CN102159527A - 用于将固体转化为燃料的系统以及方法 - Google Patents

用于将固体转化为燃料的系统以及方法 Download PDF

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CN102159527A
CN102159527A CN2009801372776A CN200980137277A CN102159527A CN 102159527 A CN102159527 A CN 102159527A CN 2009801372776 A CN2009801372776 A CN 2009801372776A CN 200980137277 A CN200980137277 A CN 200980137277A CN 102159527 A CN102159527 A CN 102159527A
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thermal cracking
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CN102159527B (zh
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A·拉蒂夫·马赫哲布
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Abstract

一种用于将固体燃料转化为燃料的系统，所述系统包括用于产生包括碳氢化合物的热裂解气的热解单元，用于将所述热裂解气转化为包括氢与一氧化碳的混合物的合成气的合成气生产单元，以及用于将所述合成气转化为燃料的气体-至-液体单元。

Description

用于将固体转化为燃料的系统以及方法
联邦赞助研究：不适用。
参考微缩胶片附录：不适用。
技术领域
本发明涉及用于将固体转化为燃料的系统以及方法，并且更具体地，涉及用于将城市固体废弃物、生物固体、废弃的橡胶和塑料、污泥、木材、木屑和煤转化为合成气并且其后将该合成气转化为液体或气体燃料。
背景技术
当前在市场中可获得各种利用费-托(Fischer-Tropsch，“F-T工艺”)工艺的实施方案的废弃物-至-液体燃料处理工艺。F-T工艺是催化化学反应，其中合成气(一氧化碳与氢的混合物)被转化为各种形式的液体碳氢化合物。该合成气可以由多种源产生，包括但不限于天然气、煤、废弃物或碳氢化合物的任何源。F-T工艺的反应可以包括如下反应：
CHn+H2O→(n/2+1)H2+CO    (合成气形成)
2n H2+CO→-(CH2-)n-+H2O  (F-T反应)
许多已知的废弃物-至-液体工艺涉及到高压下的直焰气化，而在有水蒸气存在时产生合成气。该化学反应涉及一些氧的添加并且由以下化学反应式表示：
2C+H2O+O2→CO2+H2+CO
如以上所示，大致50％的碳燃烧并且变为CO2，从而产生大量的CO2排放物。由于废弃物材料以及固体燃料的直接燃烧，该气体还可以包含有害的排放物，如二氧化氮和二氧化硫。这些已知工艺的劣势之一是导致的废气被氮和CO2稀释，使得直接燃烧几乎是不可能的。而且，为产生液体燃料而清洁生成的废气将会是非常昂贵的。此外，固体气化产生必须要被捕获、分离和处理的灰分。
因此，存在对于废弃物/固体燃料-至-液体燃料系统的需要，该系统通过在没有氧或空气存在下进行热解而偏离传统的费-托方法。作为结果，示例性工艺在热解过程(将废弃物/固体燃料转化为H2与CO的合成气)和重整过程(在催化过程中使该合成气进行反应以产生液体燃料或其他气体)二者中都产生低水平的CO2。所描述的工艺减少该合成气料流中小的灰分和碳颗粒的夹带，该合成气料流非常洁净并且具有高热值。示例性热解过程在没有氧或空气存在时发生，因此，作为结果而发生的排放物(包括二氧化氮和二氧化硫)被减少。取决于气化材料的硫含量，可能形成一些H2S，但在示例性系统中这些H2S随后在最后的重整过程之前被从气体中去除。
发明内容
