CN1014031B - 多相合成改进方法及其反应器 - Google Patents

多相合成改进方法及其反应器

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CN1014031B
CN1014031B CN88104043A CN88104043A CN1014031B CN 1014031 B CN1014031 B CN 1014031B CN 88104043 A CN88104043 A CN 88104043A CN 88104043 A CN88104043 A CN 88104043A CN 1014031 B CN1014031 B CN 1014031B
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gas
catalyst bed
radially
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flow
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乌姆勃托·萨尔迪
古奥尔吉奥·帕加尼
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Casale SA
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Abstract

多相合成改进方法及其反应器，其中将合成催化剂分布在三个轴向一径向或径向催化剂床中，温度控制是在第一和第二床层之间用新鲜气进行骤冷并在第二和第三床层之间借助换热器用其管中被加热的新鲜气间接冷却离开第二床层的气体。

Description

多相合成生产氨，甲醇以及其它产品过程中达到高反应产量的重要性是众所周知的。
明显影响反应产量的因素包括：a）催化剂床数的优化情况;b）催化剂床间气体进行中间冷却而控制反应温度的系统;c）常见小粒径（1.5÷3mm）催化剂在更先进径向或轴向一径向反应器中的效率。
已经提出了许多催化剂床中气体进行轴向流动的老式反应器，因而粒径大（6÷12mm），必须采用效率不很高的催化剂，缺点是产量低，压降大，因此能耗高。
上述反应常有数个催化剂床（Kellog反应器中高达4个），床之间进行中间骤冷（将热反应气与进料冷气混合）。
在更先进的反应器中，气体在催化剂中的流向为径向（Topsoe或Uhde等反应器）或轴向-径向如Casale氨反应器。在这类反应器中，常用更具活性的小粒径（1.5÷3mm）催化剂，反应筒中有两个或三个径向或轴向-径向床，优点是压降低，用换热器间接换热而进行床层间的中间冷却。
间接换热比骤冷优越的地方是可更有效地利用催化剂床，因此上述反应器中，转化产量高，能耗低。
最近在对现有低产量轴向反应器进行改造以将其效率提高到更现代的径向或轴向-径向反应器水平的过程中已发现明显的优越性。
申请人最近在欧洲专利申请86104911中提出对具有数个床层的轴向反应器如Kellog反应器进行改造以将其改换成效率更高的轴向-径向或径向反应器。根据上述专利申请，仅对现有反应筒进行“就地”改型（因此 保留了反应筒的大部分），其中加透气壁和底以将轴向床换成轴向-径向或径向床。根据上述申请，可获得各种筒体结构。
最近出版的“Nitrogen”No165，January-February    1987说明了申请人在工业上应用上述申请中所述系统的情况，根据其中的说明，对四床层轴向Kellog反应器进行改造以提高其效率，其中“就地”构成进行轴向-径向气流的四床层反应筒并将原料气骤冷而进行中间冷却（见文中图4）。
这样改型后的反应筒可采用小粒径高产量催化剂。
同一文章中还谈到了涉及欧洲专利86104911.2中建议的“就地”改型的不同实施方案，根据其中的说明，对具有数个催化剂床的轴向反应器进行改造以提供产量，其中构成径向气流的两床反应筒并按Topsoe建议（见文中图1）用换热器进行间接中间冷却。这样要采用粒径太小的催化剂。
申请人提出不改变催化剂床层数和中间冷却系统的解决方案通常是优选作法，因为对现有反应筒改造最少，在任何情况下都可达到极高的产量。
另一方面，根据“Nitrogen”中提出的Topsoe方案，要将反应筒改造成床层间用换热器进行中间间接冷却的带两个催化剂床反应器就必须对现有反应筒进行极大的改造。此外，所说方案还要求采用用高质量材料（Inconel    600）制成的大型昂贵换热器，因为反应条件为高温。
继续深入研究后，申请人出人意料地设计出了适于改造现有反应器以及适用于新型反应器的系统，其中将合成催化剂分布在三个轴向-径向或径向催化剂床中，温度控制是在第一和第二床层之间用新鲜气进行骤冷并在第二和第三床层之间借助换热器用其管中被加热的新鲜气间接冷却离开第二床层的气体。
上述体系中，尽管在改造现有反应器时对反应筒的改动最少，但与申 请人的申请86104911.2和“Nitrogen”一文中所述系统比较起来，仍可进一步提高反应产量，其中避免了采用高质量材料如Inconel    600制成的大型换热器。实际上，按照该新型系统，第二和第三床层间进行温度控制的换热器可大大缩小（70%）并可用普通材料如不锈钢制成。
根据本发明的特定实施方案（图1），流过轴向-径向或径向气流催化剂床的气体是：a）在第一催化剂床中从内向外流，第一和第二催化剂床层间的新鲜骤冷气从外部气体收集器顶部设置的环形分配器中通入;b）在第二和第三催化剂床中从外向内流，换热器位于第二催化剂床中心，其中管内供入新鲜原料气，而管外则供入来自第二床层的热气。
本发明方法中新鲜骤冷气为原料气总流量的至少20%，供入换热器管内的新鲜气流为总原料气流的至少20%。
根据上述实施方案的改型方案，第一催化剂床中气体轴向通过，而按申请人的瑞士专利申请No02221/86-7（图2），骤冷气环形分配器位于第一床层底部上端的反应筒外壁附近。
按照本发明另一改型方案（图3），三个床层中气体均径向流过。
上述本发明与现有技术比较的优点可总结如下：
Ⅰ-产量高
Ⅱ-投资少
Ⅲ-现有反应器“就地”改造最少
下面详述本发明非限制性实施方案：
图1示意地表明了“就地”改造现有反应器时常用的轴向-径向气流式三层催化剂床合成反应筒。原料气流1的大部分从反应器壳体M底部进入，从底部沿壳体和反应筒C之间的空间Ⅰ流到顶部，然后进入换热器S1外部以便用从反应器顶部离开的热气流5进行预热。
预热气流1′的温度由部分原料气流2控制，与换热器S2中预热的气流4混合后到达第一催化剂床，其中气体轴向-径向从内向外流，气体集 聚在反应筒C和第一床层外壁Pe间的空间Ⅰ′中并与新鲜骤冷气流3混合。混合后的低温气流1″到达第二催化剂床，其中在轴向-径向从外向内流的过程中进行反应并得以加热。热气体集聚在催化剂床内壁和位于催化剂床中心的换热器S2外壁间的空间Ⅰ″中并在从换热器S2管外从顶部向底部流动过程中得以冷却，最后集聚在换热器出口处的气流1″′进入第三催化剂床。
新鲜气流4送入换热器底部，其中在管内流动过程中进行加热并最终并入气流1′。气流Ⅰ″′最终轴向-径向从外向内流过第三催化剂床C3后集聚在中心收集器Ⅰ″′中并通过中心传送管T而到达换热器S1的管内，其中在预热气流1的过程中冷却下来并最后以气流5离开转化器。
图3为径向气流式三层催化剂床合成反应器筒剖面图。图中床层内气体在这种情况下是径向流动而不是象图1为轴向-径向，床层顶部封闭，气体如同前述流过反应器的各个部分。
实施例
下面参考图1说明这种应用方案的实施例。
在合成反应器中生产1000MTD氨，采用的是以下操作条件：
反应器入口压力：140bar
流量    温度
气流1    7970    Kmol/h    41.0%    143℃
气流2    0    Kmol/h    -    143℃
气流3    6069    Kmol/h    31.3%    143℃
气流4    5384    Kmol/h    27.7%    143℃
气流5    16992    Kmol/h    -    352℃
气流1，2，3，4组成    气流5组成
H2    66.68%    mol    H2    54.68%    mol
N2    22.22%    mol    N2    18.22%    mol
CH4    4.70%    mol    CH4    5.38%    mol
A    4.30%    mol    A    4.92%    mol
NH3    2.10%    mol    NH3    16.80%    mol
图4表明了上述操作条件下温度/反应器产量关系图（图4a）以及“Nitrogen”中图2和7所述温度/现有技术产量关系图（图4b和4c）。
如上述图所示，本发明反应器所得产量比现有技术产量提高约25～60%。
上述关系图中，温度为横座标，而反应器出口处氨浓度为纵座标。

