Khi c qua ti liu ny, nu pht hin sai st hoc ni dung km cht lng xin hy thng bo chng ti sa cha hoc thay th bng mt ti liu cng ch ca tc gi khc. Ti liu ny bao gm nhiu ti liu nh c cng ch bn trong n. Phn ni dung bn cn c th nmgia hoccui ti liu ny, hy s dng chc nng Search tm chng. Bn c th tham kho ngun ti liu c dch t ting Anh ti y:http://mientayvn.com/Tai_lieu_da_dich.htmlThng tin lin h: Yahoo mail: thanhlam1910_2006@yahoo.comGmail: frbwrthes@gmail.comINTRODUCTION OF DUNG QUAT REFINERYDUNG QUAT REFINERY Sit e 12 kmin theEast of No 1 nationalroad 7kmfromChuLai Airport, 100kmfromDaNang 38kmfromQuangNgai Town TheSiteis bounded by Dung QuatBay to the North and Viet ThanhBaytotheSouth Quang Ngai Pr ovinceArea: 5,131.51 km2Population: 1,198,500 (1999)DUNG QUAT REFINERY Capacity: 6.5 million tons crude oil/annum (148,000 BPSD) Feedstock: Sweet case: Bach Ho Crude Oil Sour Case: Mix Bach Ho + Dubai (5.5/1) Capital investment $3.0 billion.DUNG QUAT REFINERYMain products (meet ASEAN standards): LPG Polypropylene Unleaded Gasoline (RON 83 and 92) J et Fuel (J et A1)/ Burning Kerosene Auto Diesel and Industrial Diesel Fuel OilDUNG QUAT REFINERY Package 1:Refinery Inside Battery Limit Package 2:Crude Tank Farm Package 3:Product Tankage, Truck Loading, Interconnecting Pipeline, Product Export berth Package 4: Single Point Mooring (SPM) Package 5A: Breakwater Package 5B: J etty Package 7:Administration BuildingDUNG QUAT REFINERYPlot Plant:36 ha40 ha4 ha27 ha125 ha232 ha(Add. 135 ha for ProductHarbor Service Area)DUNG QUAT REFINERYEPC Package 1 (Refinery Inside Battery Limit) Includes: Process Units, Utility and Offsite facilities Main Process Units: Crude Distillation Unit (CDU) Kerosene Treating Unit (KTU) Naphtha Hydrotreating Unit (NHT) Continuous Catalytic Reforming Unit (CCR) Residue Fluid Catalytic Cracking Unit (RFCC) LPG Treating Unit (LTU) RFCC Naphtha Treating Unit (NTU) Propylene Recovery Unit (PRU)DUNG QUAT REFINERYEPC Package2: CrudeTankage StoresCrudeOil importedthroughSPM Includes six floating roof tanks with totalworkingcapacity: 390,000m3 Capacity is equal to 11day's operationat thedesign CDU feed rate ( 148,000 BPSD) +maximumparcel size(110,000DWT).DUNG QUAT REFINERYEPC package 3: Product Tankage, Truck Loading, J etty Topsides, Interconnecting pipeline Storesandexportsproducts Includes: 27 tanks with total working capacity: 397,000 m3to store anddispatch products via J etty Topsides, Truck Loading and ProductPipeline Interconnecting Pipelines: totally 10 km(7kmfromtheRefinery tothe Product Tankage and 3km fromthe Product Tankage to theProductExport Berths J etty: Loadingarms, MOV valves, sloptanks, drains, etc., as well ason-shore facilities including custody transfer flowmeters, safetyvalves, etc.DUNG QUAT REFINERYEPC Package 4: single point Mooring (SPM) Import CrudeOil fromTanker TheSPM Unit comprisesof SinglePoint MooringBuoy Interconnectinghoses PLEM submarinepipeline TheSPM buoy is locatedapproximately 3.2kmoff-shoreinViet Thanhbay.DUNG QUAT REFINERYEPCPackage5A: Beakwater Keep the Loading Operations in goodcondition TheBreakwater of about 1.6kmlongDUNG QUAT REFINERYEPC Package 5B: Product Export Berths Harbour for product export operations Includes: 2 OceanTankers Berths (Berths 1and2) providecapability forocean tankers in the range of 15,000 to 30,000 dead weighttonnage(DWT) withfacility expandableto50,000DWT. 4Coastal TankersBerths(Berths3, 4, 5, 6) providecapabilityforcoastal tankers in the range of 1,000 to 5,000 dead weighttonnage(DWT) withfacility expandableto30,000DWT.DUNG QUAT REFINERYEPC Package 7: Administration Building OperationSupports Consistsof: AdministrationBuilding FireStation/GasRescueStation Canteen/Shop/ Laundry Building First AidStation MaintenanceShop; GarageFacilities/Motor Pool BuildingDUNG QUAT REFINERYProductsBalance,tons/yearBMD BMG MMD MMGPropylene 108,333 157,000 111,000 147,666LPG 286,000 343,667 276,333 307,000GasolineA92(unlead) 1,407,667 1,952,333 1,534,333 2,081,667GasolineA83(unlead) 534,667 718,000 407,667 515,667Kerosene/JetA1 282,333 219,667 219,667 219,667AutoDiesel 2,084,333 2,115,667 2,225,333 2,321,000IndustrialDiesel 1,327,000 430,000 252,000 30,000FO 115,667 177,000 1,131,667 466,000ProductTotal 6,146,000 6,113,000 6,158,000 6,088,667Lostandconsumed 354,000 386,667 342,000 441,333Total 6,500,000 6,500,000 6,500,000 6,500,000DUNG QUAT REFINERYPROCESS UNITSDUNG QUAT REFINERYNote : Stabiliser and Naphtha Splitter are parts of CDUSPMCrude TankageCDULTURFCCGas Pl antRFCCNHT CCRKTUNTUPropyleneLPGMogas 92/83Jet A1KeroseneAuto/Ind. DieselFOLPG + FGLNHNKeroseneLGOHGOResidueLCODCORFCC NaphthaLPG LPGC3Mix C4LPGTreated HN ReformateTreated RFCC NaphthaStabiliserSplitterNote Note PRUCrude Distillation Unit (CDU) Capacity: 148,000 BPSD (6.5 millions TPA) Duty: Split Crude Oil into a number of hydrocarbon fractions by distillation process System: Desalter Fired Heater Main Fractionators & associated Strippers Stabilizers and SplittersCrude Distillation Unit (CDU)Product Streams: Light Ends: To RFCC Gas Plant Light Naphtha: To Mogas Blending Heavy Naphtha: To NHT Kerosene:To KTU/Kerosene Tankage Light Gas Oil: To Diesel Blending Heavy Gas Oil: To Diesel/Fuel Oil Blending Residue: To RFCCNaphtha Hydrotreating Unit (NHT) Capacity:21,000 BPSD Licensed by:UOP Duty: Remove sulfur, chlorite, nitrogen, oxygen, metallic compoundsin heavy naphtha stream taken fromCDU process to protect CCR catalyst by HydrotreatingNaphtha Hydrotreating Unit (NHT) A single fixed bed catalyst reactor Catalyst:Co +Mo +Al2O3 Catalyst regeneration cycle life: >2 years Treated naphtha:To CCR Off-gas: To FG Amine Absorber at RFCC Gas PlantContinuous Catalytic Reformer (CCR) Capacity:21,000 BPSD Licensed by:UOP Duty: Reform heavy naphtha straight-run from NHT to High Octane Mogas Blending components (Reformat) Catalyst: Pt/Al2O3Continuous Catalytic Reformer (CCR) Systems: 4 Reactors (Platformer) Continuous Catalyst Regenerator (Cycle Max) Combined Exchangers Reformat:To Mogas Blending Un-stabilized LPG: Blended with Refinery LPG stream and routed to LPG storageKerosene Treating Unit (KTU) Capacity:10,000 BPSD Licensed by:MERICHEM Duty: Treat kerosene stream taken from CDU to meet J et A1 specifications Technology:FIBER-FILM ContactorKerosene Treating Unit (KTU) System: NAPFINING: Naphthenic acid extraction MERICAT II: Mercaptan oxidation AQUAFINING: Water washing Remove Na+ Salt Dryer: Remove trace of free water and dry kerosene below saturation Clay Filter: Remove remaining solids, moistures, soaps, emulsions and surfactantKerosene Treating Unit (KTU) Treating reagents: NaOH 200 and 50 Be, activated carbon, salt, Attapulgus clay Catalyst: Cobalt Phthalocyanine (ARI-100 EXL, ARI-120L), MEA 50% Treated kerosene:To J et A1 Storage Spent caustic:To CNU Alkaline water:To ETPResidue Fluid Catalytic Cracker (RFCC) Capacity:69,700 BPSD Licensed by:IFP Duty: Converts heavy compounds of CDU residue into value products (lighter compounds) by catalytic cracking process Catalyst:ZeoliteResidue Fluid Catalytic Cracker (RFCC) Operation mode: Max Gasoline Max Distillate System: Reactor and 2-stage catalyst regenerator Main Fractionator Gas Recovery Section (Gas Plant)RFCC Gas Plant Process the following streams: CDU Stabilizer Off-gas CDU LPG rich stream NHT Off-gas Wet gas from RFCC Fractionator Duty: Recovers C3/C4 Removes H2S, CO2from LPG and fuel gas by DEA absorbersResidue Fluid Catalytic Cracker (RFCC) Product streams: Unsaturated off-gas: To Refinery Fuel gas Mix C3/C4:To LTU Naphtha:To NTU Light Cycle Oil (LCO): To Diesel Blending Decant Oil (DCO): To Fuel Oil Blending Other streams: Sour water: To SWS Rich amine: To ARULPG Treating Unit (LTU) Capacity:21,000 BPSD Licensed by:MERICHEM Duty: Remove Mercaptan, COS, H2S from LPG stream of RFCC Gas Plant Technology:FIBER-FILM Contactor 2-stage THIOLEX extraction systemLPG Treating Unit (LTU) Treating reagents:NaOH 200 Be Catalyst:MEA 50%wt Treated LPG:To PRU/Storage Spent caustic:To CNURFCC Naphtha Treating Unit (NTU) Capacity:45,000 BPSD Licensed by:MERICHEM Duty: Remove H2S, Mercaptan and other acidic compounds in Naphtha stream of RFCC Unit Technology:FIBER-FILM Contactor 1-stage MERICAT caustic treating systemRFCC Naphtha Treating Unit (NTU) Catalyst:Cobalt Phthalocyanine Treating reagents:NaOH 200 Be Treated naphtha:To Mogas Blending Spent caustic: To CNUSour Water Stripper (SWS) Duty: Strip NH3and H2S dissolved in sour water collected from CDU, NHT and RFCC Unit Surge drum + a single stripping column Sour gases:To SRU Stripped water:To ETP/CDU DesalterAmine Regeneration Unit (ARU) Duty: Skim hydrocarbon and strip sour gas (H2S) from rich amine stream of RFCC Unit Feed surge drum +a regeneration column Skimmed oil:To Light slops Sour gases:To SRU Stripped lean amine: To H2S absorber on RFCCSpent Caustic Neutralization Unit (CNU) Capacity: 1.5 m3/h mixed caustic stream Licensed by:MERICHEM Duty: Neutralize and remove phenolic and naphthenic oils from various spent caustic streams (KTU, LTU, NTU caustic; ETP Water; NHT alkaline water) Technology: FIBER-FILM ContactorSpent Caustic Neutralisation Unit (CNU) Caustic Deep Neutralization: Neutralize by sulphuric acid 96% and remove acid gases, naphthenic, phenolic acids from the brine Neutralization and Phenol Extraction: Neutralize to pH=7 and extract phenol from acidic brine by solvent (Kerosene) Treating reagents: H2SO496%, NaOH 50Be, Neutralized brine:To ETP Off-gas:To SRU Acid Oils/Kerosene: To Fuel Oil BlendingPropylene Recovery Unit (PRU) Capacity:21.000 BPSD Duty: Separate and purify propylene from the mixed C3/C4stream of LTU to polymer grade (99.6 wt%) specification Product stream: Propylene:To Propylene Tankage/PP Plant C3/C4:To LPG BlendingPropylene Recovery Unit (PRU) System: C3/C4Splitter: Remove C4s from LPG Propane/propylene splitting facility: De-ethaniser: Release productlighter than propylene Propane/Propylene splitting column Propylene purification: Carbonyl sulfide removal Arsenic, phosphorous and antimony removalSulfur Recovery Unit (SRU) Licensed unit Capacity: Sweet case:3 tons/day Sour case:36 tons/day Duty: Recover Sulfur in Refinery off-gas to meet environment protection requirements (SO2concentration) Product: Sulfur PowderPolypropylene (PP) Plant Licensed unit Capacity: 150,000 tons PP/annum Duty: Produce PP from Propylene product of the Refinery by polymerization process Product: Unpainted heat and light stabilized Polypropylene pellets Detailed Feasibility Study (DFS) completionWater System Duty: Produce and distribute various grade of water to users within Refinery and Product Tank Farm (PTF) as follows: Service water to users at Refinery and PTF Make-up supply to freshwater cooling system Make-up supply to Refinery potable water system Make-up supply to dematerialized water system Make-up supply to Refinery fire water systemSteam and CondensateProvides: HP, MP, LP Steam to and subsequent distribution within Refinery Collection, storage and treatment of Refinery steam condensate for reuse as HP & MP boiler feedwater (BFW) in Process Steam Generators Collection, storage and