CN101801893B - 由生物可再生原料制造柴油机燃料 - Google Patents

由生物可再生原料制造柴油机燃料 Download PDF

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CN101801893B
CN101801893B CN2008801079776A CN200880107977A CN101801893B CN 101801893 B CN101801893 B CN 101801893B CN 2008801079776 A CN2008801079776 A CN 2008801079776A CN 200880107977 A CN200880107977 A CN 200880107977A CN 101801893 B CN101801893 B CN 101801893B
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T·L·马克
P·柯卡耶夫
S·F·阿布多
T·N·卡尔奈斯
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Abstract

已经开发出由可再生原料(例如植物油、动物脂肪和油、以及油脂)制造柴油沸程燃料的方法。该方法包括通过氢化和脱氧处理可再生原料以提供柴油沸程燃料烃产物。如果需要，可以将烃产物异构化以改进冷流性质。将一部分烃产物再循环到处理区以提高反应混合物的氢溶解度。

Description

由生物可再生原料制造柴油机燃料
背景技术
本发明涉及由可再生原料(例如在例如植物油、动物油、动物脂肪和油脂之类的材料中存在的甘油酯和游离脂肪酸)制造可用作燃料的柴油沸程烃的方法。该方法包括在一个或多个步骤中的氢化、脱羧、脱羰、和/或加氢脱氧以及任选地加氢异构化。该方法以2∶1至8∶1的再循环产物与原料的体积比运行。该方法在1379kPa绝对压力(200psia)至4826kPa绝对压力(700psia)的总压力下运行。
由于对柴油沸程燃料的需求在世界范围内增长，因此日益关注用于制造柴油机燃料的非石油原油来源。一种这样的来源被称作生物可再生源。这些生物可再生源包括但不限于：植物油，例如玉米油、菜籽油、低芥酸菜籽油、豆油和藻油，动物脂肪，例如非食用牛脂、鱼油，以及各种废流，例如黄色和褐色油脂和下水道污泥。这些来源的共同特征在于它们由甘油酯和游离脂肪酸(FFA)构成。这两类化合物都含有具有8至24个碳原子的脂族碳链。甘油酯或FFAs中的脂族链可以是完全饱和的，或是单不饱和、二不饱和或多不饱和的。
本领域中有报道公开了由油类制造烃。例如，US 4,300,009公开了使用结晶硅铝酸盐沸石将植物油(例如玉米油)转化成烃(例如汽油)和化学品(例如对二甲苯)。US 4,992,605公开了通过加氢处理植物油(例如低芥酸菜籽油或葵花油)来制造柴油沸程内的烃产品。最后，US2004/0230085A1公开了通过加氢脱氧然后异构化来处理生物来源的烃成分的方法。
申请人已经开发出一种方法，其包括任选的预处理步骤，和一个或多个将原料氢化、脱羧、脱羰(和/或加氢脱氧)和任选加氢异构化的步骤，该方法可以成功地在低于在先系统的压力范围内操作。采用2∶1至8∶1的再循环烃与原料的体积比，提供了充分提高反应混合物中的氢溶解度以降低该方法的运行压力的机制。成功的再循环物与原料的体积比的范围取决于反应混合物中所需的氢溶解度。反应区可以在1379kPa绝对压力(200psia)至4826kPa绝对压力(700psia)的压力下运行。
发明概要
本方法用于由可再生原料制造可用作柴油机燃料的烃级分，本方法包括在反应区中通过在反应条件下将可再生原料氢化和脱氧而处理可再生原料，以提供包含烃级分的反应产物(该烃级分包含可用作柴油沸程燃料或燃料调合组分的正链烷烃)，并将一部分烃级分再循环到反应区，其中再循环物与原料的体积比为2∶1至8∶1。任选地，可以将该反应产物异构化以提供异构化的反应产物。
附图简述
图1是模拟数据曲线图，显示了相对于再循环物与原料的比率绘制的氢溶解度的量。
