A rectification column safety operation monitoring system

Abstract

The present invention discloses a monitoring system for the safe operation of a distillation column, specifically relating to the technical field of process production monitoring. The present invention calculates the comprehensive deviation rate of the basic operation parameters by comparing the received operation pressure, temperature, and liquid level data of the distillation column with the operation pressure, temperature, and liquid level specified in the process production plan, which can intuitively display the deviation of the basic operation parameters; calculates the actual reflux ratio, actual overall column efficiency, overall column material loss coefficient, and volatile component loss coefficient respectively, and compares the calculated actual reflux ratio and actual overall column efficiency with the reflux ratio and overall column efficiency designed in the process production plan to calculate the reflux ratio deviation rate and overall column efficiency matching degree, which intuitively displays the deviation of the operation process parameters, expands the monitoring range, is conducive to improving the reliability and comprehensiveness of the safe operation monitoring of the distillation column, and at the same time provides data support for the subsequent operation risk prediction of the distillation column.

Description

Technical Field

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

[0002] A distillation column is a commonly used device in chemical processes for separating components in a mixture through a distillation process. In traditional distillation column operations, operators usually rely on experience and regular manual inspections to monitor the operation inside the column. This method has problems of low efficiency and slow response. With the development of industrial automation, automated monitoring systems have gradually been applied to the operation of distillation columns.

[0003] Existing automated control systems for distillation column operations set up temperature sensors and pressure sensors to monitor the top temperature, bottom temperature, top pressure, and bottom pressure during the operation of the distillation column in real time. When the temperature and pressure of the distillation column deviate from the temperature and pressure specified in the production plan, an automatic alarm is triggered, and professional technicians are required to conduct inspections and maintenance. To a certain extent, this liberates human resources, realizes intelligent monitoring, and reduces the occurrence frequency of dangerous events during the operation of the distillation column.

[0004] However, the above system still has some problems: the above system only monitors the temperature and pressure in the distillation column, and the monitoring angle is not comprehensive enough, and it cannot fully show the parameter deviation situation during the operation of the distillation column. Moreover, when the temperature and pressure of the distillation column deviate from the temperature and pressure specified in the production plan, an automatic alarm is triggered, which cannot guarantee that there must be an abnormal operation of the distillation column at this time. At this time, when professional technicians conduct inspections and maintenance, unnecessary shutdown and repair situations may occur, delaying the 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 monitoring system for the safe operation of a distillation column to solve the problems raised in the above background art.

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

[0007] A sensor layout module: used to layout flow sensors, pressure sensors, liquid level sensors, temperature sensors, and corresponding flow detection sites, pressure detection sites, liquid level detection sites, temperature detection sites, and liquid component detection sites for liquid component detectors;

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

[0009] Basic operating parameter comparison and inspection module: Compare and inspect the received data of the rectification column's operating pressure, temperature, and liquid level with the rectification column's 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] In-column operating data analysis module: Calculate the actual reflux ratio, actual overall column efficiency, overall column material loss coefficient, and volatile component loss coefficient based on the received data. Compare the calculated actual reflux ratio and actual overall column efficiency with the reflux ratio and overall column efficiency designed in the process production plan to calculate the reflux ratio deviation rate and overall column efficiency matching degree. Calculate the operating process deviation rate based on the overall column material loss coefficient, volatile component loss coefficient, reflux ratio deviation rate, and overall column efficiency matching degree;

[0011] Rectification column operation hazard prediction module: Predict the operation hazard coefficient of the rectification column based on the comprehensive deviation rate of the basic operating parameters and the operating process deviation rate;

[0012] Automatic alarm module: Compare the predicted operation hazard coefficient with the preset alarm critical value. When the predicted value is greater than or equal to the preset alarm critical value, issue an alarm and automatically control the rectification column. After three consecutive alarms, automatically start the hazard elimination plan. After the hazard is eliminated, send a maintenance request to the rectification column maintenance department;

[0013] Rectification column maintenance module: Arrange maintenance personnel to conduct an abnormal inspection of the rectification column after receiving the maintenance request, record the inspection results, and perform abnormal repair tasks when abnormalities are determined. Calculate the hazard prediction accuracy rate and average abnormal repair efficiency during the operation cycle based on the maintenance results;

