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目的:在全球所有的合成树脂中,聚烯烃的产能位居榜首,在国民经济建设和社会发展中发挥着重要作用。但流化床聚合反应器内的高静电会引起颗粒团聚,一旦传热受阻,颗粒极易熔融结块,甚至导致装置爆聚停车。本研究旨在针对流化床聚合反应过程具有强放热、高静电、变粒径的特点,提出基于声发射技术的多种检测手段和信息提取方法。创新点:针对聚合过程的爆聚结块问题,本研究主要解决了以下难题:(1)流化床内颗粒和结块的原位表征技术缺失,难以检测;(2)颗粒熔融结块过程的在线干预机制不清楚,难以调控;(3)流动传热过程强耦合,反应器放大规律不明,导致反应器难放大等问题。方法:创立声发射信号的多尺度解析方法,通过小波分解和重标极差分析法分类重构将声发射信号分解为微尺度、介尺度和宏尺度信号;提出基于声发射检测的反应器操作优化技术,并通过建模确立流化床聚合反应器的时空产率数学模型。成果:新技术成功应用于“十一五”国家重点建设项目——天津百万吨乙烯工程相配套的年产30万吨气相法聚乙烯流化床反应器的设计建设。并且,新技术已成功应用于14套大型聚烯烃装置的设计或改造,所涉及的聚乙烯产能达263万吨。作者所在团队也因该技术发明获得了2016年度国家技术发明奖二等奖。
Purpose: Among all the synthetic resins in the world, the production capacity of polyolefin topped the list and played an important role in the national economic construction and social development. However, the high static electricity in the fluidized bed polymerization reactor will cause the particles to agglomerate. Once the heat transfer is blocked, the particles are easily melted and agglomerated and even cause the device to burst and park. The purpose of this study is to provide a variety of detection methods and information extraction methods based on acoustic emission technology for the characteristics of fluidized bed polymerization process with strong exothermic, high static electricity, variable particle size. Innovative point: In view of the agglomeration and agglomeration of the polymerization process, the following problems are mainly solved in this study: (1) In-situ characterization of particles and agglomerates in the fluidized bed is absent and difficult to detect; (2) Of the online intervention mechanism is not clear, it is difficult to control; (3) the flow heat transfer process is strongly coupled, the reactor amplification law unknown, resulting in difficult to enlarge the reactor and other issues. Methods: A multiscale analytical method of acoustic emission signals was established. The signals were decomposed into microscale, mesoscale and macroscale signals by wavelet decomposition and reanalysis. The operation optimization of reactor based on acoustic emission detection Technology, and through the modeling established fluidized bed polymerization reactor space-time yield mathematical model. Achievements: The new technology was successfully applied to the design and construction of an annual output of 300,000 tons of gas-phase polyethylene fluidized bed reactor which is a key national construction project of Eleventh Five-year-Tianjin million-ton ethylene project. In addition, the new technology has been successfully applied to the design or modification of 14 large-scale polyolefin plants, involving a capacity of 2,630,000 tons of polyethylene. The team of the author also received the second prize of 2016 National Technology Invention Award for the invention of the technology.