Automatic start-up method and system for catalyst regeneration unit of continuous reformer

Abstract

The application provides an automatic starting method and system of a catalyst regeneration unit of a continuous reforming device. The method comprises the following steps: determining that a starting condition is met; controlling a circulating gas fan and an electric heater to start working, and adjusting the operation load of the circulating gas fan and the electric heater; when a temperature value reaches a preset temperature, confirming that a hot shutdown interlock condition of the catalyst regeneration unit is in an untriggered state, receiving a catalyst circulation process unimpeded signal, and the catalyst isolation system is in a service state; establishing catalyst circulation of the continuous reforming device; determining that a carbon content qualified signal of spent catalyst is received, and controlling the continuous reforming device to enter a black burning state; when the catalyst circulation frequency reaches a preset frequency, and it is determined that a carbon content qualified signal of regenerated catalyst is received, the continuous reforming device is switched from the black burning state to a white burning state. The application can realize automatic starting of the catalyst regeneration unit, reduce the labor intensity of operators, and improve the stability and safety of the starting process.

Description

Technical Field

[0001] This invention relates to the field of equipment control technology, specifically to an automatic start-up method for a catalyst regeneration unit of a continuous reforming apparatus, an automatic start-up system for a catalyst regeneration unit of a continuous reforming apparatus, and a readable storage medium. Background Technology

[0002] The start-up operation of the catalyst regeneration unit in the continuous reforming unit not only occurs during the start-up process after the unit is shut down for maintenance, but also frequently causes the catalyst regeneration unit to shut down during daily operation due to unit fluctuations, equipment failures, interlocks, etc., and thus requires the start-up of the catalyst regeneration unit. Therefore, the start-up operation of the catalyst regeneration unit is relatively frequent. At present, the start-up of the catalyst regeneration unit is carried out manually by the operators according to the operating procedures, but manual operation has the following two shortcomings: (1) Human factors have a greater impact. The start-up process of the catalyst regeneration unit requires a high level of skill from the operators. Each operator has a different level of operation and operating method, which affects the stability and effectiveness of the start-up process; (2) The labor intensity is high. The start-up process of the catalyst regeneration unit generally lasts for more than 24 hours, and the long-term operation significantly increases the workload of the operators. Summary of the Invention

[0003] The purpose of this invention is to provide an automatic start-up method and system for the catalyst regeneration unit of a continuous reforming unit, so as to at least solve the problems of manual operation mentioned above: the influence of human factors is significant, the start-up process of the catalyst regeneration unit requires a high level of skill from the operators, and the different operating skills and techniques of each operator affect the stability and effectiveness of the start-up process; the labor intensity is high, the start-up process of the catalyst regeneration unit generally lasts for more than 24 hours, and the long-term operation significantly increases the workload of the operators.

[0004] To achieve the above objectives, a first aspect of the present invention provides an automatic start-up method for a catalyst regeneration unit of a continuous reforming apparatus, the method comprising: Determine that the catalyst regeneration unit of the continuous reforming unit meets the start-up conditions; The circulating gas fan and electric heater are started to work, and the operating load of the circulating gas fan and electric heater is adjusted based on the temperature value collected from the catalyst regeneration unit. If the temperature of the catalyst regeneration unit reaches the preset temperature, and the thermal shutdown interlock condition of the catalyst regeneration unit is not triggered, a signal indicating that the catalyst circulation process is unobstructed is received, and it is determined that the catalyst isolation system is in operation, then the catalyst circulation of the continuous reforming unit is established according to the preset circulation rate. Once a signal indicating that the carbon content of the catalyst to be generated is deemed acceptable is received, the continuous reforming unit is controlled to enter the black-burning state. In the black-burn state, if the catalyst cycle count reaches the preset number and a signal indicating that the carbon content of the regenerated catalyst is qualified is received, the continuous reforming unit is controlled to switch from the black-burn state to the white-burn state, thus completing the automatic start-up of the catalyst regeneration unit of the continuous reforming unit.

[0005] Optionally, the activation conditions include: The cold shutdown interlock conditions of the continuous reforming unit are all in an untriggered state, the emergency nitrogen flow rate of the continuous reforming unit is within the first preset range, the regenerator pressure value of the continuous reforming unit is within the second preset range, and the normal operation signals of the circulating gas fan and electric heater are received.

[0006] Optionally, the signals for smooth catalyst circulation, qualified carbon content of the catalyst to be generated, qualified carbon content of the regenerated catalyst, and normal operation of the circulating gas fan and electric heater are all triggered when the corresponding button state is changed.

[0007] Optionally, based on the temperature value collected from the catalyst regeneration unit, the operating load of the electric heater can be adjusted, including: The actual heating rate is determined based on the temperature values ​​collected from the catalyst regeneration unit. Based on the actual heating rate, determine the load increase of the electric heater; Based on the aforementioned increase in load, adjust the operating load of the electric heater.

[0008] Optionally, based on the heating rate, determining the load increase of the electric heater includes: The load increase is calculated using the following formula:

[0009] in, The amount of load increase for the electric heater; The increase is the amount added to the baseline load. To set the heating rate, This represents the actual heating rate.

[0010] Optionally, based on the temperature value collected from the catalyst regeneration unit, the operating load of the circulating air fan can be adjusted, including: Based on the temperature value of the catalyst regeneration unit, the operating load of the circulating air blower is obtained according to a preset relationship curve or a preset relationship table; wherein, the preset relationship curve and the preset relationship table are used to characterize the correspondence between different temperature values ​​of the catalyst regeneration unit and the operating load of the circulating air blower.

[0011] Optionally, a catalyst cycle for the continuous reforming unit is established according to a preset cycle rate, including: Within a preset time period, the secondary gas flow rate is adjusted to the preset flow rate according to the first preset rate; After the secondary gas flow rate reaches the preset flow rate, the valve position adjustment rate of the secondary gas flow regulating valve is determined based on the preset reference rate and the measured value of catalyst differential pressure. At preset time intervals, the valve position of the secondary gas flow regulating valve is adjusted according to the valve position adjustment rate until the mean and variance of the catalyst differential pressure measurement value and the catalyst differential pressure target value are within the corresponding preset difference range, thus maintaining catalyst circulation. The target value of the catalyst pressure difference is determined by a preset circulation rate.