[0014] Rectification column operation quality assessment module: Count the number of hazard events occurring during the operation cycle of the rectification column to calculate the hazard event occurrence rate. Calculate the operation quality index based on the hazard prediction accuracy rate, maintenance efficiency, and hazard event occurrence rate during the operation cycle of the rectification column;

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

[0016] Preferably, the rectification column operation real-time monitoring module 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 feed liquid through the arranged flow sensors ma , the molar flow rate L of the reflux liquid ma , the molar flow rate D of the distillate ma , and the molar flow rate W of the bottom residue ma , detects the top pressure P through the arranged pressure sensors da and the bottom pressure P fa, the bottom liquid level Z of the tower is detected by the arranged liquid level sensor da and the liquid level Z at the reflux drum ha , the top temperature T of the tower is detected by the arranged temperature sensor da and the bottom temperature T of the tower fa , the mole fraction X of the volatile components in the feed liquid is detected by the set feed liquid composition detector Fa , the mole fraction X of the volatile components in the distillate Da and the mole fraction X of the volatile components in the bottom residue 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 the same moment of each fluctuation time point as the data at the same time point; The detected data output unit sends the detected real-time operation data of the distillation column 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 comparison unit, a temperature comparison unit, a liquid level comparison unit, a basic operation parameter comprehensive offset 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 column; The standard basic operation parameter retrieval unit is used to retrieve the top pressure P of the distillation column specified in the process production plan db , the bottom pressure P of the tower fb , the top temperature T of the tower db , the bottom temperature T of the tower fb , the bottom liquid level Z of the tower db , and the liquid level Z of the reflux drum hb ; The pressure comparison unit compares the real-time pressure of the distillation column with the specified pressure to calculate the operation pressure offset rate θ P , and the specific formula is: The temperature comparison unit compares the real-time temperature of the distillation column with the specified temperature to calculate the operation temperature offset rate θ T , and the specific formula is: The liquid level comparison unit compares the real-time liquid level of the distillation column with the specified liquid level to calculate the operation liquid level offset rate θ Z , and the specific formula is: The basic operation parameter comprehensive offset rate calculation unit calculates the basic operation parameter comprehensive offset rate θ YC The specific formula is: θ YC =θ P +θ T +θ Z ; The calculation result output unit sends the calculated basic operation parameter comprehensive offset rate to the distillation column operation risk prediction module.

[0018] Preferably, 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 real-time operation data of the distillation column detected; the process design parameter retrieval unit is used to retrieve the reflux ratio R b and the overall column efficiency N b designed in the process production plan; 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 , and the specific formula is: Calculate the actual overall column efficiency N based on the mole fraction of the volatile component in the feed liquid, the mole fraction of the volatile component in the distillate, and the mole fraction of the volatile component in the bottom residue a , and the specific formula is: Calculate the overall column material loss coefficient α based on the molar flow rate of the feed liquid, the molar flow rate of the distillate, and the molar flow rate of the bottom residue m , and the specific formula is: Calculate the volatile component loss coefficient α based on the molar flow rate of the feed liquid, the molar flow rate of the distillate, the molar flow rate of the bottom residue, the mole fraction of the volatile component in the feed liquid, the mole fraction of the volatile component in the distillate, and the mole fraction of the volatile component in the bottom residue X , and the specific formula is: The process design parameter comparison unit compares the calculated actual reflux ratio and actual overall column efficiency with the reflux ratio and overall column efficiency designed in the process production plan to calculate the reflux ratio deviation rate θ R and the overall column efficiency matching degree γ N , and 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 column operation hazard prediction module.

[0019] Preferably, the distillation column operation hazard prediction module predicts the operation hazard coefficient α of the distillation column 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 the basic operation parameters and the operation process deviation rate respectively, and a2 > a1 > 0.

[0020] Preferably, the rectification column maintenance module includes a maintenance request information receiving unit, a rectification column abnormality inspection unit, an inspection result recording unit, a rectification column 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 rectification column abnormality inspection unit is used to inspect whether there is an abnormality in the rectification column. If there is an abnormality, the risk prediction is correct, otherwise the risk prediction is incorrect; the inspection result recording unit is used to record the location of the abnormality source, the number of abnormality sources, the number of correct risk predictions, and the number of incorrect risk predictions detected; the rectification column abnormality repair unit repairs the abnormality source after determining the location of the abnormality source; the abnormality repair data recording unit is used to record the duration required for abnormality repair; the maintenance data processing unit is based on the number of correct risk predictions m within the operation cycle yz and the number of incorrect risk predictions m yc to calculate the risk prediction accuracy rate β wy , and the specific formula is: Based on the number of abnormality sources m at the i-th abnormality repair within the operation cycle yai and the abnormality repair duration t yxi to calculate the average abnormality repair efficiency β yxe , and the specific formula is: n yx is the number of abnormality repairs within the operation cycle; the calculation result output unit sends the calculated risk prediction accuracy rate and average abnormality repair efficiency to the rectification column operation quality evaluation module.