本发明的一个实施方案教导了用于将固体燃料转化为液体或气体燃料的系统，该系统可以包括用于产生碳氢化合物的热裂解气(pyro gas)的热解单元，用于将该热裂解气转化为合成气(氢与一氧化碳的混合物)的合成气生产单元，以及用于将该合成气转化为燃料的气体-至-液体单元。该热解单元可以是连续热解单元。在一些实施方案中，合成气生产单元是水蒸气重整装置并且气体-至-液体单元是费-托系统。该系统还可以包括热裂解气清净单元，该热裂解气清净单元包括用于从该热裂解气去除污染物的二氧化碳去除单元和/或硫化氢去除单元。在其他实施方案中，该系统还包括合成气清净单元，该合成气清净单元包括从合成气去除污染物的硫化氢去除单元。该系统还可以包括进料预处理单元。连续热解单元可以是低NOx排放物燃烧器。固体燃料可以是城市固体废弃物、城市污泥、生物固体、橡胶、塑料、煤、有机废弃物、无机废弃物或其组合，并且液体燃料可以是柴油、汽油、喷气燃料、醇类、甲烷或其混合物。
本发明的另一个实施方案是用于将固体燃料转化为液体或气体燃料的方法。该方法可以包括如下步骤：将固体燃料热解为低二氧化碳热裂解气；将该低二氧化碳热裂解气重整为合成气；以及将该合成气转化为液体燃料。固体燃料可以是城市固体废弃物、城市污泥、生物固体、橡胶、塑料、煤、有机废弃物、无机废弃物或其组合。该方法还可以包括从低二氧化碳热裂解气去除污染物和/或从合成气去除污染物的步骤。液体燃料可以是柴油、汽油、喷气燃料、醇类、甲烷或其混合物。在一些实施方案中，可以通过连续间接火焰热解(indirect flame pyrolysis)热解固体燃料。水蒸气重整装置可以重整低二氧化碳热裂解气。费-托反应器可以转化合成气。在一些实施方案中，污染物包括H2S、COS、CO2、SO2或其混合物。污染物可以通过洗涤该热裂解气和捕获该污染物而被去除。在一些实施方案中，该方法还包括对固体燃料进行预处理。
附图说明
本发明的实施方案通过实施例的方式在附图中被图示说明，其中相似的参考数字指示相似的元件，并且其中：
图1示出将根据本申请的示例性实施方案的用于将城市固体废弃物、生物固体、废弃的橡胶和塑料、污泥以及煤转化为液体燃料的系统和工艺的示例性工艺流程图。
图2示出详细的针对气化平台(skid)的流程图的实施方案。
图3示出详细的针对液化平台的流程图的实施方案。
详细描述
本发明描述并且图示说明了用于将多种固体，包括但不限于城市固体废弃物、生物固体、废弃的橡胶和塑料、污泥以及煤，转化为液体燃料如柴油、汽油、喷气燃料、甲醇、乙醇、其他醇类或者仅甲烷气的示例性实施方案。污泥是本领域公知术语并且通常被描述为来自工业、水处理或废水处理过程的残留的半固体材料，包括生物固体。城市固体废弃物(Municipal solid waste，MSW)、污泥和煤在本申请中被共同称为“固体燃料”。如本领域普通技术人员将会理解的，本申请的示例性实施方案不限于这些固体并且因此可以使用本申请的系统和方法将多种其他的固体，如MSW、有机废弃物如木材和农业废弃物、无机废弃物如塑料、橡胶以及煤转化为液体燃料。
示例性系统以及方法在此参考图1、2和3被描述。如图1中可见，该系统包括热解单元10、热裂解气清净单元20、合成气生产单元30、合成气清净单元40以及气体至液体生产单元50。在一些实施方案中，还包括进料处理单元60。用于本发明的针对处理单元的基本排列可以通过阅读图1中呈现的流程图而被容易地理解。虽然图1和本说明书为了简化本发明的阐述而没有提及很多泵、压缩机、接收器、冷凝器、再沸器、仪器或其他公知的处理设备项。在一些实施方案中，该系统包括气化平台和液化平台。图2和图3提供本发明的优选实施方案，该优选实施方案在气化平台以及液化平台内并入一些优选设备，所述平台包括以下单元：热解单元10、热裂解气清净单元20、合成气生产单元30、合成气清净单元40以及气体至液体生产单元50。在一些实施方案中，气化平台包括热解单元10和热裂解气清净单元12，而液化平台包括合成气生产单元30、合成气清净单元40和气体至液体生产单元50。
