广西科技大学毕业设计 年产2万吨顺丁橡胶聚合车间工艺设计
摘 要
顺式-1,4-聚丁二烯橡胶（简称顺丁橡胶）是一种结晶性橡胶，分为高顺丁橡胶，中顺丁橡胶和低顺丁橡胶三种结构，是目前仅次于丁苯橡胶的世界第二大通用合成橡胶。其具有弹性好，耐磨性强和耐低温性能好，生热低，滞后损失小，耐屈挠性、抗龟裂性及动态性能好等优点，可与天然橡胶、氯丁橡胶以及丁腈橡胶等并用，在轮胎、抗冲击改性、胶带、胶管以及胶鞋等橡胶制品的生产中具有广泛的应用。
本设计从顺丁橡胶的基本性能、目前现状以及发展前景入手，对聚合工段至后处理工段进行物料衡算，得到了物料平衡图；进行聚合过程的热量衡算，为设备计算奠定基础；对聚合工段各种设备的选型、装置组成、生产方法、生产制度进行了合理的确定，确定了合理的工艺参数和操作规程。
根据确定的工艺流程和控制方案，绘制出带控制点的工艺流程图、聚合釜装配图和车间平面布置图；编制了2×107千克/年顺丁橡胶生产车间工艺设计说明书。经过最后核算，2×107千克/年顺丁橡胶生产车间工艺设计符合设计要求，各项参数均已达标。
关键词：顺丁橡胶；聚合釜；工艺设计
I
广西科技大学毕业设计 年产2万吨顺丁橡胶聚合车间工艺设计
Abstract
Cis - 1, 4 - polybutadiene rubber (hereinafter referred to as butadiene rubber) is a kind of crystalline rubber, divided into high butadiene rubber, low butadiene rubber and Lower butadiene rubber in the three kinds of structure, is currently the world's second largest after styrene-butadiene rubber general synthetic rubber. It has good elasticity, wear resistance and low temperature resistant performance is good, low heat, small hysteresis loss, flexing resistance, crack resistance, and the advantages of good dynamic performance, can and natural rubber, neoprene, nitrile rubber, etc. And, in the tire, impact modified, tape, rubber hose and rubber shoes and other rubber products are widely used in production.
This design from the basic properties of the butadiene rubber, the present status and development prospects of the polymerization section to the processing section for material balance, obtained the material balance figure; polymerization process of heat balance, lay a foundation for equipment calculation; of polymerization process of all kinds of equipment selection, equipment composition, production method, production system for the determination of reasonable, the reasonable process parameters and operating procedures. According to determine the technological process and control scheme，draw the control points of process flow diagram，the polymerization kettle assembly drawing and workshop layout；compiled the 2 x 107 kg/year cis-butadiene rubber production workshop process design manual. After the final accounting，2 x 107 kg/year cis-butadiene rubber production workshop process design comply with the design requirements，all parameters are standard.
Key words：butadiene rubber；The polymerization kettle； process design
II
广西科技大学毕业设计 年产2万吨顺丁橡胶聚合车间工艺设计
1 绪论 ............................................................................................................................................................ 1
1.1 顺丁橡胶的基本概念 ....................................................................................................................... 1 1.2 顺丁橡胶的性能 ............................................................................................................................... 1 1.3 顺丁橡胶的类别 ............................................................................................................................... 2 1.4 顺丁橡胶的用途 ............................................................................................................................... 2 1.5 国内外顺丁橡胶发展现状及发展前景 ........................................................................................... 3
1.5.1 国外现状及发展 ..................................................................................................................... 3 1.5.2 国内现状及发展 ..................................................................................................................... 3
2 工艺路线的确定 ..................................................................................................................................... 5
2.1 2.2 2.3 2.4 2.5
聚合方法的确定 ............................................................................................................................... 5 单体原料路线的确定 ....................................................................................................................... 5 溶剂的选择 ....................................................................................................................................... 5 引发剂的选择 ................................................................................................................................... 5 引发剂活性中心的形成方式 — 陈化方式 ................................................................................... 5
3 聚合反应机理及影响反应的因素 ...................................................................................................... 6
3.1 聚合反应机理 ................................................................................................................................... 6 3.2 影响反应的因素 ............................................................................................................................... 6
4 原料和产品的物理化学性质及技术指标 ........................................................................................ 7
4.1 原料的物理化学性质及技术指标 ................................................................................................... 7
4.1.1 丁二烯 ..................................................................................................................................... 7 4.1.2 溶剂油(C6油) ......................................................................................................................... 7 4.1.3 环烷酸镍 ................................................................................................................................. 7 4.1.4 三异丁基铝 ............................................................................................................................. 7 4.1.5 三氟化硼乙醚络合物 ............................................................................................................. 7 4.1.6 终止剂 ..................................................................................................................................... 7 4.1.7 防老剂 ..................................................................................................................................... 7 4.2 顺丁橡胶的物理化学性质及技术指标 ........................................................................................... 7
4.2.1 顺丁橡胶的结构 ..................................................................................................................... 7 4.2.2 生产中成品胶质量指标 ......................................................................................................... 8
5 工艺流程简述及流程示意图 ............................................................................................................... 9
5.1 工艺流程简述 ................................................................................................................................... 9
5.1.1 聚合工段 ................................................................................................................................. 9 5.1.2 后处理工段 ........................................................................................................................... 10 5.2 生产工艺流程示意图 ..................................................................................................................... 12
6 工艺计算 ................................................................................................................................................. 13
6.1 本设计采用的基础数据 ................................................................................................................. 13 6.2 物料衡算 ......................................................................................................................................... 13