[0021] Preferably, the rectification column operation quality evaluation module includes a data receiving unit, a rectification column risk event statistics unit, a risk event incidence rate calculation unit, and an operation quality index calculation unit. The data receiving unit is used to receive the risk prediction accuracy rate and average abnormality repair efficiency; the rectification column risk event statistics unit is used to count the number of risk events occurring within the operation cycle of the rectification column; the risk event incidence rate calculation unit is based on the number of risk events m occurring within the operation cycle of the rectification column wf and the operation cycle t of the rectification column y to calculate the risk event incidence rate β wf The specific formula is: The operation quality index calculation unit calculates the operation quality index Q based on the risk prediction accuracy rate, maintenance efficiency, and risk event incidence rate within the operation cycle of the rectification column YZ The specific formula is: e is the natural constant.

[0022] The technical effects and advantages of the present invention:

[0023] 1. The present invention sets up a basic operating parameter comparison and inspection module to compare and inspect the received rectification column operating pressure, temperature, and liquid level data with the rectification column operating pressure, temperature, and liquid level specified in the process production plan, to determine 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 rectification column; it sets up an in-column operation data analysis module to calculate the actual reflux ratio, actual overall column efficiency, overall column material loss coefficient, and volatile component loss coefficient respectively based on the received data, compares the calculated actual reflux ratio and actual overall column efficiency with the reflux ratio and overall column efficiency designed in the process production plan to calculate the reflux ratio deviation rate and overall column efficiency matching degree, and calculates the operation process deviation rate based on the overall column material loss coefficient, volatile component loss coefficient, reflux ratio deviation rate, and overall column efficiency matching degree, which intuitively displays the deviation of the operation process parameters, expands the monitoring range, is conducive to improving the reliability and comprehensiveness of the rectification column operation safety monitoring, and also provides data support for the subsequent operation risk prediction of the rectification column.

[0024] 2. The present invention sets up a rectification column operation risk prediction module to predict the operation risk coefficient of the rectification column based on the comprehensive deviation rate of the basic operating parameters and the operation process deviation rate, and sets up an automatic alarm module to compare the predicted operation risk coefficient with a preset alarm threshold. When the predicted value is greater than or equal to the preset alarm threshold, an alarm is issued and the rectification column is automatically regulated. After three consecutive alarms, a risk elimination plan is automatically started. After the risk is eliminated, a maintenance request is sent to the rectification column maintenance department, which can reduce the situation of the operation risk coefficient exceeding the limit caused by accidental parameter fluctuations in the rectification column to a certain extent, is conducive to improving the accuracy of the rectification column maintenance and repair, and reduces the unnecessary shutdown and maintenance of the rectification column to a certain extent. BRIEF DESCRIPTION OF THE DRAWINGS

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

[0026] Figure 2 It is a system operation flowchart of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0027] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0028] Such as Figure 1The present embodiment provides a monitoring system for the safe operation of a distillation column, including a sensor arrangement module, a real-time monitoring module for the operation of the distillation column, a comparison and inspection module for basic operation parameters, an in-column operation data analysis module, a risk prediction module for the operation of the distillation column, an automatic alarm module, a distillation column maintenance module, a quality assessment module for the operation of the distillation column, and a database. The sensor arrangement module is connected to the real-time monitoring module for the operation of the distillation column, and the real-time monitoring module for the operation of the distillation column is connected to the comparison and inspection module for basic operation parameters and the in-column operation data analysis module. The comparison and inspection module for basic operation parameters and the in-column operation data analysis module are connected to the risk prediction module for the operation of the distillation column. The risk prediction module for the operation of the distillation column, the automatic alarm module, the distillation column maintenance module, and the quality assessment module for the operation of the distillation column are connected in sequence. 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 corresponding flow detection sites, pressure detection sites, liquid level detection sites, temperature detection sites, and liquid component detection sites for the liquid component detector.

