B LAO NG - THNG BINH V X HI TNG CC DY NGH D n gio dc k thut v dy ngh (VTEP)

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Gio trnh

M un: THC TP VN HNH TRN H THNG M PHNG M s: HD O Ngh: VN HNH THIT B HA DUTrnh : lnh ngh

H Ni - 2004

Tuyn b bn quyn: Ti liu ny thuc loi sch gio trnh Cho nn cc ngun thng tin c th c php dng nguyn bn hoc trch dng cho cc mc ch v o to v tham kho. Mi mc ch khc c lch lc hoc s dng vi mc ch kinh doanh thiu lnh mnh s b nghim cm. Tng cc Dy ngh s lm mi cch bo v bn quyn ca mnh. Tng cc Dy Ngh cm n v hoan nghnh cc thng tin gip cho vic tu sa v hon thin tt hn tI liu ny.

a ch lin h: D n gio dc k thut v ngh nghip Tiu ban Pht trin Chng trnh Hc liu ..................................................... ........... M tI liu:. M quc t ISBN:..

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LI TA (Vi nt gii thiu xut x ca chng trnh v ti liu)

Ti liu ny l mt trong cc kt qu ca D n GDKT-DN .. (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/mn hc ca mt chng trnh, o to hon chnh ngh vn hnh 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. y l ti liu th nghim s c hon chnh tr thnh gio trnh chnh thc trong h thng dy ngh. H ni, ngy . thng. nm. Gim c D n quc gia

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MC LC mc Trang

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. NGHA CA 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

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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

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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 qu trnh iu khin my mc thit b c thc hin t phng iu khin trung tm nh h thng iu khin t ng. Nhn vin vn hnh theo di hot ng my mc thit b v iu khin hot ng ton b nh 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 rt ngn 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. Vi phng thc o to ny cho php n gin c chng trnh, gim c thi gian thc tp thc t, gim chi ph o to nhng vn thu 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; M t c c tnh ca mt s phn xng, loi thit b khc nhau trong cng ngh lc hoa du; Lm quen vi vn hnh nh my lc ha du hin i t phng iu khin thng qua h thng iu khin phn tn (DCS), bao gm cc nhim v khi ng (Start-up), vn hnh bnh thng (Normal Operation), dng phn xng theo k hoch v dng khn cp (Emergency Shutdown); Rt ngn c thi gian thc tp nh my hoc Pilot;

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M t v thc hin c quy trnh c bn v khi ng, dng khn cp phn xng, thit b (t phng iu khin trung tm) thng qua h thng iu khin phn tn (DCS) v h thng dng khn cp (ESD); - M t c s ng ng, thit b o lng (P&ID's) ca mt s 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:

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Khi ng c cc phn xng chnh trong 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)

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X l c mt s s c thng xy ra trong qu trnh vn hnh cc 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)

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S quan h theo trnh t hc nghAn ton lao ng Ha v c Ha hu c Ha l Ha ph t n ch Ki thc n c s nhm ngh Qu tr nh x l Chng c t chbi n d u Qu tr nh reforming Qu tr nh Cracking Cng nghch bi kh n Th p c c c t cho u x ng V k thu t KT n i KT n t i K thu t mi trng

Mn chungCh nh tr Ph p lu t

Mn c bnV l t i c ng

GDQP

GDTC

nh hng gi n ti p

S cng ngh nh m y lc d u

V hnh thi bch n t bi d kh n uThc hnh trn thi b t m phng Chuyn d phng

Bo d ng thi b t

Dng c o

nh hng gi n ti p

QT doanh nghi p

Ngo i ng

Thnghim chuyn ngnh

Thc t tt p nghi p

C k thu t To n cao c p ng hc xc t c

Tin hc

Ki thc n c s ngh Ha hc d m & u kh K thu t phng thnghi m S ph n m d m u Tn tr v v chuy n n x ng d u Qu tr nh thi b t Thc t p qu tr nh thi b t

n mn kim lo i

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 mi c 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 th phi xut trnh giy chng nhn; Trong mt s trng hp c th vn phi qua st hch li.

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CC HNH THC HC TP CHNH TRONG M UN1: Nghe gio vin gii thiu v h thng m phng 2: Thc tp vn hnh cc phn xng chnh trong cng nghip lc ho du nh: chng ct du th p sut kh quyn, Cracking xc tc cn (RFCC), Reforming ti sinh xc tc lin tc (CCR), x l Naphtha bng hydro (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: Thm quan, thc tp ti phng iu khin trung tm nh my lc ho du hoc pilot .

YU CU V NH GI HON THNH M UNV 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. - Chp hnh ng quy nh an ton trong phng thc hnh v tham quan cc c s sn xut.

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BI 1. KHI NIM H THNG M PHNG M bi: HD O1Gii thiu Ngy nay, s pht trin ca k thut iu khin lm thay i c bn yu cu k nng ca nhn vin vn hnh theo quan nim truyn thng, c bit l trong lnh vc ch bin du kh. Nhn vin vn hnh, iu khin my 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 nh my t bn iu khin hc vin thc tp, lm quen vi cng tc vn hnh. Thng qua hc tp trn h thng m phng hnh thnh cc k nng 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. - M t c chc nng, nhim v ca cc thit b trong h thng m 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. NGHA CA H THNG M PHNG o to k nng vn hnh thit b trong cng nghip ch bin du kh cn phi tri qua giai on thc tp thc t trn bn iu khin ca phng iu khin trung tm. Tuy nhin, vic thc tp s gp nhiu kh khn v c th gy ra s c nu nh hc vin cha c kin thc v vic iu khin my mc t bn iu khin hoc ln u tip xc vi h thng. Mt khc, vic tham gia ca hc vin thc tp trong phng iu khin trung tm t nhiu nh10

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 thc t, gip hc vin c nhng k nng nht nh trc khi thc tp vn hnh, ngi ta xy dng mt h thng m phng qu trnh vn hnh, 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 phng ny c th trc tuyn (i vi phng m phng ca nh my hoc h thng pilot) hoc m phng tn hiu hon ton nh phn mm. a phn cc c s o to u s dng h thng m phng bng my tnh, ngoi tr 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 phn xng cho n khi thnh tho sau s tham gia thc tp thc t ti cc c s sn xut nu iu kin cho php. Qua qu trnh thc tp trn h thng m phng hc vin xy dng cho mnh k nng vn hnh cc phn xng chnh trong cng nghip ch bin du kh. Cc k nng chnh bao gm: S dng thnh tho chc nng ca cc bn phm iu khin, cc bc vn 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 nhng gia nhn vin vn hnh trong phng iu khin trung tm v nhn11

vin vn hnh ngoi hin trng. H thng m phng qu trnh vn hnh khng ch xy dng k nng cho nhn vin vn hnh phng iu khin trung tm m cn xy dng k nng vn hnh cho nhn vin vn hnh ngoi hin 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 chc nng o to hc vin vn hnh t phng iu khin trung tm trong cc nh my ch bin du kh, s h thng m 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 tnh phc cho cng tc gim st, qun l qu trnh hc tp, kim tra v ra nhim v cho hc vin ca gio vin hng dn, mt my tnh thc hin chc nng ca nhn vin vn hnh ngoi hin trng (Field operator), my tnh 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 chnh nu trn trong h 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 Chc nng ca cc b phn trong h thng m phng vn hnh c trnh by trong cc mc di y.12

1.2.2.1. My tnh ch C chc nng thc hin cc chng trnh ci t sn gip h thng mng vn hnh theo ng chc nng thit k. Cc m hnh vn hnh c 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 Ngoi my tnh ch, my tnh ca gio vin hng dn c v tr quan trng trong qu trnh o to hc vin. Cc chc nng chnh ca my tnh gio vin hng dn bao gm: - Hin th giao din hot ng gia h thng v hc vin: Cc ch hin th m bo d dng cho qu trnh s dng gim ti a thao tc bn phm; - Cho php gio vin la chn m hnh vn hnh cho hc vin; - Cho php la chn ch hot ng ca mi m hnh: My tnh gio vin hng dn cho php ra cc lnh: + Khi ng m hnh + Tm ngng/khi phc li trng thi. Lnh khi ng: cho php gio vin khi ng m hnh o to la 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 t nht 20 trng hp trc khi a ti cc my thc hnh 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 hay chm hn so vi thi gian thc. V nhiu m hnh i hi mt rt nhiu 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 t xa cho cc thit b hin trng (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. t trc mt s s c thit b: y l vic lm cn thit trong o to nhn vin vn hnh hc vin quen vi gii quyt cc s c xy ra trong thc t.

