Monitoring system for safe operation of rectifying tower

Abstract

The invention discloses a rectifying tower safe operation monitoring system, and particularly relates to the technical field of process production monitoring. Received rectifying tower operation pressure, temperature and liquid level data are compared with rectifying tower operation pressure, temperature and liquid level specified in a process production scheme to calculate a basic operation parameter comprehensive offset rate; the deviation condition of the basic operation parameters can be visually displayed; respectively calculating a real-time reflux ratio, real-time whole-tower efficiency, a whole-tower material loss coefficient and a volatile component loss coefficient, and comparing the calculated actual reflux ratio and actual whole-tower efficiency with the reflux ratio and whole-tower efficiency designed in a process production scheme to calculate a reflux ratio offset rate and a whole-tower efficiency matching degree; the deviation condition of the operation process parameters is visually displayed, the monitoring range is expanded, the reliability and comprehensiveness of operation safety monitoring of the rectifying tower are improved, and meanwhile data support is provided for follow-up operation danger prediction of the rectifying tower.

Description

Technical Field

[0001] The present invention relates to the technical field of process production monitoring, and more specifically, to a distillation tower safe operation monitoring system. Background Art

[0002] Distillation towers are commonly used equipment in chemical processes, used to separate components in a mixture through a distillation process. In traditional distillation tower operations, operators usually rely on experience and regular manual inspections to monitor the operation of the tower. This method has problems of low efficiency and slow response. With the development of industrial automation, automated monitoring systems have gradually been applied to distillation tower operations.

[0003] The existing distillation tower operation automation control system is equipped with temperature sensors and pressure sensors to monitor the top temperature, bottom temperature, top pressure, and bottom pressure of the distillation tower in real time. When the temperature and pressure of the distillation tower deviate from the temperature and pressure specified in the production plan, it will automatically alarm and be inspected and maintained by professional technicians. This has liberated human resources to a certain extent, realized intelligent monitoring, and reduced the frequency of dangerous events during the operation of the distillation tower.

[0004] However, the above system still has some problems: the above system only monitors the temperature and pressure in the distillation tower, the monitoring angle is not comprehensive, and cannot fully display the parameter deviation during the operation of the distillation tower. In addition, it automatically alarms when the temperature and pressure of the distillation tower deviate from the temperature and pressure specified in the production plan, and cannot guarantee that the distillation tower must have operating abnormalities at this time. At this time, inspection and maintenance by professional technicians may result in unnecessary shutdowns for maintenance, slowing down production progress. Summary of the invention

[0005] In order to overcome the above-mentioned defects of the prior art, an embodiment of the present invention provides a distillation tower safe operation monitoring system to solve the problems raised in the above-mentioned background technology.

[0006] To achieve the above object, the present invention provides the following technical solution: a distillation tower safe operation monitoring system, comprising:

[0007] Sensor arrangement module: used to arrange flow sensors, pressure sensors, liquid level sensors, temperature sensors, and flow detection sites, pressure detection sites, liquid level detection sites, temperature detection sites, and liquid composition detection sites corresponding to the liquid composition detector;

[0008] Real-time monitoring module for distillation tower operation: monitors the operation of the distillation tower in real time through the arranged sensors and sends the detected real-time operation data of the distillation tower to the basic operation parameter comparison and inspection module and the tower operation data analysis module;

[0009] Basic operating parameter comparison and inspection module: compare the received distillation tower operating pressure, temperature and liquid level data with the distillation tower operating pressure, temperature and liquid level specified in the process production plan to check whether the basic operating parameters deviate and calculate the comprehensive deviation rate of the basic operating parameters;

[0010] Tower operation data analysis module: based on the received data, the real-time reflux ratio, real-time full-tower efficiency, full-tower material loss coefficient, and volatile component loss coefficient are calculated respectively; the calculated actual reflux ratio and actual full-tower efficiency are compared with the reflux ratio and full-tower efficiency designed in the process production plan to calculate the reflux ratio deviation rate and full-tower efficiency matching degree; the operation process deviation rate is calculated based on the full-tower material loss coefficient, volatile component loss coefficient, reflux ratio deviation rate, and full-tower efficiency matching degree;

[0011] Distillation tower operation hazard prediction module: predicts the operation hazard coefficient of the distillation tower based on the comprehensive deviation rate of basic operation parameters and the operation process deviation rate;

[0012] Automatic alarm module: compares the predicted operation risk factor with the preset alarm threshold value. When the predicted value is greater than or equal to the preset alarm threshold value, an alarm is issued and the distillation tower is automatically regulated. After three consecutive alarms, the risk elimination plan is automatically started. After the risk is eliminated, a maintenance request is sent to the distillation tower maintenance department.

