高寒地区原油储存过程中的传热问题研究及工艺方案优化
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摘要
近年来，随我国石油战略储备工程进展，多数大中型油库也相继完成了增储工程，总储油量随之增大。由于我国部分油田所产为三高原油，低温流动性差，加之客观的地理环境条件，导致高寒地区易凝高粘原油的安全存储问题越来越引起重视。总的来说，原油在储罐内可以有三种不同的存在状态：静态储存、加热及收发油的周转过程。针对不同运行状态，对原油流动及传热特性研究，对于制定合理的工艺方案、辅助工程决策、丰富工程传热问题的研究成果都具有重要意义。目前，该问题的研究主要集中在原油静态储存的温度场测试上，虽然给出了直接的运行数据，但对于传热机理、瞬态自然对流与温度场的耦合无法提供足够的信息。而对于加热和收发油状态，目前尚没有针对性的研究。鉴于此，本文采用数值模拟和现场测试相结合的方法，对高寒地区，浮顶罐储存原油在静态储存、加热及收发油过程中的流动及传热特性开展研究，在保证油品安全存储的前提下，优化原油储库的工艺方案，具体包括以下研究内容：
首先，采用现场测试和室内实验相结合的方法对大型浮顶储罐表面温度及散热损失进行测试，测试对象包括不同容量储罐罐顶和罐壁的不同位置，所得到的结论包括罐体表面温度分布信息，不同部位的散热损失，罐顶浮舱及罐壁保温结构等难以通过理论计算确定的结构导热系数，基于测试结果对罐体保温效果进行了评价。
其次，将浮顶罐内原油的储存状态分为静态储存、加热及收发油的周转状态，分别开展不同状态下原油流动及传热特性研究。
对于静态存储问题，将原油温降过程看做是具有复杂热边界条件的圆柱形空间内高Pr数流体的非稳态自然对流冷却问题，建立了二维轴对称计算模型及相应的数值求解方法。通过对不同工况的计算分析，确定温降过程中，对应自然对流的产生、发展、衰退及消失，原油依次经历了局部温降、整体温降、温度分层和导热为主的温降阶段，对每一阶段原油的流动及传热特性进行了细致的剖析，同时也对温降过程中低温导致的凝油产生及发展变化过程进行了相应的描述。在此基础上，回归了浮顶罐不同边界的自然对流换热关联式，改进了基于热平衡原理的原油温降预测方法，明确了储罐直径、液位和保温结构等不同因素对原油温降的影响规律，探讨了储罐的节能储油工况。
对于原油的加热问题，根据传热机理不同，以管式加热和热油循环作为两种典型的加热方式进行研究。针对管式加热，建立了单加热管、竖排及横排管束的数值计算模型，得到单加热管自然对流换热的两组实验关联式，更适用于对原油储罐管式加热方式下的热力计算分析。对于竖排管束，中心距较小时，换热恶化，随中心距增大，管束平均Nu数增加，最大可高出单管15%以上，出现换热强化和最大换热强度的临界中心距随Ra增大而减小。此外，研究结果表明竖排管束中底管羽流温度场是导致上层管Nu数随时间波动变化的主要原因。相比而言，横排管束换热更为稳定，仅中间管略有强化，但应避免中心距在2D以下，否则换热强度将显著下降。针对热油循环加热过程的研究表明该加热方式具有热浮力射流特性。稳定加热时，油温轴向分层分布；非稳定加热时，换热更强烈，油温混合效果更好，且热油循环的Fr数越大，液位越低，加热效果越好。将Fr数和相对淹没深度作为影响因素，回归出了表层最高温度点的计算模型，作为对热油循环加热方式调节的依据。进一步对两种加热方式的优缺点进行了对比分析，认为热油循环方式更适用于矿场原油库等中转油库，而管式加热方式更适于战略储备库等中转系数较小的油库。
对收发油过程中原油储罐的传热及流动特性进行了现场测试及数值计算分析，结果表明，当进油温度高于罐内油温时，原油温度及速度场分布具有热浮力射流特性，进油热量可以被有效利用，而发油温度可以近似代表相同高度处的罐内油温。不同进油参数下的计算结果指出，大排量、低温差的进油方式更有利于进油热量被充分利用。
最后，在以上研究的基础上，以储运系统总运行费用最小为目标，原油库的罐组运行模式、维温方案、罐体保温方案等为决策变量，建立了储运系统工艺方案优化的数学模型，制定了储运系统优化运行的基本准则。
In recent years, most of the medium and large scale oil depots’ reserves have beenincreased consecutively as our country strategic petroleum reserve progresses, so the oilreserving are increasing in our country. The storage security issues of crude oil in extremelycold areas have been gradually recognized because of high wax content, high freezing pointand high viscosity, the poor low-temperature fluidity, and the objective geographicalenvironment conditions of some areas. There are three existential states of the oil in a storagetank: static state, heating state and turnover process of loading and uploading oil. Research onoil flow and heat-transfer characteristics for different running states is significant informulating rational process scheme, guiding engineering practice, and enriching thetheoretical study of heat-transfer issues in engineering. At present most of the researchesfocus on the tests of oil static state temperature field. Although the direct running datas can begiven, the information is not enough for heat-transfer mechanism and coupling calculating oftransient natural convection velocity field and temperature field. And currently, there is notargeted study on heating state or loading and uploading state. Given that, this paper carriedout the research of oil flow and heat-transfer characteristics during three processes by themethodology of combining numerical models and field tests. And the paper also optimized theoil tank process scheme on the premise of ensuring reserve safety. Detailed research workincludes the following parts:
