Unipol polypropylene reactor component control method

Abstract

The invention discloses a Unipol polypropylene reactor component control method, which comprises the following steps of: introducing ethane into a reactor as inert gas instead of nitrogen by using a gas supply system, and dynamically adjusting the flow of the ethane according to reaction requirements; the flow, pressure and gas composition of ethane are monitored in real time through an intelligent sensor, and the supply amount and the circulation period of the ethane are dynamically adjusted; an ethane recovery and cyclic utilization system is established, and the discharge amount of ethane is controlled through an optimized airflow design; the proportion of ethane, propylene and hydrogen is adjusted in real time through a gas sensor and an automatic control system. The stability of gas components in the reactor is ensured. The reliability of the reaction process and the long-term stability of the catalyst are effectively improved.

Description

Technical Field

[0001] The invention relates to the technical field of Unipol polypropylene reactors, in particular to a component control method of a Unipol polypropylene reactor. Background Art

[0002] Unipol polypropylene device is a polymerization reaction device widely used in industrial production, which is mainly composed of multiple process units such as raw material supply, propylene refining, polymerization reaction, resin degassing, and exhaust gas recovery. In this system, the reactor is one of the core components, and the reactants (propylene, hydrogen) and inert gases (nitrogen, propane) enter the reactor through the circulating gas compressor to carry out polymerization reaction. Nitrogen, as an inert gas, is mainly used for purging and maintaining pressure in the reactor. However, the prior art has problems such as nitrogen purity fluctuations, high energy consumption, and unstable airflow, especially in the deoxygenation and drying process of nitrogen, the molecular sieve life is short, and the nitrogen in the reactor exhaust gas flow is lighter, and it is easy to bring out fine powder, causing downstream equipment to be blocked. Therefore, a new method is urgently needed to improve the stability and efficiency of the reactor. Summary of the invention

[0003] The purpose of the present invention is to solve the above problems and to design a Unipol polypropylene reactor component control method.

[0004] To achieve the above object, the technical solution of the present invention is that, further, in the above-mentioned Unipol polypropylene reactor component control method, the polypropylene reactor component control method comprises the following steps:

[0005] Using a gas supply system to introduce ethane into the reactor as an inert gas to replace nitrogen, and dynamically adjusting the ethane flow rate according to reaction requirements;

[0006] The ethane flow, pressure and gas composition are monitored in real time through intelligent sensors, and the ethane supply and circulation period are dynamically adjusted;

[0007] Establishing the ethane recovery and recycling system and controlling the ethane emission through optimized gas flow design;

[0008] The ratio of ethane, propylene and hydrogen is adjusted in real time through gas sensors and automatic control systems.

[0009] Furthermore, in the above-mentioned Unipol polypropylene reactor component control method, the use of a gas supply system to introduce ethane into the reactor as an inert gas to replace nitrogen comprises:

[0010] Using ethane as an inert component to replace nitrogen, wherein the molar concentration of ethane is 4 mol%-10 mol%;

[0011] After being refined, ethane is injected into the reactor through a dynamic flow control system. The injection amount is adjusted in real time according to pressure feedback. The ethane discharged from the reactor is cooled and compressed before being recycled.

[0012] The ethane addition process includes dehydration, desulfurization pretreatment and purge system integration.

[0013] Furthermore, in the above-mentioned Unipol polypropylene reactor component control method, the step of introducing ethane into the reactor as an inert gas to replace nitrogen by using a gas supply system further comprises:

[0014] The ethane gas is introduced into the reactor by using the gas supply pipeline and control valve in the raw material supply and refining unit of the Unipol polypropylene device, and the reactor at least includes a circulating cooler and a circulating gas compressor;

[0015] Propylene, hydrogen and ethane are continuously circulated through a circulating gas compressor through a fluidized bed of a reactor containing a catalyst;

[0016] The flow rate and pressure of ethane gas are monitored in real time through flow meters and pressure sensors, and the ethane gas flow rate is automatically adjusted according to the reaction stage, catalyst activity and reaction temperature in the reactor.