treatment of Power Generation Plant steam condensate for reuse as HHP BFW in Power Generation PlantSteam and Condensate Comprise of: Steam producing equipment Distribution Pipework HP to MP and MP to LP letdown stations Condensate collection and treatment facilities Dearators Associated chemical dosing packageCooling Water Duty: Supply cooling water to all users in process and utility units (except the condensers in Power Station) A closed fresh water system, cooled by once-through sea waterCooling Water Comprise of: Cooling Water Circulation Pumps Plate Heat Exchanger Expansion Tank Expansion Tank Oil Skimmer Chemical Dosing PackageSea Water IntakeProvides: Seawater to Power Station for once-through cooling in Vacuum Condensers Seawater to seawater/freshwater exchanger for cooling the closed loop cooling water systemSea Water Intake Consists of: Seawater Intake box (located offshore) Seawater Intake Basin Inlet Line Seawater Intake Basin (located onshore) Seawater circulation pumps Hypochlorite dosing Discharge facilities Hypochlorite for seawater chlorination is generated on site by electrolysis of seawaterPlant and Instrument Air Duty: Provides Plant and Instrument Air for demand of Refinery System: 3 Air Compressors Wet Air Receivers: Remove condensed water 2 refrigeration-type dryers 2 Instrument Air ReceiversNitrogen System Provides: Gaseous nitrogen to process users in normal operation Liquid nitrogen for storage and subsequent vaporisation to meet peak loads and startup demands Dedicated liquid nitrogen for storage and subsequent vaporisation for use in CCR Regeneration Section Independent high pressure system for leak testing of process equipment/pipelinesNitrogen System Comprises of: Nitrogen Generation Package Liquid Nitrogen Storage Vaporisation Package Method of generation: Cryogenic Air Separation Nitrogen purity: 96% volumeFuel Gas Duty: Provide Fuel Gas to process unit fired heaters and HHP Boilers at Power Station Major users of fuel gas: CDU charge heater RFCC process heaters NHT charge heater CCR process heaters Power Station BoilersFuel Gas Other users: Refinery Flare System Product Tankage (Flare system, steam regenerators) Comprises of: Fuel Gas Mix Drums Vaporiser Package Vaporise LPG/Propylene for use at Startup,disposal of LPG/Propylene off-spec., low FG pressure or emergency event Fuel Gas collection/distribution pipeworkRefinery Fuel Oil Duty: Supply Fuel Oil to all consumers within Refinery Comprises of: 2 Refinery Fuel Oil Storage Tanks Fuel Oil Pumps Fuel Oil Heater Supply and return pipeworkRefinery Fuel Oil Source of Refinery Fuel Oil: In normal operation: Decant Oil (DCO) from RFCC For Refinery Startup: Imported via SPM Outages of RFCC: Heavy Gas Oil (HGO) and/or CDU residue from CDUCaustic Supply Duty: Make up and provide caustic (NaOH) solution to all consumers within Refinery Comprises of: Dissolving Sump: dilutes solid caustic pellets Storage Tanks Pumping FacilitiesCaustic Supply Concentrations of NaOH solution are made up, stored and distributed on site: 500Be (49.5 wt%) Made up by dissolving solid caustic in demin. water 200Be (14.4 wt%) Made up by diluting 500Be caustic in demin. water 50Be (3.4 wt%) Made up by diluting 500Be caustic in demin. waterPower Generation & Distribution Provide: Electrical Power to Refinery and all associated facilities Steam and condensate to Refinery 4 15 MW Steam Turbine Turbo-Generators Ability to import/export power from/to EVN gridRefinery Tankage Duty: Stores and handles the intermediates and finished products of the Refinery: 1 Off-spec Propylene Sphere 1 RFCC Feed Tank 2 NHT Feed Tanks 1 Off-spec RFCC Naphtha Tank 1 Reformate Tank 1 Light Naphtha Tank 2 Mix C4s Spheres 1 HGO Tank 2 LCO Tanks Product Blending Consists of a number of separate systems and associated components for blending the final products of Refinery: 92 RON Mogas 83 RON Mogas Auto Diesel Industrial Diesel Fuel OilFlushing Oil Unit number: 055 Provides: Flushing Oil for process units and Offsite pipework Contains catalyst fines Pour point is higher than minimum daily ambient temp. Flushing Oil for SPM loop Consists of: Facilities for flushing process units Separated facilities for flushing SPM loopFlushing Oil Source of Flushing Oil: For Process units and Offsite pipework: LCO from LCO Intermediate Storage Tank For SPM loop: LGO from SPM Flushing Oil Tank as a slip stream from CDU rundown SPM loop is flushedimmediately before and after each transfer operationSlops Duty: Collects, Stores light and heavy slops from Refinery process units and Offsite areas for subsequent reprocessing in CDU or RFCC Oily Water: To Refinery ETP for further treatment Alternativedisposal routefor heavy slops: Refinery Fuel Oil SystemFlare System Consists of: Refinery Flare System Product Tank Farm Flare System Each Flare System comprises of: Main Flare Stack Sour Gas Flare Riser (handle all discharges containing H2S at levels higher than 10% vol.)Effluent Treatment Plant (ETP) Duty: Treat effluent streams to meet environment protection requirements Consists of: Refinery ETP Primary, secondary and tertiary treatment facilities to remove oils, solids and organics Product Tankage ETP Primary treatment for removing oil and solidsEffluent Treatment Plant (ETP) Products stream: Treated effluent: discharged to the sea Recovered slop oil: pumped to Refinery Heavy Slops tank for re-processing Digested biological sludge: Buried in Dedicated Area De-watered, de-oiled refinery sludge: To other facilities for special treatmentFire Water System Duty: Supply water for firefighting Comprises of 2 separate firewater systems: Refinery and nearby facilities Product Tank Farm, Truck Loading and J etty Topsides Firewater was taken from the sea at J etty B LAO NG - THNG BINH V X HI TNG CC DY NGH D n gio dc k thut v dy ngh (VTEP) Logo Gio trnh M un: THC TP VN HNH TRN HTHNG M PHNG M s: HD O Ngh: VN HNH THIT B HA DU Trnh : lnh ngh H Ni - 2004 2 M tI liu:. 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(Tm tt ni dung ca D n) (Vi nt gii thiu qu trnh hnh thnh ti liu v cc thnh phn tham gia) (Li cm n cc c quan lin quan, cc n v v c nhn tham gia ) (Gii thiu ti liu v thc trng) Ti liu ny c thit k theo tng m un/mn hc thuc h thng m un/mnhccamtchngtrnh,otohonchnhnghvnhnh thit b ch bin du kh cp trnh lnh ngh v c dng lm Gio trnh cho hc vin trong cc kho o to, cng c th c s dng cho o to ngn hn hoc cho cc cng nhn k thut, cc nh qun l v ngi s dng nhn lc tham kho. yltiliuthnghimschonchnhtrthnhgiotrnh chnh thc trong h thng dy ngh. H ni, ngy . thng. nm. Gim c D n quc gia 4 MC LC mcTrang MC LC .......................................................................................................... 4 V tr, ngha, vai tr m un ............................................................................. 6 Mc tiu ca m un ......................................................................................... 6 Mc tiu thc hin ca m un ......................................................................... 6 Ni dung chnh ca m un ............................................................................... 7 CC HNH THC HC TP CHNH TRONG M UN ................................... 9 YU CU V NH GI HON THNH M UN .......................................... 9 BI 1 KHI NIM H THNG M PHNG.................................................... 10 1.1. NGHACA H THNG M PHNG ................................................ 10 1.2. S H THNG M PHNG ............................................................. 12 1.3. CC M HNH M PHNG ..................................................................... 15 BI 2 VN HNH PHN XNG CHNG CT DU TH P SUT THNG (CDU) ............................................................................................. 17 2.1. S CNG NGH M HNH M PHNG ......................................... 18 2.2. KHI NG PHN XNG ................................................................... 21 2.3. DNG PHN XNG ............................................................................. 25 BI 3 VN HNH PHN XNG CRACKING XC TC CN ...................... 32 3.1. S CNG NGH CA M HNH M PHNG ................................ 32 3.2. CC BC KHI NG PHN XNG .............................................. 36 3.3. DNG PHN XNG ............................................................................. 40 BI 4 VN HNH PHN XNG REFORMING TI SINH XC TC LIN TC (CCR) ...................................................................................................... 50 4.1. S CNG NGH M HNH M PHNG ......................................... 50 4.2. KHI NG PHN XNG ................................................................... 52 4.3. DNG PHN XNG ............................................................................. 56 BI 5 VN HNH PHN XNG X L NAPHTHA BNG HYDRO (NHT) .. 61 5.1. S CNG NGH M HNH M PHNG ......................................... 61 5.2. KHI NG PHN XNG ................................................................... 65 5.3. DNG PHN XNG ............................................................................. 67 BI 6 VN HNH PHN XNG NG PHN HA NAPHTHA NH (ISOMER) ........................................................................................................ 77 6.1. S CNG NGH M HNH M PHNG ......................................... 78 6.2. KHI NG PHN XNG. .................................................................. 79 5 6.3. DNG PHN XNG ............................................................................. 81 BI 7 VN HNH PHN XNG X L GO BNG HYDRO (GO-HTU) ..... 88 7.1. S CNG NGH M HNH M PHNG ......................................... 89 7.2. KHI NG PHN XNG ................................................................... 92 7.3. DNG PHN XNG ............................................................................. 95 BI 8 VN HNH PHN XNG THU HI PROPYLENE (PRU) .............. 104 8.1. S CNG NGH M HNH M PHNG ....................................... 104 8.2. KHI NG PHN XNG ................................................................. 106 8.3. DNG PHN XNG ........................................................................... 107 CC THUT NG CHUYN MN ............................................................... 114 TI LIU THAM KHO .................................................................................. 