[0012] Optionally, after the secondary gas flow rate reaches the preset flow rate, the valve position adjustment rate of the secondary gas flow regulating valve is determined based on the preset reference rate and the catalyst differential pressure measurement value, including: The valve position adjustment rate is calculated using the following formula:

[0013] in, Valve position adjustment rate; This represents the target value for the catalyst differential pressure. This is the measured value of the catalyst differential pressure. As the reference rate, This is the valve position adjustment rate coefficient.

[0014] Optionally, controlling the continuous reforming unit to enter the blackening state includes: The amount of regeneration air before the catalyst regeneration unit is shut down or the amount of regeneration air calculated based on the catalyst carbon content and oxygen content is used as the baseline regeneration air amount. The opening of the upper regenerated air flow controller valve is linearly adjusted to the second preset opening according to the second preset rate; After reaching the second preset opening degree, based on the preset flow characteristic curve of the upper regenerated air valve, the valve position of the upper regenerated air flow controller is increased according to the third preset rate until the coking temperature distribution meets the preset distribution curve, the peak temperature is in the preset temperature range, and the oxygen content rise rate meets the preset rate threshold. The valve position of the upper regenerated air flow controller is reduced at the third preset rate until the measured value of regenerated air reaches the reference regenerated air volume. The second preset rate is greater than the third preset rate.

[0015] Optionally, the amount of regenerated air calculated based on the catalyst carbon content and oxygen content includes: The amount of oxygen required for complete combustion of coke is calculated based on the chemical equation for catalytic coking. The amount of regenerated air required for combustion is calculated based on the amount of oxygen required for complete combustion of coke. Calculate the volume increase of coke after combustion; The required amount of regenerated air is calculated based on the amount of regenerated air needed for combustion and the volume increase of coke after combustion, according to the oxygen balance.

[0016] Optionally, controlling the continuous reforming unit to switch from a black-burn state to a white-burn state includes: Along the axial distribution direction of the regenerator, obtain the absolute value of the temperature difference between two adjacent thermocouple temperature measuring points and the position value between two adjacent thermocouple temperature measuring points within the preset position interval; The weighted temperature position is determined based on the absolute temperature value between two adjacent thermocouple temperature measurement points and the positional value between two adjacent thermocouple temperature measurement points. Oxygen content is cascaded controlled based on the weighted temperature position.

[0017] A second aspect of the present invention provides an automatic start-up system for a catalyst regeneration unit of a continuous reforming apparatus, the system comprising: The DCS system is connected to the continuous reforming unit and is used to collect the operating parameters of the continuous reforming unit and adjust the operating status of the continuous reforming unit. An automatic start-up server is connected to the DCS system via an OPC server. The automatic start-up server is used to execute the automatic start-up method of the catalyst regeneration unit of the continuous reforming unit described above. The signal triggering device is electrically connected to the automatic start server and is used to generate and send to the automatic start server a catalyst circulation process smooth signal, a carbon content qualified signal for the catalyst to be generated, a carbon content qualified signal for the regenerated catalyst, and a normal operation signal for the circulating gas fan and electric heater.

[0018] On the other hand, the present invention provides a readable storage medium storing instructions for causing a machine to perform the above-described automatic start-up method for the catalyst regeneration unit of a continuous reforming apparatus.

[0019] This technical solution, based on the collection of multiple parameters, enables the automatic start-up of the catalyst regeneration unit, greatly reducing the labor intensity of operators, improving the stability and efficiency of the catalyst regeneration unit's start-up process, significantly reducing the fluctuation of the regenerator's heating rate, and improving the safety of the start-up process.

[0020] Other features and advantages of the embodiments of the present invention will be described in detail in the following detailed description section. Attached Figure Description

[0021] The accompanying drawings are provided to further illustrate embodiments of the present invention and form part of the specification. They are used together with the following detailed description to explain the embodiments of the present invention, but do not constitute a limitation thereof. In the drawings: Figure 1 This is a flowchart of the automatic start-up method for the catalyst regeneration unit of the continuous reforming apparatus provided by the present invention; Figure 2 This is a flowchart for determining the operating load of an electric heater, provided by the present invention. Figure 3 This is a flowchart of the catalyst circulation process for establishing a continuous reforming unit provided by the present invention; Figure 4 This is a schematic diagram of the automatic start-up system of the catalyst regeneration unit of the continuous reforming apparatus provided by the present invention; Figure 5 This is a schematic diagram of the signal flow of the automatic start-up system of the catalyst regeneration unit of the continuous reforming apparatus provided by the present invention; Figure 6 This is a schematic diagram of the program execution order control logic provided by the present invention; Figure 7 This is a flowchart of the automatic start-up method of the catalyst regeneration unit of the continuous reforming apparatus provided in the embodiments of the present invention; Figure 8 This is a schematic diagram of the temperature change of the coke bed in the catalyst regeneration unit provided by the present invention. Figure 9 This is a schematic diagram of the regenerator heating rate fluctuation in the prior art provided by the present invention; Figure 10 This is a schematic diagram of the temperature rise rate fluctuation of the regenerator in this invention.