[0017] Furthermore, in the above-mentioned Unipol polypropylene reactor component control method, the real-time monitoring of ethane flow, pressure and gas composition by intelligent sensors and the dynamic adjustment of ethane supply and circulation period include:

[0018] Installing an ethane flow sensor, a pressure sensor, a temperature sensor and a gas composition analyzer in the reactor;

[0019] The ethane flow sensor is used to continuously monitor the ethane flow rate, reactor pressure, reaction temperature, and the concentrations of ethane, propylene, and hydrogen;

[0020] The supply amount and circulation period of ethane are automatically adjusted according to the real-time data fed back by the ethane flow sensor.

[0021] Furthermore, in the above-mentioned Unipol polypropylene reactor component control method, the ethane recovery and recycling system is established to control the ethane emission through optimized gas flow design, including:

[0022] Establishing an ethane recovery pipeline to guide the unreacted ethane gas in the reactor to a recovery unit, wherein the recovery unit includes at least a gas separation device and a compression system;

[0023] Optimizing the gas flow path of the reactor by fluid mechanics to evenly distribute the ethane gas in the reactor;

[0024] According to the changes in the gas composition in the reactor, the emission of ethane is automatically adjusted, and the ethane is recycled through the recovery system.

[0025] Furthermore, in the above-mentioned Unipol polypropylene reactor component control method, the real-time adjustment of the ratio of ethane, propylene and hydrogen by means of a gas sensor and an automated control system comprises:

[0026] Install multiple gas composition sensors to monitor the concentration of reactive gases such as ethane, propylene, and hydrogen in real time;

[0027] According to the data fed back by the sensor, the ratio of ethane, propylene and hydrogen is automatically adjusted. If the ethane concentration is too high, the ethane supply is automatically reduced; if the propylene or hydrogen concentration is too low, the supply of the corresponding gas is automatically increased.

[0028] Further, in a system for implementing the above-mentioned Unipol polypropylene reactor component control method, the system includes the following units:

[0029] Raw material supply and refining unit, propylene refining unit, polymerization reaction unit, resin degassing unit, exhaust gas recovery unit, resin and additive processing unit, extrusion granulation unit, product blending and air delivery unit, condensate and flare system.

[0030] Further, in a system for implementing the above-mentioned Unipol polypropylene reactor component control method, the system also includes the following modules:

[0031] A gas replacement module, used to introduce ethane into the reactor as an inert gas to replace nitrogen using a gas supply system, and dynamically adjust the ethane flow rate according to reaction requirements;

[0032] Dynamic regulation module, which is used to monitor ethane flow, pressure and gas composition in real time through intelligent sensors, and dynamically adjust the supply and circulation period of ethane;

[0033] A flow control module, used to establish the ethane recovery and recycling system, and control the ethane emission through optimized airflow design;

[0034] The ratio adjustment module is used to adjust the ratio of ethane, propylene and hydrogen in real time through gas sensors and automatic control systems.

[0035] Its beneficial effects are that ethane is introduced into the reactor as an inert gas to replace nitrogen by using a gas supply system, and the ethane flow rate is dynamically adjusted according to the reaction requirements; the ethane flow rate, pressure and gas composition are monitored in real time by intelligent sensors, and the supply and circulation period of ethane are dynamically adjusted; the ethane recovery and recycling system is established, and the ethane emission is controlled by optimizing the gas flow design; the ratio of ethane, propylene and hydrogen is adjusted in real time by gas sensors and automatic control systems. 1. Solve the problem of nitrogen purity fluctuation: The use of ethane avoids the adverse effects of nitrogen purity fluctuation on the polypropylene reaction process and ensures the stability of the gas composition in the reactor. Since ethane has stable molecular properties and does not react with reactants such as propylene, it effectively improves the reliability of the reaction process and the long-term stability of the catalyst. 2. Optimize gas flow control and fine powder carry-out problems: The molecular weight of ethane is heavier than that of nitrogen, which makes it difficult to carry fine powder out of the reactor when the reactor gas flow is discharged, significantly reducing the risk of downstream equipment blockage, especially showing better stability in long-term production operations. 3. Ethane recovery and energy utilization efficiency improvement: The ethane recycling system designed by the present invention can effectively reduce the consumption of ethane gas, improve resource utilization efficiency, and reduce energy consumption in the production process. 4. Innovation of reactor control system: The present invention combines intelligent control technology and gas dynamic adjustment mechanism, while ensuring the stable operation of the reactor, reducing manual intervention and optimizing the control accuracy of the reaction process. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Various other advantages and benefits will become apparent to those of ordinary skill in the art by reading the following detailed description of the preferred embodiment.The drawings are only for the purpose of illustrating the preferred embodiments and are not to be construed as limiting the invention.