Claims (6)

1、多相合成改进方法，其特征是，将合成催化剂分布在三个轴向-径向或径向催化剂床中，温度控制是在第一和第二床层之间用新鲜气进行骤冷并在第二和第三床层之间借助换热器用其管中被加热的新鲜气间接冷却离开第二床层的气体。
2、权利要求1的方法，其特征是流过轴向-径向或径向催化剂床的气体是：a）在第一催化剂床中从内向外流，b）在第二和第三催化剂床中从外向内流，换热器位于第二催化剂床中心。
3、权利要求1的方法，其特征是第一催化剂床中气体轴向流过，而其余两个床层中轴向-径向或径向从外向内流。
4、权利要求2的方法，其特征是流过轴向-径向或径向催化剂床的气体是：a）在第一催化剂床中从内向外流，第一和第二催化剂床层间的新鲜骤冷气从外部气体收集器顶部设置的环形分配器中通入;b）在第二和第三催化剂床中从外向内流，换热器位于第二催化剂床中心，其中管内供入新鲜原料气，而管外则供入来自第二床层的热气。
5、权利要求1的方法，其特征是新鲜骤冷气为原料气总流量的至少20%，供入换热器管内的新鲜气流为总原料气流的至少20%。
6、实施上述权利要求所述方法而应用的合成反应器，其特征是合成催化剂分布在三个轴向-径向或径向催化剂床中，而所用换热器置于第二催化剂床中心。
CN88104043A 1987-07-03 1988-07-02 多相合成改进方法及其反应器 Expired CN1014031B (zh)

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DE3869677D1 (de) 1992-05-07
CN1030878A (zh) 1989-02-08
EP0297474A3 (en) 1989-04-05
US4963338A (en) 1990-10-16
ATE74291T1 (de) 1992-04-15
SU1671148A3 (ru) 1991-08-15
ES2030467T3 (es) 1992-11-01
EP0297474B1 (en) 1992-04-01
EP0297474A2 (en) 1989-01-04

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