Study On Prevention And Control Of Major Accidents In Ethylene Epoxy Reactor

Ethylene epoxidation reactor is an important production equipment in the petrochemical plant,which is mainly used to produce ethylene oxide and ethylene glycol.The reactor is composed of thousands of reaction tubes,and the reaction medium is characterized by high temperature,inflammability and explosion.Under the influence of parameter fluctuation,process deviation,environmental change and other factors,the reactor is prone to abnormal chemical reactions,excessive heat,the risk of flying temperature,or serious accidents such as fire and explosion.The ethylene oxide generated by the reaction is a flammable and explosive toxic carcinogen.Once the leakage occurs in the reaction process,it is effortless to cause serious accidents such as fire and explosion.This paper proposes a major accident prevention and control method based on multi-factor coupling to prevent major accidents in ethylene epoxidation reactors.The main research is as follows:(1)The risk analysis method was used to identify and analyze the primary disaster causing factors that could easily lead to the flight temperature and leakage accident in the reactor operation.Because of the flying temperature accident,the cause of excessively high temperature was analyzed based on the deviation of excessively high temperature in the reactor bed.This was done to determine the operating parameters that should be monitored in the production of ethylene oxide.For leakage incidents,check the parameters and deviations that may lead to reactor leakage.The operation parameters that have a great influence on the reactor bed temperature and leakage prevention and control are determined through the analysis,so as to provide a basis for the parameter analysis of subsequent major accidents.(2)Based on the results of risk analysis and concerning numerical simulation,single-factor impact tests were conducted on seven factors and six variables affecting the flight temperature accident.The sensitivity analysis of the parameters of the reactor was carried out to obtain the appropriate operating range of each parameter,to determine the factors leading to the flight temperature accident in the reactor.In this paper,the multi-factor coupling analysis is carried out on the disaster factors that can lead to the flying temperature in the reactor,and the mathematical model of the influence of various parameters on the bed temperature is established to provide an effective basis for the construction of the real-time monitoring and early warning module of flying temperature.(3)PHAST software was used to simulate the accident consequences of ethylene epoxidation reactor after leakage,orthogonal test analysis was carried out on the simulation data,and multi-factor correlation analysis was conducted based on the accident consequence information to determine the main influencing factors affecting the accident consequences.This paper establishes a quantitative real-time monitoring and warning mathematical model of accident consequence based on the different accident consequence information data of the main influencing factors and the coupling analysis of multiple factors.The establishment of the model provides a theoretical basis for building the real-time continuous monitoring and warning module of leakage.(4)In this paper,based on the multi-factor coupling model,KingSCADA configuration software,Foxtable software and SQLserver database are used to construct the real-time monitoring and early warning module of the ethylene epoxidation reactor for monitoring the temperature and leakage,and to form the prevention and control system of major accidents in the ethylene epoxidation reactor.The establishment of the system visualizes various parameters in the production process,realizes the real-time warning of major accidents in the ethylene epoxidation reactor,and provides a technical basis for the early warning and emergency rescue of major accidents in the reactor.Based on ethylene epoxidation reactor process risk analysis,according to the numerical simulation data,the parameter sensitivity analysis,orthogonal test analysis and multi-factor coupling analysis,establish the mathematical model of major accident consequences,an ethylene epoxidation reactor major accident prevention and control system,guarantee the safe and stable operation of the reactor,major accident warning and emergency rescue for the reactor to provide technical basis.