[0030] Specifically, in this embodiment, the flow detection sites arranged in the sensor arrangement module include the raw material liquid inlet, the reflux liquid inlet, the top product outlet, and the bottom residue outlet; the pressure detection sites arranged include the top and the bottom of the column; the liquid level detection sites arranged are at the bottom of the column and at the reflux drum; the temperature detection sites arranged include the top and the bottom of the column; the liquid component monitoring sites arranged include the raw material liquid inlet, the top product outlet, and the bottom residue outlet.

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

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

[0033] The basic operation parameter comparison and inspection module compares the received distillation column operation pressure, temperature, and liquid level data with the distillation column operation pressure, temperature, and liquid level specified in the process production plan to check whether the basic operation parameters deviate and calculate the comprehensive deviation rate of the basic operation 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 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 column; the standard basic operation parameter retrieval unit is used to retrieve the top pressure P of the distillation column specified in the process production plan db , bottom pressure P fb , top temperature T db , bottom temperature T fb , bottom liquid level Z db , and reflux drum liquid level Z hb ; the pressure comparison unit compares the real-time pressure of the distillation column with the specified pressure to calculate the operation pressure deviation rate θ P , and the specific formula is: The temperature comparison unit compares the real-time temperature of the distillation column with the specified temperature to calculate the operation temperature deviation rate θ T , and the specific formula is: The liquid level comparison unit compares the real-time liquid level of the distillation column with the specified liquid level to calculate the operation liquid level deviation rate θ Z , and the specific formula is: The basic operation parameter comprehensive deviation rate calculation unit calculates the basic operation parameter comprehensive deviation rate θ YC The specific formula is: θ YC = θ P + θ T + θ Z ; the calculation result output unit sends the calculated basic operation parameter comprehensive deviation rate to the distillation column operation risk prediction module.

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

[0036] Further, 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 real-time operation data of the distillation column detected; the process design parameter retrieval unit is used to retrieve the reflux ratio R b designed in the process production plan and the overall column efficiency N b ; the real-time process calculation unit calculates the actual reflux ratio R a based on the molar flow rate of the reflux liquid and the molar flow rate of the distillate. The specific formula is: The actual overall column efficiency N a is calculated based on the mole fraction of the volatile component in the feed liquid, the mole fraction of the volatile component in the distillate, and the mole fraction of the volatile component in the bottom residue. The specific formula is: The overall column material loss coefficient α m is calculated based on the molar flow rate of the feed liquid, the molar flow rate of the distillate, and the molar flow rate of the bottom residue. The specific formula is: The volatile component loss coefficient α X is calculated based on the molar flow rate of the feed liquid, the molar flow rate of the distillate, the molar flow rate of the bottom residue, the mole fraction of the volatile component in the feed liquid, the mole fraction of the volatile component in the distillate, and the mole fraction of the volatile component in the bottom residue. The specific formula is: The process design parameter comparison unit compares the calculated actual reflux ratio and actual overall column efficiency with the reflux ratio and overall column efficiency designed in the process production plan to calculate the reflux ratio deviation rate θ R and the overall column efficiency matching degree γ N . The specific formulas are 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 column operation hazard prediction module.

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

[0038] Furthermore, the rectification column operation risk prediction module predicts the operation risk coefficient α of the rectification column operation based on the comprehensive deviation rate of the basic operation parameters and the operation process deviation rate YW The specific formula is as follows: a1 and a2 are the weights of the comprehensive deviation rate of the basic operation parameters and the operation process deviation rate respectively, and a2 > a1 > 0.

[0039] The automatic alarm module compares the predicted operation risk coefficient with the preset alarm critical value. When the predicted value is greater than or equal to the preset alarm critical value, it issues an alarm and automatically adjusts the rectification column. After three consecutive alarms, it automatically starts the risk elimination plan. After the risk is eliminated, it sends a maintenance request to the rectification column maintenance department.

[0040] After receiving the maintenance request, the rectification column maintenance module arranges maintenance personnel to conduct an abnormal inspection on the rectification column, records the inspection results, and performs abnormal repair tasks when abnormalities are identified. It calculates the risk prediction accuracy rate and the average abnormal repair efficiency during the operation cycle based on the maintenance results.