图2是对比数据曲线图，其中针对没有烃再循环的方法和具有4∶1的再循环烃与可再生原料的体积比的方法，相对于运转小时数绘制产物中的氧含量。
图3是九组不同的脱羧和氢化反应器运行条件的结果曲线图，相对于按华氏度计的温度绘制以原料重量百分比表示的正构C17收率。
发明详述
如上所述，本发明涉及由可再生原料(例如源自植物或动物的那些原料)制造可用作柴油机燃料的烃流的方法。术语可再生原料包括除衍生自石油原油的那些原料之外的原料。用于描述这类原料的另一术语是生物可再生脂肪和油。可用于本发明的可再生原料包括任何包含甘油酯和游离脂肪酸(FFA)的可再生原料。大部分甘油酯是甘油三酸酯，但也可以存在和加工甘油单酸酯和甘油二酸酯。这些可再生原料的实例包括但不限于，低芥酸菜籽油、玉米油、豆油、菜籽油、大豆油、菜油、妥尔油、葵花油、大麻籽油、橄榄油、亚麻籽油、椰子油、蓖麻油、花生油、棕榈油、芥子油、棉籽油、麻风树油、牛脂、黄色和褐色油脂、猪油、鲸骨脂、乳脂肪(fats in milk)、鱼油、藻油、下水道污泥等等。可再生原料的另一些实例包括来自麻风树(Jatropha curcas)(Ratanjoy，野生蓖麻，JangliErandi)、Madhuca indica(Mohuwa)、Pongamia pinnata(Karanji Honge)和Azadiracta indicia(印度楝)的非食用植物油。典型的植物或动物脂肪的甘油酯和FFAs在它们的结构中含有具有8至24个碳原子的脂族烃链，大多数脂肪和油含有高浓度的具有16和18个碳原子的脂肪酸。也可以使用可再生原料和石油衍生烃的混合物或共进料作为原料。可用的、尤其是与上面列举的原料联合作为共进料组分的其它原料组分包括废机油和工业润滑剂、用过的石蜡、由煤、生物质或天然气的气化继之以下游液化步骤(例如费-托技术)制成的液体、由废塑料(例如聚丙烯、高密度聚乙烯和低密度聚乙烯)的热解聚或化学解聚制成的液体；以及作为石化和化学工艺的副产物生成的其它合成油。也可以使用上述原料的混合物作为共进料组分。使用共进料组分的一个优点是将来自石油基工艺或其它工艺的被视为废产物的材料转化成当前工艺的有价值的共进料组分。
可用于本发明的可再生原料可以含有多种杂质。例如，妥尔油是木材加工业的副产物，妥尔油除FFAs之外还含有酯和松香酸。松香酸是环羧酸。可再生原料还可能含有污染物，例如碱金属(例如钠和钾)、磷以及固体、水和洗涤剂。任选的第一步骤是尽可能多地除去这些污染物。一种可行的预处理步骤包括在预处理区中在预处理条件下使可再生原料与离子交换树脂接触。该离子交换树脂是酸性离子交换树脂，例如AmberlystTM-15，并可用作反应器中的床，原料以上行流或下行流方式流过该床。
除去污染物的另一可行手段是温和酸洗。这通过在反应器中使原料与酸(例如硫酸、硝酸或盐酸)接触来进行。酸和原料可以在分批法或连续法中接触。通常在环境温度和大气压下用稀酸溶液进行接触。如果以连续方式进行接触，其通常以对流方式进行。从原料中除去金属污染物的又一可行手段是通过使用本领域公知的保护床。这些可以包括具有或不具有脱金属催化剂(例如镍或钴)的氧化铝保护床。过滤和溶剂萃取技术是可用的其它选择。例如USAN 11/770,826(经此引用并入本文)中所述的加氢处理是可用的另一预处理技术。
原料流向在一个或多个反应器中包含一个或多个催化剂床的反应区。术语原料包括未经除污染物处理的原料以及在预处理区中净化过的那些原料。在反应区中，使原料在氢化条件下、在氢存在下与氢化或加氢处理催化剂接触，以将正链烷烃链的烯属或不饱和部分氢化。氢化或加氢处理催化剂是本领域公知的任何这样的催化剂，例如分散在高表面积载体上的镍或镍/钼。其它氢化催化剂包括分散在高表面积载体上的一种或多种贵金属催化元素。贵金属的非限制性实例包括分散在γ-氧化铝上的Pt和/或Pd。氢化条件包括200℃至300℃的温度和1379kPa绝对压力(200psia)至4826kPa绝对压力(700psia)的压力。氢化区的其它运行条件是本领域公知的。