First of all, methodology of combining field tests and numerical models was used to testthe surface temperature distributions and heat loss of large-scale floating roof tank. Testobjects include different positions of different capacity tanks’ top and wall. The conclusionsinclude tank surface temperature field distributions, different positions heat loss, and thebuoyancy module and tank wall insulation constructions’ coefficient of thermal conductivitywhich are difficult to be determined by theory methods. And the paper evaluated the heatpreservation effect of tanks based on the test results.
Secondly, the paper carried out the oil flow and heat-transfer characteristics research ofthree oil states in storage tank: static state, heating state and loading and uploading oil state.
For the static state, the paper treated oil temperature drop process as unsteady naturalconvection cooling problem of high Pr value fluid in cylindrical space which has complicatedheat boundary conditions. And the paper built two-dimension axisymmetric model and thenumerical solution method of the process. The results of different work conditions calculationand analysis have shown that the fluid heat-transfer coupled with flow during the process oftemperature drop. There are four temperature drop periods corresponding to natural convection’s creation, development, recession and disappearance processes, which are localtemperature drop, quick temperature drop, temperature stratification and heat conductionperiod. On this basis the paper regressed with the floating roof tank different boundariesnatural convection heat-transfer correlation, and presented a new way which can calculate oiltemperature drop. The way can not only predict the oil temperature changing, but also candescribe the oil temperature distributions of different periods in tank. The paper calculated oiltemperature drop in different work conditions by the new way, obtained the influence of tankdiameter, liquid level and thermal insulation construction for oil temperature drop, anddiscussed the optimal condition. For the oil heating state, the paper divided heating type intotwo types: tubular heating and hot oil circulation, according to heat-transfer mechanism. Fortubular heating, the paper established the mathematical model of single heating pipe, verticaland horizontal tubes. And the paper got two experimental relations of single heating pipenatural convection heat-transfer when Ra value is between4.2×104~1×109, Pr value isbetween97~454and Ra value is between1.3×1010~1.7×1012, Pr value is between97~910.The relations are more applicable to thermal calculation analysis of oil tank tubular heating.The heat-transfer characteristics of vertical tubes are different from single heating pipe. Theaverage Nu value of tubes is up to15%more than the single one. The adjacent tubes plumenot only changed the heat-transfer characteristics, but also made top layer Nu value fluctuatesalong with time. The further analysis has shown that the change of plume temperature field isthe main reason for the fluctuation. In contrast, horizontal tubes heat-transfer characteristicschange less, and more stable. The research on hot oil circulation heating process has shownthat this heating way has the characteristics of heated buoyant jets. When heating state isstable, oil temperature hierarchical distribution is along the axis; rather, the performance ofheat-transfer is more excellent. And the bigger the Fr value is, the better the heating effect willbe. As a basis for hot oil circulation heating method adjustment, the Fr value and relativedepth of submergence are taken as the acting factors to regress surface maximum temperaturecalculation model. The comparison of two methods shows that hot oil circulation is moreapplicable to transfer oil depots, and tubes heating is more suitable for strategic oil depots.