[0037] Figure 1 This is a schematic diagram of a first embodiment of a Unipol polypropylene reactor component control method according to an embodiment of the present invention;

[0038] Figure 2 It is a schematic diagram of a second embodiment of a Unipol polypropylene reactor component control method in an embodiment of the present invention;

[0039] Figure 3 It is a schematic diagram of a third embodiment of a Unipol polypropylene reactor component control method in an embodiment of the present invention. DETAILED DESCRIPTION

[0040] In order to make the purpose, technical solution and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0041] Those skilled in the art will appreciate that, unless otherwise stated, the singular forms "a", "an", "said" and "the" used herein may also include plural forms. It should be further understood that the term "comprising" used in the specification of the present invention refers to the presence of the features, integers, steps, operations, elements and / or components, but does not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components and / or groups thereof.

[0042] The present invention will be described in detail below in conjunction with the accompanying drawings. Figure 1 As shown, a Unipol polypropylene reactor component control method, the GEP calculation method comprises the following steps:

[0043] Step 101: using a gas supply system to introduce ethane into a reactor as an inert gas to replace nitrogen, and dynamically adjusting the ethane flow rate according to reaction requirements;

[0044] Specifically, in this embodiment, ethane is used as an inert component to replace nitrogen, wherein the molar concentration of the ethane is 4 mol%-10 mol%;

[0045] After being refined, ethane is injected into the reactor through a dynamic flow control system. The injection amount is adjusted in real time according to pressure feedback. The ethane discharged from the reactor is cooled and compressed before being recycled.

[0046] The ethane addition process includes dehydration, desulfurization pretreatment and purge system integration.

[0047] The ethane gas is introduced into the reactor by using the gas supply pipeline and control valve in the raw material supply and refining unit of the Unipol polypropylene device, and the reactor at least includes a circulating cooler and a circulating gas compressor;

[0048] Propylene, hydrogen and ethane are continuously circulated through a circulating gas compressor through a fluidized bed of a reactor containing a catalyst;

[0049] The flow rate and pressure of ethane gas are monitored in real time through flow meters and pressure sensors, and the ethane gas flow rate is automatically adjusted according to the reaction stage, catalyst activity and reaction temperature in the reactor.

[0050] Step 102: Monitor the ethane flow rate, pressure and gas composition in real time through intelligent sensors, and dynamically adjust the ethane supply and circulation period;

[0051] Specifically, in this embodiment, an ethane flow sensor, a pressure sensor, a temperature sensor and a gas composition analyzer are installed in the reactor;

[0052] The ethane flow sensor is used to continuously monitor the ethane flow, reactor pressure, reaction temperature, and the concentrations of ethane, propylene, and hydrogen.

[0053] The supply amount and circulation period of ethane are automatically adjusted according to the real-time data fed back by the ethane flow sensor.

[0054] Specifically, in this embodiment, ethane is introduced by using a gas supply system and the flow rate is adjusted:

[0055] Build an efficient and stable gas supply system, which consists of a high-pressure storage tank for storing ethane, a delivery pipeline, and supporting valves and pressure regulating devices. When starting the gas supply process, slowly open the tank outlet valve to allow ethane to enter the reactor smoothly along the well-sealed delivery pipeline under the action of the pressure difference. Unlike the traditional use of nitrogen as an inert gas, ethane has unique chemical stability and can effectively isolate interfering gases such as oxygen in a specific reaction environment. In addition, its molecular structure can promote the forward reaction in certain reaction systems.