115 6 GII THIU V M UN V tr, ngha, vai tr m un Cc nh my lc ha du hin nay u c thit k c th thc hin qutrnhiukhinmymcthitbcthchintphngiukhin trung tm nh h thng iu khin t ng. Nhn vin vn hnh theo di hot ngmy mc thit b v iu khinhot ng ton bnh my t bn iu khin phng iu khin trung tm. gip hc vin hnh thnh k nng iu khin, lm quen vi my mc thit b rtngn thi gian thc tp trc tip ti cc c s sn xut ngi ta xy dng mt h thng m phng (simulation) h thng iu khin my mc thit b t bn iu khin nh trong thc t. Viphngthcotonychophpngincchngtrnh, gimcthigianthctpthct,gimchiphotonhngvnthu c hiu qu cao. Mc tiu ca m un M un nhm o to cho hc vin c kin thc, k nng v vn hnh cc qu trnh cng ngh c bn trong cng nghip ch bin du kh. Hc xong m un ny hc vin phi c nng lc: -M t c nguyn l chung ca h thng m phng, cc thit b chnh, chc nng, nhim v ca cc thit b; -Mtcctnhcamtsphnxng,loithitbkhcnhau trong cng ngh lc hoa du; -Lmquenvivnhnhnhmylchaduhinitphngiu khinthngquahthngiukhinphntn(DCS),baogmcc nhimvkhing(Start-up),vnhnhbnhthng(Normal Operation),dngphnxngtheokhochvdngkhncp (Emergency Shutdown); -Rt ngn c thi gian thc tp nh my hoc Pilot; -M t v thc hin c quy trnh c bn v khi ng, dng khn cp phnxng,thitb(tphngiukhintrungtm)thngquah thng iu khin phn tn (DCS) v h thng dng khn cp (ESD); -Mtcsngng,thitbolng(P&ID's)camts phn xng cng ngh chnh trong cng ngh lc ha du. Mc tiu thc hin ca m un Hc xong m un ny hc vin phi c nng lc: 7 -Khi ng c cc phn xng chnhtrong cng ngh ch bin du kh (trn thit b m phng): +Phn xng chng ct du th p sut thng (CDU) +Phn xng Cracking xc tc cn (RFCC) +Phn xng Reforming ti sinh xc tc lin tc (CCR) +Phn xng x l Naphtha bng hydro (NHT) +Phn xng ng phn ha Naphtha nh (ISOMER) +Phn xng x l GO bng hydro (GO-HTU) +Phn xng thu hi Propylene (PRU) -Xlcmtsscthngxyratrongqutrnhvnhnhcc phn xng ni trn; -Dng khn cp cc phn xng theo tng tnh hung c th; -M t c khi qut qu trnh iu khin nh my lc ha du hin i t phng iu khin trung tm. Ni dung chnh ca m un Bi 1 Khi nim h thng m phng Bi 2 Vn hnh phn xng chng ct du th p sut thng (CDU) Bi 3 Vn hnh phn xng Cracking xc tc cn (RFCC) Bi 4 Vn hnh phn xng Reforming ti sinh xc tc lin tc (CCR) Bi 5 Vn hnh phn xng x l Naphtha bng hydro (NHT) Bi 6 Vn hnh phn xng ng phn ha Naphtha nh (ISOMER) Bi 7 Vn hnh phn xng x l GO bng hydro (GO-HTU) Bi 8 Vn hnh phn xng thu hi Propylene (PRU) 8 S quan h theo trnh t hc ngh An ton lao ngK thutphng thnghimThnghimchuyn ngnhBo d- ng thit bChuyn d phngMn chung Chnh trPh p lutGDQPGDTCTo n cao cpNgo i ngTin hc nh h-ng gi n tipSn phm du m n mn kim lo i ng hc xc t cKin thc c s nhm nghKin thc c snghVn hnh thit bchbin du khK thutmi trng nh hng gi n tipThc tp tt nghipThc hnh trn thit bm phngQutrnh x lChng ct -chbin duTn tr vvn chuyn x ng duMn c bnQutrnh thit bHa phn tchHa v cHa hu cHa lC k thutVt l i c-ngQT doanh nghipDng c oQutrnh reformingQutrnh CrackingCng nghchbin khTh p c c cu t cho x ngS cng nghnhm y lc duKT inKT in tVk thutHa hc du m & khThc tp qutrnh thit b Ghi ch: Thc tp vn hnh trn h thng m phng l m un c s ca ngnh ha du. Mi hc vin phi hc v t kt qu chp nhn c i vi cc bi kim tra nh gi v thi kt thc nh t ra trong chng trnh o to. Nhng hc vin qua kim tra v thi m khng t phi thu xp cho hc li nhng phn cha t ngay v phi t im chun mic php hc tip cc m un/ mn hc tip theo. Hc vin, khi chuyn trng, chuyn ngnh, nu hc mt c s o to khc ri thphi xut trnh giy chng nhn; Trong mt s trng hp c th vn phi qua st hch li. 9 CC HNH THC HC TP CHNH TRONG M UN 1: Nghe gio vin gii thiu v h thng m phng 2:Thctpvnhnhccphnxngchnhtrongcngnghiplchodu nh:chngctduthpsutkhquyn,Crackingxctccn(RFCC), Reformingtisinhxctclintc(CCR),xlNaphthabnghydro(NHT), ng phn ha Naphtha nh (ISOMER), x l GO bng hydro (GO-HTU),thu hi Propylene (PRU). 3: T nghin cu ti liu theo ch hng dn ca gio vin. 4: Thmquan, thc tp ti phng iu khin trung tmnh my lcho du hoc pilot . YU CU V NH GI HON THNH M UN V kin thc-M t c nguyn l, cu hnh h thng m phng qu trnh iu khin nh my t bn iu khin; -Khi ng c phn xng chng ct du th p sut kh quyn; -Khi ng c phn xng Cracking xc tc cn (RFCC); -Khi ng c phn xng Reforming ti sinh xc tc lin tc (CCR); -Khi ng c phn xng x l Naphtha bng hydro (NHT); -Khi ng c phn xng ng phn ha Naphtha nh (ISOMER); -Khi ng c phn xng x l GO bng hydro (GO-HTU); -Khi ng c phn xng thu hi Propylene (PRU). V k nng -S dng thng tho chc nng bn iu khin. -Thao tc khi ng cc phn xng ng cc bc yu cu; -X l c cc tnh hung s c thng thng trong qu trnh vn hnh. -iu khin c cc qu trnh cng ngh ch yu trong ch bin du kh. V thi -Tham gia y cc bui ging ca gio vin. -Tch cc nghin cu, tm hiu cc ti liu lin quan n cc phn xng cng ngh h tr cho vic vn hnh. -Chphnh ng quy nh an ton trongphng thchnh v tham quan cc c s sn xut. 10 BI 1. KHI NIM H THNG M PHNG M bi: HD O1 Gii thiu Ngynay,sphttrincakthutiukhinlmthayicbn yucuknngcanhnvinvnhnhtheoquannimtruynthng,c bitltronglnhvcchbindukh.Nhnvinvnhnh,iukhinmy mc, thit b t mt trung tm iu khin m khng cn trc tip thao tc trn mt bng. Vic o to k nng ca nhn vin vn hnh tri qua nhiu bc, trong giai on thc tp ti trung tm iu khin c mt vai tr quan trng. Tuy nhin, nu hc vin thc tp ngay trn cc bn iu khin thc khi cha c hiu bit y v h thng iu khin s gy nhiu kh khn cho vic vn hnh v nguy c xy ra ri ro do thao tc ca hc vin. gii quyt vn ny, ngi ta xy dng mt h thng m phng qu trnh hot ng, vn hnh nhmytbniukhinhcvinthctp,lmquenvicngtcvn hnh. Thng quahc tp trn h thng m phng hnh thnh cc knng vn hnh cho hc vin trc khi thc tp ti c s sn xut. Nh h thng m phng gip cho hc vin rt ngn c thi gian thc hnh thc t nhng vn m bo hiu qu o to cao. Mc tiu thc hin -M t c nguyn l hot ng ca h thng m phng. -Mtcchcnng,nhimvcaccthitbtronghthngm phng -M t v thao tc thnh tho cc chc nng ca bn iu khin, -Trnh by c cc yu cu trong vn hnh h thng m phng.Ni dung chnh -Nguyn tc hot ng ca h thng m phng -S h thng, chc nng ca cc my mc, thit b trong s . -Cc m hnh, phn mm ng dng trong h thng. 1.1. NGHACA H THNG M PHNG o to k nng vn hnh thit b trong cng nghip ch bin du kh cnphitriquagiaionthctpthcttrnbniukhincaphng iukhintrungtm.Tuynhin,victhctpsgpnhiukhkhnvc th gy ra s c nu nh hc vin cha c kin thc v vic iu khin my mctbniukhinhoclnutipxcvihthng.Mtkhc,vic tham gia ca hc vin thc tp trong phng iu khin trung tm t nhiu nh 11 hng n hot ng ca nhn vin vn hnh, v vy, thi gian thc tp cn phi c rt ngn cng tt. Tuy nhin, vic rt ngn thi gian thc tp khng c ngha l cho php gim cht lng o to. gim bt thi gian thc tp thct,giphcvincnhngknngnhtnhtrckhithctpvn hnh,ngitaxydngmththngmphngqutrnhvnhnh,hot ng ca nh my t bn iu khin. M hnh ny v hnh thc bn ngoi v p ng ging nh bn iu khin thc t, nh vy, hc vin khng gp phi kh khn khi thc tp vn hnh trn thit b thc. Hnh H.1-1. Mn hnh m phng cc thit b hin trng H thng m phngny c th trc tuyn (i vi phng m phng ca nhmyhochthngpilot)hocmphngtnhiuhontonnhphn mm. a phn cc c s o to u s dng h thng m phng bng my tnh, ngoitr cc c s o to ca nh my cho php o to trc tuyn. Nh c h thng m phng ny, hc vin thc tp vn hnh n l tng phnxngchonkhithnhthosausthamgiathctpthctti cccssnxutnuiukinchophp.Quaqutrnhthctptrnh thngmphnghcvinxydngchomnhknngvnhnhccphn xng chnh trong cng nghip ch bin du kh. Cc k nng chnh bao gm: Sdngthnhthochcnngcaccbnphmiukhin,ccbcvn hnh tng phn xng, gii quyt cc s c xy ra, thng tho cc mn hnh, ng c tuyn phc v cho qu trnh iu khin cc qu trnh. H thng m phng vn hnh gip cho hc vin lm quen, phi hp nhp nhnggianhnvinvnhnhtrongphngiukhintrungtmvnhn 12 vinvnhnhngoihintrng.Hthngmphngqutrnhvnhnh khng ch xy dng k nng cho nhn vin vn hnh phng iu khin trung tmmcnxydngknngvnhnhchonhnvinvnhnhngoihin trng. Hc vin c th nhn bit c cc thit b hin trng, phng thc vn hnh thng qua hnh nh hin th trn mn hnh ca my tnh hin trng (xem hnh H.1-1). Hnh H.1-2. S h thng m phng o to vn hnh 1.2. S H THNG M PHNG 1.2.1. S h thng m phng thc hin c chcnng o tohc vin vnhnh t phng iu khintrungtmtrongccnhmychbindukh,shthngm phng vn hnh nh my ch bin du kh c cu hnh nh hnh H.1-2. Theo s ny, h thng m phng vn hnh bao gm mt my tnh ch, mt my tnhphcchocngtcgimst,qunlqutrnhhctp,kimtravra nhim v cho hc vin ca gio vin hng dn, mt my tnh thc hin chc nngcanhnvinvnhnhngoihintrng(Fieldoperator),mytnh dnh cho thit k cc m hnh mi v cc my tnh m phng bn iu khin dnh cho hc vin thc tp. Ngoi cc thit b chnhnu trn trongh thng cn trang b cc thit b ngoi vi nh my in, modem kt ni vi mng internet,.... 1.2.2. Chc nng ca cc thnh phn Chcnngcaccbphntronghthngmphngvnhnhc trnh by trong cc mc di y. 13 1.2.2.1. My tnh ch Cchcnngthchinccchngtrnhcitsngiphthng mngvnhnhtheongchcnngthitk.Ccmhnhvnhnhc ci t v thc hin nh my tnh ch. My tnh ch thc hin chc nng va l my ch ca mng ng thi l my chy cc phn mm m phng. 1.2.2.2. My tnh gio vin hng dn Ngoimytnhch,mytnhcagiovinhngdncvtrquan trngtrongqutrnhotohcvin.Ccchcnngchnhcamytnh gio vin hng dn bao gm: -Hin th giao din hot ng gia h thng v hc vin: Cc ch hin thmboddngchoqutrnhsdnggimtiathaotcbn phm; -Cho php gio vin la chn m hnh vn hnh cho hc vin; -Chophplachnchhotngcamimhnh:Mytnhgio vin hng dn cho php ra cc lnh: +Khi ng m hnh +Tm ngng/khi phc li trng thi. Lnhkhing:chophpgiovinkhingmhnhotola chn v ra cc iu kin vn hnh ban u. Lnh tm dng/khi phc li: cho php gio vin hng dn dng ch hot ng ti thi im ra lnh v sau c th khi phc li ch hot ng ca m hnh t thi im tm dng. Ra bi cho hc vin: Gio vin c th xc nh cc iu kin m phng ban u cho tnht 20 trnghp trc khi a ti cc my thchnh ca hc vin. Cho php bin i thi gian m phng so vi thi gian thc: phc v cho cc yu cu v o to, cho php bin i thi gian m phng nhanh hn haychmhnsovithigianthc.Vnhiumhnhihimtrtnhiu thi gian nu nh p dng thi gian thc, do nh chc nng ny cho php y nhanh qu trnh thc hnh hay ko di thi gian tu theo mc ch c th. t ch iu khin txacho cc thit b hintrng (iu khin cc thit b hin trng c thc hin my tnh iu khin thit b hin trng). Gio vin c th thay i trng thi ca mt s thit b hin trng. ttrcmtsscthitb:ylviclmcnthittrongoto nhnvinvnhnhhcvinquenvigiiquytccscxyratrong thc t. 14 Thayiccthngsuvochngtrnhmphng:Hthngcho php thay i mt s thng s m phng do gio vin hng dn quyt nh ti thi im bt u chy chng trnh.Cc thng sny c lp trnh sn v ci t trong h thng. Cc thng s gio vin hng dn c th thay i nh: -Nhit tr ca nhin liu, -H s ng cn trong thit b trao i nhit; -Cc iu kin bin: nhit , p sut, lu lng; -Thay i thnh phn nguyn liu. Theodiccthngscngngh:Hthngchophpgiovinhng dnxcnhccthngscngngh(ccbin)cthctheoditrong qu trnh thc hin ti thi im bt u chy m hnh o to. Hinthlimnhnhvghiccskin:Chcnngnychophpgio vinhngdnxemlitonbiukincngnghxyrabaogmc cc thao tc ca gio vin v hc vin hin th trn mn hnh. 1.2.2.3. My tnh ph trch vn hnh thit b hin trng My tnh ny c chc nng m phng hot ng ca nhn vin vn hnh ngoi hin trng. Yu cu ny xut pht t thuc t vn hnh cc nh my lc ha du l mt s my mc thit b v l do an ton khng c iu khin t ng mphi c tc ng trc tip ca nhn vin vnhnh (nh cc van ng by-pass thit b trao i nhit, cc van by-pass van iu khin t ng, cc van chn, khi ng/ngt cc bm ph,...). Trnmnhnhmytnhnysmphngliccthitbhintrng. Trongthct,vnhnhccthitbnydatrnyucucaccnhnvn hnh ti phng iu khin trung tm yu cu nhn vin vn hnh hin trng thc hin. Hc vin thc tp trn my tnh ny s ng vai tr ca nhn vin vnhnhngoihintrng.Thaotcvnhnhthchintheoyucuca hc vin thc hnh timy tnh m phng bn iu khin trung tm. Hnh H.1-3. Hnh nh h thng m phng vn hnh 15 1.2.2.4. My tnh m phng bn iu khin cho hc vin Hcvinthctpvnhnhnhmytphngiukhintrungtms thctptrnccmytnhmphngny.Giovinhngdnsgiaocho mihcvin(hocmtnhmhcvin)thctpvnhnhmtphnxng (c m phng bng mt chng trnh). Trn mn hnh ca my tnh ny s hinthccchcnngnhbniukhintrungtmtrongthct,hcvin thctpvnhnhtbniukhinny.Ccchngtrnhcittrongh thng s p ng li cc thao tc ca hc vin nh vn hnh mt phn xng trong thc t. Cc my tnh m phng bn iu khin c m t v minh ha trong hnh H.1-3 v H.1-4. 