[0022] Explanation of reference numerals in the attached figures 1- Continuous reforming unit; 2- DCS system; 3- Automatic start-up server; 4-OPC server; 5-Signal triggering device. Detailed Implementation

[0023] The specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0024] Figure 1 This is a flowchart of the automatic start-up method for the catalyst regeneration unit of the continuous reforming apparatus provided by the present invention; Figure 2 This is a flowchart for determining the operating load of an electric heater, provided by the present invention. Figure 3 This is a flowchart of the catalyst circulation process for establishing a continuous reforming unit provided by the present invention; Figure 4This is a schematic diagram of the automatic start-up system of the catalyst regeneration unit of the continuous reforming apparatus provided by the present invention; Figure 5 This is a schematic diagram of the signal flow of the automatic start-up system of the catalyst regeneration unit of the continuous reforming apparatus provided by the present invention; Figure 6 This is a schematic diagram of the program execution order control logic provided by the present invention; Figure 7 This is a flowchart of the automatic start-up method of the catalyst regeneration unit of the continuous reforming apparatus provided in the embodiments of the present invention; Figure 8 This is a schematic diagram of the temperature change of the coke bed in the catalyst regeneration unit provided by the present invention. Figure 9 This is a schematic diagram of the regenerator heating rate fluctuation in the prior art provided by the present invention; Figure 10 This is a schematic diagram of the temperature rise rate fluctuation of the regenerator in this invention.

[0025] Specifically, continuous reforming is a secondary petroleum processing technology that primarily processes low-octane straight-run naphtha and hydrotreated naphtha. It utilizes a platinum (Pt)-rhenium (Re) bimetallic catalyst at approximately 500°C to cause molecular rearrangement and isomerization, increasing aromatic hydrocarbon production and raising the octane number of gasoline. Correspondingly, in a continuous reforming unit, the catalyst flows sequentially through three (or four) moving bed reactors connected in series. The spent catalyst exiting the last reactor contains 5%–7% carbon (mass fraction) and is transported by gravity or gas lift to a regenerator for regeneration. The regenerated catalyst, after regaining its activity, returns to the first reactor to react again, forming a closed-loop cycle within the system. From a process perspective, because the catalyst can be frequently regenerated, relatively harsh reaction conditions can be employed, namely low reaction pressure (0.8~0.35MPa), low hydrogen-to-oil ratio (molar ratio, 4~1.5), and high reaction temperature (500~530℃). This results in a more favorable reaction for alkane aromatization, with the reformed oil achieving a research octane number of over 100, and high liquid yield and hydrogen production. The specific structures of continuous reforming units and catalyst regeneration units are existing technologies known to those skilled in the art and will not be elaborated upon here.

[0026] However, during the startup process after the unit is shut down for maintenance, and during the daily operation of the unit, the catalyst regeneration unit is often shut down due to unit fluctuations, equipment failures, interlocks, etc., and it is also necessary to start up the catalyst regeneration unit. Therefore, the startup operation of the catalyst regeneration unit is relatively frequent. At present, the startup of the catalyst regeneration unit is manually operated by the operators in accordance with the operating procedures. However, manual operation has the following two shortcomings: (1) Human factors have a greater impact. The startup process of the catalyst regeneration unit requires a high level of skill from the operators. Each operator has a different level of operation and operating method, which affects the stability and effect of the startup process; (2) The labor intensity is high. The startup process of the catalyst regeneration unit generally lasts for more than 24 hours. The long-term operation significantly increases the workload of the operators.

[0027] To address the aforementioned problems, embodiments of the present invention provide an automatic start-up method for the catalyst regeneration unit of a continuous reforming apparatus, such as... Figure 1 As shown, the method includes: Step 1: Determine that the catalyst regeneration unit of the continuous reforming unit meets the start-up conditions; Step 2: Control the circulating gas fan and electric heater to start working, and adjust the operating load of the circulating gas fan and electric heater based on the temperature value collected from the catalyst regeneration unit; Step 3: When the temperature of the catalyst regeneration unit reaches the preset temperature, if the thermal shutdown interlock condition of the catalyst regeneration unit is not triggered, a catalyst circulation flow unobstructed signal is received, and it is determined that the catalyst isolation system is in operation, then the catalyst circulation of the continuous reforming unit is established according to the preset circulation rate. Step 4: Confirm that the carbon content of the catalyst to be generated is qualified, and control the continuous reforming unit to enter the black-burning state; Step 5: In the black-burn state, if the catalyst cycle count reaches the preset number and a signal indicating that the carbon content of the regenerated catalyst is qualified is received, the continuous reforming unit is controlled to switch from the black-burn state to the white-burn state, thus completing the automatic start-up of the catalyst regeneration unit of the continuous reforming unit.

[0028] Specifically, the hot shutdown interlock condition can be understood as the interlock shutdown occurring when the temperature measured at the temperature measuring point in the continuous reforming unit exceeds a preset threshold. The catalyst regeneration unit has two isolation systems. The isolation system from the reforming reactor outlet to the regenerator is the spent catalyst isolation system, which isolates the reactor (hydrogen environment) from the regenerator (oxygen environment). The isolation system from the regenerator outlet to the lower hopper outlet of the regenerator is the regenerated catalyst isolation system, which isolates the regenerator from the reactor. Both isolation systems have identical structures. In the event of a unit malfunction, the isolation systems shut down, preventing gas leakage downwards from the upper part of the isolation system and also preventing gas leakage upwards from the lower part of the isolation system.

[0029] The steps are executed sequentially, and the conditions within each step are also executed sequentially. If any step or condition is not met, the subsequent steps and conditions are not executed.

[0030] Furthermore, the activation conditions include: The cold shutdown interlock conditions of the continuous reforming unit are all in an untriggered state, the emergency nitrogen flow rate of the continuous reforming unit is within the first preset range, the regenerator pressure value of the continuous reforming unit is within the second preset range, and the normal operation signals of the circulating gas fan and electric heater are received.

[0031] Furthermore, the signals for smooth catalyst circulation, qualified carbon content of the catalyst to be generated, qualified carbon content of the regenerated catalyst, and normal operation of the circulating gas fan and electric heater are all triggered when the corresponding button states are changed.

