0-特等奖-摘要-浙江大学-C5-20万吨生物柴油项目

The marketing of biodiesel is promising and it is estimated that by 2010, China's demand for bio-diesel will reach 20 million tons per year. Our team has designed a biodiesel plant with an output of 200,000 tons per year from Jatropha curcas L. seed oil. We have handed up the feasibility research report, preliminary design specification and the process construction plans to the competition organizers.Ⅰ: T echnology Introduction1 The Choice of Raw Material & Factory Site SelectionJatropha curcas L. seed oil is used as the raw material. Jatropha curcas L, a deciduous small tree or shrub of Euphorbiaceae, widely distributed in tropical and semitropical area, can yield high and stably on barren hills. In addition, the oil percentage is as high as 67%. Y unnan province is a suitable place to invest a biodiesel plant using Jatropha curcas L. seed oil as the raw material because of its abundant barren hills, plentiful and cheap labor force, and preferential policies. Therefore, the factory is located in Honghe, Y unnan province.2 Concise Process DescriptionsA supercritical transesterification process for biodiesel continuous production from Jatropha curcas L. seed oil is designed for the output of 200,000 tons of biodiesel per year, with propane as co-solvent in the process and co-production with DME plant. The by-product—pure glycerol is converted into 1, 2-propanediol as the final product by catalytic hydrogenolysis with an annual output of 14,000 tons.3 Innovations in Process1)Supercritical technology needs no catalyst and the oil raw material does not require atreatment of removing the acid and water. It makes the product separation easier, the process simpler, and product purity higher. The process is environmental friendly, because no residue is produced and no wastewater is discharged.2)Propane as co-solvent makes the reaction condition moderate and saves energy a lot.3)The by-product propane is treated by converting into 1, 2-propanediol as the final productusing catalytic hydrogenolysis. The process is simulated as a viable route in industrialization which makes higher cost-effective.4 Innovations in Industrial Structure1)Co-production with DME plant efficiently in this way: ①use the middle pressure steam,by-product from DME plant, to heat biodiesel reaction section; ②use methanol, also the by-product from DME plant, as one of raw materials to produce biodiesel; ③mix biodiesel in proportion with DME before sales.2)1, 2-propanediol converted by propane makes higher cost-effective.3)The residue of oil-extraction from seeds can be made to fertilizer, supplied to local farmersfor growing Jatropha curcas L. trees. The circulation serves as a rational use of resources.5 Detailed Process Descriptions(1) Supercritical T ransesterification from Seed Oil with Methanol to BiodieselFresh streams of Jatropha curcas L. seed oil (stream 5) and methanol (stream 1) mix in the mixers (BA101, BA102) with fresh liquid propane (stream 4) and the recycled stream (stream 23, 27, 29) of methanol and propane. Then, the mixture (stream 8) is pumped to 12.8MPa and heated to255℃by system heat integration and middle pressure steam (5.1MPa, 265℃). Then, the mixture (stream 11) reaches the supercritical state and is fed into the reactor. The reaction is carried out in a tubular reactor (CA101).Heat conducting oil flows in the shell side to keep the reaction temperature at 300℃and the reaction lasts for 5 minutes so that the conversion rate comes to almost 100%. The exit stream (stream 12) flows into a flash evaporator (BA103) after cooling. The gas (stream 21) recycles while the liquid stream (stream 15) flows into a distillation column (KA101). The light components come out from the top (stream 24), recycling; the bottom stream (stream 16), flows into the settler unit (BA105) after cooling. Finally, biodiesel is obtained as the light phase (stream 19) while the by-product glycerol is obtained as the heavy phase (stream 20).Figure 1 Process