[0013] Distillation tower maintenance module: After receiving the maintenance request, the maintenance personnel are arranged to perform abnormal inspection on the distillation tower, record the inspection results and perform abnormal repair tasks when abnormalities are confirmed. Based on the maintenance results, the hazard prediction accuracy and average abnormal repair efficiency within the operation cycle are calculated;

[0014] Distillation tower operation quality assessment module: Count the number of dangerous events in the distillation tower during the operation cycle of the distillation tower and calculate the dangerous event incidence rate, and calculate the operation quality index based on the hazard prediction accuracy, maintenance efficiency and dangerous event incidence rate during the operation cycle of the distillation tower;

[0015] Database: used to store data information of all modules in the system.

[0016] Preferably, the real-time monitoring module for the operation of the distillation tower includes a multi-point data detection unit, a data fluctuation timeline integration unit, and a detection data output unit. The multi-point data detection unit detects the molar flow rate F of the raw material liquid through the arranged flow sensor. ma , molar flow rate of reflux liquid L ma , the molar flow rate of the distillate D ma , and the molar flow rate W of the residual liquid ma , the top pressure P is detected by the arranged pressure sensor da and the bottom pressure P fa, the liquid level Z at the bottom of the tower is detected by the arranged liquid level sensor da and the liquid level Z at the reflux tank ha , the top temperature T is detected by the arranged temperature sensor da and the tower bottom temperature T fa The molar fraction X of the volatile component in the raw material liquid is detected by the set liquid composition detector Fa , the mole fraction of the volatile component in the distillate X Da And the mole fraction of the volatile component in the kettle residue X Wa The data fluctuation timeline integration unit arranges the data fluctuation time in sequence, and marks the data detected by the multi-point data detection unit at each fluctuation time point as data at the same time point; the detection data output unit sends the detected real-time operation data of the distillation tower to the basic operation parameter comparison and inspection module and the in-tower operation data analysis module.

[0017] Preferably, the basic operation parameter comparison and inspection module includes a real-time operation data receiving unit, a standard basic operation parameter retrieval unit, a pressure control unit, a temperature control unit, a liquid level control unit, a basic operation parameter comprehensive deviation rate calculation unit, and a calculation result output unit. The real-time operation data receiving unit is used to receive the detected real-time operation data of the distillation tower; the standard basic operation parameter retrieval unit is used to retrieve the distillation tower top pressure P specified in the process production plan. db , tower bottom pressure P fb , Tower top temperature T db , tower bottom temperature T fb , tower bottom liquid level Z db , and the reflux tank level Z hb ; The pressure control unit compares the real-time pressure of the distillation tower with the specified pressure to calculate the operating pressure deviation rate θ P , the specific formula is: ; The temperature control unit compares the real-time temperature of the distillation tower with the specified temperature to calculate the operating temperature deviation rate θ T , the specific formula is: ; The liquid level control unit compares the real-time liquid level of the distillation tower with the specified liquid level to calculate the operating liquid level deviation rate θ Z , the specific formula is: ; The basic operating parameter comprehensive deviation rate calculation unit calculates the basic operating parameter comprehensive deviation rate θ YC The specific formula is: The calculation result output unit sends the calculated comprehensive deviation rate of basic operating parameters to the distillation tower operation risk prediction module.

[0018] Preferably, the tower operation data analysis module includes a real-time operation data receiving unit, a process design parameter retrieval unit, a real-time process calculation unit, a process design parameter comparison unit, an operation process deviation rate calculation unit, and a data output unit. The real-time operation data receiving unit is used to receive the detected real-time operation data of the distillation tower; the process design parameter retrieval unit is used to retrieve the reflux ratio R designed in the process production plan. b With the whole tower efficiency N b The real-time process calculation unit calculates the actual reflux ratio R based on the molar flow rate of the reflux liquid and the molar flow rate of the distillate. a , the specific formula is: , the actual total tower efficiency N is calculated based on the mole fraction of the volatile components in the raw liquid, the mole fraction of the volatile components in the distillate, and the mole fraction of the volatile components in the kettle residue. a , the specific formula is: , calculate the material loss coefficient α of the whole tower based on the molar flow rate of the raw liquid, the molar flow rate of the distillate, and the molar flow rate of the kettle residue m , the specific formula is: Calculate the volatile component loss coefficient α based on the molar flow rate of the raw liquid, the molar flow rate of the distillate, the molar flow rate of the bottom liquid, the molar fraction of the volatile component in the raw liquid, the molar fraction of the volatile component in the distillate, and the molar fraction of the volatile component in the bottom liquid X , the specific formula is: The process design parameter comparison unit compares the calculated actual reflux ratio and actual full tower efficiency with the reflux ratio and full tower efficiency designed in the process production plan to calculate the reflux ratio deviation rate θ R Matching degree with the whole tower efficiency γ N , the specific formula is as follows: , ; The operation process deviation rate calculation unit calculates the operation process deviation rate θ GY The specific formula is: ; The data output unit sends the calculated operation process deviation rate to the distillation tower operation risk prediction module.