[0032] Specifically, the signals for unobstructed catalyst circulation, qualified carbon content of the catalyst awaiting generation, qualified carbon content of the regenerated catalyst, and normal operation of the circulating gas fan and electric heater are all human-triggered signals, meaning they are manually input and sent after subjective judgment. Specifically, the unobstructed catalyst circulation signal is determined by checking whether the equipment related to the circulation process is operating normally; the qualified carbon content signals of the catalyst awaiting generation and regenerated catalyst are determined by testing the materials to determine their qualification; and the normal operation signals of the circulating gas fan and electric heater are similarly determined by checking whether the circulating gas fan and electric heater are operating normally.

[0033] Furthermore, such as Figure 2 As shown, based on the temperature value collected from the catalyst regeneration unit, the operating load of the electric heater is adjusted, including: The actual heating rate is determined based on the temperature values ​​collected from the catalyst regeneration unit. Based on the actual heating rate, determine the load increase of the electric heater; Based on the aforementioned increase in load, adjust the operating load of the electric heater.

[0034] Further, based on the heating rate, determining the load increase of the electric heater includes: The load increase is calculated using the following formula:

[0035] in, The increase in load on the electric heater; The increase is the amount added to the baseline load. To set the heating rate, This represents the actual heating rate.

[0036] Specifically, in this embodiment, the load increase is calculated using the above-mentioned calculation formula, which ensures high accuracy of the calculated load increase, enables accurate control of the electric heater load, ensures the stability of the catalyst regeneration unit start-up process, reduces the fluctuation of the regenerator heating rate, and improves the safety of the start-up process.

[0037] Furthermore, based on the temperature values ​​collected from the catalyst regeneration unit, the operating load of the circulating air blower is adjusted, including: Based on the temperature value of the catalyst regeneration unit, the operating load of the circulating air blower is obtained according to a preset relationship curve or a preset relationship table; wherein, the preset relationship curve and the preset relationship table are used to characterize the correspondence between different temperature values ​​of the catalyst regeneration unit and the operating load of the circulating air blower.

[0038] Specifically, the preset relationship curves and preset relationship tables are obtained by fitting historical data of different temperature values ​​of the catalyst regeneration unit with the operating load of the circulating gas fan.

[0039] Furthermore, such as Figure 3 As shown, the catalyst circulation of the continuous reforming unit is established according to a preset circulation rate, including: Within a preset time period, the secondary gas flow rate is adjusted to the preset flow rate according to the first preset rate; After the secondary gas flow rate reaches the preset flow rate, the valve position adjustment rate of the secondary gas flow regulating valve is determined based on the preset reference rate and the measured value of catalyst differential pressure. At preset time intervals, the valve position of the secondary gas flow regulating valve is adjusted according to the valve position adjustment rate until the mean and variance of the catalyst differential pressure measurement value and the catalyst differential pressure target value are within the corresponding preset difference range, thus maintaining catalyst circulation. The target value of the catalyst pressure difference is determined by a preset circulation rate.

[0040] Specifically, different preset circulation rates correspond to a target catalyst pressure difference value, which is obtained by fitting historical data and stored for direct retrieval when needed.

[0041] Furthermore, after the secondary gas flow rate reaches the preset flow rate, the valve position adjustment rate of the secondary gas flow regulating valve is determined based on the preset reference rate and the catalyst differential pressure measurement value, including: The valve position adjustment rate is calculated using the following formula:

[0042] in, For valve position adjustment rate; This represents the target value for the catalyst differential pressure. This is the measured value of the catalyst differential pressure. As the reference rate, This is the valve position adjustment rate coefficient.

[0043] Specifically, in this embodiment, the valve position adjustment rate is calculated using the above-mentioned calculation formula, which ensures high accuracy of the calculated valve position adjustment rate, achieves accurate control of the secondary gas flow, ensures the stability of the catalyst regeneration unit start-up process, reduces the fluctuation of the regenerator heating rate, and improves the safety of the start-up process.

[0044] Furthermore, controlling the continuous reforming unit to enter the blackening state includes: The amount of regeneration air before the catalyst regeneration unit is shut down or the amount of regeneration air calculated based on the catalyst carbon content and oxygen content is used as the baseline regeneration air amount. The opening of the upper regenerated air flow controller valve is linearly adjusted to the second preset opening according to the second preset rate; After reaching the second preset opening degree, based on the preset flow characteristic curve of the upper regenerated air valve, the valve position of the upper regenerated air flow controller is increased according to the third preset rate until the coking temperature distribution meets the preset distribution curve, the peak temperature is in the preset temperature range, and the oxygen content rise rate meets the preset rate threshold. The valve position of the upper regenerated air flow controller is reduced at the third preset rate until the measured value of regenerated air reaches the reference regenerated air volume. The second preset rate is greater than the third preset rate.

[0045] Specifically, during the process of increasing the valve position of the upper regenerated air flow controller according to the third preset rate, if the peak temperature exceeds the preset limit temperature, the regenerated air flow controller will be shut down, the load of the electric heater will be halved, and an alarm will be generated.

[0046] More specifically, the amount of regenerated air calculated based on the catalyst carbon content and oxygen content includes: The amount of oxygen required for complete combustion of coke is calculated based on the chemical equation for catalytic coking. The amount of regenerated air required for combustion is calculated based on the amount of oxygen required for complete combustion of coke. Calculate the volume increase of coke after combustion; The required amount of regenerated air is calculated based on the amount of regenerated air needed for combustion and the volume increase of coke after combustion, according to the oxygen balance.

[0047] Furthermore, controlling the continuous reforming unit to switch from a black-burn state to a white-burn state includes: Along the axial distribution direction of the regenerator, obtain the absolute value of the temperature difference between two adjacent thermocouple temperature measuring points and the position value between two adjacent thermocouple temperature measuring points within the preset position interval; The weighted temperature position is determined based on the absolute temperature value between two adjacent thermocouple temperature measurement points and the positional value between two adjacent thermocouple temperature measurement points. Oxygen content is cascaded controlled based on the weighted temperature position.

[0048] Specifically, the weighted temperature location is calculated using the following formula:

[0049] in, , For the first i and the j The absolute value of the temperature difference and the location value between the thermocouple temperature measuring points.