[0056] In terms of flow regulation, a high-precision mass flow controller based on the model predictive control (MPC) algorithm is used. The MPC algorithm predicts the ethane flow demand in the future by establishing a mathematical model that includes the dynamic characteristics of the gas supply system, the dynamic characteristics of the reaction process, and the characteristics of ethane gas. This mathematical model uses the data fed back by the ethane flow sensor, pressure sensor, temperature sensor, and gas composition analyzer as important parameters. For example, at the beginning of the reaction, based on the reaction's demand for the speed of establishing an inert environment, combined with the reaction temperature, pressure and other data monitored in real time by the sensor, the model predicts that the ethane flow needs to be increased rapidly, and the controller quickly adjusts the valve opening to increase the flow based on the calculation results; as the reaction enters the stable stage, the model continuously optimizes the prediction results based on the real-time monitoring of the reaction rate, product generation, and the latest data fed back by various sensors, and then accurately controls the ethane flow to maintain the optimal conditions for the reaction.

[0057] Intelligent sensors monitor and dynamically adjust supply and cycle times:

[0058] A series of intelligent sensors, including ethane flow sensors, pressure sensors, temperature sensors and gas composition analyzers, are installed at key locations of the reactor, such as the gas inlet, reaction chamber and gas outlet. The ethane flow sensor is used to continuously monitor the ethane flow rate, the pressure sensor monitors the reactor pressure in real time, the temperature sensor monitors the reaction temperature, and the gas composition analyzer quickly and accurately detects the concentrations of ethane, propylene and hydrogen. These sensors transmit the collected data to the central control system in real time.

[0059] The central control system uses adaptive filtering algorithms and artificial neural network models to analyze and process data. The adaptive filtering algorithm can track the changing trend of data in real time, remove noise interference, and improve the accuracy and reliability of data, especially for signal fluctuations that may be generated during sensor transmission, which can effectively filter out noise. The artificial neural network model establishes a complex mapping relationship between ethane flow, pressure, temperature, gas composition and reaction state through learning and training of a large amount of historical data. Once the ethane flow is detected to deviate from the set value, or the pressure, temperature, and gas composition fluctuate abnormally, the system first uses the adaptive filtering algorithm to pre-process the data, and then inputs it into the artificial neural network model for analysis to determine the cause of the abnormality and the possible impact. The system will immediately issue instructions to adjust the opening of the intake valve and change the supply of ethane. At the same time, according to the actual situation of the reaction, the cycle of ethane is dynamically adjusted using a cycle decision model optimized based on a genetic algorithm. The genetic algorithm optimizes and searches for various possible values ​​of the cycle by simulating the process of natural selection and genetic variation, taking into account the data such as the reaction temperature and product generation rate fed back by the sensor in real time, and finding the cycle that best suits the current reaction state. For example, when the generation rate of reaction products decreases and the temperature sensor detects a slight drop in reaction temperature, the decision model appropriately shortens the ethane cycle and speeds up the gas renewal rate based on the optimization results of the genetic algorithm to maintain the activity of the reaction.

[0060] Establish ethane recovery and recycling systems and control emissions:

[0061] In order to improve resource utilization and reduce production costs, a complete ethane recovery and recycling system is established. The system is mainly composed of equipment such as condensers, adsorption towers and distillation towers. The mixed gas discharged from the reactor first enters the condenser, and by lowering the temperature, most of the ethane and other condensable gases are liquefied, and the separated liquid enters the subsequent processing link. The uncondensed gas enters the adsorption tower, and the residual ethane is further captured by a highly selective adsorbent. The adsorbent after adsorption saturation is desorbed by increasing the temperature or reducing the pressure to release ethane. The collected ethane enters the distillation tower for purification to remove impurities and meet the standards for reuse.