[0019] Preferably, the distillation tower operation risk prediction module predicts the operation risk coefficient α of the distillation tower operation based on the comprehensive deviation rate of the basic operation parameters and the operation process deviation rate. YW The specific formula is: , a1 and a2 are the weights of the comprehensive deviation rate of basic operating parameters and the deviation rate of operating process, respectively, a2>a1>0.

[0020] Preferably, the distillation tower maintenance module includes a maintenance request information receiving unit, a distillation tower abnormality inspection unit, a inspection result recording unit, a distillation tower abnormality repair unit, an abnormality repair data recording unit, a maintenance data processing unit, and a calculation result output unit. The maintenance request information receiving unit is used to receive maintenance request information; the distillation tower abnormality inspection unit is used to inspect whether there is an abnormality in the distillation tower. If there is an abnormality, the hazard prediction is correct, otherwise the hazard prediction is wrong; the inspection result recording unit is used to record the location of the detected abnormal source, the number of abnormal sources, the number of correct hazard predictions, and the number of incorrect hazard predictions; the distillation tower abnormality repair unit repairs the abnormal source after determining the location of the abnormal source; the abnormality repair data recording unit is used to record the time required for abnormal repair; the maintenance data processing unit is based on the number of correct hazard predictions m within the operation cycle yz and the number of dangerous prediction errors m yc Calculate the risk prediction accuracy β wy , the specific formula is: , based on the number m of abnormal sources during the i-th abnormal repair in the operation cycle yai and abnormal repair time t yxi Calculate the average anomaly repair efficiency β yxe , the specific formula is: , n yx is the number of abnormal repairs within the operation cycle; the calculation result output unit sends the calculated danger prediction accuracy and average abnormal repair efficiency to the distillation tower operation quality evaluation module.

[0021] Preferably, the distillation tower operation quality assessment module includes a data receiving unit, a distillation tower dangerous event statistics unit, a dangerous event occurrence rate calculation unit, and an operation quality index calculation unit. The data receiving unit is used to receive the dangerous prediction accuracy and the average abnormal repair efficiency; the distillation tower dangerous event statistics unit is used to count the number of dangerous events in the distillation tower operation cycle; the dangerous event occurrence rate calculation unit is based on the number of dangerous events in the distillation tower operation cycle m wf and distillation tower operation cycle t y Calculate the risk of dangerous events β wf The specific formula is: The operation quality index calculation unit calculates the operation quality index Q based on the hazard prediction accuracy, maintenance efficiency and hazard event occurrence rate during the distillation tower operation cycle. YZ The specific formula is: , e is a natural constant.

[0022] Technical effects and advantages of the present invention:

[0023] 1. The present invention sets a basic operating parameter comparison and inspection module to compare the received distillation tower operating pressure, temperature and liquid level data with the distillation tower operating pressure, temperature and liquid level specified in the process production plan to check whether the basic operating parameters deviate and calculate the comprehensive deviation rate of the basic operating parameters, which can intuitively display the deviation of the basic operating parameters and provide data support for the subsequent operation risk prediction of the distillation tower; the tower operation data analysis module is set to calculate the real-time reflux ratio, real-time full-tower efficiency, full-tower material loss coefficient, and volatile component loss coefficient based on the received data, and compare the calculated actual reflux ratio and actual full-tower efficiency with the reflux ratio and full-tower efficiency designed in the process production plan to calculate the reflux ratio deviation rate and the full-tower efficiency matching degree, and calculate the operation process deviation rate based on the full-tower material loss coefficient, the volatile component loss coefficient, the reflux ratio deviation rate, and the full-tower efficiency matching degree. The deviation of the operation process parameters is intuitively displayed, the monitoring range is expanded, and it is beneficial to improve the reliability and comprehensiveness of the distillation tower operation safety monitoring, and also provides data support for the subsequent operation risk prediction of the distillation tower.

[0024] 2. The present invention sets up a distillation tower operation hazard prediction module, which predicts the operation hazard coefficient of the distillation tower based on the comprehensive deviation rate of basic operation parameters and the operation process deviation rate, and sets an automatic alarm module to compare the predicted operation hazard coefficient with a preset alarm critical value. When the predicted value is greater than or equal to the preset alarm critical value, an alarm is issued and the distillation tower is automatically regulated. After three consecutive alarms, the hazard elimination plan is automatically started, and a maintenance request is sent to the distillation tower maintenance department after the hazard is eliminated. This can reduce the situation of excessive operation hazard coefficient caused by accidental parameter fluctuations in the distillation tower to a certain extent, which is beneficial to improving the accuracy of the overhaul and maintenance of the distillation tower, and reduces the unnecessary shutdown of the distillation tower for maintenance to a certain extent. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 It is a system structure block diagram of the present invention.