上文列举的氢化和加氢处理催化剂还能催化所述原料的脱羧、脱羰和/或加氢脱氧以除去氧。脱羧、脱羰和加氢脱氧在本文中统称为脱氧反应。脱羧和脱羰条件包括3447kPa(500psia)至6895kPa(1000psia)的相对较低的压力、288℃至345℃的温度和1至4hr-1的液时空速。由于氢化是放热反应，因此，当原料流经催化剂床时温度升高，并开始发生脱羧和加氢脱氧。因此，可以想到所有反应在一个反应器中或在一个床中同时发生，并在本发明的范围内。或者，可以控制条件，以便在一个床中主要发生氢化，在第二个床中发生脱羧和/或加氢脱氧。当然，如果仅使用一个床，则氢化主要发生在床的前部，而脱羧、脱羰和加氢脱氧主要发生在该床的中部和底部。最后，所需氢化可以在一个反应器中进行，而脱羧、脱羰和/或加氢脱氧可以在独立的反应器中进行。
氢是上述反应中的反应物，为了发挥作用，必须溶解足够量的氢以最有效地参与催化反应。过去的方法在高压下运行，以使所需量的氢溶解并容易供反应使用。如果氢在催化剂的反应位置处不可得，则会在催化剂上形成焦炭并使催化剂失活。为解决这一问题，通常升高压力以确保可得到足够的氢，避免催化剂上的焦化反应。但是，与它们的较低压力对应方法相比，较高压力的操作在建设和运行上成本较高。本发明的一个优点在于运行压力为1379kPa绝对压力(200psia)至4826kPa绝对压力(700psia)，其低于其它早先操作中的压力。在另一实施方案中，运行压力为2413kPa绝对压力(350psia)至4481kPa绝对压力(650psia)，在再一实施方案中，运行压力为2758kPa绝对压力(400psia)至4137kPa绝对压力(600psia)。此外，反应速率提高，以致在给定期间内通过反应器的材料吞吐量较大。较低的运行压力在增加脱羧反应并同时减少加氢脱氧反应方面提供了额外的优点。结果是从原料组分中除去氧并制造最终产品所需的氢量减少。氢可能是进料的昂贵组分，氢需求量的减少从经济角度看是有益的。可以使氢从工艺流出物中分离并再循环到氢化和脱氧区，或者氢的量可以仅稍超过氢化和脱氧反应的氢需求量，例如过量5至25％，并因此不循环。可以使用另一精制单元(例如加氢裂化器)作为氢源，其可能消除对循环气体压缩机的需要。
通过采用大的烃再循环量，在较低压力下使所需量的氢保持溶解。其它方法利用烃再循环控制反应区内的温度，因为该反应是放热反应。但是，根据控制液相中的氢含量和因此降低失活速率的需要，设定此处所用的再循环物与原料的比率的范围。再循环量不取决于温度控制要求，而是取决于氢溶解度要求。氢在烃产物中的溶解度高于在原料中的溶解度。通过采用大的烃再循环量，大大提高了反应区中氢在液相中的溶解度，并且无需较高压力来提高氢溶解量并避免低压下的催化剂失活。在本发明的一个实施方案中，烃再循环物与原料的体积比为2∶1至8∶1，或2∶1至6∶1。在另一实施方案中，该比率为3∶1至6∶1，在再一实施方案中，该比率为4∶1至5∶1。
使用模型模拟法确定烃再循环物与原料的合适体积比的范围，在该模型模拟法中，原料是植物油，再循环物是正构C17和C18链烷烃。绘制模拟结果并显示在图1中。该模拟试验条件为在316℃(600℉)和4137kPa绝对压力(600psia)下。相对于再循环物与进料的比率(体积/体积)绘制以gm/cm3(氢克数/立方厘米的原料和再循环物总量)为单位的氢溶解度。模拟结果表明，氢溶解度迅速提高直至2∶1的再循环物与进料之比。模拟表明，在2∶1到6∶1的再循环物与进料之比的范围，氢溶解度保持较高水平。这样，根据实现脱氧反应区中的合适的氢溶解度确定再循环物与进料的体积/体积比的具体范围。
出自脱氧区中的脱氧反应的反应产物包含液态部分和气态部分。液态部分包含烃级分，该烃级分基本全是正链烷烃并具有高浓度的在9至18个碳原子范围内的链烷烃。不同原料会产生不同的链烷烃分布。在分离后，这种烃级分的一部分可用作上述烃再循环物。尽管这种烃级分可用作柴油机燃料，但因为其基本完全包含正链烷烃，因而具有差的冷流性质。如果需要改进该液体烃级分的冷流性质，可以使整个反应产物与异构化催化剂在异构化条件下接触以将正链烷烃至少部分异构化成异链烷烃。异构化所用的催化剂和条件是本领域公知的。参见例如US 2004/0230085A1，其全文经此引用并入本文。异构化可以在上述相同反应区(即相同反应器)的独立的床中进行，或异构化可以在独立的反应器中进行。