使用如图1所示系统的示例性方法提供被进料至热解单元10的固体燃料110。固体燃料110可以是城市固体废弃物、生物固体、废弃的橡胶和塑料、城市污泥、煤、有机材料或其组合。在一些实施方案中，热解单元10包括干馏甑和分离器。在优选实施方案中，为了防止在操作中将空气引入热解单元，干馏甑被密封并且装备有气密的进口阀以及出口阀。在优选实施方案中，干馏甑由美国燃烧技术股份有限公司(American Combustion Technologies，Inc.，帕拉芒特，加利福尼亚州)制造。随着固体燃料110经过干馏甑，由一个或更多个气体燃烧器施加间接加热，造成固体燃料110被转化为包含水蒸气的热裂解气120。在本发明的示例性实施方案中，热解单元的温度从约800°F至约1300°F并且维持从约-0.20”至约-1.00”水柱(W.C.)的负压。在优选实施方案中，一个或更多个气体燃烧器是低NOx排放物型燃烧器，具体地，是满足在整个燃烧速率低于30以及9ppm NOx排放物的可购自美国燃烧技术股份有限公司(帕拉芒特，加利福尼亚州)的AHS或SLE系列。在优选实施方案中，一个或更多个气体燃烧器由天然气、丙烷、热裂解气或热裂解油供能。在优选实施方案中，一个或更多个燃烧器满足南海岸空气质量管理区(South Coast Air Quality Management District)的要求。
在一些实施方案中，固体燃料110利用不锈钢螺旋输送器(augurs)穿过干馏甑。螺旋输送器的速度被控制，允许通过干馏甑的行进时间取决于被气化的固体燃料110的具体类型而不同。在示例性实施方案中，行进时间为大致一小时。
气体和水从在干馏甑中的固体燃料110蒸发并且被传到分离器以从该气体蒸汽中分离任何液体、颗粒和污泥。在优选实施方案中，分离器是旋风分离器。旋风分离器在本领域是公知的并且因此不在本申请中详细描述。旋风分离器能够去除约99.9％的全部游离液体以及为大致5微米或更大的固体，并且对于固体(如phaltines和硫化铁)的去除是有效的。大部分收集的固体是碳并且量是较少的。
在一些实施方案中，一离开热解单元10，热裂解气120就进入从其中去除污染物的热裂解气清净单元20，产生已处理的气体130。污染物可以包括，但不限于，灰分(包括焦油污泥和颗粒)、硫化氢(H2S)、氧硫化碳(COS)、二氧化碳(CO2)及其混合物。热裂解气清净单元20可以包括数种示例性子系统，例如但不限于，颗粒去除子系统、干燥子系统、气体传输子系统和CO2/H2S去除子系统。
在一些实施方案中，颗粒去除子系统是文丘里(venturi)分离器。文丘里分离器如清洗系统一样操作来去除任何与气体混合的灰尘。文丘里分离器还可以在该清洗过程期间从热裂解气中分离水蒸气和大部分SO2以及COS(如果存在)。如果气体包括H2S，一些H2S将会在文丘里分离器中被去除，然而，一些H2S将会在CO2/H2S去除子系统中被脱去，更详细的描述见下文。文丘里分离器或洗涤器在本领域是公知的并且典型地由文丘里形的入口以及分离器组成。在优选实施方案中，文丘里分离器由美国燃烧技术股份有限公司(帕拉芒特，加利福尼亚州)制造。
在一些实施方案中，在离开颗粒去除子系统后，气体行进通过干燥子系统，该子系统可以是冷凝器/除雾器，该冷凝器/除雾器可作为换热器操作，用于从气体中分离全部液体。冷凝器/除雾器在本领域是公知的并且因此不在本申请中详细描述。
在一些实施方案中，在离开干燥子系统后，气体进入气体传输子系统。该气体传输子系统可以包括真空抽风机、中间气体罐、气体压缩机、后冷却器或其任何组合，全部这些在本领域中是公知的并且因此不在本申请中详细描述。
在一些实施方案中，压缩气体自气体传输子系统进入CO2/H2S去除子系统。虽然热解单元10不产生大量的CO2，从约1％至约15％，该CO2/H2S去除子系统进一步减少CO2排放物到约0.1％至3％之间。在优选实施方案中，CO2/H2S去除子系统还减少H2S的量到7ppb以下。
在一些实施方案中，CO2/H2S去除子系统可以包括胺洗涤器、胺闪蒸罐、硫沉淀单元、硫汽提塔、饱和器或其任何组合，全部这些在本领域中是公知的并且因此不在本申请中详细描述。在热裂解气清净单元后，已处理的气体130包含在约0到7ppb之间的H2S，以及0到3％的可以被捕获和储存的CO2。应该注意的是，在热解单元10或热裂解气清净单元20中没有水被浪费。过量的水在子系统中被重获、清洁和再使用。
