摘要：
针对气化合成气制备合成氨过程中合成气组分波动大、变换及净化工序能耗高、氨合成转化率低、能量回收不充分诸种行业痛点，结合高耗能行业节能降碳改造的总体要求，以煤炭清洁高效利用及节能降碳作为核心目标，系统、严谨地开展了全流程工艺优化及能耗降低研究：先用Aspen Plus V12软件建立了“气化- 变换- 净化- 氨合成”全流程模型，再引入半废锅气化技术及新型催化变换工艺，以单因素实验和正交实验方法优化关键工艺参数，筛选高效抗中毒催化剂，最后设计热量梯级回收及系统集成优化模式。经充分验证后所得结果十分清楚、可靠：优化后的工艺使合成氨综合能耗从传统工艺的1350 kg标煤/吨降至1138 kg标煤/吨，节能幅度达15. 7%。更重要的是，合成气中H ₂/N ₂ 比例稳定控制在2. 98~3. 02，氨合成单程转化率提高到18. 7%，总氨收率已达98. 6%。CO变换率99. 7%，有机硫水解率≥ 98. 6%，净化气中各杂质含量均严格符合氨合成的原料要求。因此，该工艺真正突破了传统工艺的能耗瓶颈，形成了高效、节能、低碳高度统一的合成氨制备体系，对气化合成气制备合成氨工艺的工业升级有极其明确的理论支撑作用，也具有极好的经济效益、环境效益及产业推广价值。
关键词：气化合成气；合成氨；工艺优化；能耗降低；半废锅技术；热量梯级回收；Aspen Plus模拟
Process Optimization and Energy Consumption Reduction for Ammonia Production from Gasification Syngas
HE Huilong, LI Xiong, LI Guangyin, HE Zhengzheng
(Yulin Chemical Co., Ltd., Shaanxi Coal and Chemical Industry Group Co., Ltd., Yulin, Shaanxi 719000, China)
Abstract
Aiming at the industrial pain points in ammonia production from gasification syngas, such as large fluctuation of syngas composition, high energy consumption in shift and purification units, low ammonia synthesis conversion rate and insufficient energy recovery, combined with the requirements of energy-saving and carbon-reduction transformation in energy-intensive industries, the whole-process optimization and energy consumption reduction research was carried out with the core objectives of clean and efficient utilization of coal and energy-saving and carbon-reduction. A whole-process model of "gasification-shift-purification-ammonia synthesis" was established by Aspen Plus V12 software, integrated with semi-waste boiler gasification technology and new catalytic shift process. The key process parameters were optimized through single-factor experiments and orthogonal experiments, high-efficiency and anti-poisoning catalysts were selected, and a gradient heat recovery and system integration optimization mode was constructed. The results showed that the optimized process could reduce the comprehensive energy consumption of ammonia from 1350 kgce/t to 1138 kgce/t, with an energy-saving rate of 15.7%. The H₂/N₂ ratio of syngas was stably controlled at 2.98~3.02, the single-pass conversion rate of ammonia synthesis increased to 18.7%, and the total ammonia yield reached 98.6%. The CO conversion rate reached 99.7%, the organic sulfur hydrolysis rate was ≥98.6%, and the impurity content in purified gas fully met the requirements of ammonia synthesis. The process breaks through the energy consumption bottleneck of traditional processes, constructs a high-efficiency, energy-saving and low-carbon ammonia production system, provides theoretical support and technical reference for the industrial upgrading of ammonia production from gasification syngas, and has significant economic, environmental and industrial promotion value.
Keywords
gasification syngas; ammonia synthesis; process optimization; energy consumption reduction; semi-waste boiler technology; gradient heat recovery; Aspen Plus simulation
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