[0050] More specifically, in addition to the oxygen content control mentioned above, the transition from a black-roasted state to a white-roasted state also includes: The oxygen content controller and the upper regenerated air controller are cascaded for control. Open the lower regeneration air valve at the fourth preset rate until the amount of regeneration air in the lower part of the continuous reforming unit reaches the preset flow rate threshold. The valve position under no N2 condition corresponding to the current lower regenerated air volume is calculated based on the flow characteristic curve of the lower regenerated air valve. Close the emergency nitrogen shut-off valve. When the fluctuation of the upper regenerated air volume and the lower regenerated air volume is less than the fluctuation threshold, the valve position of the upper regenerated air valve is reduced according to the fifth preset rate until the upper regenerated air valve reaches the preset valve position.

[0051] like Figure 4 As shown, an embodiment of the present invention provides an automatic start-up system for a catalyst regeneration unit of a continuous reforming apparatus, the system comprising: DCS system 2 is connected to continuous reforming unit 1 and is used to collect the operating parameters of continuous reforming unit 1 and adjust the operating status of continuous reforming unit 1. Automatic start server 3 is connected to DCS system 2 via OPC server 4. Automatic start server 3 is used to execute the above-mentioned automatic start method for catalyst regeneration unit of continuous reforming unit. The signal triggering device 5 is electrically connected to the automatic start server 3 and is used to generate and send to the automatic start server 3 a catalyst circulation process smooth signal, a carbon content qualified signal for the catalyst to be generated, a carbon content qualified signal for the regenerated catalyst, and a normal operation signal for the circulating gas fan and electric heater.

[0052] Specifically, in this embodiment, such as Figure 5As shown, the automatic start-up method of the catalyst regeneration unit of the continuous reforming unit is used as the automatic start-up program for catalyst regeneration and is embedded in the automatic start-up server 3. The automatic start-up method of the catalyst regeneration unit of the continuous reforming unit is executed through the automatic start-up program for catalyst regeneration. During the execution of the program, the operating parameters of the continuous reforming unit that need to be used are obtained by the DCS system, and the generated control commands are also executed by the DCS system to realize the adjustment of the operating status of the continuous reforming unit 1.

[0053] The automatic start-up procedure for the catalyst regeneration unit follows a sequential control principle: the current step can only be executed after the previous step is completed, and the next step can only be executed after the current step is completed. Each step is executed only once and is not repeated. For example... Figure 6 As shown (X represents conditions, S represents steps, Y represents output) and the following specific principles: Before executing step S, it is necessary to determine whether condition X is satisfied; The next step is based on the completion of the previous step, and it is necessary to record the execution status of the previous step; To prevent repeated execution, the execution status of this step also needs to be monitored; To ensure the safety of program execution, operators should be able to terminate the program at any time during the execution process; Each time the program runs from the beginning, the operator must initialize the program.

[0054] The present invention also provides a readable storage medium storing instructions for causing a machine to execute the above-described automatic start-up method for the catalyst regeneration unit of the continuous reforming apparatus.

[0055] Example Specifically, in this embodiment, automatic start-up is performed according to the following steps: Step 1: The catalyst regeneration unit meets the start-up conditions. The step type is "automatic judgment". If all cold shutdown conditions are not met, the emergency nitrogen flow rate is within the acceptable range, and the regenerator pressure is within the acceptable range, this step is completed and an execution completion signal is output, and the next step is executed. Otherwise, an execution incomplete signal is output and the step continues.

[0056] Step 2: Catalyst regeneration. The regeneration circulating gas fan and regeneration electric heater are functioning normally, meeting the temperature rise requirements. Step type: "Manual Confirmation". If the "Manual Confirmation" button is automatically detected as pressed, the step is considered complete, and a completion signal is output, proceeding to the next step. Otherwise, an incomplete signal is output, and the step continues.

[0057] Step 3: The catalyst regeneration unit is heated, and the load of the regeneration circulating fan is automatically adjusted simultaneously. The step type is "Automatic Adjustment." The following steps are executed automatically: (1) The temperature controller of the regenerator electric heater is adjusted to manual mode and the load is set to 0; (2) Determine the increase in electric heater load based on the heating rate. ,in, The increase in load on the electric heater; The increase is the amount added to the baseline load. To set the heating rate, The actual heating rate is displayed; the electric heater load is output. When the temperature reaches the target temperature, this step is completed and a completion signal is output to proceed to the next step. Otherwise, a step incomplete signal is output and the step continues to be executed. (3) During the heating process, an alarm will be issued once every hour to remind the operator to pay attention to whether the current of the regeneration circulation fan is normal; (4) During the heating process, the load of the regeneration circulation fan is linearly adjusted according to the temperature.

[0058] Step 4: If none of the hot shutdown interlock conditions for the catalyst regeneration unit are met, the step type is "automatic judgment". If all hot shutdown conditions are automatically detected as unmet, this step is completed, an execution completion signal is output, and the next step is executed. Otherwise, an incomplete execution signal is output, and the step continues.

[0059] Step 5: Catalyst circulation process is smooth; step type: "Manual Confirmation". If the "Manual Confirmation" button is automatically detected as pressed, the step is considered complete, a completion signal is output, and the next step is executed. Otherwise, a failure signal is output, and the step continues.

[0060] Step 6: The catalyst isolation system is in operation; step type: "Automatic Setting". The system will automatically output a catalyst isolation system activation signal and an execution completion signal, then proceed to the next step.

[0061] Step 7: With the catalyst circulation button on and the circulation rate set (step type "automatic setting"), the system will automatically output a catalyst circulation button on signal, the circulation rate set value 'a', and an execution completion signal to proceed to the next step.