Flow Diagram of Biodiesel Synthesis(2) Catalytic Hydrogenolysis of Glycerol to 1, 2-propanediolThe reaction takes place in trickle-bed reactor (CA201) under 3MPa, 210℃with the mean residence time of the liquid reactant which is 20hr. The catalyst particles distribute well in the liquid phase of reactor, and its mass concentration is 5.26%.The conversion of the glycerol to 1, 2-propanediol is 80%. Then, the semifinished product is separated by distillation.Figure 2 Process Flow Diagram of Catalytic Hydrogenolysis of Glycerol to 1, 2-propanediolⅡ: Heat IntegrationTEM PERATURE COM POSITES (Real T, No Utils)Case: Sam ple Problem sHOTCOLDENTHALPY X10 3 kWT E M P E R A T U R E CFigure 3 Composite Curves DiagramThe pinch optimization technology for improving energy integration between heat exchange network and utility system is adopted. △Tmin ( minimum permissible temperature difference) is set as 10℃. Based on pinch analysis, the hot pinch temperature is 224.5℃, and the corresponding cold pinch temperature is 214.5℃; the outside world need to provide 8.7 MW heat, and 11.3 MW cold energy should be supplied. The system can be integrated for as much as 7.9 MW heat. The ratio of the energy recycled to the energy supplied is 0.9.Two heating methods-using middle pressure steam and heat conducting oil for heating, not only use resources more rationally, but also make it easier to achieve supercritical state and mix the reaction more uniform.Ⅲ: Factory Design1 Plant Layout & Facility LayoutFigure 4 Plant LayoutFigure 5 Facility LayoutAuto CAD has been adopted in plant layout and facility layout. 3DS MAX has been used to draw 3-dimensional factory.The factory is divided into four regions: production region, storage and transportation region, auxiliary production region, and the front region in factory .We not only comply with the safety rules of plant layout, but also accomplish man-vehicleseparation, use land rationally, and succeed in saving piping.2 Piping DesignPDMS, the most professional factory design software, has been used in the 3D piping design andthe 3D facility layout. The pipeline design contains pipeline trend design, nominal diametercalculation and the pipe fitting design. Totally, there are 67 pieces of drawings of the isometricdrawing and piping layout. All the design drawings can be seen in the process construction planswe have handed up.Ⅳ: T echnical and Economic Index FormNo. Item Amount No. Item Amount 1 Production Capacity 3 Energy Consumption of Unit ProductBiodiesel 200000t/a Biodiesel 1.4 kW/kg 1, 2-propanediol 13900t/a 4 Area of Factory 89557m2 2 Consumption of Material and Energy 5 Total Investment 428,199,960 RMBSeed Oil 204000t/a 6 Y early Sales Income 1,213,700,000RMB Methanol 22400t/a 7 Y early Total Cost 587,489,000RMB Copper Chromites 0.8t/a 8 Y early Gross Profit 375,990,000RMB Hydrogen Gas 480t/a 9 Financial Appraisal IndexCopper Chromites 100t/a Profit Rate on Investment 37.15% Heat Oil（HD310）16t/a Annual Taxation Ratio 47.28% Anthracite 5600t/a Payback Period 4.8years Electricity 1100kw IRR（After Tax）33.51% Medium Pressure Steam 96000t/a NPV (After Tax) 1,115,160,000RMB Soft Water 4000t/a 10 Payback Period of Loan 5 years Circulating Cooling Water 40000t/a 11 BEP 28.45%ⅤConclusionWe completed a whole report that mainly encompassed process designed by Aspen Plus, thematerial and heat balances, heat integration by Aspen Pinch, equipment design and selection, theProcess Flow Diagram (3 drawings), Piping and Instrument Diagram drawings (8 drawings),facility layout (19 AutoCAD drawings and 3 PDMS drawings), plant layout (3 AutoCADdrawings and 1 three-dimensional drawing), safety and environmental documentation, marketing,investment and economic analysis. In addition, we complete documents related to storage,electricity, utility stations, fire fighting, water supply and drainage, telecommunications and thelike. Please consult the document we hand up for details.（中文版Chinese V ersion）生物柴油市场前景广阔，预计到2010年，中国所需的生物柴油为2000万吨。