6.2.1 聚合釜物料衡算 ................................................................................................................... 13 6.2.2 凝聚釜物料衡算 ................................................................................................................... 18 6.2.3 振动筛及热水罐物料衡算 ................................................................................................... 21 6.2.4 干燥脱水物料衡算 ............................................................................................................... 23 6.2.5 包装物料衡算 ....................................................................................................................... 24 6.2.6 油水分离器物料衡算 ........................................................................................................... 25 6.2.7 溶剂回收部分物料衡算 ....................................................................................................... 26
III
广西科技大学毕业设计 年产2万吨顺丁橡胶聚合车间工艺设计
6.3 热量衡算 ......................................................................................................................................... 29
6.3.1 基础数据 ............................................................................................................................... 29 6.3.2 各聚合釜反应转化率确定 ................................................................................................... 30 6.3.3 各釜物料组成及物性据数 ................................................................................................... 31 6.3.4 各釜对流传热系数?和传热系数K的计算 ...................................................................... 32 6.3.5 聚合釜搅拌功率的计算 ....................................................................................................... 37 6.3.6 热量衡算 ............................................................................................................................... 39 6.4 设备计算及选型 ............................................................................................................................. 44
6.4.1 聚合釜计算 ........................................................................................................................... 44 6.4.2 终止釜的设计 ....................................................................................................................... 49 6.4.3 凝聚釜的确定 ....................................................................................................................... 49 6.4.4 油水分离器 ........................................................................................................................... 49 6.4.5 热水罐 ................................................................................................................................... 49 6.4.6 胶液罐 ................................................................................................................................... 49 6.4.7 引发剂配制系统设备确定 ................................................................................................... 49 6.4.8 换热器的选择 ....................................................................................................................... 50 6.4.9 泵的选择（以溶剂油泵的选择为例） ............................................................................... 55
7 原材料动力消耗定额及消耗量 ........................................................................................................ 59 8 生产控制分析 ........................................................................................................................................ 60 9 定员 .......................................................................................................................................................... 61 10三废治理与公用工程 ........................................................................................................................ 62
10.1 三废排放及处理方法 ..................................................................................................................... 62 10.2 安全措施 ......................................................................................................................................... 62 10.3 公用工程 ......................................................................................................................................... 63
10.3.1 供水 ....................................................................................................................................... 63 10.3.2 电气 ....................................................................................................................................... 64 10.3.3 采暖和通风 ........................................................................................................................... 64
11车间布置 ............................................................................................................................................... 65
11.1 车间厂房布置 ................................................................................................................................. 66 11.2 车间设备布置 ................................................................................................................................. 66 11.3 车间生产辅助区及生活区的布置 ................................................................................................. 66
12技术经济评价 ...................................................................................................................................... 67
12.1 建厂规模 ......................................................................................................................................... 67 12.2 产品规格 ......................................................................................................................................... 67 12.3 建厂投资预算 ................................................................................................................................. 67 12.4 产品价格设计 ................................................................................................................................. 68 12.5 年生产总成本预测 ......................................................................................................................... 68
12.5.1 年生产固定总成本 ............................................................................................................... 68 12.5.2 年生产变动成本总成本 ....................................................................................................... 68 12.6 经济效益分析 ................................................................................................................................. 69 12.7 财务评估 ......................................................................................................................................... 70
12.7.1 年企业投资回收率 ROI ....................................................................................................... 70 12.7.2 年企业投资利润率 ............................................................................................................... 70 12.7.3 投资回收期 ........................................................................................................................... 70
IV
广西科技大学毕业设计 年产2万吨顺丁橡胶聚合车间工艺设计
13计算机在设计中的应用.................................................................................................................... 71 结束语 ......................................................................................................................................................... 72 参考文献 .................................................................................................................................................... 73 致谢 .............................................................................................................................................................. 74 附录 .............................................................................................................................................................. 75
A主要设备一览表 .................................................................................................................................... 75 Ｂ符号说明 ............................................................................................................................................... 76
V