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Thay i cc thng s u vo chng trnh m phng: H thng cho 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 s ny 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. Theo di cc thng s cng ngh: H thng cho php gio vin hng dn xc nh cc thng s cng ngh (cc bin) c th c theo di trong qu trnh thc hin ti thi im bt u chy m hnh o to. Hin th li mn hnh v ghi cc s kin: Chc nng ny cho php gio vin hng dn xem li ton b iu kin cng ngh xy ra bao gm c 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 m phi c tc ng trc tip ca nhn vin vn hnh (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,...). Trn mn hnh my tnh ny s m phng li cc thit b hin trng. Trong thc t, vn hnh cc thit b ny da trn yu cu ca cc nhn vn 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 vn hnh ngoi hin trng. Thao tc vn hnh thc hin theo yu cu ca hc vin thc hnh ti my tnh m phng bn iu khin trung tm.

Hnh H.1-3. Hnh nh h thng m phng vn hnh14

1.2.2.4. My tnh m phng bn iu khin cho hc vin Hc vin thc tp vn hnh nh my t phng iu khin trung tm s thc tp trn cc my tnh m phng ny. Gio vin hng dn s giao cho mi hc vin (hoc mt nhm hc vin) thc tp vn hnh mt phn xng (c m phng bng mt chng trnh). Trn mn hnh ca my tnh ny s hin th cc chc nng nh bn iu khin trung tm trong thc t, hc vin thc tp vn hnh t bn iu khin ny. Cc chng trnh ci t trong h 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 Ngoi cc thit b chnh ca h thng nu trn h thng m phng cn trang b cc thit b ngoi vi nh my in, h thng lu tr s liu d phng, 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 p ng c yu cu cng vic trong thc t, hc vin cn phi c trang b tng i a dng kin thc v k nng vn hnh cc phn xng cng ngh s dng ph bin trong ch bin du kh. Trong khun kh ca chng trnh ny s cp n cc phn xng c s dng rng ri nht, cc cng ngh tng t khng cp tit kim thi gian v u t h thng. Ngoi ra, s lng cc m hnh a ra trong chng trnh c tnh n kh nng u t trang thit b ca mt c s o to ph hp vi thc tin Vit nam. Cc qu trnh cng ngh c bn, cc phn xng v cc thit b s dng trong ch bin du kh bao gm: phn xng chng ct du th p kh quyn (CDU), phn xng Cracking xc tc cn (RFCC), phn xng Reforming ti sinh xc tc lin tc (CCR), phn xng x l Naphtha bng15

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), nh my ch bin kh, cc phn xng x l LPG, Kerosene, trung ha kim, polypropylene v cc thit b quan trong trong nh my nh l t, my nn 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), c im c th ca cc m hnh ny, cc bc thc hnh c th c trnh bi trong cc bi hc tip theo ca chng trnh.

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BI 2. VN HNH PHN XNG CHNG CT DU TH P SUT THNG (CDU) M bi: HD O2Gii thiu Phn xng chng ct du th c ngha quan trng i vi nh my 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 quan trng i vi hc vin. Qua qu trnh hc tp gip cho hc vin nm c cc k nng c bn t khi ng, dng phn xng bnh thng cho ti dng khn cp phn xng v x l c mt s s c thng gp trong vn hnh. Sau qu trnh o to ny s gip hc vin gim bt c cc li thao tc trong vn hnh, x l c cc tnh hung c th xy ra trong thc 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 c th c nhng khc bit nht nh nhng khng nh hng n kh nng thao tc, vn hnh ca hc vin. Nhng s khc bit ny s c o to b sung trong qu trnh lm vic. Mc tiu thc hin Hc xong bi ny hc vin c kh nng: 1. c hiu v m t c s ng ng & thit b o lng iu 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 - S ng ng & thit b o lng iu khin (P&ID's) ca phn 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.

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2.1. S CNG NGH M HNH M PHNG 2.1.1. Gii thiu hc vin d dng tip cn vi thc t vn hnh phn xng chng ct du th p sut kh quyn (CDU), m hnh m phng c xy dng 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 Tng ng vi chc nng tch cc sn phm ny,isow cng ngh 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 xng trong m hnh m phng c m t trong cc hnh v CDU 01 n 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 hng lot cc thit b trao i nhit ca cc dng sn phm c nhit cao 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 thit b trao i nhit c gia nhit ln ti nhit thch hp cho qu trnh tch mui. Nhit du th c iu khin bng b iu khin nhit t ng (bng cch iu chnh van ng m b qua mt s cm thit b trao i nhit).18

2.1.2.2. Thit b tch mui Trong thit b tch mui, du th c trn vi nc kh khong. 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 ca nc vo du nh thit b trn tnh v van trn. Nc phn tn cng tt th kh nng tch mui ra khi du cng tt. Mui trong du th s ho tan vo nc (do kh nng ho tan mui vo nc tt hn du) v sau tch nc ra khi du th. Phng php ph bin hin nay tch mui khi du th l s dng in trng cao ph nh tng du v nc. Di in trng cao, cc ht nc nh ( ho tan mui cha trong du th) s lin kt thnh cc ht nc ln lng xung y ri c tch ra ngoi. Nc tch ra c ti s dng li hoc a ti khu x l nc thi. Du th tch ra pha trn bnh tch mui v c bm tng p y qua hng lot cc thit b trao i nhit tn dng nhit tha ca cc dng sn phm nng i ra t thp chng ct. Sau khi ra khi thit tch mui, du th chia thnh mt s 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 cc phn i lu v bc x. Lu lng ca cc dng du c iu khin nh cc van iu khin t ng FC-201, FC-202, FC-203 v FC-204. pha trn l gia nhit (phn i lu) c b tr h thng ng gia nhit hi thp p 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 ng ng dn du th b qua l gia nhit trnh trng hp du th c nhit qu cao sau l gia nhit. Dng du th ny s ho cng dng du i qua l gia nhit trc khi a vo thp chng ct chnh. Khng kh ho trn hn hp nhin liu t c gia nhit trc nh thit b trao i tn dng nhit cao ca kh thi. Khng kh y qua thit b trao i nhit ny nh mt qut y cng bc, cn kh thi l t c a qua thit b tn dng nhit bng qut ht, kh thi sau c a ra ng khi l t ri thi vo 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). Theo s cng ngh ca m hnh ph phng ca phn 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:19

- 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 thng trch ra cc dng lng trung gian nhm mc ch iu khin ch vn hnh ca thp. Cc dng du trung gian ny c s dng gia nhit s b du th. Qu trnh phn tch du th trong thp chng ct chnh din ra nh sau: Cc phn on nh bao gm phn on naphtha v hydrocacbon nh hn c tch ra nh thp sau c lm mt bng thit b trao i nhit bng khng kh v thit b ngng t. Phn hi ngng t c a vo bnh cha sn phm ngng t nh (D-202). Ti y, hn hp sn phm nh c phn tch lm 3 pha ring bit: naphtha, nc v pha hydrocacbon khng ngng t. Nc thu y b cha v c a ti phn xng 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. Cc phn on Kerosene, GO nh, GO nng c tch ra thn thp v a ti cc thp sc tng ng t bn cnh thp chng ct chnh nng cao cht lng sn phm. Pha di y thp chng ct c gia nhit bng hi, hi s dng l hi thp p qu nhit. Hi nc sc duy tr nhit ca thp ng thi tng cng qu trnh phn tch cc phn on. Cn ca du th c ly ra y thp nh bm cn. Cn c a qua mt lot cc thit b trao i 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 Bn cnh thp chng ct chnh c cc thp sc tinh ch li cc sn phm Kerosene, GO nh, GO nng. Cc thp ny c gia nhit y (thng l s dng hi sc trc tip) tch cc thnh phn nh hn ra khi phn 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.

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2.1.2.6. H thng thu hi kh Kh khng ngng (bao gm LPG v kh nhin liu) c ha lng mt 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 khng ngng t c a ti h thng kh nhin liu ca nh my. 2.2. KHI NG PHN XNG Khi ng phn xng chng ct du th trn h thng m phng nhn 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 Tu tng iu kin c th m nguyn liu s dng cho khi ng phn xng ban u c th l du th hoc du diesel nh (LGO), trong s cng ngh, m hnh ny c 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); - M van ni vi cc thit b gia nhit s b tn dng nhit mc 50% (HC-201, HC-202, HC-203); - M van ng by-pass qua l gia nhit du th (FC-201, FC-202, FC203, FC-204 mc 20% v m cc van chn); - Khi mc lng trong y thp chng ct chnh t 50%, bt bm tun hon y thp (P-203) ng thi m van iu chnh mc t ng (LC202) v van chn. Van iu chnh 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;

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- 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; - M van chn (RF-220) kh khng ngng ni t bnh ngng t nh thp chng ct chnh ti ct uc, t b iu khin p sut ch iu khin t ng, mc iu khin l 0, 35Kg/cm2 ng thi m ng bypass. 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); - M cc van chn trc v sau (RF-227) ca van iu khin nhin liu (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 - Chuyn t ch np du diesel nhe sang ch np du th bng 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 - Nng nhit dng du ra ti ch hot ng bnh thng. Nhit ny ty thuc vo loi du ch bin, thng thng trong khong 3300C3400C. Lu , duy tr tc nng nhit mc thch hp (300C/gi). - Khi ch hot ng n nh, t ch iu khin rng buc gia dng nhin liu v nhit du. t ch iu khin nhit dng du ch t ng;22

