In the technological transformation of Fujian Southeast Electrochemical Co., Ltd., the 30m3 PVC polymerizer polymerization process was innovated, and good results were achieved in terms of energy conservation and power consumption, environmental protection, and improvement of product quality and output.
First, technical measures 1. Automatic coating system will be steam atomization and automatic rotation of the electric spray valve (Beijing Jia Kong Aerospace Chemical Equipment Corporation SRV16/40 type) used in conjunction to achieve the automation of the coating process, with the role of high efficiency Sticky autoclave agent has the advantages of uniform coating tank, short operating time and good anti-sticking pot effect. After the coating and cleaning process is reformed, the Koi Kei Kettle can be opened 6 to 9 times.
2. Closed feeding process uses DCS to control the addition of dispersant, deionized water, fresh and recycled monomers. The dispersant is passed through the deionized water feed water line with the deionized water into the kettle to ensure the accurate measurement of the dispersant, avoid the residual of the dispersant in the pipeline, make the formulation inaccurate and thus affect the product quality, and at the same time, prevent the pipe from being blocked and save. Unnecessary flushing; other additives (such as initiators, etc.) that are used in small quantities can be manually added through the addition tank of the polymerization tank, and the final monomer (about 10 tons of fresh and recycled monomers) is automatically fed. When the material is closed, the remaining VCM in the kettle can be fed without draining. This eliminates steps such as replacing the monomer in the kettle, opening the lid, and pumping the gas, shortening the auxiliary time (about 30 minutes per pot), and significantly increasing the output. In addition, the closed feeding method eliminates the need to exhaust one vent and one row of vents, which can effectively reduce VCM emissions and reduce environmental pollution.
3. Discharging and VCM recycling The original 30m3 polymerizer discharging procedure is: Manually adding the terminating agent at the end of the polymerization to terminate the reaction; The unreacted gas phase VCM (about 15%) and the slurry are pressed into the kettle by itself or nitrogen pressure. In the original treatment tank, the steam is heated to the original treatment tank under stirring to recover the unpolymerized VCM to the monomer gas cabinet, the polymerization tank is vented, and finally the PVC slurry is applied to a stripping post-treatment system. During the treatment process, the temperature rise of the slurry is often too fast or the temperature is too high due to unstable steam temperature control, which causes the PVC slurry to become red and affect the quality of the resin. The recovery time is long and the monomer recovery rate is low. To solve the above problems, the design process is improved as follows:
When the terminating agent is automatically added into the kettle and the pressure drops to the specified pressure or the reaction time is ≥ 350 minutes, the terminating agent feeding system is automatically started by the DCS system (the flow rate of the terminating agent metering pump is adjusted to 540L/h), and the feeding time is controlled for about 20 seconds.
Pump discharge and monomer recovery using electric discharge valve (Beijing Jia Kong Aerospace Chemical Equipment Company EPV16/125 type), while the selection of a centrifugal pump (Dalian Shen blue pump industry CHZO-80/200 type) as the discharge pump to The pump discharge is used instead of the original self-pressing material, which is controlled by the DCS. The discharging process is as follows: When the terminating agent is added and it is confirmed that the material can be discharged, the DCS automatically starts the discharging process. The slurry is pumped to the original treatment tank by the discharge pump. The gas phase VCM (containing a small amount of entrained slurry) is the discharge valve at the top of the original treatment tank. The tangent line enters the 60m3 separation tank through the pipeline, and the cyclone separates the slurry and then separates the tank. When the set pressure is reached, the monomer recovery system is turned on, and the monomer recovery is performed through the separation tank. If the separation tank pressure is <0.35 MPa, the polymerization reactor also recovers the monomer at the same time. This process simultaneously recovers the unreacted vapor phase VCM in the polymerization tank and separation tank, reducing the recovery time, shortening the auxiliary period of about 90 minutes per pot, and the quality of the PVC resin is more stable. After the process was improved, the VCM recovery rate increased from the original 85% to more than 97%.