[0026] Figure 2 The present invention is a system operation flow chart. DETAILED DESCRIPTION

[0027] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0028] like Figure 1The embodiment shown provides a distillation tower safe operation monitoring system, including a sensor layout module, a distillation tower operation real-time monitoring module, a basic operation parameter comparison and inspection module, an in-tower operation data analysis module, a distillation tower operation risk prediction module, an automatic alarm module, a distillation tower maintenance module, a distillation tower operation quality assessment module, and a database. The sensor layout module is connected to the distillation tower operation real-time monitoring module, the distillation tower operation real-time monitoring module is connected to the basic operation parameter comparison and inspection module and the in-tower operation data analysis module, the basic operation parameter comparison and inspection module and the in-tower operation data analysis module are connected to the distillation tower operation risk prediction module, the distillation tower operation risk prediction module, the automatic alarm module, the distillation tower maintenance module, and the distillation tower operation quality assessment module are connected in sequence, and all modules in the system are connected to the database.

[0029] The sensor arrangement module is used to arrange flow sensors, pressure sensors, liquid level sensors, temperature sensors, and flow detection sites, pressure detection sites, liquid level detection sites, temperature detection sites, and liquid composition detection sites corresponding to the liquid composition detector.

[0030] What needs to be specifically explained in this embodiment is that the flow detection sites arranged in the sensor arrangement module include the raw liquid inlet, the reflux liquid inlet, the top distillate outlet, and the bottom residual liquid outlet; the set pressure detection sites include the top and the bottom; the set liquid level detection sites are the bottom and the reflux tank; the set temperature detection sites include the top and the bottom; the set liquid composition monitoring sites include the raw liquid inlet, the top distillate outlet and the bottom residual liquid outlet.

[0031] The real-time monitoring module for distillation tower operation monitors the operation of the distillation tower in real time through arranged sensors and sends the detected real-time operation data of the distillation tower to the basic operation parameter comparison and inspection module and the in-tower operation data analysis module.

[0032] Furthermore, the real-time monitoring module for the operation of the distillation tower includes a multi-point data detection unit, a data fluctuation timeline integration unit, and a detection data output unit. The multi-point data detection unit detects the molar flow rate F of the raw material liquid through the arranged flow sensor. ma , molar flow rate of reflux liquid L ma , the molar flow rate of the distillate D ma , and the molar flow rate W of the residual liquid ma , the top pressure P is detected by the arranged pressure sensor da and the bottom pressure P fa , the liquid level Z at the bottom of the tower is detected by the arranged liquid level sensor da and the liquid level Z at the reflux tank ha , the top temperature T is detected by the arranged temperature sensor da and the tower bottom temperature T faThe molar fraction X of the volatile component in the raw material liquid is detected by the set liquid composition detector Fa , the mole fraction of the volatile component in the distillate X Da And the mole fraction of the volatile component in the kettle residue X Wa The data fluctuation timeline integration unit arranges the data fluctuation time in sequence, and marks the data detected by the multi-point data detection unit at each fluctuation time point as data at the same time point; the detection data output unit sends the detected real-time operation data of the distillation tower to the basic operation parameter comparison and inspection module and the in-tower operation data analysis module.

[0033] The basic operating parameter comparison and verification module compares the received distillation tower operating pressure, temperature and liquid level data with the distillation tower operating pressure, temperature and liquid level specified in the process production plan to check whether the basic operating parameters deviate and calculate the comprehensive deviation rate of the basic operating parameters.

[0034] Further, the basic operation parameter comparison and inspection module includes a real-time operation data receiving unit, a standard basic operation parameter retrieval unit, a pressure control unit, a temperature control unit, a liquid level control unit, a basic operation parameter comprehensive deviation rate calculation unit, and a calculation result output unit. The real-time operation data receiving unit is used to receive the detected real-time operation data of the distillation tower; the standard basic operation parameter retrieval unit is used to retrieve the distillation tower top pressure P specified in the process production plan. db , tower bottom pressure P fb , Tower top temperature T db , tower bottom temperature T fb , tower bottom liquid level Z db , and the reflux tank level Z hb ; The pressure control unit compares the real-time pressure of the distillation tower with the specified pressure to calculate the operating pressure deviation rate θ P , the specific formula is: ; The temperature control unit compares the real-time temperature of the distillation tower with the specified temperature to calculate the operating temperature deviation rate θ T , the specific formula is: ; The liquid level control unit compares the real-time liquid level of the distillation tower with the specified liquid level to calculate the operating liquid level deviation rate θ Z , the specific formula is: ; The basic operating parameter comprehensive deviation rate calculation unit calculates the basic operating parameter comprehensive deviation rate θ YC The specific formula is: The calculation result output unit sends the calculated comprehensive deviation rate of basic operating parameters to the distillation tower operation risk prediction module.