1.2.2.5. Cc thit b ph Ngoiccthitbchnhcahthngnutrnhthngmphngcn trangbccthitbngoivinhmyin,hthnglutrsliudphng, modem kt ni vi mng internet, h thng cp mng ni cc my tnh. Hnh H.1-4. Hnh nh h thng bn iu khin m phng cho hc vin 1.3. CC M HNH M PHNG pngcyucucngvictrongthct,hcvincnphi ctrangbtngiadngkinthcvknngvnhnhccphn xng cng ngh s dng ph bin trong ch bin du kh. Trong khun kh ca chng trnhny s cp n cc phnxng c s dng rng ri nht,cccngnghtngtkhngcptitkimthigianvut hthng.Ngoira,s lngccmhnharatrongchngtrnhctnh nkhnnguttrangthitbcamtcsotophhpvithc tin Vit nam. Cc qu trnh cng ngh c bn, cc phn xng v cc thit b s dng trongchbindukhbaogm:phnxngchngctduthpkh quyn(CDU),phnxngCrackingxctccn(RFCC),phnxng Reformingtisinhxctclintc(CCR),phnxngxlNaphthabng 16 hydro(NHT),phnxngngphnhaNaphthanh(ISOMER),phn xng x l GO bng hydro (GO-HTU), phn xng thu hi Propylene (PRU), nh my ch bin kh, cc phn xng x l LPG, Kerosene, trung ha kim, polypropylenevccthitbquantrongtrongnhmynhlt,mynn kh,... Trong khun kh ca bi hc ny ch gii thiu mt s m hnh m phng in hnh trong cng nghip lc ha du bao gm: -M hnh vn hnh phn xng chng ct du th p sut kh quyn; -M hnh vn hnh phn xng Cracking xc tc cn (RFCC),-M hnh vn hnh phn xng Reforming ti sinh xc tc lin tc (CCR),-M hnh vn hnh phn xng x l Naphtha bng hydro (NHT),-M hnh vn hnh phn xng ng phn ha Naphtha nh (ISOMER),-M hnh vn hnh phn xng x l GO bng hydro (GO-HTU),-M hnh vn hnh phn xng thu hi Propylene (PRU), cimcthcaccmhnhny,ccbcthchnhcthc trnh bi trong cc bi hc tip theo ca chng trnh. 17 BI 2. VN HNH PHN XNG CHNG CT DU TH P SUT THNG (CDU) M bi: HD O2 Gii thiu Phnxngchngctduthcnghaquantrngivinhmy lc, ho du, trng thi hot ng ca phn xng c nh hng ln ti hot ng ca nh my. V vy, o to k nng vn hnh phn xng ny c tm quantrngivihcvin.Quaqutrnhhctpgipchohcvinnm cccknngcbntkhing,dngphnxngbnhthngcho ti dng khn cp phn xng v x l c mt s s c thng gp trong vnhnh. Sau qu trnh o tony sgiphc vin gim bt c cc li thaotctrongvnhnh,xlccctnhhungcthxyratrongthc t. M hnh m phng hot ng ca phn xng chng ct du th gii thiu trong gio trnh l m hnh in hnh, trong thc t cth c nhng khc bit nht nh nhng khng nh hng n kh nng thao tc, vn hnh ca hc vin.Nhngskhcbitnyscotobsungtrongqutrnhlm vic. Mc tiu thc hin Hc xong bi ny hc vin c kh nng: 1.chiuvmtcsngng&thitbolngiu khin (P&ID's) ca phn xng; 2.Khi ng thnh cng phn xng; 3.Khc phc c mt s s c thng gp; 4. Dng phn xng theo ng quy trnh; 5. Dng phn xng trong cc trng hp khn cp. Ni dung chnh -Sngng&thitbolngiukhin(P&ID's)caphn xng chng ct du th; -Cc bc khi ng phn xng chng ct du th; -Cc s c thng gp, gii php khc phc trong vn hnh phn xng chng ct du th; -Cc bc dng phn xng bnh thng; -Cc bc dng phn xng trong trng hp khn cp. 18 2.1. S CNG NGH M HNH M PHNG 2.1.1. Gii thiu hcvinddngtipcnvithctvnhnhphnxngchng ctduthpsutkhquyn(CDU),mhnhmphngcxydng trn s cng ngh cc phn xng chng ct s dng ph bin hin nay. M hnh chng ct du th p sut thng c xy dng trn c s cng ngh chng ct du th mt thp chnh, khng s dng thp tch s b. 2.1.2. S cng ngh v cc thit b chnh ca m hnh m phng Du th khi i qua thp chng ct c tch thnh cc sn phm chnh sau: -Phn on hydrocacbon nh; -Phn on Naphtha; -Phn on Kerosene; -Phn on Gasoil nh; -Phn on Gasoil nng; -Cn chng ct Tngngvichcnngtchccsnphmny,isowcngngh bao gm cc b phn chnh sau: -H thng cung cp du th v gia nhit s b; -Thit b tch mui; -L gia nhit; -Thp chng ct chnh; -H thng my nn v thu hi kh. S cng ngh v ng ng v thit b iu khin (P&ID's) ca phn xngtrongmhnhmphngcmttrongcchnhvCDU01n CDU-05. Cc c im chnh qu trnh cng ngh trong cc thit b chnh ca phn xng c trnh by di y. 2.1.2.1.B phn cp du th v gia nhit s b Du th t b cha du th c bm cp nguyn liu (P-201) a qua hnglotccthitbtraoinhitcaccdngsnphmcnhitcao nh cn chng ct, cc phn on Kerosene, GO nng, GO nh v cc dng du trch t thn thp hiu chnh hot ng ca thp. Du th khi qua cc thitbtraoinhitcgianhitlntinhitthchhpchoqutrnh tchmui.Nhitduthciukhinbngbiukhinnhitt ng (bng cch iu chnh van ng m b qua mt s cm thit b trao i nhit). 19 2.1.2.2. Thit b tch mui Trongthitbtchmui,duthctrnvinckhkhong. Nc c phun vo ng ng dn du th nh mt b phn iu khin t ng, lng nc b sung s c khng ch mc thch hp. S phn tn canc vo dunh thit b trn tnh v van trn. Nc phntn cng tt thkhnngtchmuirakhiducngtt.Muitrongduthshotan vonc(dokhnnghotanmuivonctthndu)vsautch nc ra khi du th. Phng php ph bin hin nay tch mui khi du thlsdngintrngcaophnhtngduvnc.Diin trngcao,cchtncnh(hotanmuichatrongduth)slin kt thnh cc ht nc ln lng xung y ri c tch ra ngoi. Nc tch ractisdnglihocatikhuxlncthi.Duthtchra pha trn bnh tch mui v c bm tng p y qua hng lot cc thit b traoinhittndngnhitthacaccdngsnphmnngirat thpchngct.Saukhirakhithittchmui,duthchiathnhmts nhnh song song gia nhit s b trc khi ti l gia nhit. 2.1.2.3. L gia nhit du th Dng du th vo l gia nhit c chia thnh bn nhnh ng gia nhit ccphniluvbcx.Lulngcaccdngduciukhin nh cc van iu khin t ng FC-201,FC-202, FC-203 v FC-204. pha trnlgianhit(phnilu)cbtrhthngnggianhithithpp thnh hi qu nhit phc v cho mc ch gia nhit y thp chng ct chnh trong phn xng. iu khin nhit ca du th, thng c mt nhnh ngngdnduthbqualgianhittrnhtrnghpduthc nhit qu cao sau l gia nhit. Dng du th ny s ho cng dng du i qualgianhittrckhiavothpchngctchnh.Khngkhho trn hn hp nhin liu t c gia nhit trc nh thit b trao i tn dng nhitcaocakhthi.Khngkhyquathitbtraoinhitnynh mtqutycngbc,cnkhthil tcaquathitbtndng nhitbngqutht,khthisaucarangkhiltrithivo mi trng. 2.1.2.4. Thp chng ct chnh Du th sau khi i qua l gia nhit (F-201) c a ti thp chng ct chnh(T-201).Theoscngnghcamhnhphphngcaphn xng ch s dng mt thp chng m khng s dng cu hnh hai thp (mt thp tch s b), v vy, cc sn phm c tch ra t thp ny s bao gm: 20 -Phn on hydrocacbon nh (bao gm LPG v kh nhin liu); -Phn on naphtha (bao gm nhaphtha nng v naphtha nh); -Phn on Kerosene; -Phn on GO nh; -Phn on GO nng v -Cn chng ct. Ngoi cc dng sn phm trn, ti cc phn nh thp v gia thn thp thngtrchraccdnglngtrunggiannhmmcchiukhinch vnhnh ca thp. Cc dng du trunggianny cs dng gianhit s b du th. Qu trnh phn tch du th trong thp chng ct chnh din ra nh sau: Ccphnonnhbaogmphnonnaphthavhydrocacbonnhhn ctchranhthpsauclmmtbngthitbtraoinhit bngkhngkhvthitbngngt.Phnhingngtcavobnh cha sn phm ngng t nh (D-202). Ti y, hn hp sn phm nh c phntchlm3pharingbit:naphtha,ncvphahydrocacbonkhng ngng t. Nc thu y b cha v c a ti phnxng x l nc chua. Naphtha c bm hi lu li thp mt phn, phn cn li c a i x l tip. Kh khng ngng c a ti h thng thu hi kh. CcphnonKerosene,GOnh,GOnngctchrathnthp vaticcthpsctngngtbncnhthpchngctchnh nng cao cht lng sn phm. Phadiythpchngctcgianhitbnghi,hisdngl hithppqunhit.Hincscduytrnhitcathpngthi tng cng qu trnh phn tch cc phn on. Cn ca du th cly ra ythpnhbmcn.Cncaquamtlotccthitbtraoi nhit trc khi a ti phn xng ch bin tip theo hoc b cha. 2.1.2.5. Cc thp sc cnh thp chng ct chnh Bncnhthpchngctchnhcccthpsctinhchliccsn phm Kerosene, GO nh, GO nng. Cc thp ny c gia nhit y (thng lsdnghisctrctip)tchccthnhphnnhhnrakhiphn on. Cc phn on nh hn tch ra nh cc thp sc li c a tr li thp chng ct chnh. Sn phm thu y thp c bm i qua cc thit b trao i nhit gia nhit s b du th trc khi a n cc phn xng/b cha pha sau. 21 2.1.2.6. H thng thu hi kh Khkhngngng(baogmLPGvkhnhinliu)chalngmt phn nh my nn. Hn hp ny c ti tip xc vi phn on naphtha ri a i phn tch thp tch butan hoc c a thng ti phn xng thu hi v x l LPG. Phn kh khngngng t c a ti h thng kh nhin liu ca nh my. 2.2. KHI NG PHN XNG Khi ng phnxng chng ctdu th trnh thng m phngnhn chung tun th theo ng cc bc cng vic trong thc t. Trn s cng ngh m phng nh trnh by trong cc hnh v (t CDU-01 n CDU-03) cc bc khi ng phn xng bao gm cc bc c th sau: 2.2.1. Np nguyn liu Tutngiukincthmnguynliusdngchokhingphn xng ban u c th l du th hoc du diesel nh (LGO), trong s cng ngh, m hnh nyc th s dng du diesel nh lm nguyn liu khi ng ban u. Cc bc np liu bao gm: -M van np du th/du nh (RF-202); -M van trn ca thit b tch mui mc 60-65% (RF-267). 2.2.2. Tun hon du LGO -Khi ng bm tun hon (P-201); -M van (PC-204) ca thit b tch mui 50% bng tay (nh my tnh m phng thit b hin trng); -Khi ng bm tch mui (P-202); -Mvanniviccthitbgianhitsbtndngnhitmc50% (HC-201, HC-202, HC-203); -Mvanngby-passqualgianhitduth(FC-201,FC-202,FC-203, FC-204 mc 20%v m cc van chn); -Khimclngtrongythpchngctchnht50%,btbmtun honythp(P-203)ngthimvaniuchnhmctng(LC-202) v van chn. Van iuchnh mc t ng c t ch iu khin t ng; -Thit lp dng du tun hon mc 50% lu lng thit k. 2.2.3. Chun b khi ng l gia nhit du th -Khi ng tt c cc thit b trao i nhit lm mt bng khng kh trong phn xng; 22 -M van a hi (thp p) vo b phn to hi qu nhit ca l, m van RF-270; -M ca vo qut ht ng khi, m van iu tit khi ca ht qut gi mc 25%, ca y mc 100%; -Khi ng qut y kh vo l t (K-202) mc dng thch hp cho ho trn hn hp nhin liu; -Mvanchn(RF-220)khkhngngngnitbnhngngtnhthp chngctchnhtictuc,tbiukhinpsutchiu khin t ng, mc iu khin l 0, 35Kg/cm2 ng thi m ng by-pass. 2.2.4. Khi ng l gia nhit du th -M cc van cp nhin liu v khi ng cc u t (pilot) (van RF-232); -Mccvanchntrcvsau(RF-227)cavaniukhinnhinliu (FC-223); -M van iu khin cp nhin liu bng tay; -Khi ng cc u t chnh ca l; -Nng nhit ca dng du ra khi l gia nhit ln 2000C. 2.2.5. Np du th -Chuyntchnpdudieselnhesangchnpduthbng cch ng van cp du nh (RF-202) v m van cp du th (RF-201); -Duy tr nhit du ra khi l gia nhit mc 2000C; -Theo di nhit ca thit b ngng t nh thp chng ct chnh; -Chuyn cn chng ct ca thp chng ct chnh v b cha du thi. -ng thi thc hin cc bc 6 v 7. 2.2.6. Bt u hi lu sn phm ngng t nh -Khi bnh ngng t nh (D-202) t mc 50%, bt u khi ng bm hi lu (P-207) -Tin hnh rt naphtha ra khi thp 2.2.7. Nng nhit dng du ti ch vn hnh bnh thng -Nngnhitdngduratichhotngbnhthng.Nhit nytythucvoloiduchbin,thngthngtrongkhong 3300C3400C.Lu,duytrtcnngnhitmcthchhp (300C/gi). -Khi ch hot ng n nh, t ch iu khin rng buc gia dng nhinliuvnhitdu.tchiukhinnhitdngdu ch t ng; 23 -Kim tra p sut ti thit b ngng t nh, trong trng hp p sut cao, m van by-pass PC-202 ln hn. 2.2.8. Khi ng bm tun hon nhit thn thp chng ct chnh -Khi ng bm tun hon nhit s 1: KhingbmP-206,mvaniukhindngFC-208vmccvan chn, t van FC-208 ch iu khin t ng; -Khi ng bm tun hon nhit s 2:KhingbmP-205,mvaniukhindngFC-209vmccvan chn, m van HC-204 v HC-205 50%, t van FC-209 ch iu khin t ng; -Khi ng bm tun hon nhit s 3:KhingbmP-204,mvaniukhindngFC-220vmccvan chn, t van FC-220 ch iu khin t ng; 2.2.9. Bt u rt cc phn on khi thp ct chnh -Rt phn on Kerosene:t iu khin mc LC-205 ch tng (mc 50%), khi mc cht lng t gii hn khi ng bm P-209 M van iu khin dng FC-211 v van chn. t van FC-211 mc t ng, ton b lng a v b cha du thi; -Rt phn on du diesel nh (LGO) t thit b iu khin mc (LC-206) ch t ng, mc t l 50%. Khi mc lng t gii hn, khi ng bm P-220 -Rt phn on du diesel nng (HGO) t thit b iu khin mc (LC-207) ch t ng, mc t l 50%. Khimclngtgiihn,khingbmP-211,mvaniukhin dng t ng FC-214 v van chn, t van iu khin lu lng ch t ng. Gi tr t mc ty thuc vo cng sut ca thp chng ct chnh c xc nh ban u v loi du d kin chy cho m hnh; 2.2.10. Sc hi y thp ivithpchngctchnh:Mvancphiiukhintng(FC-219) v cc van chn, t van iu khin lu lng hi (FC-219) ch t ng, mc lu lng dng t t ng gi tr thch hp (ty cng sut ca thp c nh trc). i vi ct sc phn on Kerosene: M van cp hi iu khin t ng (FC-216)vccvanchn,tvaniukhinlulnghi(FC-216)ch 24 tng,mclulngdngttnggitrthchhp(tycng sut ca thp c nh trc). i vi ct sc phn on diesel nh (LGO): M van cp hi iu khin t ng (FC-217) v cc van chn, t van iu khin lu lng hi (FC-217) ch t ng, mc lu lng dng t t ng gi tr thch hp (ty cng sut ca thp c nh trc). i vi ct sc phn on diesel nng (HGO): M van cp hi iu khin t ng (FC-218) v cc van chn, t van iu khin lu lng hi (FC-218) ch t ng, mc lu lng dng t t ng gi tr thch hp (ty cng sut ca thp c nh trc). 