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煤基悬浮床加氢催化剂制备瓶颈与优化
Bottlenecks and Optimization in Coal-Based Slurry Bed Hydrogenation Catalyst Preparation
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- DOI:
- 作者:
- 许辽辽，李慧杰，王东航，张海琴，薛正正
Xu Liaoliao, Li Huijie, Wang Donghang, Zhang Haiqing, Xue Zhengzheng
- 作者单位:
- 陕煤集团榆林化学有限责任公司
SHCCIG Yulin Chemical Co., Ltd.
- 关键词:
- 煤基催化剂；悬浮床加氢；工艺优化；工业化运行；过程控制
coal-based catalyst; slurry bed hydrogenation; process optimization; industrial operation; process control
- 摘要:
- 摘要：据中国石油和化学工业联合会统计，2023年中国煤制油产能已达 803×104 t/a，催化剂成本占比超总生产成本的 15%。此研究针对煤基悬浮床加氢催化剂制备系统工业化运行中存在的原料输送架桥、pH控制滞后、铁盐溶液腐蚀性输送及脱水干燥系统密封性差等瓶颈问题，实施了一系列针对性技术改造，主要包括进煤系统纯皮带称重技改、多级 pH在线监测网络构建、管式链板输送机替代为耐腐蚀泵送系统，以及DCS-PID耦合控制技术应用，实现装置运行效率提升 32%，催化剂单耗下降 12%，连续运行周期从 45 d延长至 68 d。改造投资回收期 420 d，年节约生产成本 1 200万元，废水回用率达 92%，符合《煤化工废水处理与回用技术导则》（T/CACE 064-2022）一级标准。
Abstract: According to statistics from the China Petroleum and Chemical Industry Federation, China's coal-to-liquid (CTL)production capacity reached 8.03 million tons/year in 2023, with catalyst costs exceeding 15% of total production expenses. Thisstudy addresses critical bottlenecks in industrialized coal-based suspended bed hydrogenation catalyst preparation systems,including raw material bridging during transportation, pH control hysteresis, corrosive delivery of iron salt solutions, and poorsealing in dehydration-drying systems. A systematic optimization scheme is proposed featuring: 1) Belt weighing systemmodification for coal feeding, 2) Multi-level pH online monitoring network implementation, 3) Replacement of tubular chainconveyors with corrosion-resistant pump systems, and 4) DCS-PID coupled control technology application. Post-optimizationresults demonstrate 32% operational efficiency improvement, 12% reduction in catalyst consumption, and extended continuousoperation period from 45 to 68 days. The retrofit achieved a 14-month payback period with annual production cost savings ofapproximately ¥12 million, while maintaining 92% wastewater reuse rate compliant with Tier 1 standards specified in the"Technical Guidelines for Wastewater Treatment and Reuse in Coal Chemical Industry" (T/CACE 064-2022). These optimizationsprovide significant technical references for enhancing economic viability and environmental compliance in CTL catalyst productionsystems.