- 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: Khi ng bm P-206, m van iu khin dng FC-208 v m cc van chn, t van FC-208 ch iu khin t ng; - Khi ng bm tun hon nhit s 2: Khi ng bm P-205, m van iu khin dng FC-209 v m cc van 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: Khi ng bm P-204, m van iu khin dng FC-220 v m cc van 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 t ng (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%. Khi mc lng t gii hn, khi ng bm P-211, m van iu khin 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 i vi thp chng ct chnh: M van cp hi iu khin t ng (FC219) 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) v cc van chn, t van iu khin lu lng hi (FC-216) ch

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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 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 Khi khoang cha nc chua ca bnh ngng t nh t mc 50% 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 (LC204) ch t ng Kim tra nhit du th qua l t t nhit thit k cha, nu cha t tip tc thc hin cc bc 11 v 12. Khi nhit du vo thp 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) - Khi mc cht lng trong trong thit b t mc 50%, m van LC-201 v 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. Bt u thu sn phm v a phn xng v ch vn hnh bnh thng - Khi cc sn phm t cht lng theo thit k, chuyn sn phm v cc b cha sn phm trung gian tng ng (b cha cn, LGO, HGO, Kerosene v Naphtha)..24

- a phn xng vo ch hot ng n nh, qu trnh khi ng 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 phn xng 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 du th 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 du th xung cn 40% cng sut thit k. Gim tt c cc lu lng dng sn phm v bm tun hon xung 40% nh iu chnh cc van 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; - Ngng cp nc vo thit b tch mui v tho ht nc trong thit b tch mui; - Dng ln lt tt c cc bm tun hon thn thp. Duy tr dng hi lu nh thp cng di cng tt; - Dng l gia nhit du th bng cch gim lu lng nhin liu cung cp bng cc van iu khin dng nhin liu. Dng hot ng b phn sn xut hi qu nhit ca l gia nhit. Tt cc u t ang hot ng. Khi dng kh nhin liu vo l gia nhit khng kh ngt hn, m ng bypass (b qua thit b gia nhit khng kh vo l t). a khng kh vo lm ngui l gia nhit. a hi nc 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;

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- Dng my nn kh v gim p sut trong h thng bng cch s dng cc van x. t p sut cc van x mc "0" trnh hin tng tng p sut trong h thng. Sau khi thc hin xong cc bc nu trn qu trnh dng phn xng hon thnh. 2.3.2. Dng khn cp phn xng Dng phn xng khn cp l qu trnh dng t ngt phn xng do 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 b phn sn xut hi qu nhit. M cc van by-pass kh thi l t (khng qua thit b gia nhit khng kh); - Gim lu lng dng sn phm, hng dn cc vn hnh vin ngoi 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; - Gi cc bm tun hon thn thp hot ng cc di cng tt, sau dng hot ng. Hng dn cc vn nhn vin vn hnh ngoi hin trng ngt bm cp du th v cc bm tun hon thn thp. - Dng my nn kh nh thp chng ct; - Bm ht cc cht lng cn ng y cc thp sau hng dn nhn vin vn hnh ngoi hin trng tt bm cn chng ct - Hng dn cc nhn vin vn hnh ngoi hin trng tt cc bm cn li trong phn xng. Qu trnh ngng khn cp phn xng hon thnh. 2.3.3. Cc s c v gii php khc phc Trn y l cc bc c bn chung dng phn xng trong trng hp 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 khc ring 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,...

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2.3.3.1. Mt in Khi mt in hng lot cc thit b c ng c in dn ng s ngng hot ng nh my bm np nguyn liu, bm tun hon sn phm y v cc thit b s dng ng c in khc. Hu qu km theo l cc thp chng ct ngng hot ng (do mt dng nguyn liu), thit b gia nhit y ngng hot ng do mt dng nguyn liu. Nu khng khi phc c ngun cung 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 lm mt sn phm v thit b ngng t trong thp chng ct. Mt nc lm 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 cao khi i v cc b cha. Hm lng nc cha trong cc sn phm cn lm kh cao do h thng sy khng hot ng c (thng s dng kiu 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 c nhit thch hp v b cha sn phm khi gim cng sut ch bin ca thp. Trong trng hp sn phm vn nhit qu cao, ngun nc lm mt khng c khi phc cn phi tin hnh dng phn xng theo quy trnh dng phn xng bnh 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 ng s t ng ngt bm cp du th vo thp chng ct v do phn xng s 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 cn phi gim cng sut dng nguyn liu. Nu s c hi xy ra trong thi

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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 kh nn s ngng hot ng.Nu s c mt kh nn iu khin din ra trong mt thi gian di cn tin hnh dng phn xng theo quy trnh dng phn 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 cho thit b hng hc ng thi tin hnh c lp thit b khi h thng chun b cho sa cha, bo dng; - R r mt bch ng ng, vi s c ny cn phi c sa cha kp thi. Tu thuc vo v tr ng ng v loi ng ng m quyt nh c phi dng phn xng hay khng.

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HC 201 TI 228 E-203 E-204 E-205

FC 212

AI DIST 203 AI COLOR 204 AI CFPP 205

E-220

E-218

RF-219 FI 220 E-206 HC 202

RF-219

NAPHTH CW A

RF-281

TI 229

LGO

CDU- 003

LGO

B/L

E-207

E-208

E-209

FI 221

E-202 203

230 TC 201 E-210 E-219 FI 222 RF-265 FI 625 CW FC 211 AI 209 CW E-216 E-217 FC 214 M E-211 E-212

E-213

FI 226

P-201

E-201 RF-218 RF-221 HC 206 RF-280 RF-283 RF-282 RF-220

ST

RF-236

RF-202 RF-218 RF-221

RF-220 TC 216

RF-201 DIST. AI 202

DIST COLOR CFPP

RF-266

RF-266

AI 206 AI 207 AI 208

B/L

B/L

HGO

B/L

B/L

B/L

CDU-003

HGO

N0-2 PA

CDU-003

N0-3 PA

N0-1 PA

CDU-002

N0-2 PA

N0-3 PA

CDU-003

CDU-003

CDU-003

CRUDE RESIDU E

CDU-003

CDU-003

CDU-003

CDU-003

LGO FOR START UP B/L N0-1 PA CDU-003

KEROSENE

KEROSENE

CRUDE TO DESALTER

CDU-002

Hnh H2-1. S h thng CDU-001

CRUDE FROM DESALTER

RESIDUE

CDU-002

29

TI 225

AI 210 FUEL GAS TO STACK RF-234

RF-233 RF-270 RF27 RF-206 3 STEA M TI 227

FC 201

FC 202 TI 202 RF-207 FC 203 F-201 RF-208 FC 204 RF-209 TI 203 PI 203 TI 204 TI 220 TI 205 PC 204 TI 206 D-201 LC 201 RF229 RF228 TI 221 TI 222 TI 223 RF232 RF231 RF230 TI 226 RF-227 RF-279 RF240 RF28 4 RF239 RF20 5 TC 207 FC 223 RF20 5 RF-227 RF-268 E-221 TI 224

TI 232

224 RF-269

M RF-264 K-203 INDUCED DRAFF FAN

M RF-263 K-202 FORCED DRAFF FAN

PDI 201

RF-267

RF204

ST RF238

RF-203

RF-203

RF-289

FC 213

M RF-237

I RF235 I

CDU-001

BAT LIM

CRUDE FROM E-202

CDU-001 CRUDE TO E-203, E-206 & E-210

FOUL WATER TO B. L.

BAT LIM

CRUDE FROM E213

CRUDE TO C201

P-202 A/B

HEATER XS 201 SHUTDOWN SWITC H

PROCESS WATER FROM B/L.

