究发现可提高减压塔进料段汽化率或降低减压炉出口温度并实现节能。
The transfer line refers to a pipeline connection between the furnace and the vacuum column in the crude oil diatillation unit. A well-designed transfer line can increase the evaporation rate of the feed in the vacuum distillation tower, improve oil product quality and save energy for vacuum distillation unit. Different mathematical models have been established in this paper to improve fundamental understanding of gas-liquid two-phase flashing flow in the transfer line. Moreover, the distribution regularities of pressure, temperature and other parameters in the transfer lines with various structures have been investigated with the models on the basis of a large amount of filed data.
Firstly, the one-dimensional, two-phase flow model is developed on the basis of pressure drop model and the multi-stage flash model. The axial pressure, temperature, velocity and evaporation rate are predicted by the model and it is found that variations of parameters principally occur in the transition section and the junction site. The analysis of the seven industrial transfer lines show that the pressure drops of Type A are bigger than others because the transition section merged to the low speed section directly, the pressure decreased gradually in the transfer lines of Type B, the pressure drop of which is the lowest; the pressure drop of Type C with two-stage enlargement structure decreased sharply twice.
Secondly, the three-dimensional, compressible single flow model is developed by a commercial computational fluid dynamics (CFD) package. The results of the CFD simulation provided an insight into the phenomena occurring within the flow field in the pipe. It is also found that the secondary motion occurred at the transiton section and swirls existed at the junction section, which are the main reasons for the pressure drop of the two sections. The flow field analysis of the seven transfer lines shows that the bends, difference in elevation, diameter and junction structures have great influence on the pressure drop. Moreover, the suitable junction structure and two-stage enlargement is useful for decreasing the pressure drop.
Thirdly, the three-dimensional multi-stage flash & VOF two-phase flow coupling model is developed to simulate the true situation in the transfer line. The results show that the pressure drop mainly occurred in the last segment of the transition section and the first segment of the junction. In addition, the flow regime shows a transition situation between annular flow and mist flow, and liquid are large droplets. The analysis and comparison of the three models developed in this thesis are also studied.
Last, the structure optimization of the transition section, junction and low-speed section are studied by single flow model and a retrofitted structure is developed. The retrofitted structure is simulated by three-dimensional multi-stage flash & two-phase flow coupling model and it is found that the pressure drop of the new structure compared with the original one can be decreased by 36.8%. The decrease of pressure drop has a great influence on the vacuum distillation unit. On the one hand, the evaporation rate can be improved at a certain vacuum furnace outlet temperature. On the other hand, the outlet temperature of the vacuum furnace can be lowered at a certain transfer line outlet pressure, which can improve product quality and also has the advantage of energy conservation.
基于多级闪蒸模型和压降模型建立了转油线的一维两相流模型。模型求解可以得到转油线内压力、温度、流速和汽化率沿转油线轴向的变化情况,结果表明,各参数的变化主要发生在过渡段和合流段,低速段变化不大。对七套工业转油线的计算结果表明,A型直插式转油线合流处压力陡降,压降最大;B型渐扩式转油线合流处压力缓慢下降,压降最小;C型二次扩径式结构压力出现两处陡降,压降较小。
利用计算流体力学(CFD)方法建立了变质量可压缩三维拟单相流数学模型,用于描述可压缩气体各物理量在转油线内分布情况。模拟结果表明,合流段克服流动阻力损失的能量最多,其次是过渡段。过渡段弯管会产生二次流动现象,合流处有旋涡区存在,这些局部损失是过渡段与合流段压降较大的主要原因。对七套工业减压转油线的流场变化规律综合分析表明:过渡段中弯头、高差、管径以及合流段的连接方式对转油线的压降影响很大;在合流段采用裤形三通连接以及二次扩径均有利于减小转油线的压降。
利用多级闪蒸模型和VOF两相流模型建立了多级闪蒸与两相流耦合三维数学模型,分段考察了转油线内气液两相流动过程中的压降和流型。研究发现,过渡段最后管段及合流段第一段管段压降最大;液相在转油线内以大液滴的形式存在,呈现出环状流与雾状流之间的一种过渡流型,而且,不同的转油线结构合流处液体分布情况不同。另外,对所建立的三种模型进行了综合对比分析。
在以上研究的基础上,为减小转油线压降、以提高常压渣油拔出率或降低减压炉出口温度,利用单相流模型对转油线的过渡段、合流段和低速段直径分别进行了优化,并提出了改进结构。利用已建立的多级闪蒸与两相流动耦合模型对改进结构进行了准确计算,结果表明改进结构比原结构压降减小36.8%。利用一维两相流模型考察了改进结构对减压蒸馏单元的影响,研究发现可提高减压塔进料段汽化率或降低减压炉出口温度并实现节能。
The transfer line refers to a pipeline connection between the furnace and the vacuum column in the crude oil diatillation unit. A well-designed transfer line can increase the evaporation rate of the feed in the vacuum distillation tower, improve oil product quality and save energy for vacuum distillation unit. Different mathematical models have been established in this paper to improve fundamental understanding of gas-liquid two-phase flashing flow in the transfer line. Moreover, the distribution regularities of pressure, temperature and other parameters in the transfer lines with various structures have been investigated with the models on the basis of a large amount of filed data.
Firstly, the one-dimensional, two-phase flow model is developed on the basis of pressure drop model and the multi-stage flash model. The axial pressure, temperature, velocity and evaporation rate are predicted by the model and it is found that variations of parameters principally occur in the transition section and the junction site. The analysis of the seven industrial transfer lines show that the pressure drops of Type A are bigger than others because the transition section merged to the low speed section directly, the pressure decreased gradually in the transfer lines of Type B, the pressure drop of which is the lowest; the pressure drop of Type C with two-stage enlargement structure decreased sharply twice.
Secondly, the three-dimensional, compressible single flow model is developed by a commercial computational fluid dynamics (CFD) package. The results of the CFD simulation provided an insight into the phenomena occurring within the flow field in the pipe. It is also found that the secondary motion occurred at the transiton section and swirls existed at the junction section, which are the main reasons for the pressure drop of the two sections. The flow field analysis of the seven transfer lines shows that the bends, difference in elevation, diameter and junction structures have great influence on the pressure drop. Moreover, the suitable junction structure and two-stage enlargement is useful for decreasing the pressure drop.
Thirdly, the three-dimensional multi-stage flash & VOF two-phase flow coupling model is developed to simulate the true situation in the transfer line. The results show that the pressure drop mainly occurred in the last segment of the transition section and the first segment of the junction. In addition, the flow regime shows a transition situation between annular flow and mist flow, and liquid are large droplets. The analysis and comparison of the three models developed in this thesis are also studied.
Last, the structure optimization of the transition section, junction and low-speed section are studied by single flow model and a retrofitted structure is developed. The retrofitted structure is simulated by three-dimensional multi-stage flash & two-phase flow coupling model and it is found that the pressure drop of the new structure compared with the original one can be decreased by 36.8%. The decrease of pressure drop has a great influence on the vacuum distillation unit. On the one hand, the evaporation rate can be improved at a certain vacuum furnace outlet temperature. On the other hand, the outlet temperature of the vacuum furnace can be lowered at a certain transfer line outlet pressure, which can improve product quality and also has the advantage of energy conservation.
引文
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