[0041] Furthermore, the rectification column maintenance module includes a maintenance request information receiving unit, a rectification column abnormal inspection unit, an inspection result recording unit, a rectification column abnormal repair unit, an abnormal 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 rectification column abnormal inspection unit is used to check whether there are abnormalities in the rectification column. If there are abnormalities, the risk prediction is correct, otherwise the risk prediction is incorrect; the inspection result recording unit is used to record the location of the abnormal source, the number of abnormal sources, the number of correct risk predictions, and the number of incorrect risk predictions detected; the rectification column abnormal repair unit repairs the abnormal source after determining the location of the abnormal source; the abnormal repair data recording unit is used to record the duration required for abnormal repair; the maintenance data processing unit calculates the risk prediction accuracy rate β yz and the number of incorrect risk predictions m yc Calculate the risk prediction accuracy rate β wy , and the specific formula is as follows: Based on the number of abnormal sources m yai and the abnormal repair duration t yxi during the i-th abnormal repair in the operation cycle, calculate the average abnormal repair efficiency β yxe , and the specific formula is as follows: n yx is the number of abnormal repairs during the operation cycle; the calculation result output unit sends the calculated risk prediction accuracy rate and average abnormal repair efficiency to the rectification column operation quality evaluation module.

[0042] The rectification column operation quality evaluation module counts the number of dangerous events occurring in the rectification column during the operation cycle, calculates the incidence rate of dangerous events, and calculates the operation quality index based on the dangerous prediction accuracy rate, maintenance efficiency, and incidence rate of dangerous events during the rectification column operation cycle.

[0043] Furthermore, the rectification column operation quality evaluation module includes a data receiving unit, a rectification column dangerous event statistics unit, a dangerous event incidence rate calculation unit, and an operation quality index calculation unit. The data receiving unit is used to receive the dangerous prediction accuracy rate and the average abnormal repair efficiency; the rectification column dangerous event statistics unit is used to count the number of dangerous events occurring in the rectification column during the operation cycle; the dangerous event incidence rate calculation unit is based on the number of dangerous events m wf occurring in the rectification column operation cycle t y to calculate the dangerous event incidence rate β wf The specific formula is: The operation quality index calculation unit calculates the operation quality index Q based on the dangerous prediction accuracy rate, maintenance efficiency, and dangerous event incidence rate during the rectification column operation cycle YZ The specific formula is: e is the natural constant.

[0044] In this embodiment, it should be specifically noted that dangerous events include explosion, leakage, scalding, equipment failure, seal failure, equipment fracture, operation error, and illegal operation behavior.

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

[0046] In this embodiment, it should be specifically noted that the preset values, specified values, and weights are all selected based on actual needs, and no specific value limitations are made here.

[0047] Such as Figure 2 This embodiment provides an operation process of a rectification column safe operation monitoring system, including the following steps:

[0048] S1: Arrange the flow sensors, pressure sensors, liquid level sensors, temperature sensors, and the corresponding flow detection points, pressure detection points, liquid level detection points, temperature detection points, and liquid component detection points of the liquid component detector;

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

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

[0051] S4: Calculate the actual reflux ratio, actual overall column efficiency, overall column material loss coefficient, and volatile component loss coefficient respectively. Compare the calculated actual reflux ratio and actual overall column efficiency with the reflux ratio and overall column efficiency designed in the process production plan to calculate the reflux ratio deviation rate and overall column efficiency matching degree. Calculate the operating process deviation rate based on the overall column material loss coefficient, volatile component loss coefficient, reflux ratio deviation rate, and overall column efficiency matching degree;

[0052] S5: Predict the operating risk coefficient of the distillation column based on the comprehensive deviation rate of the basic operating parameters and the operating process deviation rate;

[0053] S6: Compare the predicted operating risk coefficient with the preset alarm critical value. When the predicted value is greater than or equal to the preset alarm critical value, send an alarm and automatically control the distillation column. Automatically start the risk elimination plan after three consecutive alarms. After the risk is eliminated, send a maintenance request to the distillation column maintenance department;

[0054] S7: Arrange maintenance personnel to conduct abnormal inspection on the distillation column after receiving the maintenance request, record the inspection results, and execute the abnormal repair task when abnormalities are determined. Calculate the risk prediction accuracy rate and average abnormal repair efficiency during the operating cycle based on the inspection results;

[0055] S8: Count the number of dangerous events occurring in the distillation column during the operating cycle to calculate the dangerous event occurrence rate. Calculate the operating quality index based on the risk prediction accuracy rate, maintenance efficiency, and dangerous event occurrence rate during the distillation column operating cycle.

