超大型空分裝備工藝—結構—能耗關聯設計方法研究報告

劉振宇

摘 要：空氣分離類成套裝備是典型的由多工藝、多機組、多變量組成的復雜系統。圍繞復雜空氣分離類成套裝備在超大型低能耗設計方面的技術難題，提出了超大型化空分裝備工藝-結構-能耗關聯設計方法。提出了關鍵機組能耗與工藝結構參數耦合關聯方法。提出了關鍵工藝結構設計參數與能耗的全局敏感性計算方法，實現了不同工藝結構設計參數對流動損失影響的重要程度排序。提出了關鍵工藝結構設計參數與流動損失的交互敏感性計算方法，進行了結構參數與能耗的變關聯分析，找到了從小型空分到大型空分需要重點研究的設計參數。建立了關鍵機組設計中具有變關聯特性的強耦合變量與能耗的耦合設計模型。提出了超大型空分裝備關聯設計模型解耦與簡化方法。提出了基于多重耦合度的設計模型解耦方法，實現了以聚合度最小為目標的復雜設計模型解耦。提出了基于奇異攝動理論的模型等效與簡化方法，降低了設計模型的復雜度。構建了用于能耗分析的空分裝備工藝-結構-能耗多變量綜合設計域。提出了超大型機組多單元聯動的組合關聯設計方法。實現了多股流換熱器的工況參數、通道布局、翅片結構與換熱器換熱性能間關聯計算與多工況通道布局優化設計，提高了換熱器在多工況下的換熱性能，降低了能耗。

關鍵詞：設計參數匹配 變關聯分析 組合關聯設計 低能耗設計

Abstract：Air separation equipment is one of typical complex industrial systems which are multi-process， multi-unit， multi-variable. For large-scale and low-energy design of air separation equipment， the process-structure-energy correlation design method for super-large air separation equipment is proposed. Firstly， the correlation between energy and structural design variables of key units is analyzed. A method of global sensitivity calculation for key structural design parameters and flow loss is proposed. By using variance-based decomposition and uniform sampling， the correlation degree of structural design parameters and flow loss is obtained to arrange the influence of the difference structural design parameters to flow loss. A method of interaction sensitivity calculation for key structural design parameters and flow loss is also proposed for the coupling degree calculation of structural design parameters. The dynamic correlation between structural design parameters and flow loss is established. A model based on the dynamic correlation is constructed for the design of large-scale turbo expander. Then the correlation model of air separation units is decomposed and simplified. A design decomposition method based on clustering with multiple couplings is proposed， and the model is decomposed to reach the greatest clustering degrees. The design model is simplificated based on singular perturbation theory， and the complexity of design model is reduced to speed up the calculation under variable operating conditions. Then the design space of flow variables-structural design variable- energy comsuption is established for energy analysis. Finally， the combined correlation design of multi units is proposed. The correlation model among heat transfer rate， passage arrangement and fin design parameters is constructed. Then， the passage arrangement under multi-operating conditions is designed. Through designing the passage arrangement of main heat exchanger in 80000Nm3 air separation unit， the heat transfer rate is enhanced and the energy consumption is reduced.

Key Words：Design parameter matching；Dynamic correlation analysis；Combined correlation design；Low-energy design

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