[0035] The in-tower operation data analysis module calculates the real-time reflux ratio, real-time whole-tower efficiency, whole-tower material loss coefficient, and volatile component loss coefficient based on the received data, compares the calculated actual reflux ratio and actual whole-tower efficiency with the reflux ratio and whole-tower efficiency designed in the process production plan, calculates the reflux ratio deviation rate and the whole-tower efficiency matching degree, and calculates the operation process deviation rate based on the whole-tower material loss coefficient, volatile component loss coefficient, reflux ratio deviation rate, and whole-tower efficiency matching degree.

[0036] Furthermore, the tower operation data analysis module includes a real-time operation data receiving unit, a process design parameter retrieval unit, a real-time process calculation unit, a process design parameter comparison unit, an operation process deviation rate calculation unit, and a data output unit. The real-time operation data receiving unit is used to receive the detected real-time operation data of the distillation tower; the process design parameter retrieval unit is used to retrieve the reflux ratio R designed in the process production plan. b With the whole tower efficiency N b The real-time process calculation unit calculates the actual reflux ratio R based on the molar flow rate of the reflux liquid and the molar flow rate of the distillate. a , the specific formula is: , the actual total tower efficiency N is calculated based on the mole fraction of the volatile components in the raw liquid, the mole fraction of the volatile components in the distillate, and the mole fraction of the volatile components in the kettle residue. a , the specific formula is: , calculate the material loss coefficient α of the whole tower based on the molar flow rate of the raw liquid, the molar flow rate of the distillate, and the molar flow rate of the kettle residue m , the specific formula is: Calculate the volatile component loss coefficient α based on the molar flow rate of the raw liquid, the molar flow rate of the distillate, the molar flow rate of the bottom liquid, the molar fraction of the volatile component in the raw liquid, the molar fraction of the volatile component in the distillate, and the molar fraction of the volatile component in the bottom liquid X , the specific formula is: The process design parameter comparison unit compares the calculated actual reflux ratio and actual full tower efficiency with the reflux ratio and full tower efficiency designed in the process production plan to calculate the reflux ratio deviation rate θ R Matching degree with the whole tower efficiency γ N , the specific formula is as follows: , ; The operation process deviation rate calculation unit calculates the operation process deviation rate θ GY The specific formula is: ; The data output unit sends the calculated operation process deviation rate to the distillation tower operation risk prediction module.

[0037] The distillation tower operation risk prediction module predicts the operation risk coefficient of the distillation tower operation based on the comprehensive deviation rate of basic operation parameters and the operation process deviation rate.

[0038] Further, the distillation tower operation risk prediction module predicts the operation risk coefficient α of the distillation tower operation based on the basic operation parameter comprehensive deviation rate and the operation process deviation rate. YW The specific formula is: , a1 and a2 are the weights of the comprehensive deviation rate of basic operating parameters and the deviation rate of operating process, respectively, a2>a1>0.

[0039] The automatic alarm module compares the predicted operating risk factor with the preset alarm critical value. When the predicted value is greater than or equal to the preset alarm critical value, an alarm is issued and the distillation tower is automatically regulated. After three consecutive alarms, the risk elimination plan is automatically started, and a maintenance request is sent to the distillation tower maintenance department after the risk is eliminated.

[0040] After receiving the maintenance request, the distillation tower maintenance module arranges maintenance personnel to perform abnormal inspection on the distillation tower, records the inspection results and executes abnormal repair tasks when abnormalities are determined, and calculates the hazard prediction accuracy and average abnormal repair efficiency within the operation cycle based on the maintenance results.