4. Safety measures As the polymerization reaction is a violent exothermic reaction, if the conditions fluctuate, over-temperature, over-pressure, and explosions may occur. Therefore, the following security measures are set: the system is set up with security interlock, and each operation step can be monitored, alarmed, and interlocked by the computer, which greatly improves the security of the polymerization production. Urgently add high-pressure water, terminator, etc. If over temperature or overpressure occurs during polymerization, the DCS will alarm. At this time, the high-pressure water system can be remotely opened and the water in the kettle can be urgently cooled to a normal state; if there is explosion or over temperature, If the pressure is too high and the temperature and pressure in the kettle cannot be normalized after the emergency pressure water is added to reduce the temperature, the DCS will start the remote stop and add the terminator program, stop the reaction, discharge the material halfway, and recover the monomer. Sewage tanks were set up, and the polymerization tank coating wastewater (containing a small amount of VCM) was discharged to the newly added sewage tanks. The tank is heated by a steam jacket, and the tank-outgassing pipe is equilibrated with the VCM single-piece gas cabinet so that the monomer can be recovered more completely and the VCM emission can be reduced.
Second, the technical effects of more than one year of running statistics show that a single pot production cycle can be reduced from the original 9h to about 7h, single pot production increased by 25% to 35%; product quality rate of 95.47%, higher than the original About 3%; qualified product rate reached 99.75%, an increase over the original. According to the PVC market average price of 5500 yuan / ton, this technical reform of 2 sets of 30m3 polymerizer, annual income 71.5 million yuan, according to the average cost of PVC 4900 yuan / ton, the annual increase in profit of 7800000 yuan / year, more than technology Changed the previous year's profit by 1.8 million yuan; the pump discharge can reduce about 20 tons of resin equivalent to the resin produced by human factors every year, equivalent to a fund of about 110,000 yuan; the monomer recovery rate is increased, and about 164.19 kg of monomer is recovered per pot. With an average monomer price of 4,000 yuan per ton, and two kettles feeding 1,800 pots per year, the annual cost savings will be 1.182 million yuan.
First, technical measures 1. Automatic coating system will be steam atomization and automatic rotation of the electric spray valve (Beijing Jia Kong Aerospace Chemical Equipment Corporation SRV16/40 type) used in conjunction to achieve the automation of the coating process, with the role of high efficiency Sticky autoclave agent has the advantages of uniform coating tank, short operating time and good anti-sticking pot effect. After the coating and cleaning process is reformed, the Koi Kei Kettle can be opened 6 to 9 times.
2. Closed feeding process uses DCS to control the addition of dispersant, deionized water, fresh and recycled monomers. The dispersant is passed through the deionized water feed water line with the deionized water into the kettle to ensure the accurate measurement of the dispersant, avoid the residual of the dispersant in the pipeline, make the formulation inaccurate and thus affect the product quality, and at the same time, prevent the pipe from being blocked and save. Unnecessary flushing; other additives (such as initiators, etc.) that are used in small quantities can be manually added through the addition tank of the polymerization tank, and the final monomer (about 10 tons of fresh and recycled monomers) is automatically fed. When the material is closed, the remaining VCM in the kettle can be fed without draining. This eliminates steps such as replacing the monomer in the kettle, opening the lid, and pumping the gas, shortening the auxiliary time (about 30 minutes per pot), and significantly increasing the output. In addition, the closed feeding method eliminates the need to exhaust one vent and one row of vents, which can effectively reduce VCM emissions and reduce environmental pollution.