在本申请的示例性实施方案中，已处理的气体130被以具有约350°F的温度和约50psi的压力的水蒸气饱和。在一些实施方案中，水蒸气的压力范围可以从约120psig至约200psig。饱和的已处理的气体130被进料至合成气生产单元30。合成气生产单元30产生典型地具有2∶1、3∶1和4∶1的H2/CO比率的合成气140。取决于最终产品的需要，该H2/CO比率可以在从1至6的范围内。在一些实施方案中，为了在合成气生产单元30内将碳氢化合物重整为CO和H2，已处理的气体130被预热到，例如，约1600°F或略高并且具有为大致150psi的压力。
如本领域普通技术人员将会理解的，合成气生产单元30中的水蒸气重整反应包括将已处理的气体130的碳氢化合物与水蒸气反应以形成氢、一氧化碳、甲烷和二氧化碳。一般地，通过水蒸气重整进行的碳氢化合物的重整包含大规模的吸热反应。在一些实施方案中，合成气生产单元30包括固定床反应器。在其他实施方案中，合成气生产单元30包括浆料反应器。
在合成气生产单元30内应当采用适当量的水。使用低量的水可以导致低H2产量和更重的液体燃料在气体-至-液体生产单元50内产生。更大的水蒸气注射量可以导致更高水平的H2产量，该H2随后用于将CO2重整回CO。
CO2+H2→CO+H2O
合成气140中的低量H2还可以指示合成气生产单元30中过量水蒸气的缺乏。水蒸气有助于防止碳在合成气生产单元30内的固定床反应器中的催化剂上的形成，碳的形成最终可以使该催化剂减活。在固定床反应器的一些实施方案中，如果小量溶剂被注射入合成气生产单元30来延长催化剂的寿命并且防止碳形成所致的污染，这是有益的。
合成气生产单元30内的条件是被监控的以获得CO和H2的一致的合成气140的组成。在一些实施方案中，CO和H2被分离并以预先决定的比率回过来混合在一起，以获得一致的合成气140的组成。合成气140的形成根据以下化学反应进行：
CH4+H2O→CO+3(H2)
C2H6+2(H2O)→2(CO)+5(H2)
这个过程可以施加于已处理的气体130内的所有碳氢化合物。
合成气140可以包含一些氮。氮的量非常低并且可以不是必须被去除的。然而，如果氮先于该气体被带出到液体生产单元50，燃料产品160将不会包含任何氮相关的液体产品。在一些实施方案中，合成气140在产生经处理的合成气150的合成气清净单元40中被处理。在一些实施方案中，合成气清净单元40从合成气140去除污染物。在示例性实施方案中，合成气清净单元40包括氧化锌床以去除任何残留的H2S。
在优选的实施方案中，经处理的合成气150在气体-至-液体生产单元50中被加压和加热。在一些实施方案中，气体-至-液体生产单元50包括一个或更多个反应器。当使用两个反应器时，第一反应器的压力在从约300至1000psig的范围内，更优选地从约500至750psig并且温度在600°F以下。在优选的实施方案中，第一反应器在约520°F的温度运行。在第一反应器后，气体被冷却和加压至在从约300至1000PSIG的压力范围内的压力。被加压的气体然后被加热并且通过第二反应器。在一些实施方案中，第一反应器是浆料反应器，该浆料反应器采用钴或氧化铁催化剂并且保持恒定温度以最大化液体产量。在一些实施方案中，50％的蜡在浆料反应器中产生，所述的蜡可以进一步经由氢化作用被处理为柴油燃料。在一些实施方案中，蜡包括具有大于40的碳数的组分。在优选的实施方案中，浆料反应器在从约300psig至约500psig范围内的压力和在从约430至约460°F范围内的温度运行。
在一些实施方案中，第二反应器采用基于镍的催化剂，该基于镍的催化剂取决于进料的氢与一氧化碳的比率来增加醇类和甲烷的形成。在一些实施方案中，第二催化剂对于将醇类脱水为柴油或轻液体燃料是必需的。在可替换的实施方案中，氧化铁或钴催化剂可以被用于产生柴油或轻液体燃料。
取决于气体的压力和温度以及气体-至-液体单元50中使用的催化剂的类型，在合成气生产单元30内改变H2与CO的比率将会影响来自气体-至-液体单元50的燃料产品160。燃料产品160使用蒸馏柱(未示出)被分离为汽油、喷气燃料、醇类和柴油燃料。在一些实施方案中，燃料产品160可以是气态的。燃料产品160内的燃料产生基本范围可以大致为：
柴油燃料                       70％
汽油、喷气燃料和轻溶剂         20％
与氧化合的物质(CH3OH，等等)    10％
在一些实施方案中，燃料产品160已被适当分离后，进一步处理使它们成为合格的标准燃料将不是必需的。
