CN101389403A - 催化剂结构 - Google Patents

催化剂结构 Download PDF

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CN101389403A
CN101389403A CNA2007800065254A CN200780006525A CN101389403A CN 101389403 A CN101389403 A CN 101389403A CN A2007800065254 A CNA2007800065254 A CN A2007800065254A CN 200780006525 A CN200780006525 A CN 200780006525A CN 101389403 A CN101389403 A CN 101389403A
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paper tinsel
paddy
peak
catalyst structure
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D·J·韦斯特
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CompactGTL PLC
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Abstract

一种催化剂结构，包括作为基片的箔带(10)，且该箔带已被切割并成形从而限定出多个峰(15)和谷(16)，每个峰和谷的轴线都横过该箔带延伸，以使峰和谷横过该箔带(10)交替。这种波纹基片上可设置加入催化材料的陶瓷涂层。这种波纹增强了紧凑型催化反应器的流动通道内的湍流。

Description

催化剂结构
技术领域
本发明涉及一种适于应用在包含用于化学反应的通道的催化反应器中的催化剂结构，一种制造这种催化剂结构的方法，和包含这种催化剂结构的化学反应器。
背景技术
WO01/51194和WO03/033131(Accentus plc)中描述了一种方法，其中甲烷与蒸汽反应，在第一催化反应器中生成一氧化碳和氢气；接着得到的气体混合物被用于在第二催化反应器中执行费-托合成。总结果是将甲烷转变为具有更大分子量的更长链烃，这些链烃在周围条件下通常是液态或蜡状。该工艺的两个阶段，蒸汽/甲烷重整和费-托合成，需要不同的催化剂，并且催化反应器要针对每个阶段描述。在每种情况下，催化剂可以包括涂覆有催化材料的波纹箔。该波纹沿每个通道的长度延伸，具有将该通道细分为多个平行的子通道的效果。尽管这种催化剂结构是有效的，但是它们必须被仔细地制造以确保它们能够适合通道，这是因为波纹的高度必须适于通道的高度，同时波纹的高度又会影响波纹箔的宽度，所述波纹箔的宽度通常也需要适合通道的宽度。
发明内容
按照本发明，提供了一种包括箔的催化剂结构，所述箔已被切割并成形从而限定出多个峰和谷，每个峰和谷的轴线都横过该箔延伸，以使峰和谷横过该箔交替。
沿该箔的长度方向可以有峰线和谷线，或作为选择，可以有峰和谷沿其交替的线。
峰和谷可以具有任何适合的形状，例如可以为三角形。
这种催化剂结构可以增强湍流。它可被插入横截面一般为矩形的通道中，该箔的宽度适合该通道的宽度；形成峰和谷不会改变该箔的宽度。
本发明也提供了一种用于制造催化剂结构的方法，该方法包括以下步骤：选择合适宽度的箔；在箔上切割出多个平行的狭缝，该狭缝在长度方向上延伸；和使相邻狭缝之间的箔部分变形为峰和谷，从而该箔限定出多个峰和谷，每个峰和谷的轴线都横过该箔延伸，如此布置使得峰和谷横过该箔交替。
在第三方面，本发明还提供了一种限定出多个第一和第二流动通道的紧凑型催化反应器，该第一和第二流动通道在反应器中交替布置，用于分别容纳第一和第二流体，其中至少第一流体进行化学反应；每个第一流动通道都包括一个可移除的透气催化剂结构，该催化剂结构包括一个已被切割并成形从而限定出多个峰和谷的金属箔基片，每个峰和谷的轴线都横过该箔延伸，以使峰和谷横过该箔交替。
该反应器可由铝合金、不锈钢、高镍合金或其他钢合金制成，取决于反应所需的温度和压力，以及流体的性质，所述流体包括反应物和生成物。该催化剂结构并不提供反应器的强度，因此反应器自身必须足够结实以抵抗工作中产生的任何压力。应当理解的是该反应器可以封闭在一个压力容器内从而降低它所承受的压力，或该压力仅为压缩力。
该反应器还必须具有集流管以便向流动通道供给流体，并且优选每个第一集流管都包括连接到反应器外侧并与多个第一流动通道相通的室，且每个第二集流管都包括连接到反应器外侧并与多个第二流动通道相通的室，这样就使得移除集流管后，在流动通道内的相应的催化剂结构也可移除。这确保了当催化剂用尽时可被容易地替换。
该催化剂结构优选包括陶瓷涂层以承载催化材料。优选的是，该催化剂结构的金属箔是当加热时形成了铝氧化物粘附表面涂层的钢合金，例如，带有铝的铁素体钢，如具有15％铬、4％铝和0.3％钇的铁(如Fecralloy(TM))。当这种金属在空气中被加热时，它形成了氧化铝的粘附氧化物涂层，该涂层保护合金免受进一步的氧化并避免其被腐蚀。在陶瓷涂层是氧化铝的情况下，这看起来像在其表面粘合氧化物涂层。优选的基片是薄的金属箔，例如其厚度小于100μm。催化剂结构的金属基片增强了催化剂结构内的热交换，避免了热点或冷点，增加了催化剂表面积并提供了机械强度。