[0062] Computational fluid dynamics (CFD) models are used to optimize gas flow design and control emissions. The CFD model numerically simulates the gas flow in the entire recovery system and analyzes the gas flow distribution under different pipeline layouts, equipment structures, and operating parameters. According to the simulation results, the diameter, length, and connection method of the pipeline are optimized, and the positions of equipment such as condensers, adsorption towers, and distillation towers are reasonably arranged to reduce the resistance and leakage of gases during transportation and processing. At the same time, combined with the emission concentration target, the linear programming algorithm is used to optimize the operating parameters of each processing link, and the data fed back by the pressure sensor and gas composition analyzer in the reactor are linked to the emission concentration target to strictly control the emission of ethane to meet environmental protection standards.

[0063] Gas sensors and automated control systems adjust the gas ratio:

[0064] In the reaction system, various types of gas sensors are installed to monitor the concentrations of ethane, propylene and hydrogen. These sensors transmit real-time data to the automatic control system. At the same time, combined with the data fed back by the ethane flow sensor, pressure sensor and temperature sensor, more comprehensive information is provided to the automatic control system.

[0065] The automatic control system is based on a composite control algorithm that combines an advanced proportional integral differential (PID) control algorithm and a fuzzy control algorithm. According to the chemical stoichiometric relationship of the reaction and the requirements for the generation of the target product, the required ratio of ethane, propylene and hydrogen is accurately calculated. The PID control algorithm performs proportional, integral and differential operations on the deviation of the gas flow rate, quickly responds and adjusts the valve opening to make the gas flow rate close to the set value. The fuzzy control algorithm adjusts the parameters of the PID controller online through fuzzy inference rules for the uncertainty and nonlinear factors in the reaction process, thereby improving the robustness and adaptability of the control. For example, in some catalytic reactions, a specific ratio of ethane, propylene and hydrogen can significantly improve the selectivity and yield of the target product. Through the precise adjustment of the composite control algorithm, combined with the reaction temperature, pressure and other data monitored in real time by the sensor, the efficient and stable operation of the reaction process can be achieved, and the production efficiency and product quality can be improved.

[0066] Step 103: Establishing the ethane recovery and recycling system, and controlling the ethane emission through optimized airflow design;

[0067] Specifically, in this embodiment, an ethane recovery pipeline is established to guide the unreacted ethane gas in the reactor to a recovery unit, and the recovery unit includes at least a gas separation device and a compression system;

[0068] Optimizing the gas flow path of the reactor by fluid mechanics to evenly distribute the ethane gas in the reactor;

[0069] According to the changes in the gas composition in the reactor, the emission of ethane is automatically adjusted, and the ethane is recycled through the recovery system.

[0070] Step 104: Real-time adjustment of the ratio of ethane, propylene and hydrogen through gas sensors and an automated control system.

[0071] Specifically, in this embodiment, multiple gas composition sensors are installed to monitor the concentration of reaction gases such as ethane, propylene, and hydrogen in real time;

[0072] According to the data fed back by the sensor, the ratio of ethane, propylene and hydrogen is automatically adjusted. If the ethane concentration is too high, the ethane supply is automatically reduced; if the propylene or hydrogen concentration is too low, the supply of the corresponding gas is automatically increased.