在一些实施方案中，燃料产品160可以包含一些水，这些水或者在CO2与H2的反应过程中产生，或者由没有参与反应的水蒸气部分所导致。该水从燃料中被分离并且该燃料在使用前被进一步清洁和分离。水分离过程简单并且能够或者通过闪蒸分离处理或者通过使用蒸馏柱进行。二者都是常见的并且易于设计和建立。
在一些实施方案中，至少70％经处理的合成气150气体被转化为燃料产品160。在优选的实施方案中，超过90％的经处理的合成气150气体被转化为燃料产品160。在一些实施方案中，燃料产品160的更轻的碳氢化合物可以被回收到合成气生产单元30来增加燃料产品160的形成。
在一些实施方案中，固体燃料110是来自进料预处理单元60的产品，以在进入热解过程10之前消除结块性。
如本领域技术人员将会理解的，本申请不限于在此描述的精确的示例性实施方案，各种变化和修改在不背离本申请的精神和范围的情况下是可行的。例如，不同的示例性实施方案的元素和/或特征可以在本说明书和所附权利要求书的范围内相互组合、相互替代和/或扩展。此外，阅读本说明书和附图后对于本领域普通技术人员变得明显的改进和修改被视为在本申请的精神和范围内。

Claims (27)

1.一种用于将固体燃料转化为燃料的系统，所述系统包括：
用于产生包括碳氢化合物的热裂解气的热解单元，
用于将所述热裂解气转化为合成气的合成气生产单元，所述合成气包括氢与一氧化碳的混合物，以及
用于将所述合成气转化为燃料的气体-至-液体单元。
2.如权利要求1所述的系统，其中所述热解单元是连续热解单元。
3.如权利要求1所述的系统，其中所述合成气生产单元包括水蒸气重整装置。
4.如权利要求1所述的系统，其中所述气体-至-液体单元包括费-托系统。
5.如权利要求1所述的系统，还包括用于从所述热裂解气去除污染物的热裂解气清净单元。
6.如权利要求1所述的系统，其中所述热裂解气清净单元包括二氧化碳去除单元。
7.如权利要求1所述的系统，其中所述热裂解气清净单元包括硫化氢去除单元。
8.如权利要求1所述的系统，还包括用于从所述合成气除去污染物的合成气清净单元。
9.如权利要求1所述的系统，其中所述合成气清净单元包括硫化氢去除单元。
10.如权利要求1所述的系统，还包括进料预处理单元。
11.如权利要求2所述的系统，其中所述连续热解单元包括低NOx排放物燃烧器。
12.如权利要求1所述的系统，其中所述固体燃料包括城市固体废弃物、城市污泥、生物固体、橡胶、塑料、煤、有机废弃物、无机废弃物或其组合。
13.如权利要求1所述的系统，其中所述燃料是液体或者气体。
14.如权利要求13所述的系统，其中所述液体燃料包括柴油、汽油、喷气燃料、醇类、甲烷或其混合物。
15.用于将固体燃料转化为燃料的方法，所述方法包括：
将所述固体燃料热解为低二氧化碳热裂解气；
将所述低二氧化碳热裂解气重整为合成气；以及
将所述合成气转化为所述燃料。
16.如权利要求15所述的方法，其中所述固体燃料包括城市固体废弃物、城市污泥、生物固体、橡胶、塑料、煤、有机废弃物、无机废弃物或其组合。
17.如权利要求15所述的方法，还包括从所述低二氧化碳热裂解气去除污染物的步骤。
18.如权利要求15所述的方法，还包括从所述合成气去除污染物的步骤。
19.如权利要求15所述的系统，其中所述燃料是液体或者气体。
20.如权利要求19所述的方法，其中所述液体燃料包括柴油、汽油、喷气燃料、醇类、甲烷或其混合物。
21.如权利要求15所述的方法，其中热解所述固体燃料的步骤包括连续间接火焰热解。
22.如权利要求15所述的方法，其中重整所述低二氧化碳热裂解气的步骤包括水蒸气重整装置。
23.如权利要求15所述的方法，其中转化所述合成气的步骤包括费-托反应器。
24.如权利要求17所述的方法，其中所述污染物包括H2S、COS、CO2、SO2或其混合物。
25.如权利要求17所述的方法，其中去除污染物的步骤包括洗涤所述热裂解气。
26.如权利要求17所述的方法，其中去除污染物的步骤包括洗涤和捕获所述污染物，所述污染物包括H2S、COS、CO2、SO2或其混合物。
27.如权利要求15所述的方法，还包括预处理所述固体燃料的步骤。
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