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三相精馏:非平衡模拟与参数估计
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摘要
按照传统的观点,在精馏塔内应该避免出现多个液相共存的情况——因为多相会给操作和控制带来很多不确定的因素。然而,在流程工业中,特别是在诸如共沸精馏、萃取精馏、反应精馏等高附加值的化工生产中,往往不可避免地出现第二个液相,从而形成汽-液-液三相共存的复杂精馏过程。
     由于流动特征和传质机理过去复杂,三相精馏的研究一度停滞不前。近年来,随着计算能力的提高和实验设施的进步,探索汽-液-液三相精馏的条件逐渐成熟。因此,有必要深入研究三相精馏过程及其本质属性,并以此为契机来提高精馏效率,优化生产工艺,实现节能降耗。
     本文致力于三相(填料)精馏过程的建模与仿真。在研究中分别建立了三相精馏的平衡(EQ)模型和非平衡(NEQ)模型,并利用柏林工业大学的实验设施开展了系统化的填料精馏实验。结果表明,汽-液-液三相间本质上处于非平衡态。因此,基于板效率和HETP概念的EQ模型不适用于三相体系;NEQ模型是三相精馏过程建模的首选。然而,三相精馏NEQ模型的应用也存在一些制约因素,主要的问题是缺乏估算相间传质参数(如相接触面积、传质系数)的有效方法,这是本文的研究重点之一。
     本文的主要贡献和创新点总结如下:
     1.针对汽-液-液三相精馏的流态多样性,在综合文献成果和实验观测的基础上,提出了三种改进的NEQ模型、即M_1,M_2,M_3模型。这些模型基于不同的流态简化和模型假设,可根据塔板或填料上的三相流动特征甄别选用。同时,针对三相精馏普遍存在的液相稳定性问题,提出了内置相稳定性算法的非平衡模拟方法。这对实际生产中大量存在的两相/三相混合精馏过程具有重要意义。
     2.针对三相精馏中传质参数计算的难点,开展了基于NEQ模型的参数估计研究。提出了一种分层估计策略以归类不同被估参数,成功地实现了多数据集参数估计问题的分解降维。根据参数估计结果,建立了一些扩展的传质经验关联式,首次有效地解决了非平衡模拟中传质参数难以估算的问题。研究表明,在三相精馏模拟中采用扩展的传质关联式可以显著地提升NEO模型的预测性能。
     3.通过分析汽-液-液三相在填料上的流动特征,建立了三相精馏的传质机理模型,可以用来定量计算汽-液-液三相界面上的所有传质参数(填补了文献上的空白)。研究表明,第二液相的流动模式将对三相精馏的分离效率产生显著影响。本文通过参数估计的方法,基于大量的三相精馏实验数据,辨识了不同操作条件下第二液相的流动模式,进而揭示了三相精馏的一些本质特征,对于学术界有关三相填料精馏的分离效率(上升或者下降)的争论,也能够给予合理的解释。
     4.为了研究三相精馏塔的控制和优化命题,建立了三相精馏过程的动态EQ模型和NEQ模型。对比了EQ模型与NEQ模型的动态仿真差异,并通过实验数据验证了动态NEQ模型的可靠性。此外,开展了基于三相精馏动态NEQ模型的参数估计研究,并印证了前文关于第二液相流动模式的辨识结果的准确性。
     最后总结了全文并建议了未来的研究方向。
From a conventional point of view, the presence of more than one liquid phase within a distillation column should be generally avoided due to the uncertainties caused by multi-liquid-phase in operation and control. However, the appearance of a second liquid sometimes is inevitable in chemical industry, especially in some high-value added processes like azeotropic distillation, extractive distillation and reactive distillation, where the complex vapor-liquid-liquid three-phase distillation may appear.
     In the past, the research on three-phase distillation has been generally ignored because of the complexity of the three-phase hydrodynamics. These years, with the aid of advanced computation ability and experiment facilities, it is time to explore the essence of three-phase distillation, and to utilize its unique characteristics to enhance efficiency, optimize operation, save energy and reduce consumption.
     This thesis focuses on the aspects of modeling and simulation of three-phase (packed) distillation. Modeling concepts of equilibrium (EQ) and nonequilibrium (NEQ) are employed. Meanwhile, systematic experimental investigations on packed distillation have been conducted at TU Berlin. Due to the nonequilibrium nature of three-phase hydrodynamics, the EQ concept using stage efficiency or HETP is found not suitable for modeling three-phase distillation. The NEQ concept should be primarily considered. However, the three-phase NEQ modeling was severely restricted due to the lack of methods to predict the interphase transfer parameters, which is the main research topic of this dissertation.
     The contributions and innovations of this thesis are as follows:
     1. To describe the diversity of vapor-liquid-liquid flow, three improved NEQ models (i.e. M_1, M_2, M_3) were proposed based on literature results and experimental observations. Each model can be applied to certain three-phase flow on a tray and a packing. One unique feature of the models is the using of embedded phase stability algorithm in the NEQ simulation, which is of great significance to the mixed two/three-phase distillation largely existing in real distillation practice.
     2. NEQ model based parameter estimations using multiple experimental data sets have been performed. A hierarchical estimation strategy has been proposed for parameter classification and problem decomposition. As a result, some literature correlations have been extended, and can be used in the transfer parameters prediction for three-phase distillation. Model validation has shown that the prediction ability of three-phase NEQ model can be significantly improved by using the extended correlations.
     3. Principle three-phase mass transfer model has been developed on the basis of a thorough analysis of the three-phase flow behaviors on packings. The model enables, for the first time, rigorous computation of all the transfer parameters. The flow pattern of the second liquid was found to play a critical role on the efficiency of three-phase distillation. Therefore, its unknown flow pattern has been identified based on comprehensive experimental data sets. The identified flow behavior can give a reasonable explanation to the discrepancy existing in the separation efficiency of three-phase packed distillation.
     4. In the scope of distillation operation and control, dynamic EQ and NEQ models for three-phase distillation have been developed. (EQ and NEQ) model validation and comparison with experimental data have been carried out. Moreover, dynamic parameter estimation based on the NEQ model has been conducted, the identified dynamic flow pattern of the second liquid phase corresponds well with previous studies.
     Finally, conclusions and future research prospects are given.
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