2.2.11. Khi ng my nn (K-201) -Kim tra m bo van iu khin p sut (PV-202 B) ca bnh ngng t nh m, m cc van chn; -Khi ng my nn K-201 -Thu gom kh nn v phn xng thu gom v x l kh trong nh my (m van RF-212), ng thi tin hnh chy th h thng thu gom nc chua bc tip theo. 2.2.12. Chy th h thng thu gom nc chua Khikhoangchancchuacabnhngngtnhtmc50%tin hnh chuyn nc chua v phn xng x l nc chua bng cc thao tc : -Bt bm P-208 -M van LC v van chn, t van iu khin mc nc chua t ng (LC-204) ch t ng Kimtranhitduthqualttnhitthitkcha,nu chattiptcthchinccbc11v12.Khinhitduvothp chng ct chnh t nhit thit k tin hnh cc bc tip theo. 2.2.13. Khi ng thit b tch mui -in y thit b tch mui bng nc (m van FC-213 v cc van chn) -Khimcchtlngtrongtrongthitbtmc50%,mvanLC-201v van chn, t van LC-201 ch t ng, bt ngun my bin p thit b tch mui, t thit b chnh p (PC-204) ch iu khin t ng. 2.2.14.Btuthusnphmvaphnxngvchvnhnh bnh thng -Khi cc sn phm tcht lng theo thit k, chuyn sn phm v cc bchasnphmtrunggiantngng(bchacn,LGO,HGO, Kerosene v Naphtha).. 25 -aphnxngvochhotngnnh,qutrnhkhing hon thnh. 2.3. DNG PHN XNG 2.3.1. Dng theo k hoch (bnh thng) Dng phn xng bnh thng l qu trnh dng phnxng mt cch ch ng theo lch bo dng, thanh tra nh k thit b. Cc bc dng phn xng theo k hoch bao gm cc thao tc c bn sau: -Khi bt u dng phn xng bc u tin l gim nhit , lu lng p sut ca thit b trong phn xng; -a tt c cc dng i ra t phn xng v b cha du thi tng ng; -Gim nhit du th vo thp chng ct vi tc khong 2500C/gi, iu chnh lu lng qut ht v qut y l gia nhit duth duy tr hot ng ca l t mt cch thch hp; -Khi nhit dng du th ra khi l gia nhit t 2500C, gim lu lng duthxungcn40%cngsutthitk.Gimttccclulng dngsnphmvbmtunhonxung40%nhiuchnhccvan iu khin dng tng ng; -Gim t t hi sc tt c cc y thp v gi tri "0". Dng thit b ngng t sn phm nh thp ct chnh; -Ngngcpncvothitbtchmuivthohtnctrongthitb tch mui; -Dng ln lt tt c cc bm tunhonthn thp. Duy tr dnghi lu nh thp cng di cng tt; -Dng l gia nhit du th bng cch gim lu lng nhin liu cung cp bngccvaniukhindngnhinliu.Dnghotngbphnsn xuthi qunhit ca l gia nhit. Tt cc u t anghot ng. Khi dngkhnhinliuvolgianhitkhngkhngthn,mngby-pass (b qua thit b gia nhit khngkhvo l t). a khng kh vo lm ngui l gia nhit. ahinc vo lm sch bung t. Dng cc qut ht v qut y l t. -Dng bm cp du th; -Bm ton b cc cht lng tn ng trong cc thp sc ra ngoi sau dng bm cn chng ct. -Kim tra lin tc mc cht lng cc v tr. Khi mc cht lng mc thp dng tt c cc bm trong phn xng; 26 -Dngmynnkhvgimpsuttronghthngbngcchsdng cc vanx. t p sut cc vanx mc "0" trnhhin tng tng p sut trong h thng. Saukhithchinxongccbcnutrnqutrnhdngphnxng hon thnh. 2.3.2. Dng khn cp phn xng Dngphnxngkhncplqutrnhdngtngtphnxngdo mt s c nghim trng. Vic dng khn cp l m an ton my mc thit b. Vi phn xng chng ct du th p sut kh quyn, dng phn xng khn cp bao gm cc bc c bn sau: -Gim dng du th cung cp xung "0" qua cc thit b iu khin dng t ng, ng thi ngt l t bng nt ngt khn cp. Ngng hot ng bphnsnxuthiqunhit.Mccvanby-passkhthilt (khng qua thit b gia nhit khng kh); -Gimlulngdngsnphm,hngdnccvnhnhvinngoi hin trng m van thu cc dng sn phm v b cha du thi; -Gim v dng hn hi sc trong cc thp; -Dng m t qut thit b ngng t nh thp chng ct chnh; -Giccbmtunhonthnthphotngccdicngtt,sau dnghotng.Hngdnccvnnhnvinvnhnhngoihin trng ngt bm cp du th v cc bm tun hon thn thp. -Dng my nn kh nh thp chng ct; -Bmhtccchtlngcnngyccthpsauhngdnnhn vin vn hnh ngoi hin trng tt bm cn chng ct -Hngdnccnhnvinvnhnhngoihintrngttccbmcn li trong phn xng. Qu trnh ngng khn cp phn xng hon thnh. 2.3.3. Cc s c v gii php khc phc Trnylccbccbnchungdngphnxngtrongtrng hp bnh thng v trongnhng trnghp khn cp. Trong thc txy ra nhiu s c nh hng ti hot ng ca phn xng, tu trng hp c th mcccgiiphpringkhcphcsckhcringhocphidngphn xng. Cc s c ln xy ra phi c cc bc x l thch hp nh: mt in, mt hi, mt nc lm mt, h thng cp nguyn liu gp s c, h thng kh iu khin gp s c,... 27 2.3.3.1. Mt in Khimtinhnglotccthitbcngcindnngsngng hotngnhmybmnpnguynliu,bmtunhonsnphmyv cc thit b s dng ng c in khc. Hu qu km theo l cc thp chng ctngnghot ng (do mt dngnguyn liu), thit b gia nhit yngng hotngdomtdngnguynliu.Nukhngkhiphccnguncung cp th nhanh chng gim p sut h thng v dng phn xng theo trnh t dng phn xng bnh thng nh trnh by mc 1 trn. 2.3.3.2. Mt nc lm mt Nc lm mt cung cp cho phn xng chng ct du th ch yu lmmtsnphmvthitbngngttrongthpchngct.Mtnclm mt s lm cho khng ngng t c sn phm, p sut cc thp chng ct tng ln. Cc sn phm ca thp chng ct chnh v cc ct sc nh ct sc naphtha, kerosene, phn on diesel nng, phn on diesel nh c nhit caokhiivccbcha.Hmlngncchatrongccsnphmcn lmkhcaodohthngsykhnghotngc(thngsdngkiu sy chn khng s dng thit b ngng t). Khi xy ra s c ny cn thc hin cc thao tc: -a sn phm v cc b cha du thi;-Gim cng sut thp chng ct xung; -Thu gom cc sn phm cnhit thch hp v b cha sn phm khi gim cng sut ch bin ca thp. Trong trng hp sn phm vn nhitqucao,ngunnclmmtkhngckhiphccnphi tinhnhdngphnxngtheoquytrnhdngphnxngbnh thng nh m t trn. 2.3.3.3. H thng nguyn liu gp s c Khi h thng cp nguyn liu gp s c, h thng iu khin t ngs tngngtbmcpduthvothpchngctvdophnxngs dng hot ng theo ch ngng khn cp .Nu s c mt nguyn liu xy ra trong khi khi ng phn xng th ngay lp tc phi a kh ni-t vo h thng thit b. 2.3.3.4. H thng hi v h thng kh nn iu khin gp s c Khi h thng hi gp s c, sn phm chng ct s nhanh chng khng t yu cu v phi chuyn v b cha du thi. Khi h thng hi gp s c cnphigimcngsutdngnguynliu.Nuschixyratrongthi 28 gian di gy ra hu qu hng lot cc thit b phi ngng hot ng v do phi ngng hot ng ca phn xng.Khi h thng cp kh nn iu khin gp s c, cc van iu khin bng khnnsngnghotng.Nuscmtkhnniukhindinratrong mtthigiandicntinhnhdngphnxngtheoquytrnhdngphn xng bnh thng nh trnh by trn. 2.3.3.5. Cc my mc c kh gp s c -Nu cc my mc c kh thng thng gp s c c d phng, th trc ht khi ng thit b d phng (nu khng t ng khi ng). m bo an ton chothit b hnghc ng thi tinhnh c lp thit b khih thng chun b cho sa cha, bo dng; -Rrmtbchngng,viscnycnphicsachakp thi. Tu thuc vo v tr ng ng v loi ng ng m quyt nh c phi dng phn xng hay khng. 29 230229TIAI206207AIAI208214FCRF-220201HCFI220TC216HC206E-210221FIHC202MFI625209AIC D U - 0 0 3B / LRF-283RF-221203FI222DISTCOLORCFPPE-218CWNAPHTHAE-220AI203204AIB / LLGOAI205RF-219RF-219RF-281212FCC D U - 0 0 3LGODIST.E-201202AIC D U - 0 0 2201TCFC211B / LRF-218RF-280P-201STC D U - 0 0 3RF-236FI226B / LRF-202RF-201RF-266B / LB / LRF-266RF-266RF-266L G O F O RS T A R T U PE-202N 0 - 1 P AN 0 - 1 P AC D U - 0 0 3E-219CWRF-218C D U - 0 0 3K E R O S E N EK E R O S E N EC R U D E T OD E S A L T E RC R U D E F R O MD E S A L T E RC D U - 0 0 2E-216RF-265RF-221R E S I D UEC D U - 0 0 3N 0 - 2 P AC D U - 0 0 3N 0 - 2 P AE-211E-203E-206E-204C D U - 0 0 3C D U - 0 0 3N 0 - 3 P AN 0 - 3 P AE-212CWRF-220RF-282DISTCOLORCFPPC D U - 0 0 3C D U - 0 0 3C D U - 0 0 2H G OB / LE-213TI228E-205E-207E-208E-209H G OR E S I D U EC R U D EE-217Hnh H2-1. S h thng CDU-001 30 FC223B A T L I MFUEL GASTI225203TI205TITI204FC204RF-209203FCFC202201FCTI202RF-208RF-207RF-206RF232224TIPI203220TITI221222TITI223227TIRF-270STEAM226TI210AIMRF-264RF-263M224RF273RF231RF230RF229RF228201XSIIHEATERSHUTDOWNSWITCHRF-268RF-269RF-234RF-233232TIFUEL GASTO STACKK-202FORCEDDRAFF FANK-203INDUCEDDRAFF FANE-221F-201D-201C R U D EF R O M E - 2 0 2C D U - 0 0 1FC213B A T L I MP R O C E S S W A T E RF R O M B / L .C R U D E T O E - 2 0 3 ,E - 2 0 6 & E - 2 1 0C D U - 0 0 1201PDIPC204201LCRF205RF205RF284B A T L I MFOUL WATERTO B. L.C R U D E F R O M E -2 1 3C D U - 0 0 1C D U - 0 0 3C R U D E T O C -2 0 1RF-237MSTRF-238RF-289RF-203RF-203RF-240RF-239P-202 A/BRF-204RF-267207TCSTEAMRF-235TI206RF-279RF-227RF-227Hnh H2-2. S h thng CDU-002 31 N 0 1 P A T O E - 2 0 1P A N 0 - 2 T O E - 2 1 1P A N 0 - 3 F R O M E - 2 0 4P A N 0 - 3 T O E - 2 1 2212TILC203RF-262K201GAS COMPRESSORRF-226E-214D-202BATO FLARET-203T-202T-204TI213RF-241RF-243P-203 A/BT-201S I G N A L T O R E S I D U E F R O M E - 2 1 6RF-246 RF-288PGTI215214TIPGRF287RF-286PGP-204 A/BTI213TI218P-205 A/BRF-212B A T L I MO F F G A S T O B / LLI201MRF-272RF-211RF-211RF-210RF-210RF-271PC202206FIAI201209TIP-207MRF-257RF-274RF-213RF-213N A P H T H A T O B / LB A T L I MRF-275CWE-215MLC204RF-214RF-214RF-258MS O U R W A T E R T O B / LB A T L I MP-208205FCSTEAMSTEAMSTEAM RF-225RF-222RF-223206LCRF-224TI211210TILC2051P-210C D U - 0 0 1L G O T O E - 2 2 0MRF-260217FCRF-259MK E R O S E N E T O E - 2 0 2C D U - 0 0 1P-209FC2161P-211C D U - 0 0 1H G O T O E - 2 0 9MRF-261STEAM218FC1207LC207FIFC219MRF-244RF-242STR E S I D U E T OE - 2 1 3C D U - 0 0 152474337362623222118141312 4 1C D U - 0 0 1202LCTC208P206 A/BC D U - 0 0 1C R U D E F R O M F - 2 0 1RF-278FC210RF-216RF-217C D U - 0 0 1RF-252MRF-245RF-247STC D U - 0 0 1STRF-250RF-251RF-249MC D U - 0 0 1RF-216RF-216209FCRF-277RF-252C D U - 0 0 1P A N 0 - 2 F R O ME - 2 1 0 & E - 2 0 6217TIMRF253RF-255RF-256RF-254STRF-276FC208RF-215RF-215C D U - 0 0 1N 0 1 P A F R O M E - 2 0 1C D U - 0 0 1Hnh H2-3. S h thng CDU-003 32 BI 3. VN HNH PHN XNG CRACKING XC TC CN M bi: HD O3 Gii thiu Cracking l qu trnh cng ngh quan trng ch bin du kh gia tng gitrsnphmlchaduvadnghasnphm.Vnhnhphn xngcrackingxctccnlmttrongnhngnhimquantrngcanhn vinvnhnh.Vvy,trongchngtrnhotonhnvinvnhnhu phi tri qua giai on thctp vnhnh phnxng crackingxc tc cn. y l mt trong nhng kin thc, k nng cn c c ca nhn vin vn hnh. Mc tiu thc hin Hc xong bi ny hc vin ckh nng: 1.chiuvmtcsngng&thitbolngiu khin (P&ID's) ca phn xng cracking xc tc cn; 2.Khi ng thnh cng phn xng; 3.Khc phc c mt s s c thng gp; 4. Dng phn xng theo ng quy trnh; 5. Dng phn xng trong cc trng hp khn cp. Ni dung chnh -Sngng&thitbolngiukhin(P&ID's)caphn xng cracking xc tc cn; -Cc bc khi ng phn xng cracking xc tc cn; -Cc s c thng gp, gii php khc phc trong vn hnh phn xng cracking xc tc cn; -Cc bc dng phn xng; -Cc bc dng phn xng trong trng hp khn cp. 3.1. S CNG NGH CA M HNH M PHNG 3.1.1. Gii thiu hc vin d dng tip cn vi thc t vn hnh phn xng cracking xc tc cn tng si (RFCC/FCC), cc m hnh m phng c xy dng trn scngnghccphnxngcrackingsdngphbinhinnay.M hnh qutrnh crackingxc tc cn trong khun kh gio trnhny cxy dng trn c s cng ngh cracking xc tc cn tng si vi h thng ti sinh xc tc mt bc. 33 3.1.2. S cng ngh v cc thit b chnh m hnh m phng MhnhmphngqutrnhhotngcaphnxngRFCClqu trnh m phng thi gian thc qu trnh cng ngh din ra trongthit b phn ng, thit b ti sinh xc tc mt bc, thp chng ct chnh, b phn thu gom xlkh,ccnihitndngnhitthi,ccthitbphtrvthitbo lng iu khin. Nguyn liu thit k cho m hnh c th s dng trong mt khong rng t cn chng ct chn khng, cn chng ct kh quyn hoc hn hp hai nguyn liu ny. S cng ngh, ng ng v thit b iu khin (P&ID's) ca m hnh mphngcmttrongcchnhvFCC-001nFCC-003.Ccc im chnh qu trnh cng nghxy trong phn xng v thit b chnh c trnh by di y. 3.1.2.1. B phn chun b nguyn liu Nguynliuqutrnhcrackingcatbnngoiphnxng(b chahoctrctiptphnxngchngctchnkhng/chngctp sut kh quyn) ti thit b phn ng nh bm vn chuyn nguyn liu. Trc khi nguyn liu i vo l phn ng, nguyn liu c gia nhit s b bng cc thitbtraoinhitgianguynliu/snphmythpchngctchnh. Nguyn liu c trn cng vi mt phn dng du cn cracking t y thp chng ct chnh hp thnh nguyn liu vo l phn ng. Mt dng nguyn liu na c a ti l phn ng l dng du tun hon rt ra t gia thn thp chng ct chnh. 3.1.2.2. Khu vc thit b phn ng Nguynliuqutrnhcrackingsaukhihotrncatiyca ngphnng,ngthixctcsaukhitisinhtthitbtisinh(R-302) cng c a ti y ng phn ng qua van vn chuyn xc tc. m ca vanvn chuynxc tc ti sinh cnhim viu khinnhit ca l phn ng.Mtlngnhhivkhnhinliu(khnng)cavoyng phnngvnchuynxctcvtngkhnngtipxcgiaxctcvi nguyn liu. Nguyn liu nhanh chng b bay hi do xc tc nhit tng i cao (trn 6500C) v mang mt nhit lng rt ln. Xc tc c cun theo dng hi v kh nng i ln pha trn ca ng phn ng nh dng hi nguyn liu.Nhitlngcungcpchoqutrnhphnngcrackingdoxctccung cp. Xc tc v nguyn liu tip xc vi nhau trong sut qu trnh vn chuyn lnphatrn,phnngcrackinghydrocacbonnngxyratcrtcao. 