[0062] Step 8: Establish catalyst circulation, step type "Auto-adjust". The following steps will be executed automatically: (1) The secondary gas flow controller is set to manual mode and the valve position is set to 0; the differential pressure controller is set to manual mode. (2) Coarse adjustment: The secondary gas flow rate is linearly opened to d% within the set time t. (3) Fine-tuning: Adjust the secondary gas flow controller valve position once every g seconds at a certain reference rate f. ,in, For valve position adjustment rate; This represents the target value for the catalyst differential pressure. This is the measured value of the catalyst differential pressure. As the reference rate, The valve position adjustment rate coefficient is used; during this period, the mean and variance of the differential pressure controller measurement values ​​are detected. If both the mean and variance meet the requirements, it indicates that the differential pressure is stable near the target value of the differential pressure controller. Then, step (4) is executed; otherwise, step (3) is executed. (4) The secondary gas flow controller is set to cascade mode, the differential pressure controller is set to cascade mode, and the material level controller is set to automatic mode. (5) Once this step is completed, an execution completion signal will be output, and the next step will be executed.

[0063] Step 9: Confirm that the carbon content of the catalyst to be produced is qualified and can proceed with black burning. Step type: "Manual Confirmation". If the "Manual Confirmation" button is automatically detected when this step is pressed, the step is completed, a completion signal is output, and the next step is executed. Otherwise, a failure signal is output, and the step continues.

[0064] Step 10, Blackening, Step type "Auto-adjust". The following steps will be executed automatically: (1) Automatically obtain the amount of regenerated air before the hot shutdown, or calculate the amount of regenerated air based on the catalyst carbon content and oxygen content input in the DCS, the catalyst coking process mechanism and process equipment characteristics, and the strict oxygen balance calculation method proposed by experts, and use it as the benchmark regenerated air amount. The benchmark regenerated air amount plus a certain value is used as the maximum regenerated air amount. (2) Linearly open the upper regenerated air flow controller valve to a% at a certain speed. (3) According to the flow characteristic curve of the upper regenerated air valve, increase the valve position of the upper regenerated air flow controller at a rate of b cubic meters per minute. When the coking temperature distribution, peak temperature and oxygen content increase rate meet the requirements, then execute step (4); otherwise, continue to execute step (3). (4) Reduce the valve position of the upper regenerated air flow controller at a speed of b cubic meters per minute. When the measured value of the regenerated air volume is close to the reference regenerated air volume, execute step (5); otherwise, continue to execute step (4). During the execution of step (4), monitor the temperature distribution. When the peak temperature is greater than the limit temperature, shut off the regenerated air, reduce the load of the electric heater by half, stop the program execution, and alarm. (5) The upper regenerated air flow controller is set to cascade mode, and the oxygen content controller is set to automatic mode; (6) Once this step is completed, an execution completion signal will be output, and the next step will be executed.

[0065] The principle of "calculating the regeneration air volume based on the catalyst carbon content and oxygen content input from the DCS, the catalyst coking process mechanism, and the characteristics of the process equipment, combined with expert experience, using a rigorous oxygen balance calculation method" is based on the rigorous oxygen balance of the catalyst coking process, including: Based on the chemical equation for catalytic coking, the amount of O2 required for complete combustion of coke is obtained; Calculate the amount of regenerated air required for combustion based on the required O2 content; Calculate the volume increase of coke after combustion; The required amount of regenerated air, V, is calculated based on the oxygen balance.

[0066] The condition "when the coking temperature distribution, peak temperature, and oxygen content increase rate meet the requirements" (skipping the conditions in step (3)) is achieved by identifying the temperature change trend at point 9 in the coking bed, such as... Figure 8 As shown. The rate of temperature change at point 9 is monitored in real time. When the rate of temperature change changes from "positive" to "negative" (… Figure 8 (At the middle circle), step (3) is complete.

[0067] Step 11: In the black-burnt state, the catalyst cycle count meets the requirement, and the step type is "automatic judgment". When the automatic detection shows that the catalyst cycle count meets the requirement, this step is completed, an execution completion signal is output, and the next step is executed; otherwise, an execution incomplete signal is output, and the step continues to be executed.

[0068] Step 12: The carbon content of the regenerated catalyst is qualified; step type: "Manual Confirmation". When the "Manual Confirmation" button for this step is automatically detected, the step is completed, a completion signal is output, and the next step is executed. Otherwise, a "Step Not Completed" signal is output, and the step continues.

[0069] Step 13: Cut the black-brown simmered ... (1) Advanced control of temperature distribution and oxygen content is put into use; cascade control of oxygen content controller and upper regenerated air controller is put into use; the system automatically analyzes the coking temperature distribution curve and, based on the oxygen content control method of "weighted coking peak temperature position", realizes stable control of coking temperature and oxygen content, and ensures stable coking process. The advanced control design for temperature distribution and oxygen content is as follows: Specifically, this includes: along the axial distribution direction of the regenerator, obtaining the absolute temperature value between two adjacent thermocouple temperature measuring points and the position value between two adjacent thermocouple temperature measuring points within a preset position interval; The weighted temperature position is determined based on the absolute value of the temperature difference between two adjacent thermocouple temperature measuring points and the positional value between two adjacent thermocouple temperature measuring points. Oxygen content is controlled based on weighted temperature location.

[0070] In one specific implementation, taking the 4th to 10th thermocouple temperature measuring points as an example, it includes: (a) Calculate the absolute value of the temperature difference between adjacent points of the 4th to 10th thermocouple measuring points distributed along the regenerator axis from top to bottom, ΔT. 5-4 , △T 5-6 , △T 6-7 , △T 7-8 , △T 8-9 , △T 9-10 .