[0041] Furthermore, the distillation tower maintenance module includes a maintenance request information receiving unit, a distillation tower abnormality inspection unit, an inspection result recording unit, a distillation tower abnormality repair unit, an abnormality repair data recording unit, a maintenance data processing unit, and a calculation result output unit. The maintenance request information receiving unit is used to receive maintenance request information; the distillation tower abnormality inspection unit is used to inspect whether there is an abnormality in the distillation tower. If there is an abnormality, the hazard prediction is correct, otherwise the hazard prediction is wrong; the inspection result recording unit is used to record the detected abnormal source location, the number of abnormal sources, the number of correct hazard predictions, and the number of incorrect hazard predictions; the distillation tower abnormality repair unit repairs the abnormal source after determining the abnormal source location; the abnormality repair data recording unit is used to record the time required for abnormality repair; the maintenance data processing unit is based on the number of correct hazard predictions m within the operation cycle yz and the number of dangerous prediction errors m yc Calculate the risk prediction accuracy β wy , the specific formula is: , based on the number m of abnormal sources during the i-th abnormal repair in the operation cycle yai and abnormal repair time t yxi Calculate the average anomaly repair efficiency β yxe , the specific formula is: , n yxis the number of abnormal repairs within the operation cycle; the calculation result output unit sends the calculated danger prediction accuracy and average abnormal repair efficiency to the distillation tower operation quality evaluation module.

[0042] The distillation tower operation quality assessment module calculates the occurrence rate of dangerous events by counting the number of dangerous events during the distillation tower operation cycle, and calculates the operation quality index based on the hazard prediction accuracy, maintenance efficiency and dangerous event occurrence rate during the distillation tower operation cycle.

[0043] Further, the distillation tower operation quality assessment module includes a data receiving unit, a distillation tower dangerous event statistics unit, a dangerous event occurrence rate calculation unit, and an operation quality index calculation unit. The data receiving unit is used to receive the dangerous prediction accuracy and the average abnormal repair efficiency; the distillation tower dangerous event statistics unit is used to count the number of dangerous events in the distillation tower operation cycle; the dangerous event occurrence rate calculation unit is based on the number of dangerous events in the distillation tower operation cycle m wf and distillation tower operation cycle t y Calculate the risk of dangerous events β wf The specific formula is: The operation quality index calculation unit calculates the operation quality index Q based on the hazard prediction accuracy, maintenance efficiency and hazard event occurrence rate during the distillation tower operation cycle. YZ The specific formula is: , e is a natural constant.

[0044] It should be specifically noted in this embodiment that dangerous events include explosion, leakage, scalding, equipment failure, seal failure, equipment breakage, operating error, and illegal operating behavior.

[0045] The database is used to store data information of all modules in the system.

[0046] It should be specifically noted in this embodiment that the preset values, specified values ​​and weights used are all selected based on actual needs and are not limited to specific values ​​here.

[0047] like Figure 2 This embodiment provides an operation process of a distillation tower safe operation monitoring system, comprising the following steps:

[0048] S1: Arrange flow sensors, pressure sensors, liquid level sensors, temperature sensors, and flow detection sites, pressure detection sites, liquid level detection sites, temperature detection sites, and liquid composition detection sites corresponding to the liquid composition detector;

[0049] S2: Real-time monitoring of the operation of the distillation column through arranged sensors;

[0050] S3: Compare the operating pressure, temperature and liquid level data of the distillation tower with the operating pressure, temperature and liquid level of the distillation tower specified in the process production plan to check whether the basic operating parameters deviate and calculate the comprehensive deviation rate of the basic operating parameters;

[0051] S4: respectively calculating the real-time reflux ratio, the real-time whole-tower efficiency, the whole-tower material loss coefficient, and the volatile component loss coefficient, and comparing the calculated actual reflux ratio and the actual whole-tower efficiency with the reflux ratio and the whole-tower efficiency designed in the process production plan to calculate the reflux ratio deviation rate and the whole-tower efficiency matching degree, and calculating the operation process deviation rate based on the whole-tower material loss coefficient, the volatile component loss coefficient, the reflux ratio deviation rate, and the whole-tower efficiency matching degree;

[0052] S5: Predict the operation risk factor of the distillation tower based on the comprehensive deviation rate of basic operation parameters and the deviation rate of operation process;

[0053] S6: Compare the predicted operation risk factor with the preset alarm threshold value. When the predicted value is greater than or equal to the preset alarm threshold value, an alarm is issued and the distillation tower is automatically regulated. After three consecutive alarms, the risk elimination plan is automatically started. After the risk is eliminated, a maintenance request is sent to the distillation tower maintenance department.

[0054] S7: After receiving the maintenance request, arrange maintenance personnel to perform abnormal inspection on the distillation tower, record the inspection results and perform abnormal repair tasks when abnormalities are determined, and calculate the hazard prediction accuracy and average abnormal repair efficiency within the operation cycle based on the maintenance results;

[0055] S8: Calculate the occurrence rate of dangerous events by counting the number of dangerous events that occur during the operation period of the distillation tower, and calculate the operation quality index based on the hazard prediction accuracy, maintenance efficiency and dangerous event occurrence rate during the operation period of the distillation tower.