34 Ccyutnhhngnqutrnhphnngbaogm:nhit,tlxc tc/du, thi gian lu v hot tnh ca xc tc. Sn phm chnh ca qu trnh cracking bao gm: hydrocacbon nh (C2-), propylene, propane, butene, butan,naphtha cracking, LCO, HCO v du cn. Ngoi ra, trong qu trnhphnng cn to ra mt lngcoke tng i ln bmtrnbmthtxctcdoqutrnhtchhydrocahydrocacbonnng. Xc tc s mt dn hot tnh do coke bm trn b mt, duy tr hot tnh xc tc sau khi tham gia phn ng, ngi ta tin hnh ti sinh xc tc lin tc. Hisnphmphnngsaukhirakhingphnngnhanhchng cavobphntchxctc(nmcuingphnng)nhmtrnh ccphnngphxyralmgimhiusutthuhisnphmmongmun. Hi sn phm sau phnng tip tc c tch ccht bi xc tcko theo (bng h thng cc cyclone nhiu bc) ri a ti thp chng ct chnh. 3.1.2.3. B phn ti sinh xc tc Xctcctisinhbngcchtcokevikhngkhtrongkhong nhit 7000C n 7600C, coket chy chuynho thnh CO, CO2 vhi nc.Khngkhcpchoqutrnhtisinhxctcnhmtmynnkiu hng trc (K-301).Mynnny thng cdn ng bngtuc binhi nc hoc tuc bintn dng p sut, nhit cao ca dng kh thi t thit b ti sinh xc tc. Lulngdngkhhotrnciukhindatrnthnhphnkh thicaqutrnhtisinhhocnhitcalpmxctcangtisinh. Thitbtisinhxctccthitksaochohnchhintngchysau lp m do qu trnh-xyho CO thnhCO2 lm tng qu caonhit ca lp m xc tc. Thng qu trnh ti sinh tin hnh trong iu kin thiu kh hn ch qu trnh -xy ho CO v gim kh nng ph hoi xc tc (do d tha -xy s kt hp vi cc thnh phn kim loi nng to ra hp cht c c tnh vi xc tc). Chnh v vy, trong kh thi ca qu trnh ti sinh cha nhiu CO.tndngnhitlngvnhitcaocangunkhthi,ngita thng lp t ni hi tn dng ngun nng lng d tha ny. Trong mt s trng hp, cc tuc bin kh c lp t sn xut in. 3.1.2.4. Thp chng ct chnh Hi sn phm phn ng c a ti thp chng ct chnh. Ti y, hn hp phn ng c phn tch thnh cc phn on chng ct chnh sau: du cn,phnondutunhonnng(HCO),dutunhonnh(LCO)v phn on hydrocac bon nh (bao gm phn on naphtha, LPG v kh nhin 35 liu).Phnondunngnht(ducncracking)ctchraythp chng ct, ti y cc ht xc tc nh ko theo cng c lng ng li y thp.Ducncaisnxuthinc,gianhitchonguynliu trc kh vo l phn ng v mt phn c a ti thit b phn tch thu hi du cn sch pha trn du t l (FO) hoc lm nhin liu cho ni b nh my. kim sot lng cht lng trong thp, gia thn thp ngi ta trch ra mt dng du sau em trao i nhit vi xng cracking. Dng duny sau khi trao i nhit c a quay tr li thp chng ct chnh.3.1.2.5. Ct tch du tun hon nh Phnondutunhonnhctchratthnthpchngctri a ti ct sc tinh ch thm. Mc ch ca ct sc ny l tch cc cu tnhhn ra khi phn on. Cc cut nh tch ra khi nhthp sc v c a tr li thp chng ct chnh, sn phm l du tun honnh c tch ra y thp. Du tun hon nh c a ti b cha hoc a thng tiphnxngxltiptheo(thnglphnxngxlGO/LCObng hydro). 3.1.2.6. Ct tch du tun hon nng Chcnng ca ct sc du tunhonnng cng tng tnh ctsc du tun hon nh. Du tun hon nng cng c tch tthn thp chng ct chnh ri a ti ct sc, ti y, cc thnh phn c nhit bay hi thp hnsctchranhthpscvatunhonlithpchngct chnh,phnondutunhonnngctchraythpsaukhilm mt s a ti b cha. 3.1.2.7. H thng thu hi sn phm nh Hi tch ra t nh thp chng ct chnh c lm mt v ngng t mt phntrongthitblmmtbngkhngkh(E-304)vthitbngngtlm mt bng nc (E-305). Trc khi i vo cc thit b ngng t, hi nh thp c phun nc tch cc kh chua ra khi hi hydrocacbon. Hn hp hai phalng\hisaucatibnhchasnphmngngtnhthp chngctchnh(D-302).Phnhihydrocacbonkhngngngt(khkhv LPG)ctchranhbnhchaiticahtmynnkht.Kh hydrocacbon sau khi nn c a ti b phn thu hi v x l kh trong nh my nm ngoi phm vi ca m hnh m phng. 36 3.2. CC BC KHI NG PHN XNG Khingphnxngcrackingxctccncscngnghin hnh nh m hnh m phng nh trnh by trn bao gm cc bc chnh sau: 3.2.1. Sc hi nc vo h thng thit b -ng cc van vn chuynxc tc cha ti sinh v ti sinh t thit b phn ng sang thit b ti sinh v ngc li; -M van iu khin p sut bnh ngng t nh thp chng ct chnh trn ng ng ni ti ct uc; -uikhngkhtrongthitbphnngbnghinc:Mvanschi (FC-301,FC-302)mc20%vmccvanchnccvaniukhin ny; -uikhngkhtrongthpchngctchnhbnghi:Mvancphi nc(RF-348)vothpchngctchnh:MvanRF-348mc60%, m van cp hi vo ct sc LCO (FC-316), m van (FC-315) cp hi vo ct sc phn on diesel cracking nng (HCO). -Khikhngkhcuirakhithitb,btuakhnhinliu vothpchngctchnh,nithngthpchnhvictscLCObng cch m van RF-364 mc 20%. -Khingthitbtraoinhitlmmt,ngngtsnphmnh thp chng ct chnh (E-304 v E-305); -Khingbmncngngttrongythpvtrongbnhchasn phm nh nu cn thit (m bm P-302). 3.2.2. Nng p sut h thng Vi thit b ti sinh xc tc cn thc hin cc bc sau: -M van thng kh ca thit b ti sinh xc tc mc cao nht (TDC-320) -Khi ng my nn cung cp khng kh cho thit b ti sinh (K-301) -M van cp khng kh vo thit b ti sinh (RF-308); -tvaniukhinpsutcahthngmctngduytrp sut ca thit b ti sinh thp hnp sut ca thit b phn ng (khong 0,1Kg/cm2).3.2.3. Khi ng thit b gia nhit khng kh -M van cp khnhin liu cho l t (van RF-309 v van iu khin lu lng kh theo nhit khng kh); -Khingutltvtngnhitcaltisinhlntikhong 6500C vi tc 2000C/gi; 37 -Vithpchngctchnh:Duytrpsutthptrongkhong 0,71,0Kg/cm2 nh van iu khin p sut t ng PC-320; -Duy tr nhit nh thp mc 1051150C (ty thuc vo loi du ch bin) Vithitbphnngduytrpsutkhong0,9Kg/cm2nhvaniu khin p sut t ng PC-311. 3.2.4. Tun hon du trong h thng -anguynliu(cnchngctchnkhnghoccnchngctkh quyn)vothpchngctchnh(sdngngngby-passlphn ng). Khi ng bm P-301, m van RF-327 v FC-311 mc ti a; -Khi nguyn liu in y 80% mc cht lng y thp chng ct chnh theothitk,ngngcpnguynliubngcchngtbmP-301ng cc van RF-327 v FC-311; -Bt u tinhnh tunhon du y thp: Khi ng bm tun hon y P-302, m cc van RF-329, FC-313 v van by-pass RF-323. -M van cp hi (RF-368) si nng thit b to hi (E-302) bng hi nc,ngthimvanthonc(FC-326)kimsotmctrong thit b to hi. -Khi ngh thng dngdu LCO: khi ng bm P-301, m vanFC-311. Sau m vanRF-328, khi ngbm P-305 v m van FC-317. Khi dng n nh, ng van RF-328 v van FC-311, dng bm P301; -Duy tr nhit nh thp gii hn thch hp theo thit k (ty vo loi duthngtrongkhong1100Cn1150C)bngthitbtraoinhit E-305. Kimtraxemnhitcathitbtisinhttigitrthchhpcha (khong6500Ctythucvoloiduvcngnghcth).Nutgitr thch hp s chuyn sang bc tip theo. 3.2.5. Np xc tc -MvanRF-311hontonnpxctcvothitbtisinhnhanh chng; -Duytrnhitkhngkhuracathitbgianhitmckhong 6500C nh van iu chnh nhin liu cp (TC-322). 3.2.6. Khi ng h thng cp du nhin liu vo l ti sinh xc tc -Khi nhit ca xc tc t gi tr thchhp (ty thuc vo loi xc tc, du v cng ngh trong ln cn 5800C), khi ng u phn phi nhin liu vo l ti sinh. M van cp du nguyn liu (RF-306) v van cp hi 38 (RF-305),ccvannymmctngnglnltl70%v20%. Khi khi ng h thng ny nhit l ti sinh s tng ngay tc thi -Nng t t nhit ca xc tc ln gi tr thch hp (khong 6500C) bng cch iu chnh lu lng du nhin liu v khng kh -Khi nhit ca thit b ti sinh t 6500C, ngng cp hi nc ti thp chng ct chnh v cc ct sc cnh thp. 3.2.7. Tun hon xc tc Khi chnh lch p sut gia thit b phn ng v thit b ti sinhxc tc t 0,4Kg/cm2, tin hnh tng p sut ca thit b phn ng v thit b ti sinh xc tc ln gi tr thch hp. p sut l phn ng tng ln 2,0Kg/cm2, p sut thit b ti sinh xc tc l 2,6Kg/cm2. Tin hnh cc bc cng vic tip theo: -Duy tr lngxc tc trong thit b ti sinh mc 50% yu cunh t iu khin mc t ng (LI-308) v van cp xc tc b sung (RF-311). -Tng lng du nhin liu vo l ti sinh xc tc cn bng vi lng xc tc mi b sung; -Tng nhit ca l phn ng t t ln gi tr thch hp (khong 5200C). 3.2.8. Tin hnh kim tra cc thng s cng ngh 3.2.8.1. Vi thit b ti sinh xc tc -Kim tra nhit (xem t c gi tr thch hp 6500C cha) -Kim tra p sut : 2,6Kg/cm2; -Lu lng dng khng kh cp vo l ti sinh; -Shotngnnhcathitbgianhitkhngkhvcpdunhin liu. 3.2.8.2. L phn ng -Nhit t gi tr yu cu cha (gi tr thch hp khong 5200C); -p sut t gi tr thch hp cha (2,0Kg/cm2); 3.2.8.3. ng phn ng (Riser) -Kim tra n nh ca qu trnh tun hon xc tc; -Dng hi cp. 3.2.8.4. Thp chng ct chnh -Kim tra tun hon sn phm y thp; -Kim tra nhit ca nh thp. 3.2.9. Np nguyn liu vo l phn ng -Phn y thp chng ct chnh: M van tun hon y RF-318 ng van FC-312; 39 -Chy th thit b to hi nc (ni hi tn dng nhit): Ngng cung cp hincvothitbtraoinhitE-302vngvanRF-326.Mvan cung cpnc ni hi LC-306 v m van thunc chuangng t nh FC-313; -MvancpnhinliuRF-319vFC-311tt,khingbmP-301 (phi m bo rng van RF-327 trng thi ng hon ton); -Tng lu lng dng nguyn liu ti 25% gi tr thit k; -t thit b iu khin t ng ca l phn ng ch t ng, gi tr tl5200C,mvanchuynxctcchvnhnhtaychnh nhit l phn ng; -Duytrnhitcaphaxctctrongthitbtisinhnhit6500C. Khi xc tc bt u c coke bm cn tng lng khng khp ng yu cutcokebngcchtnglulngcamynnkhK-301,gim lng kh nn x vo mi trng (gim m van x TDC-320); -Khinhitycathpchngctchnht1500C:Tinhnhtun honquathitbtraoinhitE-308.tchiukhinrngbuc vi cm binnhit TC-324. t TC-324 ch t ng. ng van RF-318; -tchtngchochaivanvnchuynxctcPDC,vaniu khin mc xc tc LC 301. 3.2.10. Thit lp hot ng ca thp chng ct chnh -Bt u tun hon du: M van RF-335 ca thit b trao i nhit E-303, khi ng bm P-303 v m cc van FC-304, FC-319; -Btuhilusnphmnh:Khibnhchasnphmnhtmc yu cu khi ng bm P-306 v m van FC-305; -Tng tc nguyn liu bng van iu chnh lu lng dng FC-311; -t b iu khin chnh lchnhit trong thit b ti sinh ch t ng, mc t l 150C; -M van RF-363 thu hi kh v phn xng thu hi x l kh; -t cc van iu khin p sutbnh cha sn phm ngng t nh ch t ng mc p sut thit k (PC-311 v PC-312). 3.2.11. Thit lp ch ly sn phm trung gian cnh thp -Tun hon du diesel nng: t van iu khin mc LC-305 ch t ng;khimcchtlngtrongthpscdunng(T-303)tmcyu cu, khi ng bm vn chuynP-304, m van FC-318 v t van ch t ng; 40 -Visnphmngngtnh(Naphtha):KhingbmP-307,tvan iu khin mc LC-302 ch t ng v iu khin lin kt vi van chnh lu lng FC-314; -Thu hi du nng: Khi ng thit b trao i nhit E-307 v bm P-320, m v t van iu khin lu lng FC-307 ch t ng; -Tun hon du diesel nh (LCO): t van iu khin mc LC-304 ch t ng, khi mc cht lng trong thp sc LCO (T-302) t mc yu cu khi ng bm vn chuyn P-305, m van FC-317 v t ch t ng; -Thu hi du LCO: Khi ng thit b trao i nhit E-306 v bm P-309, m v t van iu khin lu lng FC-306 ch t ng; -Tin hnh sc hi nc vo y cc thp T-302 v T-303; -Thu hi du cn cracking: Khi ng thit b trao i nhit E-320 v bm P-311. M van FC-320 v t ch iu khin rng buc vi cm bin o mc LC-307; -Tun hon du cn cracking: t van iu khin dng du cn tun hon (FC-308) ch t ng. M van iu khin dng du cn FC-309 v cc van chn. 3.2.12. Thit lp ch hot ng ca l phn ng v thit b ti sinh xc tc -Khikhngkhnncungcpvothitbtisinht75%gitrthitk, dng thit b gia nhit khng kh; -Chy th tua-bin kh tn dng nhit bng cch m van RF-370; -iukhinmcxctctrongthitbtisinhbngccvanRF-311v RF-312,iukhinmcxctctronglphnngbngbiukhin LC-301. t cc thit b iu khin mc ch t ng; -iukhinpsuttrongthitbtisinhvgitrthitk(thngl 2.5Kg/cm2). 