[0073] Its beneficial effects are that ethane is introduced into the reactor as an inert gas to replace nitrogen by using a gas supply system, and the ethane flow rate is dynamically adjusted according to the reaction requirements; the ethane flow rate, pressure and gas composition are monitored in real time by intelligent sensors, and the supply and circulation period of ethane are dynamically adjusted; the ethane recovery and recycling system is established, and the ethane emission is controlled by optimizing the gas flow design; the ratio of ethane, propylene and hydrogen is adjusted in real time by gas sensors and automatic control systems. 1. Solve the problem of nitrogen purity fluctuation: The use of ethane avoids the adverse effects of nitrogen purity fluctuation on the polypropylene reaction process and ensures the stability of the gas composition in the reactor. Since ethane has stable molecular properties and does not react with reactants such as propylene, it effectively improves the reliability of the reaction process and the long-term stability of the catalyst. 2. Optimize gas flow control and fine powder carry-out problems: The molecular weight of ethane is heavier than that of nitrogen, which makes it difficult to carry fine powder out of the reactor when the reactor gas flow is discharged, significantly reducing the risk of downstream equipment blockage, especially showing better stability in long-term production operations. 3. Ethane recovery and energy utilization efficiency improvement: The ethane recycling system designed by the present invention can effectively reduce the consumption of ethane gas, improve resource utilization efficiency, and reduce energy consumption in the production process. 4. Innovation of reactor control system: The present invention combines intelligent control technology and gas dynamic adjustment mechanism, while ensuring the stable operation of the reactor, reducing manual intervention and optimizing the control accuracy of the reaction process.

[0074] See also Figure 2 In a Unipol polypropylene reactor composition control method, ethane is introduced into the reactor as an inert gas to replace nitrogen using a gas supply system, comprising the following steps:

[0075] Step 201, using the gas supply pipeline and control valve in the raw material supply and refining unit of the Unipol polypropylene device to introduce ethane gas into the reactor, wherein the reactor at least includes a circulating cooler and a circulating gas compressor;

[0076] Step 202, propylene, hydrogen and ethane are continuously circulated through a circulating gas compressor through a fluidized bed of a reactor containing a catalyst;

[0077] Step 203: Monitor the flow rate and pressure of ethane gas in real time through the flow meter and the pressure sensor, and automatically adjust the flow rate of ethane gas according to the reaction stage, catalyst activity and reaction temperature in the reactor.

[0078] See also Figure 3 In a Unipol polypropylene reactor component control method, real-time monitoring of ethane flow, pressure and gas composition by intelligent sensors and dynamic adjustment of ethane supply and cycle period include the following steps:

[0079] Step 301, installing an ethane flow sensor, a pressure sensor, a temperature sensor and a gas composition analyzer in the reactor;

[0080] Step 302: Continuously monitor the ethane flow rate, reactor pressure, reaction temperature, and concentrations of ethane, propylene, and hydrogen using the ethane flow sensor;

[0081] Step 303: Automatically adjust the supply amount and circulation period of ethane according to the real-time data fed back by the ethane flow sensor.

[0082] Specifically, the Unipol polypropylene unit in this embodiment is composed of the following process systems: raw material supply and refining unit, propylene refining unit, polymerization reaction unit, resin degassing unit, exhaust gas recovery unit, resin and additive processing unit, extrusion granulation unit, product blending and air delivery unit, and other auxiliary units (condensate and flare system).

[0083] The reaction system consists of a reactor, a circulating cooler, and a circulating gas compressor / turbine. The gaseous reactants (propylene, hydrogen) and inert components (nitrogen, propane) are continuously circulated through the circulating gas compressor through the reactor fluidized bed containing the catalyst. The heat generated by the polymerization reaction is carried away by the reaction gas and released in the external water-cooled circulating gas cooler.

[0084] As an inert component, nitrogen enters the reactor through the purge system. The normal purge gas is propylene gas. When the reactor pressure is low, nitrogen is used to maintain the reactor pressure. Therefore, during normal production, there is 4mol% to 10mol% nitrogen component in the reactor.

[0085] Specifically, the present embodiment also includes: using the gas supply system to introduce ethane and adjust the flow rate: first, build an efficient and stable gas supply system, which consists of a high-pressure storage tank for storing ethane, a delivery pipeline, and a matching valve and pressure regulating device. When starting the gas supply process, slowly open the tank outlet valve so that ethane can enter the reactor smoothly along the well-sealed delivery pipeline under the action of the pressure difference. Unlike the traditional use of nitrogen as an inert gas, ethane has unique chemical stability, can effectively isolate interfering gases such as oxygen in a specific reaction environment, and its molecular structure can promote the forward progress of the reaction in certain reaction systems. At the same time, according to the real-time changes in the reaction process, a high-precision mass flow controller is used to dynamically adjust the flow rate of ethane. For example, when the reaction is in the initial stage and an inert environment needs to be quickly created, the ethane flow rate can be appropriately increased; as the reaction enters the stable stage, the ethane flow rate is accurately controlled according to the reaction rate and product generation to maintain the optimal conditions for the reaction.