如果需要异构化，则将脱氧反应区的产物在异构化条件下在氢存在下与异构化催化剂接触，以将正链烷烃异构化成支链烷烃。只需要足以克服正链烷烃的冷流问题的最低支化。由于显著支化的尝试具有产生高程度的不想要的裂化的危险，因此主要异构化产物是单支链烃。
链烷烃产物的异构化可以以本领域已知的任何方式或使用本领域已知的任何合适的催化剂实现。合适的催化剂包含周期表第VIII族(IUPAC8-10)的金属和载体材料。合适的第VIII族金属包括铂和钯，它们各自可以独自使用或联合使用。载体材料可以是非晶或结晶的。合适的载体材料包括非晶氧化铝、非晶二氧化硅-氧化铝、镁碱沸石、ALPO-31、SAPO-11、SAPO-31、SAPO-37、SAPO-41、SM-3、MgAPSO-31、FU-9、NU-10、NU-23、ZSM-12、ZSM-22、ZSM-23、ZSM-35、ZSM-48、ZSM-50、ZSM-57、MeAPO-11、MeAPO-31、MeAPO-41、MeAPSO-11、MeAPSO-31、MeAPSO-41、MeAPSO-46、ELAPO-11、ELAPO-31、ELAPO-41、ELAPSO-11、ELAPSO-31、ELAPSO-41、浊沸石、钙霞石、钾沸石、stillbite的氢形式、丝光沸石的镁或钙形式、和帕水硅铝钙石(partheite)的镁或钙形式，它们各自可以独立使用或联合使用。ALPO-31描述在US 4,310,440中。SAPO-11、SAPO-31、SAPO-37和SAPO-41描述在US 4,440,871中。SM-3描述在US 4,943,424；US 5,087,347；US 5,158,665；和US 5,208,005中。MgAPSO是一种MeAPSO，这是金属铝硅磷酸盐分子筛的首字母缩略词，其中金属Me是镁(Mg)。合适的MeAPSO-31催化剂包括MgAPSO-31。MeAPSOs描述在US 4,793,984中，且MgAPSOs描述在US 4,758,419中。MgAPSO-31是优选的MgAPSO，其中31是指具有结构类型31的MgAPSO。具有最初降低的孔径的许多天然沸石，例如镁碱沸石，可以如US 4,795,623和US 4,924,027中教导的那样通过经铵离子交换除去缔合的碱金属或碱土金属、并煅烧产生基本氢形式来转化成适用于烯烃骨架异构化的形式。在US 5,510,306、US 5,082,956和US 5,741,759中公开了用于骨架异构化的其它催化剂和条件。
该异构化催化剂还可以包含如US 5,716,897和US 5,851,949中所述的选自由镧、铈、镨、钕、钐、钆、铽及其混合物组成的组的改性剂。其它合适的载体材料包括ZSM-22、ZSM-23和ZSM-35，它们在US 5,246,566和S.J.Miller著的题为“New molecular sieve process for lube dewaxing bywax isomerization(通过蜡异构化将润滑油脱蜡用的新型分子筛法)”的文章，Microporous Materials 2(1994)439-449中被描述用于脱蜡。US4,310,440；US 4,440,871；US 4,793,984；US 4,758,419；US 4,943,424；US5,087,347；US 5,158,665；US 5,208,005；US 5,246,566；US 5,716,897；和US 5,851,949的教导经此引用并入本文。
US 5,444,032和US 5,608,968教导了由非晶二氧化硅-氧化铝凝胶和一种或多种属于第VIIIA族的金属构成的合适的双官能催化剂，其在含有多于15个碳原子的长链正链烷烃的加氢异构化中有效。US 5,981,419和US5,908,134教导了合适的双官能催化剂，其包含：(a)与β-沸石同结构的多孔结晶材料，选自硼硅酸盐(BOR-B)和硼-铝-硅酸盐(Al-BOR-B)，其中摩尔比SiO2∶Al2O3高于300∶1；(b)一种或多种属于第VIIIA族的金属，选自铂和钯，其量在0.05至5重量％的范围内。Article V.Calemma等人，App.Catal.A：Gen.，190(2000)，207教导了另一合适的催化剂。