在通道深度不超过3mm的情况下，催化剂结构例如可以是单个成形箔。可选的并且特别的是，在通道深度大于约2mm的情况下，该催化剂结构可以包括多个这种成形箔，这些成形箔由基本平直的箔相互分隔。为确保所需的良好的热接触，例如和费-托反应器的热接触，该通道优选小于20mm深，更优选的是小于10mm深，而对于蒸汽/甲烷重整反应器，该通道优选小于5mm深。但是该通道优选至少1mm深，否则难以插入该催化剂结构，并且工程公差变得更为关键。需要的是，通道内的温度横过通道的宽度保持一致，在约2-4℃以内，并且通道越大这个要求就越难以达到。
反应器可以包括一叠薄板。例如，第一和第二流动通道可由各个薄板上的凹槽来限定，这些薄板被堆叠然后被粘合到一起。可选的是，流动通道可由呈齿形并与平板交替堆叠的薄金属板来限定；流动通道的边缘可由密封条限定。形成反应器的这叠薄板，例如通过扩散粘合、钎焊或热等静压等方式被粘合到一起。作为示例，这些薄板(在平面内)的宽度可以在0.05m直到1m的范围内，并且其长度在0.2m直到2m的范围内，且流动通道的高度优选在1mm到20mm或更小的范围内(取决于化学反应的性质，如上所指出的)。例如，这些薄板可为0.3m宽1.5m长，限定通道5mm高。
附图说明
现在将仅以示例的方式并参考附图进一步并更具体地描述本发明，其中：
图1示出了在催化插入物的制造过程中金属箔的立体图；
图2示出了图1中的金属箔在随后阶段中的立体图；和
图3示出了图2中金属箔在图2中的箭头3的方向上的侧视图。
具体实施方式
现在参照图1，用于插入紧凑型催化反应器的矩形通道中的催化剂结构由采用Fecralloy合金钢制成的箔制造，其厚度典型地在10-200μm范围内，例如50μm。选择的箔10的宽度要略小于该箔待插入的通道的宽度，这个宽度差提供了足够的间隙(如0.5mm或1.0mm)以确保它能自由地滑入通道。在这个例子中，箔10的宽度为12mm，但该箔可以是任何适合的宽度。箔10首先进行切割工艺以形成一组狭缝12，所有的狭缝12都沿纵向延伸，每个狭缝的长度都相同(如5mm)。狭缝12横过箔10的宽度隔开，在这个例子中间隔2mm，从而在整个宽度上形成一排狭缝12，并且这排狭缝在纵向方向与下一排狭缝12也相互间隔，如间隔2mm，这样沿箔10的长度方向以5mm的间隔有多个未开狭缝的箔部分14。
接下来箔10进行波纹加工工艺，例如采用合适的齿形辊，以产生如图2和3所示的波纹。该工艺使每个狭缝12两侧的箔部分形成峰15(在一侧)和谷16(在另一侧)，从而使峰15和谷16横过该条带的宽度交替。在图2示出的实施例中，在纵向方向上连续的部分全部形成峰15或全部形成谷16。在每种情况下，峰15或谷16的轴线(也就是沿峰顶或沿谷底延伸的线，或是平行于这些线中的一条的线)垂直于箔10的纵轴延伸。
接着箔10可被切割成适合待插入的通道的长度，优选横过一个未开狭缝的箔部分14切割。然后通过直接将催化金属沉积在箔10的表面，或者通过首先用陶瓷涂层对箔10进行涂覆然后再将催化金属沉积在陶瓷上，在箔10的波纹部分上设置催化表面。将催化材料沉积到箔基片上的工序对本领域一般工艺人员来说是已知的。例如，箔10可以涂覆陶瓷涂层(未示出)，如厚度典型地在30-80μm范围内的氧化铝(例如用于燃烧或蒸汽重整)，接着活性催化材料(如铂/铑，在蒸汽重整的情况下)被加入陶瓷。应当理解该陶瓷涂层和催化金属的性质取决于反应器中进行的反应。
应当理解这个工艺使催化剂插入物可被制成任何需要的长度，并且其宽度由箔的宽度预先确定，这个宽度不会被波纹加工工艺改变。峰15和谷16的高度可被选择并调整到适合箔待插入的通道的高度。还应当理解在某些情况下，例如通道的高度大于约4mm时，优选采用由基本平直的箔分隔开的波纹催化剂结构的组合件，所述基本平直的箔也可以包含催化涂层。例如，在6mm的通道中可以有两个波纹箔催化剂结构，每个的总高度为2.5mm，并由基本平直的箔相互分隔。在任何情况下该波纹箔10都将足够柔韧从而使其波纹能被压缩，这样当向通道中插入或从中取出波纹催化剂结构时能够降低箔被卡住的风险。
箔的轮廓增强了通道内的湍流，这可以导致更大的热量和质量交换，并由此导致整个通道内更均匀的温度分布，因此改善了反应性能。
应当理解波纹可以用与上面描述的不同的方式制出。例如，如图1所示开狭缝的箔，其波纹可以布置成沿纵向线连续的部分交替为峰15和谷16。该波纹可具有与图2所示不同的形状，例如为矩形或圆形而不是三角形。在上面示出的箔10中，未开狭缝的箔部分14沿垂直于箔10的纵轴延伸的直线延伸，但是应当理解狭缝12也可代之以布置成使未开狭缝的箔部分沿倾斜的直线延伸，从而使横过箔宽度方向的峰和谷轻微交错。该狭缝12实际上也可代之以布置成使未开狭缝的箔部分横过箔10的宽度方向限定出一条曲线或者甚至是Z字形。
还应当理解狭缝12可用任何适当的方式制造，例如通过化学蚀刻，或通过机械冲压；并且狭缝12的长度和间隔也可与上面提到的值不同。

