超大型空分装备工艺—结构—能耗关联设计方法研究报告

刘振宇

摘 要：空气分离类成套装备是典型的由多工艺、多机组、多变量组成的复杂系统。围绕复杂空气分离类成套装备在超大型低能耗设计方面的技术难题，提出了超大型化空分装备工艺-结构-能耗关联设计方法。提出了关键机组能耗与工艺结构参数耦合关联方法。提出了关键工艺结构设计参数与能耗的全局敏感性计算方法，实现了不同工艺结构设计参数对流动损失影响的重要程度排序。提出了关键工艺结构设计参数与流动损失的交互敏感性计算方法，进行了结构参数与能耗的变关联分析，找到了从小型空分到大型空分需要重点研究的设计参数。建立了关键机组设计中具有变关联特性的强耦合变量与能耗的耦合设计模型。提出了超大型空分装备关联设计模型解耦与简化方法。提出了基于多重耦合度的设计模型解耦方法，实现了以聚合度最小为目标的复杂设计模型解耦。提出了基于奇异摄动理论的模型等效与简化方法，降低了设计模型的复杂度。构建了用于能耗分析的空分装备工艺-结构-能耗多变量综合设计域。提出了超大型机组多单元联动的组合关联设计方法。实现了多股流换热器的工况参数、通道布局、翅片结构与换热器换热性能间关联计算与多工况通道布局优化设计，提高了换热器在多工况下的换热性能，降低了能耗。

关键词：设计参数匹配 变关联分析 组合关联设计 低能耗设计

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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