[0056] Finally: The above are only the preferred embodiments of the present invention and are not used to limit the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principles of the present invention shall be included within the protection scope of the present invention.

Claims

1. A monitoring system for the safe operation of a distillation column, characterized in that: Including: Real-time monitoring module for the operation of the distillation column: The operation of the distillation column is monitored in real time through the arranged sensors, and the real-time operation data of the distillation column detected is sent to the basic operation parameter comparison and inspection module and the in-column operation data analysis module; The real-time monitoring module for the rectification column operation includes a multi-point data detection unit, a data fluctuation timeline integration unit, and a detected data output unit. The multi-point data detection unit detects the molar flow rate F of the feed liquid through the arranged flow sensors ma , the molar flow rate L of the reflux liquid ma , the molar flow rate D of the distillate ma , and the molar flow rate W of the bottom residue ma . The top pressure P and the bottom pressure P are detected through the arranged pressure sensors da ; the bottom liquid level Z and the liquid level Z at the reflux drum are detected through the arranged liquid level sensors fa ; the top temperature T and the bottom temperature T are detected through the arranged temperature sensors da ; the mole fraction X of the volatile component in the feed liquid, the mole fraction X of the volatile component in the distillate, and the mole fraction X of the volatile component in the bottom residue are detected through the set feed liquid composition detector ha ; da ; fa ; Fa ; Da ; Wa ; The data fluctuation timeline integration unit arranges the data fluctuation times in sequence, and marks the data detected by the multi-point data detection unit at the same moment of each fluctuation time point as the data at the same time point; The detection data output unit sends the detected real-time operation data of the distillation column to the basic operation parameter comparison and inspection module and the in-column operation data analysis module; Basic operation parameter comparison and inspection module: Compare the received operation pressure, temperature and liquid level data of the distillation column with the operation pressure, temperature and liquid level of the distillation column specified in the process production plan to check whether the basic operation parameters deviate and calculate the comprehensive deviation rate of the basic operation parameters; 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 column; The standard basic operation parameter retrieval unit is used to retrieve the top pressure P of the distillation column specified in the process production plan db , the bottom pressure P fb , the top temperature T db , the bottom temperature T fb , the bottom liquid level Z db , and the reflux drum liquid level Z hb ; The pressure comparison unit compares the real-time pressure of the distillation column with the specified pressure to calculate the operation pressure deviation rate θ P , and the specific formula is: The temperature comparison unit compares the real-time temperature of the distillation column with the specified temperature to calculate the operation temperature deviation rate θ T , and the specific formula is: The liquid level comparison unit compares the real-time liquid level of the distillation column with the specified liquid level to calculate the operation liquid level deviation rate θ Z , and the specific formula is: The basic operation parameter comprehensive deviation rate calculation unit calculates the basic operation parameter comprehensive deviation rate θ YC The specific formula for is: θ YC = θ P + θ T + θ Z ; The calculation result output unit sends the calculated basic operation parameter comprehensive deviation rate to the distillation column operation risk prediction module; In-column operation data analysis module: Calculate the actual reflux ratio, actual overall column efficiency, overall column material loss coefficient, and volatile component loss coefficient based on the received data. Compare the calculated actual reflux ratio and actual overall column efficiency with the reflux ratio and overall column efficiency designed in the process production plan to calculate the reflux ratio deviation rate and overall column efficiency matching degree. Calculate the operation process deviation rate based on the overall column material loss coefficient, volatile component loss coefficient, reflux ratio deviation rate, and overall column efficiency matching degree; The in-column 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 column; The process design parameter retrieval unit is used to retrieve the reflux ratio R designed in the process production plan b and the overall 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 , and the specific formula is as follows: Calculate the actual overall column efficiency N based on the mole fraction of the volatile component in the feed liquid, the mole fraction of the volatile component in the distillate, and the mole fraction of the volatile component in the bottom residue a , and the specific formula is as follows: Calculate the overall column material loss coefficient α based on the molar flow rate of the feed liquid, the molar flow rate of the distillate, and the molar flow rate of the bottom residue m , and the specific formula is as follows: Calculate the volatile component loss coefficient α based on the molar flow rate of the feed liquid, the molar flow rate of the distillate, the molar flow rate of the bottom residue, the mole fraction of the volatile component in the feed liquid, the mole fraction of the volatile component in the distillate, and the mole fraction of the volatile component in the bottom residue X , and the specific formula is as follows: The process design parameter comparison unit compares the calculated actual reflux ratio and actual overall column efficiency with the reflux ratio and overall column efficiency designed in the process production plan to calculate the reflux ratio deviation rate θ R and the overall column efficiency matching degree γ N , and the specific formula is as follows: Run the process deviation rate calculation unit to calculate the running process deviation rate θ GY The specific formula is: The data output unit sends the calculated running process deviation rate to the rectification column operation hazard prediction module; Distillation column operation risk prediction module: Predict the operation risk coefficient of the distillation column operation based on the comprehensive deviation rate of the basic operation parameters and the operation process deviation rate; The rectification column operation risk prediction module predicts the operation risk coefficient α of the rectification column operation based on the comprehensive deviation rate of the basic operation parameters and the operation process deviation rate YW The specific formula is as follows: a1 and a2 are the weights of the comprehensive deviation rate of the basic operation parameters and the operation process deviation rate respectively, and a2 > a1 > 0; Automatic alarm module: Compare the predicted operation risk coefficient 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 column 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 column maintenance department; Distillation column maintenance module: Arrange maintenance personnel to conduct abnormal inspections on the distillation column after receiving the maintenance request, record the inspection results and perform abnormal repair tasks when abnormalities are determined. Calculate the risk prediction accuracy rate and average abnormal repair efficiency during the operation cycle based on the maintenance results; Distillation column operation quality evaluation module: Count the number of distillation column risk events occurring during the operation cycle of the distillation column to calculate the risk event occurrence rate, and calculate the operation quality index based on the risk prediction accuracy rate, maintenance efficiency, and risk event occurrence rate during the operation cycle of the distillation column.