CDU-001

CDU-003

FUEL GAS

Hnh H2-2. S h thng CDU-002

BAT LIMSTEAM

30

TO FLARE

TC 208

E-214RF-210 RF-211 M RF-226 1 E-215 RF-210 4 A 12 CW B RF-211 RF-271 RF-272

FC13 1

PC 202

205

14

TI18

K201 D-202GAS COMPRESSOR

RF-262 M

210

T-20221

LC22

LI LC 204 203 201

23

LC TI 205 211RF-212

26

36 1 37

TI FC 209 216

43 1

T-203

FI 207 TI 214

RF-222

T-201212

TI

LC

TI 213

TI 215

T-204

206STEAM

TI 21747 PG RF287 RF-288 PG

TI

218M

PG

RF-286

LC 207RF-258

RF-255

RF-251

RF-247

FC LC52

P-208217

202M

M

P-205 A/BRF-249 RF-245

P-204 A/B

M RF-223 M

P206 A/B

RF253

FC 218 FC 219RF-252 RF-252

RF-214 RF-257

P-207STEAMRF-224 RF-275

AI 201

RF-256

FC 210ST RF-250 RF-246 ST

FC

FCRF-225

FIRF-214

208

209

ST

206

RF-254

TI 213RF-216 RF-217

STEAM STEAMRF-213 RF-244 RF-274 ST RF-242 M M M

RF-215

RF-276

RF-277

RF-278

RF-215

RF-216

RF-216

P-203 A/B

RF-261

RF-260

RF-259 RF-213

SIGNAL TO RESIDUE FROM E-216

P-211

P-210

P-209

N01 PA FROM E-201

N01 PA TO E-201

RF-243

E-213M RF-241

KEROSENE TO E-202

SOUR WATER TO B/L

PA N0-2 FROM

CDU-001

E-210 & E-206

CDU-001

CDU-001

CDU-001

PA N0-3 TO E-212

CDU-001

CDU-001

CDU-001

RESIDUE TO

HGO TO E-209

PA N0-2 TO E-211

PA N0-3 FROM E-204

LGO TO E-220

CDU-001

BAT LIM

BAT LIM

NAPHTHA TO B/L

OFF GAS TO B/L CDU-001 CDU-001 CDU-001

CDU-001

Hnh H2-3. S h thng CDU-003

CRUDE FROM F-201

BAT LIM

31

BI 3. VN HNH PHN XNG CRACKING XC TC CN M bi: HD O3Gii thiu Cracking l qu trnh cng ngh quan trng ch bin du kh gia tng gi tr sn phm lc ha du v a dng ha sn phm. Vn hnh phn xng cracking xc tc cn l mt trong nhng nhim quan trng ca nhn vin vn hnh. V vy, trong chng trnh o to nhn vin vn hnh u phi tri qua giai on thc tp vn hnh phn xng cracking xc 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 c kh nng: 1. c hiu v m t c s ng ng & thit b o lng iu 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 - S ng ng & thit b o lng iu khin (P&ID's) ca phn 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 s cng ngh cc phn xng cracking s dng ph bin hin nay. M hnh qu trnh cracking xc tc cn trong khun kh gio trnh ny c xy dng trn c s cng ngh cracking xc tc cn tng si vi h thng ti sinh xc tc mt bc.

32

3.1.2. S cng ngh v cc thit b chnh m hnh m phng M hnh m phng qu trnh hot ng ca phn xng RFCC l qu trnh m phng thi gian thc qu trnh cng ngh din ra trong thit b phn ng, thit b ti sinh xc tc mt bc, thp chng ct chnh, b phn thu gom x l kh, cc ni hi tn dng nhit thi, cc thit b ph tr v thit b o 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 m phng c m t trong cc hnh v FCC-001 n FCC-003. Cc c im chnh qu trnh cng ngh xy trong phn xng v thit b chnh c trnh by di y. 3.1.2.1. B phn chun b nguyn liu Nguyn liu qu trnh cracking c a t bn ngoi phn xng (b cha hoc trc tip t phn xng chng ct chn khng/chng ct p 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 thit b trao i nhit gia nguyn liu/sn phm y thp chng ct chnh. 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 Nguyn liu qu trnh cracking sau khi ho trn c a ti y ca ng phn ng, ng thi xc tc sau khi ti sinh t thit b ti sinh (R-302) cng c a ti y ng phn ng qua van vn chuyn xc tc. m ca van vn chuyn xc tc ti sinh c nhim v iu khin nhit ca l phn ng. Mt lng nh hi v kh nhin liu (kh nng) c a vo y ng phn ng vn chuyn xc tc v tng kh nng tip xc gia xc tc vi 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. Nhit lng cung cp cho qu trnh phn ng cracking do xc tc cung cp. Xc tc v nguyn liu tip xc vi nhau trong sut qu trnh vn chuyn ln pha trn, phn ng cracking hydrocacbon nng xy ra tc rt cao.

33

Cc yu t nh hng n qu trnh phn ng bao gm: nhit , t l xc 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 trnh phn ng cn to ra mt lng coke tng i ln bm trn b mt ht xc tc do qu trnh tch hydro ca hydrocacbon nng. 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. Hi sn phm phn ng sau khi ra khi ng phn ng nhanh chng c a vo b phn tch xc tc (nm cui ng phn ng) nhm trnh cc phn ng ph xy ra lm gim hiu sut thu hi sn phm mong mun. Hi sn phm sau phn ng tip tc c tch cc ht bi xc tc ko 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 Xc tc c ti sinh bng cch t coke vi khng kh trong khong nhit 7000C n 7600C, coke t chy chuyn ho thnh CO, CO 2 v hi nc. Khng kh cp cho qu trnh ti sinh xc tc nh mt my nn kiu hng trc (K-301). My nn ny thng c dn ng bng tuc bin hi nc hoc tuc bin tn dng p sut, nhit cao ca dng kh thi t thit b ti sinh xc tc. Lu lng dng kh ho trn c iu khin da trn thnh phn kh thi ca qu trnh ti sinh hoc nhit ca lp m xc tc ang ti sinh. Thit b ti sinh xc tc c thit k sao cho hn ch hin tng chy sau lp m do qu trnh -xy ho CO thnh CO2 lm tng qu cao nhit 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. tn dng nhit lng v nhit cao ca ngun kh thi, ngi ta 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, phn on du tun hon nng (HCO), du tun hon nh (LCO) v phn on hydrocac bon nh (bao gm phn on naphtha, LPG v kh nhin34

liu). Phn on du nng nht (du cn cracking) c tch ra y thp chng ct, ti y cc ht xc tc nh ko theo cng c lng ng li y thp. Du cn c a i sn xut hi nc, gia nhit cho nguyn liu 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 du ny sau khi trao i nhit c a quay tr li thp chng ct chnh. 3.1.2.5. Ct tch du tun hon nh Phn on du tun hon nh c tch ra t thn thp chng ct ri a ti ct sc tinh ch thm. Mc ch ca ct sc ny l tch cc cu t nh hn ra khi phn on. Cc cu t nh tch ra khi nh thp sc v c a tr li thp chng ct chnh, sn phm l du tun hon nh c tch ra y thp. Du tun hon nh c a ti b cha hoc a thng ti phn xng x l tip theo (thng l phn xng x l GO/LCO bng hydro). 3.1.2.6. Ct tch du tun hon nng Chc nng ca ct sc du tun hon nng cng tng t nh ct sc du tun hon nh. Du tun hon nng cng c tch t thn thp chng ct chnh ri a ti ct sc, ti y, cc thnh phn c nhit bay hi thp hn s c tch ra nh thp sc v a tun hon li thp chng ct chnh, phn on du tun hon nng c tch ra y thp sau khi lm 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 phn trong thit b lm mt bng khng kh (E-304) v thit b ngng t lm 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 pha lng\hi sau c a ti bnh cha sn phm ngng t nh thp chng ct chnh (D-302). Phn hi hydrocacbon khng ngng t (kh kh v LPG) c tch ra nh bnh cha i ti ca ht my nn kh t. 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.

35

3.2. CC BC KHI NG PHN XNG Khi ng phn xng cracking xc tc cn c s cng ngh in 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 chuyn xc 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; - ui khng kh trong thit b phn ng bng hi nc: M van sc hi (FC-301, FC-302) mc 20% v m cc van chn cc van iu khin ny; - ui khng kh trong thp chng ct chnh bng hi: M van cp hi nc (RF-348) vo thp chng ct chnh: M van RF-348 mc 60%, 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). - Khi khng kh c ui ra khi thit b, bt u a kh nhin liu vo thp chng ct chnh, ni thng thp chnh vi ct sc LCO bng cch m van RF-364 mc 20%. - Khi ng thit b trao i nhit lm mt, ngng t sn phm nh thp chng ct chnh (E-304 v E-305); - Khi ng bm nc ngng t trong y thp v trong bnh cha sn 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); - t van iu khin p sut ca h thng mc t ng duy tr p sut ca thit b ti sinh thp hn p sut ca thit b phn ng (khong 0,1Kg/cm2). 3.2.3. Khi ng thit b gia nhit khng kh - M van cp kh nhin liu cho l t (van RF-309 v van iu khin lu lng kh theo nhit khng kh); - Khi ng u t l t v tng nhit ca l ti sinh ln ti khong 6500C vi tc 2000C/gi;36