Claims (8)

1.一种催化剂结构，其包括已被切割并成形从而限定出多个峰和谷的箔，每个峰和谷的轴线都横过该箔延伸，以使峰和谷横过该箔交替。
2.如权利要求1所述的催化剂结构，其中沿该箔的长度方向有峰线和谷线。
3.如权利要求1所述的催化剂结构，其中沿该箔的长度方向有峰和谷沿其交替的线。
4.如前述任一项权利要求所述的催化剂结构，其中峰和谷横过该箔交替的线垂直于该箔的纵轴延伸。
5.如权利要求1-3中任一项所述的催化剂结构，其中峰和谷横过该箔交替的线倾斜于该箔的纵轴延伸。
6.如前述任一项权利要求所述的催化剂结构，其中峰和谷呈三角形。
7.一种用于制造催化剂结构的方法，该方法包括以下步骤：选择合适宽度的箔；在该箔上切割出多个平行的狭缝，该狭缝在长度方向上延伸；以及使相邻狭缝之间的箔部分变形为峰或谷，从而该箔限定出多个峰和谷，每个峰和谷的轴线都横过该箔延伸，如此布置使得峰和谷横过该箔交替。
8.一种限定出多个第一和第二流动通道的紧凑型催化反应器，该第一和第二流动通道在反应器中交替布置，用于分别容纳第一和第二流体，其中至少第一流体进行化学反应；每个第一流动通道都包括一个可移除的透气催化剂结构，该催化剂结构包括一个已被切割并成形从而限定出多个峰和谷的金属箔基片，每个峰和谷的轴线都横过该箔延伸，以使峰和谷横过该箔交替。
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