[0071] (b) Based on the positions of thermocouples 4 to 10, as shown in Table 1 below, calculate the midpoint between adjacent thermocouples 4 to 10; Table 1. Schematic diagram of thermocouple locations

[0072] We introduce "weighted temperature position" to characterize the temperature distribution curve. The formula for calculating the weighted temperature position is as follows:

[0073] in, , This represents the absolute value of the temperature difference and the location value between the 4th and 5th thermocouple measuring points; , This represents the absolute value of the temperature difference and the location value between the 5th and 6th thermocouple measuring points; , This represents the absolute value of the temperature difference and the location value between the 6th and 7th thermocouple measuring points; , This represents the absolute value of the temperature difference and the location value between the 7th and 8th thermocouple measuring points; , This represents the absolute value of the temperature difference and the location value between the 8th and 9th thermocouple measuring points; , This represents the absolute value of the temperature difference and the location value between the 9th and 10th thermocouple measuring points.

[0074] The value of the "weighted position" corresponding to the normal temperature distribution curve is relatively stable, remaining stable around 1245 for a long time. Since the temperature distribution is a curve, it is difficult to directly control the oxygen content through the temperature distribution. Therefore, the "weighted temperature position" is used to replace the temperature distribution to achieve cascade control with the oxygen content, thus achieving the goal of stable temperature distribution control.

[0075] (2) Open the lower regeneration air valve at a certain speed until the lower regeneration air volume reaches a cubic meter / hour; (3) Calculate the valve position corresponding to the current amount of regenerated air in the lower part without N2 based on the flow characteristic curve of the lower regenerated air valve, and simultaneously execute 1) set the lower regenerated air valve position, 2) close the emergency nitrogen shut-off valve; (4) Once the upper and lower regenerated air volumes are stable, the oxygen content is switched from the upper regenerated air valve to the lower regenerated air valve via cascade control. (5) Close the upper regeneration air valve at a certain speed until the upper regeneration air valve is closed; (6) The upper regeneration air valve is set to a relatively small valve position to prevent chlorine corrosion; (7) Once this step is completed, an execution completion signal will be output, and the next step will be executed.

[0076] like Figure 9 and Figure 10 As shown, by comparing the regenerator heating rate fluctuations of different methods, it can be clearly concluded that the automatic start-up method of the catalyst regeneration unit of the continuous reforming unit using this scheme can further reduce the heating rate fluctuations of the regenerator and improve the safety of the regeneration start-up process.

[0077] The fourth step of the implementation of this invention is as follows: The program in step three is deployed to the automatic start-up server for catalyst regeneration; the required tag numbers for the automatic start-up program for catalyst regeneration are configured into the real-time database, and data is collected in real time to drive the automatic start-up program to run. These tag numbers include all the tag numbers involved in steps two and four, and the data collection frequency is not less than 5 seconds. The fifth step in implementing this invention involves configuring the automatic start-up process steps in steps two and four, along with the related buttons and status displays, into the DCS to form an automatic regeneration start-up operation screen. The color of each step varies depending on its execution status: gray when not in operation, yellow when in operation, and green when completed, allowing operators to easily monitor the progress of the automatic start-up program.

[0078] This invention constructs an automated start-up system for the catalyst regeneration unit of a continuous reforming unit, achieving for the first time an automated start-up process for the catalyst regeneration unit in a continuous reforming unit. The automated start-up process improves the stability rate of the catalyst regeneration unit's heating process and the black-burning-white-burning process by over 30%. Compared to manual start-up, which requires nearly 700 operations from the operator, the automated start-up system of this invention requires only 6 button clicks to complete the start-up process, greatly reducing the operator's workload. Furthermore, using the automated start-up system for the regeneration unit significantly reduces fluctuations in the regenerator's heating rate, improving the safety of the regeneration start-up process.

[0079] Those skilled in the art will understand that all or part of the steps in the methods of the above embodiments can be implemented by a program instructing related hardware. This program is stored in a storage medium and includes several instructions to cause a microcontroller, chip, or processor to execute all or part of the steps of the methods described in the various embodiments of the present invention. The aforementioned storage medium includes various media capable of storing program code, such as a USB flash drive, a portable hard drive, a read-only memory (ROM), a random access memory (RAM), a magnetic disk, or an optical disk.

[0080] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional units and modules is merely an example. In practical applications, the above functions can be assigned to different functional units and modules as needed, that is, the internal structure of the device can be divided into different functional units or modules to complete all or part of the functions described above. The functional units and modules in the embodiments can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or as a software functional unit. Furthermore, the specific names of the functional units and modules are only for easy differentiation and are not intended to limit the scope of protection of this application.

[0081] The optional embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the embodiments of the present invention are not limited to the specific details described above. Within the scope of the technical concept of the embodiments of the present invention, various simple modifications can be made to the technical solutions of the embodiments of the present invention, and these simple modifications all fall within the protection scope of the embodiments of the present invention. It should also be noted that the various specific technical features described in the above specific embodiments can be combined in any suitable manner without contradiction. To avoid unnecessary repetition, the embodiments of the present invention will not further describe the various possible combinations.

[0082] Furthermore, various different embodiments of the present invention can be combined in any way, as long as they do not violate the spirit of the embodiments of the present invention, they should also be regarded as the content disclosed by the embodiments of the present invention.