- Vi thp chng ct chnh: Duy tr p sut thp trong khong 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) Vi thit b phn ng duy tr p sut khong 0,9Kg/cm2 nh van iu khin p sut t ng PC-311. 3.2.4. Tun hon du trong h thng - a nguyn liu (cn chng ct chn khng hoc cn chng ct kh quyn) vo thp chng ct chnh (s dng ng ng by-pass l phn 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 theo thit k, ngng cp nguyn liu bng cch ngt bm P-301 ng cc van RF-327 v FC-311; - Bt u tin hnh tun hon 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, ng thi m van tho nc (FC-326) kim sot mc trong thit b to hi. - Khi ng h thng dng du LCO: khi ng bm P-301, m van FC311. Sau m van RF-328, khi ng bm 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 du thng trong khong 1100C n 1150C) bng thit b trao i nhit E-305. Kim tra xem nhit ca thit b ti sinh t ti gi tr thch hp cha (khong 6500C ty thuc vo loi du v cng ngh c th). Nu t gi tr thch hp s chuyn sang bc tip theo. 3.2.5. Np xc tc - M van RF-311 hon ton np xc tc vo thit b ti sinh nhanh chng; - Duy tr nhit khng kh u ra ca thit b gia nhit mc khong 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 thch hp (ty thuc vo loi xc tc, du v cng ngh trong ln cn 580 0C), khi ng u phn phi nhin liu vo l ti sinh. M van cp du nguyn liu (RF-306) v van cp hi37

(RF-305), cc van ny m mc tng ng ln lt l 70% v 20%. 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 sinh xc 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/cm 2, p sut thit b ti sinh xc tc l 2,6Kg/cm2. Tin hnh cc bc cng vic tip theo: - Duy tr lng xc tc trong thit b ti sinh mc 50% yu cu nh 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; - S hot ng n nh ca thit b gia nhit khng kh v cp du nhin 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;

38

- Chy th thit b to hi nc (ni hi tn dng nhit): Ngng cung cp hi nc vo thit b trao i nhit E-302 v ng van RF-326. M van cung cp nc ni hi LC-306 v m van thu nc chua ngng t nh FC-313; - M van cp nhin liu RF-319 v FC-311 t t, khi ng bm P-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 t l 5200C, m van chuyn xc tc ch vn hnh tay chnh nhit l phn ng; - Duy tr nhit ca pha xc tc trong thit b ti sinh nhit 6500C. Khi xc tc bt u c coke bm cn tng lng khng kh p ng yu cu t coke bng cch tng lu lng ca my nn kh K-301, gim lng kh nn x vo mi trng (gim m van x TDC-320); - Khi nhit y ca thp chng ct chnh t 150 0C: Tin hnh tun hon qua thit b trao i nhit E-308. t ch iu khin rng buc vi cm bin nhit TC-324. t TC-324 ch t ng. ng van RF-318; - t ch t ng cho c hai van vn chuyn xc tc PDC, van iu 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; - Bt u hi lu sn phm nh: Khi bnh cha sn phm nh t mc 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 lch nhit 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 sut bnh 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; khi mc cht lng trong thp sc du nng (T-303) t mc yu cu, khi ng bm vn chuyn P-304, m van FC-318 v t van ch t ng;39

- Vi sn phm ngng t nh (Naphtha): Khi ng bm P-307, t van 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 - Khi khng kh nn cung cp vo thit b ti sinh t 75% gi tr thit k, dng thit b gia nhit khng kh; - Chy th tua-bin kh tn dng nhit bng cch m van RF-370; - iu khin mc xc tc trong thit b ti sinh bng cc van RF-311 v RF-312, iu khin mc xc tc trong l phn ng bng b iu khin LC-301. t cc thit b iu khin mc ch t ng; - iu khin p sut trong thit b ti sinh v gi tr thit k (thng l 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) Dng phn xng cracking xc tc cn theo k hoch c thc hin ch ng cn c theo k hoch bo dng, hoc thanh tra my mc, thit b40

nh k. Vic dng phn xng c thc hin theo cc bc nh sn m bo an ton v gim thiu sn phm khng t tiu chun. Cc bc 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; - Gim nhit l phn ng xung 15 0C. Gim nhit l phn ng s lm gim nhit ca thit b ti sinh do lng coke to thnh trn b 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 liu vo phn xng, lng xc tc tun hon v lu lng du tun hon; - Gim lng bm tun hon thn thp chng ct chnh trnh chi ph cho qu trnh lm mt, gi thit b iu khin nhit nh thp v lu lng dng hi lu sn phm nh ch t ng gim bt nng lng cn lm mt sn phm nh. Cc van iu chnh p sut t ng ca bnh ngng t s iu chnh t duy tr p sut khi dng nguyn liu v nhit thit b phn ng gim. - Gim t l khng kh vo l ti sinh duy tr tt hn hp chy v gim p sut ca l ti sinh m khng ra hin tng chy li. Khi khng th gim lu lng khng kh c na, tiu th lng -xy d tha b sung thm lng du t. Vic ny c th trnh c hin tng chy li nhng li lm tng nhit ca lp xc tc. S dng hi lm gim nhit ca lp m xc tc. - a hi nc vo ng phn ng khi tc nguyn liu vo ng phn ng gim xung di 50% tc nguyn liu thit k. Cn phi duy tr 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 650 0C. Ch s dng du nhin liu duy tr nhit ca thit b ti sinh nu m bo rng xc tc c ti sinh; - Duy tr mc xc tc trong thit b ti sinh mc ti thiu theo yu cu m bo thit b vn hot ng tt khi rt xc tc ra;41

- Khi tc ca nguyn liu vo ng phn ng mc 40% so thit k, 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 sang thit b ti sinh qua van chuyn xc tc cha ti sinh. Gi p sut ca thit b ti sinh thp hn p sut thit b phn ng khong 0,10,2Kg/cm2 . Duy tr hi sc vo ng phn ng gi mc chnh p sut gia thit b ti sinh v l phn ng to thnh lp cch ly gia thp chng ct chnh v thit b ti sinh xc tc; - a xc tc ra khi thit b ti sinh ng thi dng cp du vo thit b ti sinh. Gi hot ng my nn kh (ngay c khi thit b ti sinh khng cn xc tc) lm mt thit b. Tc lm ngui thit b khng c vt qu 1200C/gi; - Bm tt c cc lng cn ng li y thp theo ng ng du thi. Gim dn p sut ca thp chng ct chnh. Tip tc sc hi vo ng phn ng; - Khi nhit ca thit b ti sinh gim xung cn 1500C, dng my nn 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 trnh hin tng pht la ca coke bm trn thnh thit b. y l bc cui cng dng phn xng cracking xc tc cn. Cn lu , dng phn xng cracking cn phi dng cc thit b ph khc nh ni hi tn dng nhit, my nn theo quy trnh ring, tuy nhin, phn cng vic ny khng nm trong phm vi ca m hnh m phng. 3.3.2. Dng khn cp Vic phi dng khn cp phn xng cracking xc tc cn l do s c ca cc my mc, thit b trong phn xng hoc do yu t bn ngoi nh h thng cung cp nng lng, ph tr ca nh my gp s c. Cc nguyn nhn chnh dn n vic phi dng khn cp bao gm: mt in, h thng kh42

iu khin, h thng khng kh to tng si cho thit b ti sinh, h thng cp hi, h thng cp nc cho ni hi, h thng nc lm mt, h thng my 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 s c ny nhn vin vn hnh c thao tc khc nhau dng phn xng 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 c th thc hin t ng thng qua h thng ngng khn cp (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 Trn y l cc bc c bn dng phn xng trong trng hp 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 Khi gp s c mt in cn thc hin cc bc sau dng khn cp phn xng: - Ngng cp nguyn liu vo phn xng, gim p sut l phn ng xung nhanh chng, gim chnh lch p sut van vn chuyn xc tc cha ti sinh; - Thc hin khn cp cc bc: Khi ng h thng iu khin dng khn cp phn cp nguyn liu, ng tt c cc ng cp nguyn liu vo ng phn ng, dng cp ph gia c ch n mn vo h thng, gim lu lng khng kh ha trn trong bung t xung 50% so vi hot ng 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 Nh cp trong cc m un khc, h thng kh nn iu khin c vai tr quan trng trong hot ng ca nh my lc ha du, rt nhiu van c vn hnh v iu khin bng h thng kh nn. Thng thng s c thng gp vi h thng kh nn iu khin l hin tng gim p sut kh nn trong giai on ngn. Phn xng s khi ng li ngay khi p sut h 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:43

- Khi ng h thng dng khn cp dng cp nguyn liu vo ng 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 vi nhu cu bnh thng v gim lng hi sc xung 50% so vi lu 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; - Khi nguyn liu cp vo ng phn ng dng hn, iu chnh p sut trong l phn ng duy tr mc chnh p sut trc v sau van vn 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 ca xc tc bng du t; - Khi h thng kh nn hot ng li bnh thng, phn xng s khi 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 Mt hi l mt s c nghim trng i vi hot ng ca phn xng cracking xc tc cn v hng lot cc my mc thit b quan trng ca phn 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 bypass 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; - Khi cn thit hiu chnh p sut duy tr chnh p gia pha trc v sau van vn chuyn xc tc mt hot tnh;44