[0086] Intelligent sensor monitoring and dynamic adjustment of supply and cycle: A series of intelligent sensors are installed at key parts of the reactor, such as the air inlet, reaction chamber, and air outlet. These sensors include thermal mass flow meters for accurate measurement of ethane flow, pressure sensors for real-time monitoring of pressure changes in the reaction system, and gas composition sensors based on spectral analysis technology, which can quickly and accurately detect the proportion of each component in the reaction gas. The sensor transmits the collected data to the central control system in real time, and the control system analyzes and processes the data through preset algorithms and models. Once the ethane flow rate deviates from the set value, or the pressure and gas composition fluctuate abnormally, the system will immediately issue a command to adjust the opening of the air inlet valve and change the supply of ethane. At the same time, the cycle of ethane is dynamically adjusted according to the actual situation of the reaction. For example, when the generation rate of the reaction product decreases, the cycle of ethane can be appropriately shortened to speed up the gas renewal rate to maintain the activity of the reaction.

[0087] Establish an ethane recovery and recycling system and control emissions: In order to improve resource utilization and reduce production costs, a complete ethane recovery and recycling system is established. The system is mainly composed of equipment such as condensers, adsorption towers and distillation towers. The mixed gas discharged from the reactor first enters the condenser, and by lowering the temperature, most of the ethane and other condensable gases are liquefied, and the separated liquid enters the subsequent treatment link. The uncondensed gas enters the adsorption tower, and the residual ethane is further captured by a highly selective adsorbent. The adsorbent after adsorption saturation is desorbed by increasing the temperature or reducing the pressure to release ethane. The collected ethane enters the distillation tower for purification and removal of impurities to meet the standards for reuse. In addition, by optimizing the airflow design of the entire system, rationally arranging pipelines and equipment, reducing gas leakage and loss during transportation and processing, and strictly controlling ethane emissions to meet environmental protection standards.

[0088] Gas sensors and automated control systems adjust gas ratios: Various types of gas sensors are installed in the reaction system to monitor the concentrations of ethane, propylene, and hydrogen. These sensors transmit real-time data to the automated control system, which accurately calculates the required ratios of ethane, propylene, and hydrogen based on advanced ratio control algorithms, according to the stoichiometric relationship of the reaction and the generation requirements of the target product. Then, by controlling the opening of the intake valves of each gas, the flow rates of the three gases are dynamically adjusted to ensure that they always maintain the optimal ratio in the reaction zone. For example, in some catalytic reactions, a specific ratio of ethane, propylene, and hydrogen can significantly improve the selectivity and yield of the target product. Through precise adjustment of the automated control system, efficient and stable operation of the reaction process can be achieved, improving production efficiency and product quality.

[0089] The above shows and describes the basic principles, main features and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited by the above embodiments. The above embodiments and descriptions are only preferred examples of the present invention and are not intended to limit the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, which fall within the scope of the present invention. The scope of protection of the present invention is defined by the attached claims and their equivalents.

Claims

1. A Unipol polypropylene reactor component control method, characterized in that: The polypropylene reactor component control method comprises the following steps: Using a gas supply system to introduce ethane into the reactor as an inert gas to replace nitrogen, and dynamically adjusting the ethane flow rate according to reaction requirements; The ethane flow, pressure and gas composition are monitored in real time through intelligent sensors, and the ethane supply and circulation period are dynamically adjusted; Establishing the ethane recovery and recycling system and controlling the ethane emission through optimized gas flow design; The ratio of ethane, propylene and hydrogen is adjusted in real time through gas sensors and automatic control systems.

