The fact that the overall technological level of large-scale tower separation devices in the refining and petrochemical industries in China is behind that of foreign countries has become history. Nanjing University has creatively established a direct mathematical relationship between the energy consumption in the separation process and the structural parameters of the trays, the mass transfer kinetics of the trays, and fluid mechanics, and guided the development of new trays in the separation column at the theoretical height. Based on this, the company developed the SVT valve to benefit all the industrial processes related to the separation of the tower cranes, and also allowed the Chinese tower separation equipment to leap into the international leader in this field. This achievement has thus won the second prize of 2011 National Science and Technology Progress Award.
In the petrochemical and chemical production processes, separation operations are required for the purification of raw materials, product separation, and the harmless disposal of emissions. Separation engineering and therefore reaction engineering are also called the two pillars of chemical engineering. The separation of the towers is a thermal separation process, which is the main unit of energy consumption and accounts for a large proportion of the total energy consumption of chemical production facilities. Therefore, the separation efficiency, flux, and resistance drop of towers are crucial to the energy-saving and emission reduction performance of petrochemical and chemical companies, and the key to the performance of these towers is the mass transfer elements.
“The existing plate towers have the disadvantages of small flux, low efficiency, and high energy consumption. In the past 100 years, whether in the United States, Japan, or Europe, or in China, research and development of a new type of plate was based on empirical methods and experience. The inherent defects of the law make it difficult to truly develop advanced and efficient tray separation equipment.Starting from the non-equilibrium thermodynamic theory, the research and development of new types of super tray equipment is one of the most fundamental and technological breakthroughs that captures the commanding heights of the world's panel tower technology. However, it is also the most difficult technical route. Our team has used the entropy increase rate objective function method in non-equilibrium thermodynamic theory for the first time to develop a super-valve tray.†The professor said.
The actual production proves that in the same tower separation process, SVT is the lowest mass transfer plate mass transfer element, and it has high efficiency, high flux, low pressure drop, wide operating flexibility and so on. Taking the separation process of benzene and toluene as an example, compared with the conventional device, the SVT device of the same size can increase the processing throughput by 36%, the efficiency can be increased by 18% to 20%, and the operation elasticity can be double that of the original, and the overall energy saving can be achieved. 15% to 16%.
In order to facilitate engineering design and mass production, Zhang Zhibing team further developed SVT's industrial design software and special abrasive tools and production lines. It is understood that SVT has now been applied to more than 60 sets of devices, distributed in petrochemical, coal chemical, metallurgy, fertilizer, pharmaceutical, textile and other industries, across 18 provinces and regions. As of December 2010, it has cumulatively recovered 1.05 million tons of organic solvents such as n-butanol; reduced the use of nitrogen oxides (NOx) gases by 435,000 tons, and produced 50% of the 1.45 million tons of nitric acid for recycling; the energy-saving equivalent to 181,500 Tons of standard coal (an average of 31,380,000 tons per year); water saving of 3.25 million tons (an average of 500,000 tons per year). Since 1998, the cumulative new output value was 22.928 billion yuan, and the new profit and tax was 4.571 billion yuan. The total tax revenue for the past three years was 2.06 billion yuan.
On the basis of new equipment such as SVT, Zhang Zhibing's team has also developed a number of new energy-saving and emission-reduction technology systems including NOx recycling, dimethylacetamide ultra-high purification, and low-level organic solvent recycling.
NOx, commonly known as “Huanglongâ€, is one of the major sources of atmospheric pollution. It is generally treated at home and abroad with high-temperature catalytic reduction, which requires the consumption of large amounts of thermal energy and precious metal catalysts. The ton treatment cost is between 1,000 and 10,000 US dollars, and the efficiency is difficult to reach 95%. “Our original MOAPTS process technology system introduces NOx exhaust gas into the reaction absorption system installed with SVT trays. It does not need any catalyst at normal temperature and does not require any chemical solvent. Just blow air into the system and add appropriate amount of water. NOx can be trapped and made into nitric acid." Zhang Zhibing said that the application of the process in five companies in PetroChina, Sinopec and the Chinese Academy of Sciences showed that the conversion rate of NOx active components was as high as 99.5% or more, compared with SCRs of the United States and NPCP of Japan. Compared with technology, tons of processing costs less than 1/10 of it.
In addition, the ISAD process technology system they developed solved the problem of recovery of dimethylacetamide (DMAc), a dangerous product in spandex production, and achieved a purity of 99.995% of DMAc, which fully meets the requirements for medical grade spandex. This technology has not only reversed the situation in which domestic companies can only import from Japan, the United States, and South Korea, but has also been adopted by foreign companies in China, and has been evaluated by experts as the best level of international technology of its kind.
This new tray manufacturing technology route was evaluated by the Academician Ouyang Pingkai of the Academy of Engineering as "Technology has reached the international advanced level, among which SVT and other technologies are the first in the world." In the international arena, SVT has also been widely recognized. Zhang Zhibing told reporters: “Our theoretical work is in an authoritative academic journal of the chemical industry - the American Association of Chemical Engineers' AIChE
J. published three consecutive articles in the important publication of the American Chemical Society, Ind. Eng. Chems.
Res." published five articles. Up to now, he has published more than 30 articles in various important international and domestic publications, and has obtained invention patent authorizations in China, the United States, and Europe. â€
In front of the honors, Zhang Zhibing expressed his feelings: “With the country’s urgent need for scientific development, improvement of the quality of industry development, and energy conservation and emissions reduction, we will further optimize the technology and use this method to develop new types of mass transfer elements and standardize them. Program development and other follow-up work will continue to broaden the application of tower separation in the field of energy conservation and emission reduction in China."
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