- Chuyn cng nhiu cng tt xc tc trong vng sc xc tc trong kh nng c th sang thit b ti sinh; - Khi my thi kh dng, thit b ti sinh s dng hn, khng s dng du nhin liu duy tr nhit ca thit b ti sinh v xc tc; - ng tt c cc van chn u cp hi trc khi p sut h thng cp hi gim xung; - Nu s c d on khi phc trong vng 48 gi th cn s dng du 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 cp dng tt c cc dng nguyn liu vo ng phn ng v a nguyn liu b qua (by-pass) thit b phn ng. Nu bm nguyn liu d phng c th khi ng ngay cp nguyn liu bng ng khc th c th a phn xng tr li hot ng trong thi gian ngn. Trong trng hp khng khi phc c cp nguyn liu ngay, cn duy tr phn xng tnh trng "nng". Cc bc cng vic cn tin hnh bao gm: - iu chnh hi phn tn du vo ng phn ng mc ln nht theo thit k; - Chuyn van vn chuyn xc 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. - Khi nguyn liu c th cung cp tr li khi phc hot ng ca phn 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 cho thit b hng hc ng thi tin hnh c lp thit b khi h thng chun b cho sa cha, bo dng; - Nu my nn kh t gp s c th cn tin hnh dng khn cp phn xng theo trnh t trnh by phn 2. Tin hnh c lp my nn v

45

ui hydrocacbon ra khi ng ng v my nn trc kh tin hnh bt c cng vic sa cha no tip theo; - R r mt bch ng ng, vi s c ny cn phi c sa cha kp thi. Tu thuc vo v tr ng ng v loi ng ng m quyt nh c phi dng phn xng hay khng.

46

BAT LIM TO CO BOILER

FCC-002 AI 301 302 309 AI PDI

R-301 EFFLUENT D-301

PI 310 PDI 307 302

PC

PI

301

R-301 VENT TI TC 321 TDC TI 305 GE-301 R-302 LC 301 308 TI 301 308 304 AIR PDC 305 TI LI K-301 M/G 320 RF-307 306 RF-372

TI

303

TI

302

FC

301

STEAM

RF-301

RF-301

BAT LIM FC RF-311 ZI 301 FRESH CATALYST 303 PI 303

RF-302

FC

302

RF-303 FI PDC 322 306 RF-308

RF-303

BAT LIM USED CATALYST RF-312

RF-304

TI

301

FEED ZI TC 322 302

FCC - 002

FCC - 002

FI

CIRC OIL FROM P-303

320

RF-305 F-301

FUEL GAS

FI

321 RF-310 FI 323 RF-309

BAT LIM

TORCH OIL

RF-306

Hnh H3-1. S h thng FCC-001

47

FROM GAS CONC. PLANT TI E-304 RF-362 TI 304 AI M 308 BAT LIM RF-361 CW 303 323 TC TI 311 RF-363 PC 326 TO GAS PLANT FI E-305 307 TO FLARE

BAT LIM

INJECTION WATER

2

RF-369 1 FC RF-355 D-302 302 LC 305 RF-356

RF-358 RF-357 RF-360 T-301 FC TI 308 P-306 A/B 5 RF-353 P-307 FROM T-302 7 FCC-003 P-308 RF-354 LCO FROM E-312 FCC-003 RF-359 314 303 SOUR WATER BAT LIM C5+ GASOLINE BAT LIM

TO T-302 12 FCC-003 TI 311 14 HCO FROM E-311 BAT LIM

FC FROM T-303 17 FCC-003

319

RECYCLE OIL TO REACTOR

FCC-001

RF-335 22

TO T-303 FCC-003

FC

304

TI

315 27 314 29 P-303 34 FEED FROM 35 FC 308 45 RF-327 RF-352 RF-349 BAT LIM STORAGE RF-336 RF-350 TI RF-337

E-303

RF-348

STEAM

FCC-001

RF365 TI 316 RF-367 LG RF-318 321 FI RF-329 FC 309 RF-330 RF-330 RF-351 P-301 A/B FCC-001 R-301 FEED

R-301 EFFLUENT

LC

TO FIC- 310

307

FI RF-331 FROM BFW RF-313 317 PG D-303 BAT LIM RF-314 RF-322 RF-322 RF-332 E-309 RF-317 FC RF-316 312 RF-320 RF-323 P-302 A/B TC 324 E-308 RF-321 RF-319 RF-320 E-310 P-311 FC 311 RF-315 CW RF-333 310 319 DECANT OIL TI LC-307 FC TI

STEAM

325

BAT LIM

TI

FC

318

313

STEAM

RF-368

LC

306

RF-366

LG

E-302

RF-324

RF-324

RF-326

FCC- 003

BFW FROM E-301

RF-325

48

Hnh H3-2. S h thng FCC-002

TO T-301

FCC- 002

TI 309 T-302

FROM T-301

FCC-002 1

FC

317 RF-345 4 RF-364 FUEL GAS RF-344 LC P-305 304 316 STEAM FC 306 RF-343 E-306 TI 310 LCO PRODUCT FC

TO T-301

FCC-002

E-312

STRIPPER BOTTOM

BAT LIM

TO T-301 RF-342 CW 309 RF-346

FCC-002

TI 312 T-303

FROM T-301

FCC-002 1

FC 4

318

TO T-301

FCC-002 RF-341 RF-340 7 LC P-304 305 FC 315 STEAM FC 307 RF-339 E-301 E-307 TI 313 HCO PRODUCT

E-311

STABILIZED GASOLINE

BAT LIM

RF-338 CW RF-347 P-310

49

FCC-002

BFW

Hnh H3-3. S h thng FCC-003

BI 4. VN HNH PHN XNG REFORMING TI SINH XC TC LIN TC (CCR) M bi: HD O4Gii thiu Phn xng reforming c c bit quan trng trong nh my lc, ha du v y l phn xng sn xut cu t pha xng cao cp v nguyn liu 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 ln hin nay s dng cng ngh reforming vi h thng ti sinh xc tc lin tc. Trong khun kh chng trnh s gii thiu m hnh m phng phn xng reforming vi s cng ngh ph bin nht hin nay. Mc tiu thc hin Hc xong bi ny hc vin c kh nng: 1. c hiu v m t c s ng ng & thit b o lng iu 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 - S ng ng & thit b o lng iu khin (P&ID's) ca phn 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 cng ngh reforming vi thit b ti sinh xc tc lin tc. Tuy nhin, do vic vn hnh phn ti sinh xc tc phc tp, khng nm trong k nng i hi vi50

trnh o to, v vy, phn vn hnh b phn ti sinh xc tc khng c cp trong m hnh m phng. y c th c xem l phn kin thc nng cao trong qu trnh thc hnh cng nh l phn kin thc hc vin s c o to tip trong qu trnh lm vic. 4.1.2. S cng ngh v cc thit b chnh m hnh m phng M hnh m phng qu trnh hot ng ca phn xng reforming xc tc l qu trnh m phng thi gian thc qu trnh cng ngh din ra trong thit b phn ng, thit b ti sinh xc tc, thp chng ct,... Nguyn liu cho m hnh l naphtha nng ca qu trnh chng ct p sut kh quyn. S cng ngh, ng ng v thit b iu khin (P&ID's) ca phn xng trong m hnh m phng c m t trong cc hnh v CCR-001. Cc c im chnh qu trnh cng ngh xy ra trong qu trnh reforming c 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 Nguyn liu t b cha hoc t phn xng x l naphtha bng hydro (thp tch naphtha) c a ti bnh cha nguyn liu (D-401). Mc cht 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 nhit nguyn liu/sn phm sau phn ng. Kh giu hydro t bnh cha (D403) c my nn tun hon (K-201) nn ti p sut thch hp. My nn ny c dn ng bng tuc bin hi. Tc ca tuc bin hi c iu khin nh b iu khin tc ST-401. Hi sau tuc bin c ngng t trong thit b ngng t E-407. Nc ngng c bm ti h thng thu gom v x l 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 th nht. Do qu trnh reforming l qu trnh thu nhit, nn gia cc l phn 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.51

4.1.2.2.Thit b phn ng v phn tch sn phm M hnh m phng trong khun kh gio trnh ny s dng 03 l phn ng (R-401, R-402 v R-403). Cc phn ng xy ra trong qu trnh reforming tng th l cc phn ng thu nhit (phn ng tch hydro, phn ng isome ho, phn ng vng ho v cracking). V vy, cc l gia nhit trung gian gia hai l phn ng nhm cung cp nhit lng cho cc phn ng trong l phn ng k tip. Hn hp sn phm sau phn ng i ra t l phn ng cui cng (R-303) c lm mt nh gia nhit s b cho nguyn liu trong thit b gia 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 gia nhit s b bng thit b trao i nhit (E-403) vi dng reformate i ra t y thp. Sn phm reformate c n nh nh qu trnh bay hi tch cc cu t c nhit bay hi thp ra khi sn phm din ra trong thp. y thp c gia nhit nh thit b gia nhit y (E-404). Tc nhn gia nhit l du c nhit cao. Cc cu t c nhit bay hi thp c tch ra nh thp n nh. Dng hi ny c lm mt, ngng t mt phn v chuyn ti bnh cha sn phm nh. Mt lng hi nc trong hn hp hi nh thp c ngng 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 ti h thng x l nc chua trong nh my. Lng sn phm nh ly ra c kim sot nh b iu khin mc lng trong bnh cha. Sn phm reformate n nh c thu hi y thp chng ct. 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 cha hoc phn xng ch bin tip theo. 4.2. KHI NG PHN XNG Khi ng phn xng reforming ti sinh xc tc lin tc thc hin theo cc bc chnh nh sau:52