2. A Unipol polypropylene reactor component control method as claimed in claim 1, characterized in that: The method of using a gas supply system to introduce ethane into the reactor as an inert gas to replace nitrogen comprises: Using ethane as an inert component to replace nitrogen, wherein the molar concentration of ethane is 4 mol%-10 mol%; After being refined, ethane is injected into the reactor through a dynamic flow control system. The injection amount is adjusted in real time according to pressure feedback. The ethane discharged from the reactor is cooled and compressed before being recycled. The ethane addition process includes dehydration, desulfurization pretreatment and purge system integration.

3. A Unipol polypropylene reactor component control method as claimed in claim 1, characterized in that: The method of using a gas supply system to introduce ethane into the reactor as an inert gas to replace nitrogen also includes: The ethane gas is introduced into the reactor by using the gas supply pipeline and control valve in the raw material supply and refining unit of the Unipol polypropylene device, and the reactor at least includes a circulating cooler and a circulating gas compressor; Propylene, hydrogen and ethane are continuously circulated through a circulating gas compressor through a fluidized bed of a reactor containing a catalyst; The flow rate and pressure of ethane gas are monitored in real time through flow meters and pressure sensors, and the ethane gas flow rate is automatically adjusted according to the reaction stage, catalyst activity and reaction temperature in the reactor.

4. A Unipol polypropylene reactor component control method as claimed in claim 1, characterized in that: The method of monitoring the ethane flow, pressure and gas composition in real time through intelligent sensors and dynamically adjusting the ethane supply and cycle period includes: Installing an ethane flow sensor, a pressure sensor, a temperature sensor and a gas composition analyzer in the reactor; The ethane flow sensor is used to continuously monitor the ethane flow rate, reactor pressure, reaction temperature, and concentrations of ethane, propylene, and hydrogen; The supply amount and circulation period of ethane are automatically adjusted according to the real-time data fed back by the ethane flow sensor.

5. A Unipol polypropylene reactor component control method as claimed in claim 1, characterized in that: The ethane recovery and recycling system is established to control the ethane emission through optimized gas flow design, including: Establishing an ethane recovery pipeline to guide the unreacted ethane gas in the reactor to a recovery unit, wherein the recovery unit includes at least a gas separation device and a compression system; Optimizing the gas flow path of the reactor by fluid mechanics to evenly distribute the ethane gas in the reactor; According to the changes in the gas composition in the reactor, the emission of ethane is automatically adjusted, and the ethane is recycled through the recovery system.

6. A Unipol polypropylene reactor component control method as claimed in claim 1, characterized in that: The method of adjusting the ratio of ethane, propylene and hydrogen in real time by using a gas sensor and an automatic control system includes: Install multiple gas composition sensors to monitor the concentration of reactive gases such as ethane, propylene, and hydrogen in real time; According to the data fed back by the sensor, the ratio of ethane, propylene and hydrogen is automatically adjusted. If the ethane concentration is too high, the ethane supply is automatically reduced; if the propylene or hydrogen concentration is too low, the supply of the corresponding gas is automatically increased.

7. A system for implementing a Unipol polypropylene reactor component control method as claimed in claim 1, characterized in that: The system comprises the following units: Raw material supply and refining unit, propylene refining unit, polymerization reaction unit, resin degassing unit, exhaust gas recovery unit, resin and additive processing unit, extrusion granulation unit, product blending and air delivery unit, condensate and flare system.

8. A system for implementing a Unipol polypropylene reactor component control method as claimed in claim 1, characterized in that: The system also includes the following modules: A gas replacement module, used to introduce ethane into the reactor as an inert gas to replace nitrogen using a gas supply system, and dynamically adjust the ethane flow rate according to reaction requirements; Dynamic regulation module, which is used to monitor ethane flow, pressure and gas composition in real time through intelligent sensors, and dynamically adjust the supply and circulation period of ethane; A flow control module, used to establish the ethane recovery and recycling system, and control the ethane emission through optimized airflow design; The ratio adjustment module is used to adjust the ratio of ethane, propylene and hydrogen in real time through gas sensors and automatic control systems.

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