3. Discharging and VCM recycling The original 30m3 polymerizer discharging procedure is: Manually adding the terminating agent at the end of the polymerization to terminate the reaction; The unreacted gas phase VCM (about 15%) and the slurry are pressed into the kettle by itself or nitrogen pressure. In the original treatment tank, the steam is heated to the original treatment tank under stirring to recover the unpolymerized VCM to the monomer gas cabinet, the polymerization tank is vented, and finally the PVC slurry is applied to a stripping post-treatment system. During the treatment process, the temperature rise of the slurry is often too fast or the temperature is too high due to unstable steam temperature control, which causes the PVC slurry to become red and affect the quality of the resin. The recovery time is long and the monomer recovery rate is low. To solve the above problems, the design process is improved as follows:
When the terminating agent is automatically added into the kettle and the pressure drops to the specified pressure or the reaction time is ≥ 350 minutes, the terminating agent feeding system is automatically started by the DCS system (the flow rate of the terminating agent metering pump is adjusted to 540L/h), and the feeding time is controlled for about 20 seconds.
Pump discharge and monomer recovery using electric discharge valve (Beijing Jia Kong Aerospace Chemical Equipment Company EPV16/125 type), while the selection of a centrifugal pump (Dalian Shen blue pump industry CHZO-80/200 type) as the discharge pump to The pump discharge is used instead of the original self-pressing material, which is controlled by the DCS. The discharging process is as follows: When the terminating agent is added and it is confirmed that the material can be discharged, the DCS automatically starts the discharging process. The slurry is pumped to the original treatment tank by the discharge pump. The gas phase VCM (containing a small amount of entrained slurry) is the discharge valve at the top of the original treatment tank. The tangent line enters the 60m3 separation tank through the pipeline, and the cyclone separates the slurry and then separates the tank. When the set pressure is reached, the monomer recovery system is turned on, and the monomer recovery is performed through the separation tank. If the separation tank pressure is <0.35 MPa, the polymerization reactor also recovers the monomer at the same time. This process simultaneously recovers the unreacted vapor phase VCM in the polymerization tank and separation tank, reducing the recovery time, shortening the auxiliary period of about 90 minutes per pot, and the quality of the PVC resin is more stable. After the process was improved, the VCM recovery rate increased from the original 85% to more than 97%.
4. Safety measures As the polymerization reaction is a violent exothermic reaction, if the conditions fluctuate, over-temperature, over-pressure, and explosions may occur. Therefore, the following security measures are set: the system is set up with security interlock, and each operation step can be monitored, alarmed, and interlocked by the computer, which greatly improves the security of the polymerization production. Urgently add high-pressure water, terminator, etc. If over temperature or overpressure occurs during polymerization, the DCS will alarm. At this time, the high-pressure water system can be remotely opened and the water in the kettle can be urgently cooled to a normal state; if there is explosion or over temperature, If the pressure is too high and the temperature and pressure in the kettle cannot be normalized after the emergency pressure water is added to reduce the temperature, the DCS will start the remote stop and add the terminator program, stop the reaction, discharge the material halfway, and recover the monomer. Sewage tanks were set up, and the polymerization tank coating wastewater (containing a small amount of VCM) was discharged to the newly added sewage tanks. The tank is heated by a steam jacket, and the tank-outgassing pipe is equilibrated with the VCM single-piece gas cabinet so that the monomer can be recovered more completely and the VCM emission can be reduced.
Second, the technical effects of more than one year of running statistics show that a single pot production cycle can be reduced from the original 9h to about 7h, single pot production increased by 25% to 35%; product quality rate of 95.47%, higher than the original About 3%; qualified product rate reached 99.75%, an increase over the original. According to the PVC market average price of 5500 yuan / ton, this technical reform of 2 sets of 30m3 polymerizer, annual income 71.5 million yuan, according to the average cost of PVC 4900 yuan / ton, the annual increase in profit of 7800000 yuan / year, more than technology Changed the previous year's profit by 1.8 million yuan; the pump discharge can reduce about 20 tons of resin equivalent to the resin produced by human factors every year, equivalent to a fund of about 110,000 yuan; the monomer recovery rate is increased, and about 164.19 kg of monomer is recovered per pot. With an average monomer price of 4,000 yuan per ton, and two kettles feeding 1,800 pots per year, the annual cost savings will be 1.182 million yuan.
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