4.2.1. B phn n nh sn phm (thp Stabilizer) - a nguyn liu khi ng ban u t b cha ti thp n nh bng ng dnh cho khi ng ban u; - Khi mc cht lng trong y thp t 70%, ngng cp nguyn liu vo 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 vt qu mc, khi ng bm hi lu sn phm nh (P-403), m cc van u y ca bm (RF-438). t mc iu khin t ng (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 - iu chnh p sut trong cc l phn ng t ti thiu l 0,5Kg/cm2 (hin th trn PC-402) bng cch m van thch hp hydro qua van RF404. 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 (E407); - Khi ng tua-bin dn ng (ST-401) ca my nn K-401 bng hi qua ng by-pass (RF-408). a vn tc ca tuc bin v 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. ng ng by-pass cp hi (RF-408). Khi mc cht lng trong thit b ngng t (E-407) hin th trn thit b iu khin mc (LC-405), khi ng bm P-404 v m van ca y ca bm ny. t thit b iu khin mc ch iu khin t ng duy tr mc cht lng trong thit b ngng t mc 50%. M cc van chn RF-413 v ng van F414;53

- 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 m van RF-404 tng p sut ca ht my nn ln khong 5Kg/cm2. ng van RF-404 li; - M cc van by-pass (RF-422, RF-424 v RF-426), van iu khin kh nhin liu (FC-401, FC-402 v FC-403) vo cc l gia nhit nguyn liu ca cc l phn ng tng ng; - Bt cc u t l gia nhit, s dng b iu khin nhit l t nng nhit ca dng nguyn liu ln 4300C vi tc khong 550C/gi. M cc van chn trc v chn sau van iu khin t ng 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; - Khi nhit u vo ca tt c cc m xc tc l phn ng t t nht 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 van ng cp hydro 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, tin hnh a nguyn liu vo bnh cha nguyn liu (D-401) bng cch m van qua ng b qua van iu khin dng (LC-401). t b iu khin mc nguyn liu bnh D-401 ch t ng, t gi tr mc cht lng mc hot ng bnh thng, ng thi ng van trn ng b 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), m cc van chn trc v sau van iu khin FC-401 ng thi t b iu khin dng ch t ng, t t ng van ng bypass. 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 iu54

khin nhit (TC-407, TC-408 v TC-409). Tip tc nng nhit u ra l gia nhit vt qu 430 0C 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); - Khi lng cht lng xut hin trong bnh phn tch hn hp phn ng tng i ln (DC-402), khi ng bm P-402 v m van trn ca y ca bm (RF-433). M van by-pass van iu khin dng cht lng ra khi thit b phn tch (RF-429), sau m van chn pha trc v sau van iu khin dng (RF-428). t b iu khin mc cht lng trong bnh phn tch ch iu khin t ng, gi tr t 50%. ng van by-pass; - Khi sn phm t cc l reforming bt u chy vo thp n nh, t t a sn phm v b cha bng cch m van chn trc, sau (RF-448) ca van iu khin mc cht lng y thp n nh (LC-404) v t b phn iu khin mc cht lng y thp n nh (Stabilizer) ch iu khin t ng; - Dng tay m van cp nc lm mt (RF-455) cho thit b lm mt E-406 sn phm y (reformate) ca thp n nh gim nhit ca dng sn phm ti gi tr thch hp; - Khi sn phm ca cc l phn ng thay th lng reformate (lm nguyn liu ban u cho thp n nh) th lu lng dng hi sn phm nh thp v p sut trong thp s tng ln, b phn iu khin p sut t ng ca thp n nh (PC-401) c nhim v duy tr p sut ca thp trong gii hn thch hp. Tng nhit ca thit b gia nhit y ti nhit thit k; - Khi mc cht lng trong bnh cha sn phm ngng t nh tng ln (hin th trn thit b iu khin mc LC-403), t gi tr hi lu vo b iu khin duy tr ch s hi lu thch hp. 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.55

4.3. DNG PHN XNG 4.3.1. Dng theo k hoch (bnh thng) m bo an ton cho thit b v gim thiu thit hi v kinh t khi dng phn xng (lu phn xng reforming khng ch c ngha quan trng trong vic sn xut xng cao cp m cn l ngun cung cp hydro cho cc phn xng x l v ngun kh nhin liu) th vic dng phn xng phi thc hin theo ng trnh t nh sn. Cc bc dng phn xng theo k hoch bao gm: - Gim nhit nguyn liu vo ca tt c cc l phn ng vi tc 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 lu lng nguyn liu (bng b iu khin FC-401) cho ti khi dng nguyn liu cung cp gim cn 50% gi tr ch hot ng bnh thng; - Khi nhit nguyn liu vo ca tt c cc l phn ng t 430 0C tin hnh ng cc van chn trn ng ng cp kh nhin liu cho l t (FC-421, FC-423, FC-425), ngt ch iu khin nhit l t ng ca b iu khin; - ng van chn trn ng ng b sung clo (RF-405) v ng cp 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 iu khin ny (RF-419). Dng bm cp nguyn liu (P-401) v ng van ca y ca bm; - Khi mc cht lng trong bnh phn tch lng (D-402) chm mc thp nht, dng bm vn chuyn sn phm sau phn ng (P-402) v ng van ca y ca bm (FR-433). Tho ton b cht lng cn ng li trong bnh phn tch v b cha du thi (RF-454); - Ngng cp nhit cho thit b gia nhit y (s dng du nng hoc hi cao p, trong s cng ngh ny s dng hi co p). Dng ch 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 cp hi cho tuc bin hi ca my nn (RF-407). Bm nc ngng trong thit b ngng t (E-407) cho ti khi mc nc trong thit b t ti mc thp nht sau dng bm ng56

thi ng van chn ca y ca bm. Ngt h thng iu khin mc 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; - Khi mc cht lng trong y thp n nh gim xung mc thp, t t 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 thu hi sn phm LPG. Tho ton b sn phm lng trong bnh cha bng cch m van y bnh (RF-436); - M van ng by-pass ca van iu khin p sut thp n nh, ng thi gim p sut ca thp xung ngang bng p sut ca u thu gom kh nhin liu trong nh my. Ngt b iu khin p sut thp n nh. 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 trong h thng bng kh ni-t sau ngng cp ni-t khi t yu cu. Qu trnh dng phn xng kt thc. 4.3.2. Dng khn cp Phn xng reforming c lin quan n hot ng ca nhiu phn xng trong nh my (c bit l cc phn xng x l bng hydro, phn xng BTX,...), v vy, khi ngng khn cp phi tin hnh theo mt trnh t m bo an ton vn hnh chung ca nh my. Cc bc chnh dng khn 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 cp nhin liu v lp tc a hi vo khoang t lm ngui l. a ton b hi cao p c sn xut trong phn xng ra ngoi mi trng qua h thng x c gim m; - Ngng bm cung cp nguyn liu ti phn xng;

57

- Gi cho my nn tun hon chy cng lu trong phm vi cho php lm ngui l phn ng v a ht hydrocacbon cn cha trong l phn ng ra bnh phn tch cao p; - Dng bm cp kh hydro cho cc phn xng x l s dng ngun hydro t phn xng reforming, dng bm vn chuyn cht lng ca 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 Trn y l cc bc c bn chung dng phn xng trong trng hp 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,... 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 nn (my nn kh tun hon) s dng b dn ng tuc bin hi tip tc hot ng lm ngui l phn ng v y ht hydrocacbon trong thit b ra bnh phn tch cao p; - Kim tra m bo nhit ca nguyn liu vo thit b phn ng khng vt qu cao trc khi ngng cp nguyn liu; - Gim cng sut l gia nhit v s dng hi lm ngui l t; - Nu ngun in khng c khi phc ngay (c th bng ngun in d phng) th tin hnh dng khn cp phn xng theo trnh t mc 2 trn. 4.3.3.2. Mt nc lm mt Nc lm mt cung cp cho phn xng reforming ch yu cho cc thit b trao i nhit (ngng t, lm mt) v cho mc ch lm mt cc ti trng ln (nh my nn kh tun hon). V vy, mt nc lm mt l s c ln gy ra nhng hu qu nghim trng nh: lm tng nhit cc , cc