3.2.13. Chuyn phn xng v ch vn hnh bnh thng Sau cc bc cng vic trn hon thnh, cc ch cng ngh n nh cng tc khi ng hon thnh, phn xng chuyn sang ch vn hnh bnh thng. 3.3. DNG PHN XNG 3.3.1. Dng theo k hoch (bnh thng) Dngphnxngcrackingxctccntheokhochcthchin ch ng cn c theo k hoch bo dng, hoc thanh tra my mc, thit b 41 nh k. Vic dng phn xng c thc hin theo cc bc nh sn mboantonvgimthiusnphmkhngttiuchun.Ccbc dng phn xng bao gm: -Gim bt sn phm y thp chng ct chnh bng cch tng sn lng LCO; -Gim lu lng dng du tun hon li l phn ng; -Gimnhitlphnngxung150C.Gimnhitlphnngs lmgimnhitcathitbtisinhdolngcoketothnhtrnb mt xc tc gim; -Gim dn lng xc tc trong thit b ti sinh i 1020%; -Khi lng xc tc trong thit b ti sinh gim i 20% bt u gim nguyn liuvophnxng,lngxctctunhonvlulngdutun hon; -Gimlngbmtunhonthnthpchngctchnhtrnhchiph choqutrnhlmmt,githitbiukhinnhitnhthpvlu lngdnghilusnphmnhchtnggimbtnng lng cn lm mt sn phm nh. Ccvan iu chnh p sut t ng cabnhngngtsiuchnhtduytrpsutkhidngnguyn liu v nhit thit b phn ng gim. -Gim t l khng kh vo l ti sinh duy tr tthnhp chy v gim psutcaltisinhmkhngrahintngchyli.Khikhngth gim lu lng khng kh cna, tiu th lng -xy d tha b sung thm lng du t. Vic ny c th trnh c hin tng chy li nhnglilmtngnhitcalpxctc.Sdnghilmgim nhit ca lp m xc tc. -ahincvongphnngkhitcnguynliuvongphn nggimxungdi50%tcnguynliuthitk.Cnphiduytr vic tun hon xc tc; -Gim p sut ca thit b ti sinh i khong 0,10,2Kg/cm2 trong khi duy tr p sut l phn ng gi tr 2Kg/cm2; -Gim mc xc tc trong thit b phn ng xung mc ti thiu; -Duy tr nhit ca l ti sinh mc 6500C. Ch s dng du nhin liu duy tr nhit ca thit b ti sinh nu m bo rng xc tc c ti sinh; -Duytrmcxctctrongthitbtisinhmctithiutheoyucu m bo thit b vn hot ng tt khi rt xc tc ra; 42 -Khitccanguynliuvongphnngmc40%sothitk, a hi nc vo ng phn ng. Ngng tun hon du cn t b phn chng ct sang l phn ng ng thi a nguyn liu sang thp chng ct chnh bng ng by-pass thit b phn ng. Ngng cp nguyn liu vo l phn ng v ngt bm cp nguyn liu. -Khi nhit ca thit b ti sinh gim xung di 6250C (chng t lng ln coke c t chy), ng van cp xc tc ti sinh. Lm sch ng phn ng bng hi nc; -a ton b xc tc trong ng phn ng ti phn sc xc tc v sau sangthitbtisinhquavanchuynxctcchatisinh.Gipsut cathitbtisinhthphnpsutthitbphnngkhong 0,10,2Kg/cm2 . Duy tr hi sc vo ng phn ng gi mc chnh p sutgiathitbtisinhvlphnngtothnhlpcchlygia thp chng ct chnh v thit b ti sinh xc tc; -axc tcra khi thit b ti sinh ng thi dngcp duvo thit b tisinh.Gihotngmynnkh(ngayckhithitbtisinhkhng cnxctc)lmmtthitb.Tclmnguithitbkhngc vt qu 1200C/gi; -Bmttccclngcnngliythptheongngduthi. Gimdnpsutcathpchngctchnh.Tiptcschivong phn ng; -Khinhitcathitbtisinhgimxungcn1500C,dngmynn kh; -Khi nhit ca l phn ng t ti nhit ca hi nc, dng cp hi nc. Khng c a khng kh vo thit b phn ng khi nhit bn trong trn 2000C trnhhin tng pht la ca coke bm trn thnh thit b. y l bc cui cng dng phnxng cracking xc tccn. Cn lu , dng phn xng cracking cn phi dng cc thit b ph khc nh ni hitndngnhit,mynntheoquytrnhring,tuynhin,phncngvic ny khng nm trong phm vi ca m hnh m phng. 3.3.2. Dng khn cp Vicphidngkhncpphnxngcrackingxctccnldosc ca cc my mc, thit b trong phn xng hoc do yu t bn ngoi nh h thngcungcpnnglng,phtrcanhmygpsc.Ccnguyn nhn chnh dn n vic phi dng khn cp bao gm: mt in, h thng kh 43 iu khin, h thng khng kh to tng si cho thit b ti sinh, h thng cp hi,hthngcpncchonihi,hthngnclmmt,hthngmy nn kh, h thng cung cp nguyn liu, h thng cp kh nhin liu, my nn kh hydrocacbon, cc van vn chuyn xc tc, gp s c. Tng ng vi mi scnynhnvinvnhnhcthaotckhcnhaudngphnxng khn cp m bo an ton cho phn xng. Cc bc c bn dng khn cp phn xng vi tng s c c trnh by di y. Vic dng khn cp cththchintngthngquahthngngngkhncp(ESD)hoc thc hin bng tay theo cc trnh t m bo an ton. 3.3.3. Cc s c v gii php khc phc Trnylccbccbndngphnxngtrongtrnghp bnh thng v trong nhng trng hp khn cp. Trong thc t xy ra nhiu s c nh hng ti hot ng ca phn xng, tu trng hp c th m c cc gii php ring khc phc s c hoc phi dng phn xng. Cc s c ln xy ra phi c cc bc x l thch hp nh: mt in, mt hi, mt nc lm mt, h thng cp nguyn liu gp s c, h thng kh iu khin gp s c,... 3.3.3.1. Mt in Khigpscmtincnthchinccbcsaudngkhncp phn xng: -Ngngcpnguynliuvophnxng,gimpsutlphnng xungnhanhchng,gimchnhlchpsutvanvnchuynxctc cha ti sinh; -Thc hin khn cp cc bc: Khi ng h thng iu khin dng khn cpphncpnguynliu,ngttcccngcpnguynliuvo ng phn ng, dng cp ph gia c ch n mn vo h thng, gim lu lngkhngkhhatrntrongbungtxung50%sovihotng bnh thng, gim ti a lng hi sc vo ng phn ng. 3.3.3.2. H thng cung cp kh nn iu khin gp s c Nhcptrongccmunkhc,hthngkhnniukhinc vaitrquantrngtronghotngcanhmylchadu,rtnhiuvan cvnhnhviukhinbnghthngkhnn.Thngthngsc thnggpvihthngkhnniukhinlhintnggimpsutkh nntronggiaionngn.Phnxngskhinglingaykhipsuth thng kh iu khin tr li bnh thng. Khi gp s c h thng cung cp kh nn iu khin cn thc hin cc bc sau dng khn cp phn xng: 44 -Khinghthngdngkhncpdngcpnguynliuvong phn ng (bao gm c cn v du nng tun hon), tip tc cp hi vo ng phn ng lm sch ng phn ng; -t van vn chuyn xc tc v ch vn hnh tay v ng van li; -Khi mc xc tc phn sc xc tc bt u gim, t van vn chuyn xc tc cha ti sinh ch vn hnh tay v ng van ny li; -t mc iu khin lng hi cung cp cho phn sc mc 50% so vinhucubnhthngvgimlnghiscxung50%sovilu lng hot ng bnh thng; -iu chnh khng kh cp vo thit b ti sinh (cho t coke) mc 50% so vi mc hot ng bnh thng; -Khinguynliucpvongphnngdnghn,iuchnhpsut tronglphnngduytrmcchnhpsuttrcvsauvanvn chuyn xc tc cha ti sinh; -M van cp du nguyn liu vo thit b ti sinh xc tc, duy tr nhit ca l ti sinh trong khong 6000C; -Nu s c d on l khng qu 24 gi th cn duy tr nhit caxc tc bng du t; -Khihthngkhnnhotnglibnhthng,phnxngskhi ng hot ng li, cc van vn hnh bng kh nn tr li hot ng bnh thng. 3.3.3.3. H thng cp hi nc gp s c Mthilmtscnghimtrngivihotngcaphnxng crackingxctccnvhnglotccmymcthitbquantrngcaphn xng nh cc thp chng ct, my nn kh, my thi kh,,, u s dng hi nc. Mt hi l s c cn dng phn xng khn cp ton b phn xng. Cc bc dng khn cp phn xng bao gm: -Khi ng h thng dng khn cp phn xng a nguyn liu by-pass l phn ng, ng tt c cc van cp nguyn liu dn ti ng phn ng, ngng h thng b sung cht c ch n mn; -ng van vn chuyn xc tc ti sinh, duy tr lng hi phn tn trong ng phn ng cng di cng tt y ht xc tc ra khi ng phn ng; -Khi mc xc tc vng sc xc tc bt u gim, ng van vn chuyn xc tc b mt hot tnh li; -Khicnthithiuchnhpsutduytrchnhpgiaphatrcv sau van vn chuyn xc tc mt hot tnh; 45 -Chuyncngnhiucngttxctctrongvngscxctctrongkh nng c th sang thit b ti sinh; -Khi my thi kh dng, thit b ti sinh s dnghn, khng s dng du nhin liu duy tr nhit ca thit b ti sinh v xc tc; -ng tt c cc van chn u cphi trc khi p sut h thng cp hi gim xung; -Nuscdonkhiphctrongvng48githcnsdngdu nhin liu duy tr nhit ca xc tc, nu s c qu 48 gi th cn rt ton b xc tc ra khi thit b. 3.3.3.4. H thng cp nguyn liu gp s c Khi cp nguyn liu gp s c s t ng kch hot h thng ngng khn cpdngttcccdngnguynliuvongphnngvanguyn liu b qua (by-pass) thit b phn ng. Nu bm nguyn liu d phng c th khingngaycpnguynliubngngkhcthcthaphn xngtrlihotngtrongthigianngn.Trongtrnghpkhngkhi phc c cp nguyn liu ngay, cn duy tr phn xng tnh trng "nng". Cc bc cng vic cn tin hnh bao gm: -iu chnhhi phn tn du vo ng phn ng mc lnnht theo thit k; -Chuyn van vn chuynxc tc c ti sinh sang ch vn hnh tay v kim sot tun hon xc tc; -ng van iu khin lu lng nguyn liu; -iu chnh p sut thit b ti sinh v l phn ng m bo p sut l phn ng lun cao hn so thit b ti sinh; -Khi ng h thng cung cp du t vo thit b ti sinh xc tc duy tr xc tc lun nhit 6000C. -Khinguynliucthcungcptrlikhiphchotngcaphn xng li ch hot ng bnh thng. 3.3.3.5. Cc my mc c kh gp s c -Nu cc my mc c kh thng thng gp s c c d phng, th trc ht khi ng thit b d phng (nu khng t ng khi ng). m bo an ton chothit b hnghc ng thi tinhnh c lp thit b khih thng chun b cho sa cha, bo dng; -Numynnkhtgpscthcntinhnhdngkhncpphn xng theo trnh t trnh by phn 2. Tin hnh c lp my nn v 46 ui hydrocacbon ra khi ng ng v my nn trc kh tin hnh bt c cng vic sa cha no tip theo; -Rrmtbchngng,viscnycnphicsachakp thi. Tu thuc vo v tr ng ng v loi ng ng m quyt nh c phi dng phn xng hay khng. 47 FCC-002R-301 EFFLUENTZI301ZI302VENTD-301PI301310PCPI302PDI307301LC303TITI302R-301TI306305TITI304PDC305TC321308301FCSTEAMFC302306PDC301TIFCC - 002FCC - 002FEEDCIRC OIL FROM P-303FI320321FIBAT LIMTORCH OIL322TCFI323LI308320TDCFRESH CATALYSTBAT LIMFUEL GAS301AIAI302309PDIBAT LIMUSED CATALYST303PIFC303322FITI301TOCOBOILERBAT LIMGE-301K-301R-302M / GAIRRF-307RF-372RF-301RF-301RF-302RF-303RF-303RF-304RF-305RF-306RF-310RF-309RF-312RF-308RF-311F-301Hnh H3-1. S h thng FCC-001 48 E-304E-305MRF-361CWRF-362TI307RF-353RF-359TO FLARERF-363FC314RF-367RF-324RF-324RF-325RF-366E-302RF-326TI318FC313RF-322RF-322RF-323RF-313E-308RF-315RF-317RF-314RF-316P-302 A/BRF-318RF-329RF-320RF-321RF-327RF-320RF-319RF-337P-303RF-336RF-330RF-330RF-331RF-332FROM LC-307BFWCWE-309E-310P-311RF-333RF-350RF-352RF-349P-301 A/BRF-351RF365RF-360RF-356RF-358RF-355RF-357RF-354P-308P-307P-306 A/BD-302RF-369RF-335RF-348RF-368RECYCLE OIL TO REACTORFCC-001E-303319FCFCC-001TO FIC- 310325FIT-301D-303157121417222729343545LG307LC317TIPGLGLC306BFW FROM E-301FCC- 003STEAMBAT LIMSTEAMTI316321FIFC312324TCFC308310FCTI319FC311FC309R-301 FEEDFCC-001BAT LIMDECANT OILBAT LIMFEED FROM STORAGE314TITI308311TITO T-303FCC-003FCC-003FROM T-303HCO FROME-311BAT LIMFCC-003TO T-302FROM T-302FCC-003FCC-003LCO FROME-312R-301 EFFLUENTSTEAMTI315304FC304TIAI303323TC305FC303302LCC5+ GASOLINEBAT LIMBAT LIMSOUR WATERPC311TO GASPLANTBAT LIM326FITI308INJECTION WATERFROM GAS CONC. PLANTBAT LIM2Hnh H3-2. S h thng FCC-002 49 7P-310309P-305TO T-301FCC-002318FCFCC-002FROM T-301FCC-002TO T-301305LCT-3034 1TI312BFWFCC-002E-301309TI14T-302LC304TOT-301FCC- 002FROM T-301FCC-002FC317FCC-002TO T-301RF-345STRIPPERBOTTOME-312RF-344FC306316FCRF-342310TIBAT LIMLCO PRODUCTRF-364FUEL GASSTEAMRF-343RF-346E-306CWCWE-307RF-347RF-339STEAMHCO PRODUCTBAT LIMTI313RF-338FC315307FCRF-340E-311STABILIZEDGASOLINERF-341P-304Hnh H3-3. S h thng FCC-003 50 BI 4. VN HNH PHN XNG REFORMING TI SINH XC TC LIN TC (CCR) M bi: HD O4 Gii thiu Phnxngreformingccbitquantrngtrongnhmylc,ha duvylphnxngsnxutcutphaxngcaocpvnguynliu cho ha du (BTX). K nng vn hnh qu trnh cng ngh ny l trong nhng yu cu c bn i nhn vin vn hnh. Phn ln cc nh my c cng sut lnhinnaysdngcngnghreformingvihthngtisinhxctclin tc.Trongkhunkhchngtrnhsgiithiumhnhmphngphn xng reforming vi s cng ngh ph bin nht hin nay. Mc tiu thc hin Hc xong bi ny hc vin ckh nng: 1.chiuvmtcsngng&thitbolngiu khin (P&ID's) ca phn xng; 2.Khi ng thnh cng phn xng; 3.Khc phc c mt s s c thng gp; 4. Dng phn xng theo ng quy trnh; 5. Dng phn xng trong cc trng hp khn cp. Ni dung chnh -Sngng&thitbolngiukhin(P&ID's)caphn xng Reforming; -Cc bc khi ng phn xng Reforming; -Cc s c thng gp, gii php khc phc trong vn hnh phn xng Reforming; -Cc bc dng phn xng; -Cc bc dng phn xng trong trng hp khn cp. 4.1. S CNG NGH M HNH M PHNG 4.1.1. Gii thiu hc vin d dng tip cn vi thc t vn hnh phn xng reforming ti sinh xc tc lin tc (CCR), cc m hnh m phng c xy dng trn s cng ngh cc phn xng reforming s dng ph bin hin nay. M hnh qu trnh reforming trong khun kh gio trnh ny c xy dng trn c s cngnghreformingvithitbtisinhxctclintc.Tuynhin,dovic vn hnh phn ti sinh xc tc phc tp, khng nm trong k nng i hi vi 51 trnh o to, v vy, phn vnhnh b phn ti sinh xc tc khng c cp trong m hnh m phng. y c th c xem l phn kin thc nng caotrongqutrnhthchnhcngnhlphnkinthchcvinsc o to tip trong qu trnh lm vic. 4.1.2. S cng ngh v cc thit b chnh m hnh m phng Mhnhmphngqutrnhhotngcaphnxngreformingxc tclqutrnhmphngthigianthcqutrnhcngnghdinratrong thit b phn ng, thit b ti sinhxc tc, thp chng ct,... Nguyn liu cho m hnh l naphtha nng ca qu trnh chng ct p sut kh quyn. Scngngh,ngngvthitbiukhin(P&ID's)caphn xng trong m hnh m phng c m t trong cc hnh v CCR-001. Cc cimchnhqutrnhcngnghxyratrongqutrnhreformingc trnh by di dy. Phn xng reforming bao gm cc b phn chnh sau: -B phn chun b v gia nhit s b nguyn liu ; -Thit b phn