[0056] Finally: The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A distillation tower safe operation monitoring system, characterized in that: include: Real-time monitoring module for distillation tower operation: monitors the operation of the distillation tower in real time through the arranged sensors and sends the detected real-time operation data of the distillation tower to the basic operation parameter comparison and inspection module and the tower operation data analysis module; Basic operating parameter comparison and inspection module: compare the received distillation tower operating pressure, temperature and liquid level data with the distillation tower operating pressure, temperature and liquid level specified in the process production plan to check whether the basic operating parameters deviate and calculate the comprehensive deviation rate of the basic operating parameters; Tower operation data analysis module: based on the received data, the real-time reflux ratio, real-time full-tower efficiency, full-tower material loss coefficient, and volatile component loss coefficient are calculated respectively; the calculated actual reflux ratio and actual full-tower efficiency are compared with the reflux ratio and full-tower efficiency designed in the process production plan to calculate the reflux ratio deviation rate and full-tower efficiency matching degree; the operation process deviation rate is calculated based on the full-tower material loss coefficient, volatile component loss coefficient, reflux ratio deviation rate, and full-tower efficiency matching degree; Distillation tower operation hazard prediction module: predicts the operation hazard coefficient of the distillation tower based on the comprehensive deviation rate of basic operation parameters and the operation process deviation rate; Automatic alarm module: compares the predicted operation risk factor with the preset alarm threshold value. When the predicted value is greater than or equal to the preset alarm threshold value, an alarm is issued and the distillation tower is automatically regulated. After three consecutive alarms, the risk elimination plan is automatically started. After the risk is eliminated, a maintenance request is sent to the distillation tower maintenance department. Distillation tower maintenance module: After receiving the maintenance request, the maintenance personnel are arranged to perform abnormal inspection on the distillation tower, record the inspection results and perform abnormal repair tasks when abnormalities are confirmed. Based on the maintenance results, the hazard prediction accuracy and average abnormal repair efficiency within the operation cycle are calculated; Distillation tower operation quality assessment module: The number of dangerous events in the distillation tower during the operation cycle of the distillation tower is counted to calculate the incidence rate of dangerous events, and the operation quality index is calculated based on the hazard prediction accuracy, maintenance efficiency and the incidence rate of dangerous events during the operation cycle of the distillation tower.

2. A distillation tower safe operation monitoring system according to claim 1, characterized in that: The real-time monitoring module for the operation of the distillation tower includes a multi-point data detection unit, a data fluctuation timeline integration unit, and a detection data output unit. The multi-point data detection unit detects the molar flow rate F of the raw material liquid through the arranged flow sensor. ma , molar flow rate of reflux liquid L ma , the molar flow rate of the distillate D ma , and the molar flow rate of the residual liquid W ma , the top pressure P is detected by the arranged pressure sensor da and the bottom pressure P fa , the liquid level Z at the bottom of the tower is detected by the arranged liquid level sensor da and the liquid level Z at the reflux tank ha , the top temperature T is detected by the arranged temperature sensor da and the tower bottom temperature T fa The molar fraction X of the volatile component in the raw material liquid is detected by the set liquid composition detector Fa , the mole fraction of the volatile component in the distillate X Da And the mole fraction of the volatile component in the kettle residue X Wa ; The data fluctuation timeline integration unit arranges the data fluctuation time in sequence, and marks the data detected by the multi-point data detection unit at each fluctuation time point as data at the same time point; The detection data output unit sends the detected real-time operation data of the distillation tower to the basic operation parameter comparison and inspection module and the tower operation data analysis module.

3. A distillation tower safe operation monitoring system according to claim 2, characterized in that: The basic operation parameter comparison and inspection module includes a real-time operation data receiving unit, a standard basic operation parameter retrieval unit, a pressure comparison unit, a temperature comparison unit, a liquid level comparison unit, a basic operation parameter comprehensive deviation rate calculation unit, and a calculation result output unit. The real-time operation data receiving unit is used to receive the detected real-time operation data of the distillation tower; The standard basic operating parameter retrieval unit is used to retrieve the distillation tower top pressure P specified in the process production plan. db , tower bottom pressure P fb , Tower top temperature T db , tower bottom temperature T fb , tower bottom liquid level Z db , and the reflux tank level Z hb ; The pressure control unit compares the real-time pressure of the distillation tower with the specified pressure to calculate the operating pressure deviation rate θ P , the specific formula is: ; The temperature control unit compares the real-time temperature of the distillation tower with the specified temperature to calculate the operating temperature deviation rate θ T , the specific formula is: ; The liquid level control unit compares the real-time liquid level of the distillation tower with the specified liquid level to calculate the operating liquid level deviation rate θ Z , the specific formula is: ; The basic operating parameter comprehensive deviation rate calculation unit calculates the basic operating parameter comprehensive deviation rate θ YC The specific formula is: ; The calculation result output unit sends the calculated comprehensive deviation rate of basic operating parameters to the distillation tower operation risk prediction module.