Field test and numerical compute analysis performed on heat-transfer and flowcharacteristics in oil tank shows that when inlet temperature is higher, oil temperature andvelocity fields have the features of heated buoyant jets. And outlet temperature isapproximately equal to the oil temperature at the same liquid level in tank. The results atdifferent parameters show that oil inlet heat can be in full use when flow is mass andtemperature difference is less.
Finally, based on the research work above, the paper established oil storage and transportsystem process scheme optimization models and operation principles using minimized cost ofoperation as objective function and tanks operation mode, heating scheme and insulationscheme as decision variables.
首先，采用现场测试和室内实验相结合的方法对大型浮顶储罐表面温度及散热损失进行测试，测试对象包括不同容量储罐罐顶和罐壁的不同位置，所得到的结论包括罐体表面温度分布信息，不同部位的散热损失，罐顶浮舱及罐壁保温结构等难以通过理论计算确定的结构导热系数，基于测试结果对罐体保温效果进行了评价。
其次，将浮顶罐内原油的储存状态分为静态储存、加热及收发油的周转状态，分别开展不同状态下原油流动及传热特性研究。
对于静态存储问题，将原油温降过程看做是具有复杂热边界条件的圆柱形空间内高Pr数流体的非稳态自然对流冷却问题，建立了二维轴对称计算模型及相应的数值求解方法。通过对不同工况的计算分析，确定温降过程中，对应自然对流的产生、发展、衰退及消失，原油依次经历了局部温降、整体温降、温度分层和导热为主的温降阶段，对每一阶段原油的流动及传热特性进行了细致的剖析，同时也对温降过程中低温导致的凝油产生及发展变化过程进行了相应的描述。在此基础上，回归了浮顶罐不同边界的自然对流换热关联式，改进了基于热平衡原理的原油温降预测方法，明确了储罐直径、液位和保温结构等不同因素对原油温降的影响规律，探讨了储罐的节能储油工况。
对于原油的加热问题，根据传热机理不同，以管式加热和热油循环作为两种典型的加热方式进行研究。针对管式加热，建立了单加热管、竖排及横排管束的数值计算模型，得到单加热管自然对流换热的两组实验关联式，更适用于对原油储罐管式加热方式下的热力计算分析。对于竖排管束，中心距较小时，换热恶化，随中心距增大，管束平均Nu数增加，最大可高出单管15%以上，出现换热强化和最大换热强度的临界中心距随Ra增大而减小。此外，研究结果表明竖排管束中底管羽流温度场是导致上层管Nu数随时间波动变化的主要原因。相比而言，横排管束换热更为稳定，仅中间管略有强化，但应避免中心距在2D以下，否则换热强度将显著下降。针对热油循环加热过程的研究表明该加热方式具有热浮力射流特性。稳定加热时，油温轴向分层分布；非稳定加热时，换热更强烈，油温混合效果更好，且热油循环的Fr数越大，液位越低，加热效果越好。将Fr数和相对淹没深度作为影响因素，回归出了表层最高温度点的计算模型，作为对热油循环加热方式调节的依据。进一步对两种加热方式的优缺点进行了对比分析，认为热油循环方式更适用于矿场原油库等中转油库，而管式加热方式更适于战略储备库等中转系数较小的油库。
对收发油过程中原油储罐的传热及流动特性进行了现场测试及数值计算分析，结果表明，当进油温度高于罐内油温时，原油温度及速度场分布具有热浮力射流特性，进油热量可以被有效利用，而发油温度可以近似代表相同高度处的罐内油温。不同进油参数下的计算结果指出，大排量、低温差的进油方式更有利于进油热量被充分利用。
最后，在以上研究的基础上，以储运系统总运行费用最小为目标，原油库的罐组运行模式、维温方案、罐体保温方案等为决策变量，建立了储运系统工艺方案优化的数学模型，制定了储运系统优化运行的基本准则。
In recent years, most of the medium and large scale oil depots’ reserves have beenincreased consecutively as our country strategic petroleum reserve progresses, so the oilreserving are increasing in our country. The storage security issues of crude oil in extremelycold areas have been gradually recognized because of high wax content, high freezing pointand high viscosity, the poor low-temperature fluidity, and the objective geographicalenvironment conditions of some areas. There are three existential states of the oil in a storagetank: static state, heating state and turnover process of loading and uploading oil. Research onoil flow and heat-transfer characteristics for different running states is significant informulating rational process scheme, guiding engineering practice, and enriching thetheoretical study of heat-transfer issues in engineering. At present most of the researchesfocus on the tests of oil static state temperature field. Although the direct running datas can begiven, the information is not enough for heat-transfer mechanism and coupling calculating oftransient natural convection velocity field and temperature field. And currently, there is notargeted study on heating state or loading and uploading state. Given that, this paper carriedout the research of oil flow and heat-transfer characteristics during three processes by themethodology of combining numerical models and field tests. And the paper also optimized theoil tank process scheme on the premise of ensuring reserve safety. Detailed research workincludes the following parts:
First of all, methodology of combining field tests and numerical models was used to testthe surface temperature distributions and heat loss of large-scale floating roof tank. Testobjects include different positions of different capacity tanks’ top and wall. The conclusionsinclude tank surface temperature field distributions, different positions heat loss, and thebuoyancy module and tank wall insulation constructions’ coefficient of thermal conductivitywhich are difficult to be determined by theory methods. And the paper evaluated the heatpreservation effect of tanks based on the test results.