58

sn phm nh khng c ngng t,... Khi s c mt nc lm mt xy ra cn tin hnh cc bc sau: - Dng khn cp phn xng theo cc bc nh nu trong phn 2 (dng khn cp) trn; - Dng tt c cc l t v ng tt c cc van cp kh nhin liu; - Cp hi lm ngui l t. 4.3.3.3. Mt hi Khi mt hi my nn kh tun hon dng (s dng tuc bin hi), thp tch (Debutanizer) cng ngng hot ng. Khi mt hi cn tin hnh dng khn cp phn xng nh cc bc phn 2 trn. 4.3.3.4. H thng cung cp nguyn liu gp s c Nhn chung s c v cp nguyn liu thng khng dn n hu qu phi dng ngay phn xng. Khi c s c v h thng cung cp nguyn liu xy ra, cn phi c cc hnh ng khc phc s c kp thi: - Gim nhit l t v nhit nguyn liu, ng thi duy tr kh tun hon; - Chuyn ton b sn phm thp tch butane (debutanizer) v b cha du thi nh. t ch hi lu thp ch 200%; - Nu s c mt nguyn liu ko di tin hnh dng phn xng theo quy trnh dng phn xng theo k hoch (bnh thng) nh trnh by phn 1 trn. 4.3.3.5. 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 cho thit b hng hc ng thi tin hnh c lp thit b khi h thng chun b cho sa cha, bo dng; - Nu my nn kh tun hon gp s c th cn tin hnh dng khn cp phn xng theo trnh t trnh by phn 2. Tin hnh c lp my nn v ui hydrocacbon ra khi ng ng v my nn trc kh tin hnh bt c cng vic sa cha no tip theo; - R r mt bch ng ng, vi s c ny cn phi c sa cha kp thi. Tu thuc vo v tr ng ng v loi ng ng m quyt nh c phi dng phn xng hay khng.

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TO FLARE

FUEL GAS BAT LIM

RF-430 RF-463

RF-431

CHLORIDE

RF-405 RF-430 CW

BAT LIM

RF-406

E-405

H2O C3/C4 PRODUCTS BAT LIM

HYDROGEN

RF-458

RF-459

BAT LIM PG

TO FLARE

D-404

LC 402

FEED

BAT LIM

PC

F-401RF-465

402 LC 402 TI 406

LG

D-402

RF-401

RF-456

FIRF-451 RF-454

RF-402

RF-457

405

TC

R-401

RF-436

D-403

407

RF-401 RF-421 RF-461 RF-421

RF-456

PC 401

FI

404 TIRF-422

4031

RF-427

LC

401

D-401RF-441 RF-443

F-402 T-401RF-442 RF-444

AI

N2

401RF-441 RF-443

RF403

FIRF-452

FC TC 408

TI17

FC 402 401 403

MAKE-UP

AI 406

H2

R-402 E-402CW

402

RF404

E-403

RF-423

RF-423

CW RF-461

TIRF-424 RF-440

404 TC

RF-407

RF-407

PI 403

E-406

HP STEM

410

RF-464

RF-439

RF-455

PGRF-447 36N2

RF-438

RF-408

F-403RF-462 RF-437

FI

FC TI

409RF-419 RF-419

401

S/U

402 LC 404RF-445 RF-445 LG

RF-418

P-403 A/B

SC

401

ST-401

K-401 R-403FI FIRF-453

RF-466

408 TC 409RF-428 RF-448

HOT OIL

RF-417

RF-416 RF-420

407

CW

SC

RF-446 RF-425 RF-425 RF-429 RF-449 RF-450

P-401A/BRF-426 RF-428 RF-448

RF-415

LC

405

AIRF-461

AIRPV

403

404REFORMATE

E-407 FUEL GAS

RF-413

RF-413

TI 405OCTANE RF-435 No. BAT LAM

RF-410

RF-409

RF-434

RF-414

E-401RF-433

RF-412

CONDENSATE

RF411

RF-432

P-404 A-B P-402 A/B

Hnh H4-1. S h thng CCR-001

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BI 5. VN HNH PHN XNG X L NAPHTHA BNG HYDRO (NHT) M bi: HD O5Gii thiu Phn xng x l Naphtha bng hydro (NHT) c nhim v kh cc tp cht trong phn on naphtha nng p ng cho yu cu qu trnh reforming v isome ha (trong mt s trng hp, phn xng ny cn c nhim v no ha olefins, trong khun kh chng trnh khng cp chc nng ny). i vi cc nh my lc, ho du, phn xng ny gn lin vi qu trnh reforming to cu t quan trng sn xut xng cao cp v nguyn liu cho ho du (sn xut BTX). Hu nh nh my lc du no cng c phn xng ny. V vy, vn hnh phn xng x l naphtha bng hydro l k nng yu cu gn nh bt buc i vi nhn vin vn hnh trong lnh vc ch bin du kh. Mc tiu thc hin Hc xong bi ny hc vin c kh nng: 1. c hiu v m t c s ng ng & thit b o lng iu 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 - S ng ng & thit b o lng iu khin (P&ID's) ca phn xng x l naphtha bng hydro; - Cc bc khi ng phn xng x l naphtha bng hydro; - Cc s c thng gp, gii php khc phc trong vn hnh phn xng x l naphtha bng hydro; - Cc bc dng phn xng; - Cc bc dng phn xng trong trng hp khn cp. 5.1. S CNG NGH M HNH M PHNG 5.1.1. Gii thiu hc vin d dng tip cn vi thc t vn hnh phn xng x l naphtha bng hydro (NHT), m hnh m phng c xy dng trn s cng ngh cc phn xng x l naphtha s dng ph bin hin nay. M hnh61

m phng qu trnh hot ng ca phn xng ny c xy dng trn c s nguyn liu l phn on naphtha thu t phn xng chng ct p sut kh quyn, thit b phn ng l kiu l phn ng c lp m xc tc c nh. Phn ti sinh xc tc khng c gii thiu trong chng trnh v y l hot ng t xy ra (vng ti xc tc khong 23 nm) v i hi trnh vn hnh cao. 5.1.2. S cng ngh v cc thit b chnh ca m hnh m phng M hnh m phng qu trnh hot ng ca phn xng x l naphtha cng l qu trnh m phng thi gian thc qu trnh cng ngh din ra trong thit b phn ng, thp chng ct,... S cng ngh, ng ng v thit b iu khin (P&ID's) ca phn xng trong m hnh m phng c m t trong cc hnh v NHT-01 n NHT-05. Cc c im chnh qu trnh cng ngh xy ra trong qu trnh ny c trnh by di y. Cng ngh x l naphtha bng hydro bao gm cc b phn chnh sau: - B phn chun b nguyn liu v l phn ng; - B phn nn kh; - B phn phn tch sn phm cao p v thp p; - B phn chng ct. Thit b quan trng nht ca qu trnh x l naphtha bng hydro l thit b phn ng c lp m xc tc c nh. Nguyn liu lng (naphtha) c tip xc vi kh hydro ti lp xc tc ny nhit , p sut thch hp. Ngoi vai tr l cu t tham gia phn ng, hydro c a vo thit b phn ng cn c vai tr lm mt thit b. Sn phm phn ng (naphtha, sn phm kh v hydro d khng tham gia phn ng) c a ti thit b phn tch p sut cao v thit b phn tch p sut thp. Hu ht cc sn phm dng lng c tch ra thit b phn tch p sut cao v p sut thp. Sn phm lng sau c a ti thp sc tch kh a xt (H2S) v tch cc cu t nh hn naphtha. Naphtha sau khi x l c a ti b cha hoc a thng ti phn xng reforming (sau khi phn chia naphtha nh). Kh khng ngng tch ra t thit b phn tch cao p c a tun hon tr li l phn ng nh my nn tun hon. Kh giu hydro ny c x l tch H2S trc khi a vo ca ht my nn. Trong khun kh chng trnh ny (cng nh a s cc chng trnh m phng khc), thp hp th H2S c m phng di dng mt hp en, ngha l khi dng kh i qua thit b ny th H2S c mc nh l c x l t ti sch yu cu, khi dng kh khng i qua thit b hp th ny (by-pass) th coi nh H2S cha62

c tch ra khi dng kh. Kh chua tch ra t thit b phn tch thp p v thp sc c a ti thit b x l (thit b hp th amine), thit b ny khng nm trong phm vi m hnh m phng. Chi tit qu trnh cng ngh trong tng cm thit b c m t chi tit trong cc mc di y. 5.1.2.1. B phn chun b nguyn liu v l phn ng Nguyn liu t b cha hoc t cc phn xng chng ct du th c a ti b cha nguyn liu (V-501) sau khi c gia nhit s b trong thit b trao i nhit E-501. Nguyn liu sau c bm t b cha ny ti thit b phn ng. Hydro c trn cng dng nguyn liu trc khi a vo l phn ng. Hn hp nguyn liu phn ng c nng ti nhit thch hp cho qu