异构化催化剂可以是本领域公知的任何这样的催化剂，如上文描述和列举的那些。异构化条件包括150℃至360℃的温度和1034kPa绝对压力(150psia)至2068kPa绝对压力(300psia)或1724kPa绝对压力(250psia)至4726kPa绝对压力(700psia)的压力。在另一实施方案中，异构化条件包括300℃至360℃的温度和3102kPa绝对压力(450psia)至3792kPa绝对压力(550psia)的压力。低压运行允许不借助补充压缩机从氢装置任选引入氢。当不将氢循环时，送入异构化区的氢量仅稍高于消耗量，超出消耗需求量的5至25％。异构化区的其它运行条件是本领域公知的。
无论是否进行异构化，都通过一个或多个分离步骤加工最终流出物流，即在已实施所有反应后获得的物流，以获得可用作柴油沸程燃料或燃料调合组分的纯化的烃流。由于最终流出物流既包含液态组分又包含气态组分，因此使用分离器(例如冷分离器)分离液态和气态组分。分离的液态组分包含可用作柴油机燃料的产物烃流。可以实施进一步的分离，以从产物烃流中除去石脑油和LPG。分离的气态组分主要包含来自脱羧反应的氢和二氧化碳。可以通过本领域公知的手段、与热碳酸盐溶液反应、变压吸收等从氢中除去二氧化碳。也可以在如与本申请同一日提交并经此引用并入本文的共同待审的申请Docket No.H0013966和Docket No.H0017132中所述的方法中用胺吸收。如果需要，可以通过将废吸收介质再生来回收基本纯的二氧化碳。可以将除去二氧化碳后留下的氢再循环至反应区(在此主要发生氢化)和/或任何后继床/反应器。
最后，将一部分产物烃再循环至氢化和脱氧反应区。再循环流可以取自氢化和脱氧反应器之后的产物烃流和分离形式的气态组分，并再循环回氢化和脱氧反应器。或者再循环流可以取自例如位于脱氧反应区和异构化反应区之间的分离单元(例如热高压分离器)的流出物。尽管可行，但较不优选从异构化产物中提取再循环流，因为异构化产物在氢化和脱氧反应区中比正链烷烃更容易裂化。如果必要，也可以将来自例如热高压分离器或冷高压分离器的一部分烃流冷却，并用作脱氧反应区的床之间的骤冷液，以进一步控制反应热和提供应急骤冷液。可以将再循环流送入脱氧反应区和/或任何后继床或反应器的入口。烃再循环的一个益处是控制各个床中的温度升高。但是，如上所述，烃再循环量在这里取决于反应区中的所需氢溶解度。提高反应混合物中的氢溶解度就可以在较低压力和因此较低成本下成功运行。以高的再循环水平运行并保持氢在液相中的高含量有助于耗散催化剂表面的热点，并减少导致焦化和催化剂失活的不合意重质组分的形成。
列出下列实施例以举例说明本发明，但不是要不适当地限制如所附权利要求所述的本发明的宽范围。
实施例
在下行流喷淋床反应器中以1LHSV加工经过精制的低芥酸菜籽油，所述反应器包含200cc负载在氧化铝上的被助催化的镍-钼催化剂。以200cc/hr或1LHSV的速率经1000小时连续加入低芥酸菜籽油。在运转的最初300小时中，如图2中所示改变运行条件。图2中所示的数据表明，2068kPa绝对压力(300psia)的低运行压力是成功的。在接下来的700小时中，在3447kPa绝对压力(500psia)和321至327℃(610至620℉)下稳态运行该方法。没有烃产物被再循环到反应器中。定期测量产物的氧含量。在运转750小时后，产物中的氧含量开始不断升高，表明催化剂显著失活且甘油三酸酯不足以反应。
用相同催化剂在3447kPa绝对压力(500psia)和315℃(600℉)的稳态条件下重复该实验。但在该对比实验中，使烃产物以4∶1的再循环物与原料的体积比再循环到反应器中。同样定期测量产物的氧含量。在此实验中，催化剂运转超过2300小时仍保持高的活性，并且没有表现出失活迹象。图3显示了对比实验的结果，该图绘制了产物中的氧百分比相对于运转小时数的图。