2. The safety operation monitoring system of a rectification column according to claim 1, characterized in that: The rectifying column maintenance module includes a maintenance request information receiving unit, a rectifying column abnormality inspection unit, an inspection result recording unit, a rectifying column 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 rectifying column abnormality inspection unit is used to inspect whether there is an abnormality in the rectifying column. If there is an abnormality, the risk prediction is correct; otherwise, the risk prediction is incorrect; The inspection result recording unit is used to record the position of the abnormality source, the number of abnormality sources, the number of correct risk predictions, and the number of incorrect risk predictions detected; The rectification column anomaly repair unit repairs the anomaly source after determining its location; the anomaly repair data recording unit is used to record the duration required for anomaly repair; the maintenance data processing unit calculates the hazard prediction accuracy rate β based on the number of correct hazard predictions m yz and the number of incorrect hazard predictions m yc during the operation cycle, and the specific formula is: wy Based on the number of anomaly sources m and the anomaly repair duration t yai during the i-th anomaly repair within the operation cycle, the average anomaly repair efficiency β yxi is calculated, and the specific formula is: yxe where n is the number of anomaly repairs within the operation cycle; yx ​ The calculation result output unit sends the calculated risk prediction accuracy rate and average abnormality repair efficiency to the rectifying column operation quality evaluation module.

3. A rectification column safety operation monitoring system according to claim 2, characterized in that: The rectifying column operation quality evaluation module includes a data receiving unit, a rectifying column risk event statistics unit, a risk event occurrence rate calculation unit, and an operation quality index calculation unit. The data receiving unit is used to receive the risk prediction accuracy rate and average abnormality repair efficiency; The rectifying column risk event statistics unit is used to count the number of risk events occurring during the operation cycle of the rectifying column; The calculation unit of the dangerous event incidence rate calculates the dangerous event incidence rate β based on the number of occurrences m of dangerous events during the operation cycle of the rectification column wf and the operation cycle t of the rectification column y The specific formula for calculating the dangerous event incidence rate β is as follows: wf The specific formula is: The operation quality index calculation unit calculates the operation quality index Q based on the dangerous prediction accuracy rate, maintenance efficiency, and dangerous event incidence rate during the operation cycle of the rectification column YZ The specific formula is as follows: e is the natural constant

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