4. A distillation tower safe operation monitoring system according to claim 3, characterized in that: The in-tower operation data analysis module includes a real-time operation data receiving unit, a process design parameter retrieval unit, a real-time process calculation unit, a process design parameter comparison unit, an operation process deviation rate calculation unit, and a data output unit. The real-time operation data receiving unit is used to receive the detected real-time operation data of the distillation tower; The process design parameter retrieval unit is used to retrieve the reflux ratio R designed in the process production plan. b With the whole tower efficiency N b ; The real-time process calculation unit calculates the actual reflux ratio R based on the molar flow rate of the reflux liquid and the molar flow rate of the distillate. a , the specific formula is: The actual total tower efficiency N is calculated based on the mole fraction of the volatile components in the raw liquid, the mole fraction of the volatile components in the distillate, and the mole fraction of the volatile components in the kettle residue. a , the specific formula is: , calculate the material loss coefficient α of the whole tower based on the molar flow rate of the raw liquid, the molar flow rate of the distillate, and the molar flow rate of the kettle residue m , the specific formula is: Calculate the volatile component loss coefficient α based on the molar flow rate of the raw liquid, the molar flow rate of the distillate, the molar flow rate of the bottom liquid, the molar fraction of the volatile component in the raw liquid, the molar fraction of the volatile component in the distillate, and the molar fraction of the volatile component in the bottom liquid X , the specific formula is: ; The process design parameter comparison unit compares the calculated actual reflux ratio and actual full tower efficiency with the reflux ratio and full tower efficiency designed in the process production plan to calculate the reflux ratio deviation rate θ R Matching degree with the whole tower efficiency γ N , the specific formula is as follows: , ; The operation process deviation rate calculation unit calculates the operation process deviation rate θ GY The specific formula is: ; The data output unit sends the calculated operation process deviation rate to the distillation tower operation risk prediction module.

5. A distillation tower safe operation monitoring system according to claim 4, characterized in that: The distillation tower operation risk prediction module predicts the operation risk coefficient α of the distillation tower operation based on the comprehensive deviation rate of basic operation parameters and the operation process deviation rate. YW The specific formula is: , a1 and a2 are the weights of the comprehensive deviation rate of basic operating parameters and the deviation rate of operating process, respectively, a2>a1>0.

6. A distillation tower safe operation monitoring system according to claim 1, characterized in that: The distillation tower maintenance module includes a maintenance request information receiving unit, a distillation tower abnormality inspection unit, an inspection result recording unit, a distillation tower abnormality repair unit, an abnormality repair data recording unit, a maintenance data processing unit, and a calculation result output unit. The maintenance request information receiving unit is used to receive maintenance request information; The distillation tower abnormality inspection unit is used to inspect whether the distillation tower has abnormalities. If abnormalities are present, the risk prediction is correct, otherwise, the risk prediction is wrong. The inspection result recording unit is used to record the locations of the detected abnormal sources, the number of abnormal sources, the number of correct danger predictions, and the number of incorrect danger predictions; The distillation tower abnormality repair unit repairs the abnormal source after determining the location of the abnormal source; the abnormality repair data recording unit is used to record the time required for abnormality repair; the maintenance data processing unit is based on the correct number of danger predictions m within the operation cycle yz and the number of dangerous prediction errors m yc Calculate the risk prediction accuracy β wy , the specific formula is: , based on the number m of abnormal sources during the i-th abnormal repair in the operation cycle yai and abnormal repair time t yxi Calculate the average anomaly repair efficiency β yxe , the specific formula is: , n yx The number of abnormal repairs during the operation cycle; The calculation result output unit sends the calculated danger prediction accuracy and average abnormal repair efficiency to the distillation tower operation quality evaluation module.

7. A distillation tower safe operation monitoring system according to claim 6, characterized in that: The distillation tower operation quality assessment module includes a data receiving unit, a distillation tower dangerous event statistics unit, a dangerous event occurrence rate calculation unit, and an operation quality index calculation unit, and the data receiving unit is used to receive the danger prediction accuracy and the average abnormality repair efficiency; The distillation tower dangerous event statistical unit is used to count the number of dangerous events that occur during the distillation tower operation cycle; The dangerous event occurrence rate calculation unit is based on the number of dangerous events occurring during the distillation tower operation cycle m. wf and distillation tower operation cycle t y Calculate the risk of dangerous events β wf The specific formula is: ; The operation quality index calculation unit calculates the operation quality index Q based on the hazard prediction accuracy, maintenance efficiency and hazard event occurrence rate during the distillation tower operation cycle. YZ The specific formula is: , e is a natural constant.

Images