Claims

1. An automatic start-up method for a catalyst regeneration unit in a continuous reforming apparatus, characterized in that, The method includes: The catalyst regeneration unit of the continuous reforming unit is determined to meet the start-up conditions, which include: the cold shutdown interlock conditions of the continuous reforming unit are all in an untriggered state, the emergency nitrogen flow rate of the continuous reforming unit is within a first preset range, the regenerator pressure value of the continuous reforming unit is within a second preset range, and the normal operation signals of the circulating gas fan and electric heater are received. The circulating gas fan and electric heater are started to work, and the operating load of the circulating gas fan and electric heater is adjusted based on the temperature value collected from the catalyst regeneration unit. If the temperature of the catalyst regeneration unit reaches the preset temperature, and the thermal shutdown interlock condition of the catalyst regeneration unit is not triggered, a signal indicating that the catalyst circulation process is unobstructed is received, and it is determined that the catalyst isolation system is in operation, then the catalyst circulation of the continuous reforming unit is established according to the preset circulation rate. Upon receiving a signal confirming that the carbon content of the catalyst to be generated is within acceptable limits, the continuous reforming unit is controlled to enter the black-burn state, including: The amount of regeneration air before the catalyst regeneration unit is shut down or the amount of regeneration air calculated based on the catalyst carbon content and oxygen content is used as the baseline regeneration air amount. The opening of the upper regenerated air flow controller valve is linearly adjusted to the second preset opening according to the second preset rate; After reaching the second preset opening degree, based on the preset flow characteristic curve of the upper regenerated air valve, the valve position of the upper regenerated air flow controller is increased according to the third preset rate until the coking temperature distribution meets the preset distribution curve, the peak temperature is in the preset temperature range, and the oxygen content rise rate meets the preset rate threshold. The valve position of the upper regenerated air flow controller is reduced at the third preset rate until the measured value of regenerated air reaches the reference regenerated air volume. Among them, the second preset rate is greater than the third preset rate; In the black-burn state, if the catalyst cycle count reaches the preset number and a signal indicating that the carbon content of the regenerated catalyst is qualified is received, the continuous reforming unit is controlled to switch from the black-burn state to the white-burn state, thus completing the automatic start-up of the catalyst regeneration unit of the continuous reforming unit. The control of the continuous reforming device switching from the black-burning state to the white-burning state includes: Along the axial distribution direction of the regenerator, obtain the absolute value of the temperature difference between two adjacent thermocouple temperature measuring points and the position value between two adjacent thermocouple temperature measuring points within the preset position interval; The weighted temperature position is determined based on the absolute temperature value between two adjacent thermocouple temperature measurement points and the positional value between two adjacent thermocouple temperature measurement points. Oxygen content cascade control is performed based on the weighted temperature position; The catalyst circulation of the continuous reforming unit, established according to a preset circulation rate, includes: Within a preset time period, the secondary gas flow rate is adjusted to the preset flow rate according to the first preset rate; After the secondary gas flow rate reaches the preset flow rate, the valve position adjustment rate of the secondary gas flow regulating valve is determined based on the preset reference rate and the measured value of catalyst differential pressure. At preset time intervals, the valve position of the secondary gas flow regulating valve is adjusted according to the valve position adjustment rate until the mean and variance of the catalyst differential pressure measurement value and the catalyst differential pressure target value are within the corresponding preset difference range, thus maintaining catalyst circulation. The target value of the catalyst pressure difference is determined by a preset circulation rate; After the secondary gas flow rate reaches the preset flow rate, the valve position adjustment rate of the secondary gas flow regulating valve is determined based on the preset reference rate and the catalyst differential pressure measurement value, including: The valve position adjustment rate is calculated using the following formula: in, For valve position adjustment rate; This represents the target value for the catalyst differential pressure. This is the measured value of the catalyst differential pressure. As the reference rate, This is the valve position adjustment rate coefficient.

2. The automatic start-up method for the catalyst regeneration unit of the continuous reforming unit according to claim 1, characterized in that, The signals for smooth catalyst circulation, qualified carbon content of the catalyst to be generated, qualified carbon content of the regenerated catalyst, and normal operation of the circulating gas fan and electric heater are all triggered when the corresponding button status is changed.

3. The automatic start-up method for the catalyst regeneration unit of the continuous reforming unit according to claim 1, characterized in that, Based on the temperature values ​​collected from the catalyst regeneration unit, the operating load of the electric heater is adjusted, including: The actual heating rate is determined based on the temperature values ​​collected from the catalyst regeneration unit. Based on the actual heating rate, determine the load increase of the electric heater; Based on the aforementioned increase in load, adjust the operating load of the electric heater.

4. The automatic start-up method for the catalyst regeneration unit of the continuous reforming unit according to claim 3, characterized in that, Based on the heating rate, the increase in load on the electric heater is determined, including: The load increase is calculated using the following formula: in, The increase in load on the electric heater; The increase is the amount added to the baseline load. To set the heating rate, This represents the actual heating rate.

5. The automatic start-up method for the catalyst regeneration unit of the continuous reforming unit according to claim 1, characterized in that, Based on the temperature values ​​collected from the catalyst regeneration unit, the operating load of the circulating air blower is adjusted, including: Based on the temperature value of the catalyst regeneration unit, the operating load of the circulating air blower is obtained according to a preset relationship curve or a preset relationship table; wherein, the preset relationship curve and the preset relationship table are used to characterize the correspondence between different temperature values ​​of the catalyst regeneration unit and the operating load of the circulating air blower.

6. The automatic start-up method for the catalyst regeneration unit of the continuous reforming unit according to claim 1, characterized in that, The amount of regenerated air calculated based on the catalyst carbon content and oxygen content includes: The amount of oxygen required for complete combustion of coke is calculated based on the chemical equation for catalytic coking. The amount of regenerated air required for combustion is calculated based on the amount of oxygen required for complete combustion of coke. Calculate the volume increase of coke after combustion; The required amount of regenerated air is calculated based on the amount of regenerated air needed for combustion and the volume increase of coke after combustion, according to the oxygen balance.

7. An automatic start-up system for a catalyst regeneration unit of a continuous reforming apparatus, characterized in that, The system includes: The DCS system is connected to the continuous reforming unit and is used to collect the operating parameters of the continuous reforming unit and adjust the operating status of the continuous reforming unit. An automatic start-up server is connected to the DCS system via an OPC server. The automatic start-up server is used to execute the automatic start-up method of the catalyst regeneration unit of the continuous reforming unit as described in any one of claims 1-6. The signal triggering device is electrically connected to the automatic start server and is used to generate and send to the automatic start server a catalyst circulation process smooth signal, a carbon content qualified signal for the catalyst to be generated, a carbon content qualified signal for the regenerated catalyst, and a normal operation signal for the circulating gas fan and electric heater.

8. A readable storage medium storing instructions for causing a machine to perform an automatic start-up method for a catalyst regeneration unit of a continuous reforming apparatus according to any one of claims 1-6.

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