ng v phn tch sn phm; -B phn chng ct n nh sn phm. 4.1.2.1. B phn chun b v gia nhit s b nguyn liu Nguynliutbchahoctphnxngxlnaphthabnghydro (thptchnaphtha)catibnhchanguynliu(D-401).Mccht lng trong b cha nguyn liu c iu khin t ng. Nhim v bnh cha ny m bo dng nguyn liu cung cp vo l phn ng n nh. Nguyn liu t bnh cha ny c bm ti l phn ng, lu lng ca dng nguyn liu c iu khin t ng nh cc van iu khin dng. Nguyn liu c trn ln cng vi dng kh du hydro tun hon trc khi a vo thit b gia nhitnguynliu/snphmsauphnng.Khgiuhydrotbnhcha(D-403) c my nn tun hon (K-201) nn ti p sut thch hp. My nn ny cdn ng bng tuc binhi. Tc ca tuc bin hi c iu khin nh b iu khin tc ST-401. Hi sau tuc bin c ngng t trong thit bngngtE-407.Ncngngcbmtihthngthugomvxl nc ngng. Hn hp nguyn liu lng v kh hydro sau khi gia nhit s b c un nng v bay hi ri a vo l gia nhit nguyn liu (F-401) ca l phn ng thnht.Doqutrnhreforminglqutrnhthunhit,nngiacclphn ng b tr cc l gia nhit trung gian. Trong m hnh m phng ny s dng 3 l phn ng nn s l gia nhit trung gian l 02 l (F-402 v F-403). Cc l gia nhit ny l cc l s dng kh nhin liu. 52 4.1.2.2.Thit b phn ng v phn tch sn phm Mhnhmphngtrongkhunkhgiotrnhnysdng03lphn ng (R-401, R-402 v R-403). Cc phn ng xy ra trong qu trnh reforming tngthlccphnngthunhit(phnngtchhydro,phnngisome ho, phn ng vng ho v cracking). V vy, cc l gia nhit trung gian gia hai l phn ngnhm cung cpnhit lng cho cc phn ng trongl phn ng k tip. Hn hp sn phm sau phn ng i ra t l phn ng cui cng (R-303)clmmtnhgianhitsbchonguynliutrongthitbgia nhit (E-401) sau tip tc c lm mt v ngng t mt phn nh thit b lm mt bng nc (E-402). Hn hp lng/hi sn phm phn ng sau c a ti thit b phn tch (D-402), ti y phn kh khng ngng c thu v ca ht my nn kh tun hon, phn lng y bnh phn tch c bm ti thp chng ct di s iu khin ca b iu khin mc lng trong bnh phn tch. 4.1.2.3. B phn chng ct n nh sn phm Nguyn liu a ti thp chng ct (thp n nh) c gianhit s b bng thit b trao i nhit(E-403)vi dngreformate i ra t ythp. Sn phm reformate c n nh nh qu trnh bay hi tch cc cu t c nhit bayhithprakhisnphmdinratrongthp.ythpcgianhit nh thit b gia nhit y (E-404). Tc nhn gia nhit l du c nhit cao. Cccutcnhitbayhithpctchranhthpnnh. Dng hi ny c lm mt, ngng t mt phn v chuyn ti bnh cha sn phm nh. Mt lnghinc tronghnhphi nh thp cngng t tch ra thnh pha ring bit. Dng sn phm nh sau khi qua thit b ngng t c a ti bnh cha sn phm nh (D-404). Ti bnh cha ny, sn phm c bm hi lu mt phn li thp chng ct, phn cn li c a ti b phn thu hi x l LPG. Nc chua thu hi di y bnh cha v c bm tihthngxlncchuatrongnhmy.Lngsnphmnhlyra c kim sot nh b iu khin mc lng trong bnh cha. Snphmreformatennhcthuhiythpchngct. Reformate c lm mt mt phn trong thit b trao i nhit vi nguyn liu (E-403) v sau l trong thit b lm mt (E-406) ri a ti b chahoc phn xng ch bin tip theo. 4.2. KHI NG PHN XNG Khi ng phnxng reforming ti sinh xc tc lin tc thchin theo cc bc chnh nh sau: 53 4.2.1. B phn n nh sn phm (thp Stabilizer) -anguynliukhingbanutbchatithpnnhbng ng dnh cho khi ng ban u; -Khimcchtlngtrongythpt70%,ngngcpnguynliuvo thp n nh; -Khi ng thit b gia nhit y, a dng du tun hon qua thit b gia nhit y (E-404), khi ng b iu khin t ng nhit y thp v t mc iu khin nhit 1800C. M cc van chn trc v sau van iu khin t ng dng (RF-445) v ng ng by-pass; -M cc van chn trc, sau van iu khin dng hi lu sn phm nh (RF-441), van iu khin dng C3/C4 (RF-443) v van iu chnh p sut thp n nh (RF-430). t p sut iu khin cho b iu khin p sut ca thp gi tr khong 17Kg/cm2. -Duy tr n nh p sut ca thp n nh, m bo van iu khin p sut thp (PV-401) trng thi ng. Nu mc cht lng trong bnh ngng t vtqumc,khingbmhilusnphmnh(P-403),mcc vanuycabm(RF-438).tmciukhintng(FC-402) dng hi lu sn phm nh duy tr mc cht lng trong bnh ngng t sn phm nh mc bnh thng. 4.2.2. Phn thit b phn ng -iuchnhpsuttrongcclphnngttithiul0,5Kg/cm2 (hin th trn PC-402) bng cch m van thch hp hydro qua van RF-404. Khi p sut trong l phn ng t gi tr thch hp ng van RF-404 li; -ng van by-pass ng thot nc ngng ca thit b trao i nhit (E-407); -Khingtua-bindnng(ST-401)camynnK-401bnghiqua ng by-pass (RF-408). a vn tc ca tuc binv gi tr hot ng bnh thng ng thi m cc van chn trc sau van iu khin hi t ng vo tuc bin . t b phn iu khin tc tuc bin ch t ng.ngngby-passcphi(RF-408).Khimcchtlngtrong thitbngngt(E-407)hinthtrnthitbiukhinmc(LC-405), khi ng bm P-404 v m van ca y ca bm ny. t thit b iu khinmcchiukhintngduytrmcchtlngtrong thit b ngng t mc 50%. M cc van chn RF-413 v ng vanF-414; 54 -M van x (RF-459) ni vi ct uc ca nh my v cc van chn trc sau thit b iu khin p sut ca ht my nn kh hydro. M rng thm mvanRF-404tngpsutcahtmynnlnkhong 5Kg/cm2. ng van RF-404 li; -Mccvanby-pass(RF-422,RF-424vRF-426),vaniukhinkh nhinliu(FC-401,FC-402vFC-403)vocclgianhitnguynliu ca cc l phn ng tng ng; -Btccutlgianhit,sdngbiukhinnhitlt nngnhitcadngnguynliuln4300Cvitckhong 550C/gi.Mccvanchntrcvchnsauvaniukhintng dng kh nhin liu (RF-421, RF-423 v RF-425) ng thi ng cc van by-pass trc khi t gi tr nhit cho b iu khin t ng. Kim tra hm lng nc bn trong kh nguyn liu tun hon; -Khinhituvocattcccmxctclphnngttnht 3000C (ch th trn cc ng h o nhit (TC-407, TC-408 v TC-409), m van RF-404 nng p sut ca ca ht my nn hydro ln khong 7Kg/cm2 sau ng van ny li; -t gi tr iu khin p sut t ng trong khong t 79Kg/cm2 cho b iu khin p sut PC-402. M vanngcphydro b sung RF-458) v ng van x (RF-459); -Khi nhit dng kh tun hon ra khi cc l gia nhit t gi tr n nh 4300C,tinhnhanguynliuvobnhchanguynliu(D-401) bng cch m van qua ng b qua van iu khin dng (LC-401). t biukhinmcnguynliubnhD-401chtng,tgitr mcchtlngmchotngbnhthng,ngthingvantrn ngb qua (by-pass); -Khi mc cht lng trong bnh cha nguyn liu t 50% gi tr hot ng bnh thng, khi ng bm cp nguyn liu cho l phn ng, ng thi m van ca y bm (RF-416, RF-418); -Sau m t t van by-pass (RF-420), van iu khin dng nguyn liu (FC-401),mccvanchntrcvsauvaniukhinFC-401ng thi t b iu khin dng ch t ng, t t ng van ng by-pass. Nng lin tc lu lng dng nguyn liu ti 50% gi tr thit k; -Kim tra hm lng nc cha trong hydrcacbon tun hon m bo hm lng nc thp hn 200ppm. Nng nhit u ra ca tt c cc l gia nhit ln 4300C vi tc 300C/gi bng cch iu chnh b iu 55 khinnhit (TC-407, TC-408 v TC-409). Tip tcnngnhit u ra l gia nhit vt qu 4300C ti gi tr nhit thch hp (ty thuc vo tnh cht nguyn liu) vi tc 140C/gi; -Khi p sut ca ca h thng tng ln (do hydro to ra), t b iu khin p sut t ng gi tr thch hp (ln cn 8Kg/cm2); -Khilngchtlngxuthintrongbnhphntchhnhpphnng tngiln(DC-402),khingbmP-402vmvantrncay cabm(RF-433).Mvanby-passvaniukhindngchtlngra khi thit b phn tch (RF-429), sau m van chn pha trc v sau vaniukhindng(RF-428).tbiukhinmcchtlngtrong bnhphntchchiukhintng,gitrt50%.ngvan by-pass; -Khisnphmtcclreformingbtuchyvothpnnh,tt a sn phm v b cha bng cch m van chn trc, sau (RF-448) cavaniukhinmcchtlngythpnnh(LC-404)vtb phniukhinmcchtlngythpnnh(Stabilizer)ch iu khin t ng; -Dng tay m van cp nc lm mt (RF-455) cho thit b lm mt E-406 snphmy(reformate)cathpnnhgimnhitcadng sn phm ti gi tr thch hp; -Khi sn phm ca cc l phn ng thay th lng reformate (lm nguyn liubanuchothpnnh)thlulngdnghisnphmnh thpvpsuttrongthpstngln,bphniukhinpsutt ngcathpnnh(PC-401)cnhimvduytrpsutcathp trong gii hn thch hp. Tng nhit ca thit b gia nhit y ti nhit thit k; -Khimcchtlngtrongbnhchasnphmngngtnhtngln (hinthtrnthitbiukhinmcLC-403),tgitrhiluvob iu khin duy tr ch s hi lu thchhp. Chy th cc thit b iu khin dng LPG v th ch t ng ca b iu khin; -iu chnh tng t t lu lng nguyn liu ti gi tr thit k nh b iu khin dng FC-401; -Bt u b sung hp cht clo vo h thng. M van chn ng b sung clo v nc; Ti y qu trnh khi ng phn xng kt thc, iu chnh phn xng v ch hot ng bnh thng. 56 4.3. DNG PHN XNG 4.3.1. Dng theo k hoch (bnh thng) mboantonchothitbvgimthiuthithivkinhtkhi dngphnxng(luphnxngreformingkhngchcnghaquan trng trong vic snxutxng cao cp m cn l ngun cung cphydro cho cc phn xng x l v ngun kh nhin liu) th vic dng phn xng phi thchintheongtrnhtnhsn.Ccbcdngphnxngtheok hoch bao gm: -Gimnhitnguynliuvocattccclphnngvitc khong 250C/gi cho ti khi nhit ca nguyn liu vo l phn ng t 4300C. Kim tra m bo chc chn rng p sut ca ht my nn t t nht l 8Kg/cm2. Sau khi gim nhit nguyn liu tin hnh gim lulngnguynliu(bngbiukhinFC-401)chotikhidng nguynliucungcpgimcn50%gitrchhotngbnh thng; -Khinhitnguynliuvocattccclphnngt4300Ctin hnhngccvanchntrnngngcpkhnhinliucholt (FC-421,FC-423,FC-425),ngtchiukhinnhitltng ca b iu khin; -ngvanchntrnngngbsungclo(RF-405)vngcp nc (RF-406); -t mc iu khin dng nguyn liu trong b iu khin (FC-401) xung gi tr bng khng "0" ng thi ng cc van chn trc, chn sau van iukhinny(RF-419).Dngbmcpnguynliu(P-401)vng van ca y ca bm; -Khimcchtlngtrongbnhphntchlng(D-402)chmmcthp nht,dngbmvnchuynsnphmsauphnng(P-402)vng vancaycabm(FR-433).Thotonbchtlngcnngli trong bnh phn tch v b cha du thi (RF-454); -Ngngcpnhitchothitbgianhity(sdngdunnghochi caop,trongscngnghnysdnghicop).Dngch iu khin t ng nhit y thp; -Khi nhit u vo l phn ng gim xung cn khong 2000C, ngng my nn kh bng cch ng van cphi cho tuc binhi ca mynn (RF-407).Bmncngngtrongthitbngngt(E-407)chotikhi mcnctrongthitbttimcthpnhtsaudngbmng 57 thingvanchncaycabm.Ngththngiukhinmc cht lng trong thit b ngng t E-407; -t b iu khin p ca ht ca my nn hydro (PC-402) v chuyn b iu khin tuc bin my nn v ch vn hnh tay; -ng van chn trc v chn sau van iu khin dng hi lu nh thp n nh v dng ch iu khin t ng; -Khimcchtlngtrongythpnnhgimxungmcthp,tt m van ng by-pass (RF-449) v tho ton b lng ra khi thp. ng van chn trn ng by-pass, ng cc van chn trc v chn sau van iu khin dng (RF-448), ngt b iu khin mc cht lng y thp; -Khi mc cht lng trong bnh cha sn phm ngng t nh gim xung mc thp, dng bm hi lu sn phm nh (P-403). Ngt b iu khin thuhisnphmLPG.Thotonbsnphmlngtrongbnhcha bng cch m van y bnh (RF-436); -Mvanngby-passcavaniukhinpsutthpnnh,ng thi gim p sut ca thpxungngangbng p sut ca u thugom khnhinliutrongnhmy.Ngtbiukhinpsutthpnnh. ng van chn trc, chn sau van iu khin p sut (PC-401) v van chn trn ng by-pass. M van x (RF-463) ni h thng vi ct uc nh my, gim p sut h thng cn bng vi p sut h thng ct uc. ui hydrocacbon trongh thng bng khni-t sau ngng cpni-t khi t yu cu. Qu trnh dng phn xng kt thc. 4.3.2. Dng khn cp Phnxngreformingclinquannhotngcanhiuphn xngtrongnhmy(cbitlccphnxngxlbnghydro,phn xng BTX,...), v vy, khi ngng khn cp phi tin hnh theo mt trnh t mboantonvnhnhchungcanhmy.Ccbcchnhdngkhn xng khn cp bao gm: -Dng v c lp b phn ti sinh xc tc; -Tt cc u t ca tt c cc l trong phn xng. ng van cpnhin liu v lp tc a hi vo khoang t lm ngui l. a ton b hi caopcsnxuttrongphnxngrangoimitrngquah thng x c gim m; -Ngng bm cung cp nguyn liu ti phn xng; 58 -Gichomynntunhonchycnglutrongphmvichophp lmnguilphnngvahthydrocacboncnchatrongl phn ng ra bnh phn tch cao p; -Dngbmcpkhhydrochoccphnxngxlsdngngun hydrotphnxngreforming,dngbmvnchuynchtlngca bnh phn tch cao p; -Dng thit b x l LPG; -a cc sn phm phn ng v b cha du thi nh; -Dng my nn kh tun hon; -Dng cc phn khc ca phn xng theo trinhg t an ton. 4.3.3. Cc s c v gii php khc phc Trnylccbccbnchungdngphnxngtrongtrng hp bnh thng v trongnhng trnghp khn cp. Trong thc txy ra nhiu s c nh hng ti hot ng ca phn xng, tu trng hp c th mcccgiiphpringkhcphcschocphidngphnxng. Cc s c ln xy ra phi c cc bc x l thch hp nh: mt in, mt hi, mtnclmmt,hthngcpnguynliugpsc,hthngkhiu khin gp s c,... 4.3.3.1. Mt in Khi mt in tt c cc bm s dng, vic cp cc ho cht, ph gia b sung vo cng phi dng. -Cc my n