摘要本设计为4万吨37.4%甲醛水溶液的生产工艺初步设计，本设计采用银催化法工艺，首先简单介绍了我国甲醛工业的发展，现状及以后的发展趋势。

根据设计要求对工艺流程进行了选择与论证，对整个装置进行了物料与能量的衡算，对主要设备和管道进行了设计及选型，同时对本装置的安全生产与“三废”治理作了相关讨论并进行经济的初步核算。

本设计配有设计说明书一本，附图4张。

说明书包括:1、总论；2、工艺流程的选择及论证；3、年产4万吨37.4%甲醛水溶液工艺计算；4、非标准设备的计算及定性设备的选型；5、工艺管道计算；6、安全以及“三废”治理；7、技术经济初步核算。

图纸包括：1、带控制点的工艺管道及工艺流程图；2、氧化器装配图；3、装置平面图；4、装置立面图。

关键词：甲醛；甲醇；氧化；工艺；电解银AbstractThe design is primary for the manufacturing process of formaldehyde 40,000 tons per year, and adopts Ag as catalyst. According to the design, the craft production way of formaldehyde was selected and the technology was investigated. The main equipments and pipes were designed or selected. At the same time, safely producing and dealing with “three waste ”were argued and technology economic was originally estimated.The design consists of an instruction book and a series of diagram. The instruction book includes:1.Introduction.2.Choice and demonstration of the technological process.3.40,000 tons per year 37.4% formaldehyde crafts for production were designed.4.It is not a selecting type of the equipment of calculation and finalizing the design of the standard device.5.The craft pipeline calculating.6.Security and abatement of ”three waste”.7.Economic initial estimate of technology. The diagram include:1.The pipeline of the device and process flow sheet with controlled pot.2.Assemblage chart of the oxidant.3.Plane figure of the device.4.The blueprints of factory.Keywords: formaldehyde; Methanol; Oxidation; Technology; Electrolysis Silver目录第一章前言 ..................................................................................................................... - 1 -第二章绪论 ..................................................................................................................... - 2 -2.1 我国甲醛工业的发展过程.................................................................................... - 2 -2.1.1 起步阶段..................................................................................................... - 2 -2.1.2 发展阶段..................................................................................................... - 2 -2.1.3 快速增长阶段............................................................................................. - 2 -2.2 我国甲醛工业的现状............................................................................................ - 3 -2.2.1 生产工艺..................................................................................................... - 3 -2.2.2 生产能力和产量......................................................................................... - 3 -2.2.3 技术指标..................................................................................................... - 4 -2.3 影响我国甲醛价格的主要因素............................................................................ - 5 -2.3.1 生产成本..................................................................................................... - 5 -2.3.2 下游需求状况............................................................................................. - 5 -2.3.3 地区差异..................................................................................................... - 6 -2.4 产品说明................................................................................................................ - 6 -2.4.1 产品名称..................................................................................................... - 6 -2.4.2 产品性质..................................................................................................... - 6 -2.5 产品用途................................................................................................................ - 8 -2.6 原材料说明............................................................................................................ - 8 -2.7 甲醛工业的发展趋势............................................................................................ - 9 -2.7.1 开发选用优良的催化剂............................................................................. - 9 -2.7.2需求量增加.................................................................................................. - 9 -2.7.3 采用新进的生产工艺流程......................................................................... - 9 -2.7.4设备组合化大型化.................................................................................... - 10 -2.7.5 产品简介................................................................................................... - 10 -2.8 甲醛的主要技术指标.......................................................................................... - 10 -第三章合成方法及生产技术比较.......................................................................... - 11 -3.1 甲醛的合成方法................................................................................................... - 11 -3.1.1 甲醛空气氧化法........................................................................................ - 11 -3.1.2 二甲醚催化氧化法.................................................................................... - 11 -3.1.3 低碳烷烃直接氧化法................................................................................ - 11 -3.1.4 甲缩醛氧化法............................................................................................ - 11 -3.2 生产工艺比较...................................................................................................... - 12 -3.2.1 工艺技术比较........................................................................................... - 12 -3.2.2 银催化剂法和铁钼催化剂法的特点的比较........................................... - 13 -3.3 国内外甲醛装置能耗比较.................................................................................. - 13 -3.4生产工艺方案的选择........................................................................................... - 14 -第四章工艺流程介绍 ................................................................................................ - 15 -4.1 流程说明.............................................................................................................. - 15 -4.2 生产工艺影响因素.............................................................................................. - 16 -4.2.1 反应器的结构与状态............................................................................... - 16 -4.2.2 催化剂的性能和状态............................................................................... - 17 -4.2.3 反应温度................................................................................................... - 17 -4.2.4 氧醇比....................................................................................................... - 17 -4.2.5 水醇比....................................................................................................... - 18 -4.2.6 停留时间和空间速度............................................................................... - 18 -4.2.7反应压力.................................................................................................... - 18 -4.2.8 原料混合气的纯度将影响催化剂的活性与寿命................................... - 18 -4.3 主要工艺指标...................................................................................................... - 18 -第五章年产4万吨37.4%甲醛的工艺计算 ...................................................... - 21 -5.1 计算依据.............................................................................................................. - 21 -5.2 物料衡算.............................................................................................................. - 21 -5.2.1产品............................................................................................................ - 21 -5.2.2 原料甲醇投入量....................................................................................... - 22 -5.2.3 空气投入量（根据氧醇比求）............................................................... - 22 -5.2.4 尾气中各组分含量的计算....................................................................... - 22 -5.2.5 核对........................................................................................................... - 23 -5.2.6 主要设备物料衡算（以小时计）........................................................... - 24 -5.3 热量衡算.............................................................................................................. - 29 -5.3.1 物性参数及计算公式............................................................................... - 29 -5.3.2 主要设备热量衡算................................................................................... - 29 -第六章主要非定型设备的计算及定型设备的选型 ........................................ - 35 -6.1 蒸发器.................................................................................................................. - 35 -6.1.1 蒸发室的体积V与高度H的计算 ......................................................... - 35 -6.1.2 蒸发器的换热器计算............................................................................... - 35 -6.2 过热器.................................................................................................................. - 36 -6.2.1 传热面积的估算....................................................................................... - 36 -6.2.2 径的计算................................................................................................... - 36 -6.3 氧化器.................................................................................................................. - 36 -6.3.1 氧化器直径............................................................................................... - 36 -6.3.2 热锅炉的主要尺寸................................................................................... - 37 -6.3.3 氧化器下部的急冷段............................................................................... - 38 -6.3.4 废锅辅助设备—汽包............................................................................... - 39 -6.4 吸收一塔.............................................................................................................. - 39 -6.4.1气体重度r气............................................................................................... - 39 -6.4.2液相重度.................................................................................................... - 39 -6.4.3 液相粘度（单位Mpa或Cp）................................................................ - 40 -6.4.4 填料........................................................................................................... - 40 -6.4.5 喷淋密度................................................................................................... - 40 -6.4.6 液相流量................................................................................................... - 41 -6.4.7 泛点气速计算........................................................................................... - 41 -6.4.8 塔径及空塔气速的计算........................................................................... - 42 -6.4.9 高度........................................................................................................... - 42 -6.4.10 填料层阻力计算..................................................................................... - 42 -6.5 吸收二塔.............................................................................................................. - 43 -6.5.1气体重度.................................................................................................... - 43 -6.5.2液相重度.................................................................................................... - 44 -6.5.3 液相粘度（单位Mpa或Cp）................................................................ - 44 -6.5.4 填料........................................................................................................... - 44 -6.5.5 喷淋密度................................................................................................... - 45 -6.5.6 液相流量................................................................................................... - 45 -6.5.7 泛点气速计算........................................................................................... - 45 -6.5.8 塔径及空塔气速的计算........................................................................... - 46 -6.5.9 高度........................................................................................................... - 46 -6.5.10 填料层阻力计算..................................................................................... - 46 -6.6 主要非定型设备一览表...................................................................................... - 47 -6.7 主要定型设备选型.............................................................................................. - 47 -6.7.1 上料泵（两台）....................................................................................... - 47 -6.7.2 鼓风机（两台）....................................................................................... - 47 -6.7.3 炉给水泵（两台）................................................................................... - 47 -6.7.4 塔循环泵（两台）................................................................................... - 48 -6.7.5 塔循环泵（两台）................................................................................... - 48 -6.7.6 成品泵（两台）....................................................................................... - 48 -第七章主要工艺管道计算及选型.............................................................. - 49 -7.1 主要工艺管道计算及选型.................................................................................. - 49 -7.1.1 空气吸入管（空气过滤器→风机口）................................................... - 49 -7.1.2 空气压出管（风机口→蒸发器）........................................................... - 49 -7.1.3 二元气体管（蒸发器→过热器）........................................................... - 49 -7.1.4三元气体管（过热器→氧化器）............................................................ - 50 -7.1.5 产品气管（氧化器→塔底）................................................................... - 50 -7.1.6 一塔顶出气管（一塔底→二塔底）....................................................... - 50 -7.1.7 尾气管（二塔顶→尾气处理车间）....................................................... - 50 -7.1.8 配料蒸汽管（蒸汽分配缸→过热器前）............................................... - 51 -7.1.9 甲醇管（原料泵→蒸发器）................................................................... - 51 -7.1.10 甲醛管（一塔循环管→成品槽）......................................................... - 51 -7.1.11 工艺管道（软水管→二塔顶） ............................................................. - 51 -7.1.12 一塔循环管（一塔底→一塔顶）......................................................... - 52 -7.1.13 二塔循环管（二塔底→二塔顶）......................................................... - 52 -7.2 主要工艺管道汇总表.......................................................................................... - 52 -第八章安全与“三废”处理 ....................................................................................... - 54 -8.1工艺物料特性及防护措施................................................................................... - 54 -8.2 三废处理.............................................................................................................. - 54 -8.2.1 废气处理................................................................................................... - 54 -8.2.2 废水处理................................................................................................... - 54 -8.2.3噪声防治.................................................................................................... - 55 -第九章技术经济初步评估甲醛及市场................................................................ - 56 -9.1 产品甲醛及原料市场分析.................................................................................. - 56 -9.1.1 甲醛及原料市场价格分析....................................................................... - 56 -9.1.2 甲醛市场的供求分析............................................................................... - 56 -9.1.3 甲醛市场未来分析................................................................................... - 56 -9.2 经济效益初步梳算.............................................................................................. - 57 -9.2.1 投资估算................................................................................................... - 57 -9.2.2 生产成本和销售收益的估算................................................................... - 57 -9.2.3 销售收益估算........................................................................................... - 57 -9.2.4 经济效率评估........................................................................................... - 58 -结束语............................................................................................................................... - 59 -参考文献 .......................................................................................................................... - 60 -致谢............................................................................................................................. - 61 -第一章前言甲醛是重要的有机化工基础原料，是甲醇最重要的衍生物产品之一，甲醛的用途十分广泛，主要用于生产脲醛树脂、酚醛树脂、聚甲醛树脂、三聚氰胺树脂、季戊四醇、乌洛托品、维尼纶纤维、1,4—丁二醇、新戊二醇和异戊二烯等，同时甲醛在农药、医药、炸药和染料工业中还可做杀虫剂、消毒剂、溶剂和还原剂等，在农业上还可做尿素——甲醛型缓效肥料。