Secondly, the paper carried out the oil flow and heat-transfer characteristics research ofthree oil states in storage tank: static state, heating state and loading and uploading oil state.
For the static state, the paper treated oil temperature drop process as unsteady naturalconvection cooling problem of high Pr value fluid in cylindrical space which has complicatedheat boundary conditions. And the paper built two-dimension axisymmetric model and thenumerical solution method of the process. The results of different work conditions calculationand analysis have shown that the fluid heat-transfer coupled with flow during the process oftemperature drop. There are four temperature drop periods corresponding to natural convection’s creation, development, recession and disappearance processes, which are localtemperature drop, quick temperature drop, temperature stratification and heat conductionperiod. On this basis the paper regressed with the floating roof tank different boundariesnatural convection heat-transfer correlation, and presented a new way which can calculate oiltemperature drop. The way can not only predict the oil temperature changing, but also candescribe the oil temperature distributions of different periods in tank. The paper calculated oiltemperature drop in different work conditions by the new way, obtained the influence of tankdiameter, liquid level and thermal insulation construction for oil temperature drop, anddiscussed the optimal condition. For the oil heating state, the paper divided heating type intotwo types: tubular heating and hot oil circulation, according to heat-transfer mechanism. Fortubular heating, the paper established the mathematical model of single heating pipe, verticaland horizontal tubes. And the paper got two experimental relations of single heating pipenatural convection heat-transfer when Ra value is between4.2×104~1×109, Pr value isbetween97~454and Ra value is between1.3×1010~1.7×1012, Pr value is between97~910.The relations are more applicable to thermal calculation analysis of oil tank tubular heating.The heat-transfer characteristics of vertical tubes are different from single heating pipe. Theaverage Nu value of tubes is up to15%more than the single one. The adjacent tubes plumenot only changed the heat-transfer characteristics, but also made top layer Nu value fluctuatesalong with time. The further analysis has shown that the change of plume temperature field isthe main reason for the fluctuation. In contrast, horizontal tubes heat-transfer characteristicschange less, and more stable. The research on hot oil circulation heating process has shownthat this heating way has the characteristics of heated buoyant jets. When heating state isstable, oil temperature hierarchical distribution is along the axis; rather, the performance ofheat-transfer is more excellent. And the bigger the Fr value is, the better the heating effect willbe. As a basis for hot oil circulation heating method adjustment, the Fr value and relativedepth of submergence are taken as the acting factors to regress surface maximum temperaturecalculation model. The comparison of two methods shows that hot oil circulation is moreapplicable to transfer oil depots, and tubes heating is more suitable for strategic oil depots.
Field test and numerical compute analysis performed on heat-transfer and flowcharacteristics in oil tank shows that when inlet temperature is higher, oil temperature andvelocity fields have the features of heated buoyant jets. And outlet temperature isapproximately equal to the oil temperature at the same liquid level in tank. The results atdifferent parameters show that oil inlet heat can be in full use when flow is mass andtemperature difference is less.
Finally, based on the research work above, the paper established oil storage and transportsystem process scheme optimization models and operation principles using minimized cost ofoperation as objective function and tanks operation mode, heating scheme and insulationscheme as decision variables.
引文
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