图3表明，在运转700小时后，来自无再循环的实验的产物的氧含量开始提高，表明催化剂失活。与此相比，图3还表明，来自具有4∶1的再循环物与原料的体积比的实验的产物仍基本不含氧。

Claims (9)

1.由可再生原料制造烃产物的方法，所述烃产物包含具有8至24个碳原子的链烷烃，该方法包括：在反应区中通过在反应条件下在氢存在下将可再生原料氢化和脱氧而处理该原料，以提供包含具有8至24个碳原子的链烷烃的反应产物，并将一部分所述反应产物再循环到反应区，其中再循环物与原料的体积比为2∶1至8∶1，
其中通过使所述可再生原料与氢化和脱氧催化剂在1379kPa绝对压力至4826kPa绝对压力的压力接触而将该原料氢化和脱氧，其中温度为200℃至300℃。
2.权利要求1的方法，进一步包括通过在异构化条件下与异构化催化剂接触而将至少一部分链烷烃异构化，从而将至少一部分链烷烃异构化成支链烷烃。
3.权利要求1的方法，进一步包括在预处理区中在预处理条件下预处理所述可再生原料，以除去该可再生原料中的至少一部分污染物。
4.权利要求1的方法，其中将过量氢再循环到反应区。
5.权利要求1的方法，其中脱氧包括脱羧、脱羰和加氢脱氧中的至少一种。
6.权利要求1的方法，进一步包括在反应区中处理由石油衍生的烃原料。
7.权利要求1的方法，其中所述可再生原料包含至少一种选自由下述材料组成的组的组分：低芥酸菜籽油、玉米油、豆油、菜籽油、妥尔油、葵花油、大麻籽油、橄榄油、亚麻籽油、椰子油、蓖麻油、花生油、棕榈油、芥子油、棉籽油、麻风树油、牛脂、猪油、鲸骨脂、乳脂肪、鱼油、藻油、下水道污泥、印度楝树油及其混合物。
8.权利要求1的方法，其中所述可再生原料进一步包含至少一种选自由下述材料组成的组的共进料组分：废机油、废工业润滑剂、用过的石蜡、由煤的气化继之以下游液化步骤制成的液体、由生物质的气化继之以下游液化步骤制成的液体、由天然气的气化继之以下游液化步骤制成的液体、由废塑料的热解聚或化学解聚制成的液体、和作为石化和化学工艺的副产物生成的合成油。
9.权利要求1的方法，其中所述可再生原料包含至少一种选自由下述材料组成的组的组分：油脂、下水道污泥及其混合物。
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US20040230085A1 (en) * 2002-09-06 2004-11-18 Juha Jakkula Process for producing a hydrocarbon component of biological origin
US20060264684A1 (en) * 2005-05-19 2006-11-23 Petri John A Production of diesel fuel from biorenewable feedstocks

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US20090082606A1 (en) 2009-03-26
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EP2188235A2 (en) 2010-05-26
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CN101801893A (zh) 2010-08-11
US8003836B2 (en) 2011-08-23
WO2009039000A2 (en) 2009-03-26
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AU2008302503A1 (en) 2009-03-26
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US20110024327A1 (en) 2011-02-03
US7982076B2 (en) 2011-07-19

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