CN102639226A - 包括多孔结构以及优化多孔结构与反应器内壁的接触的成分的催化反应器 - Google Patents
包括多孔结构以及优化多孔结构与反应器内壁的接触的成分的催化反应器 Download PDFInfo
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Abstract
本发明涉及一种催化反应器,该催化反应器包括:反应室;至少一个催化结构,该催化结构由至少一个多孔催化组织组成,多孔催化组织的外部尺寸比反应室的内部尺寸最多小10%;反应室的内壁与多孔组织之间的环形空间;以及定位在环形空间中的至少一个第二结构,该第二结构从以下中选择:a)纤维结构,或b)包括至少一个金属套环的结构,所述金属套环紧密地包围多孔组织的至少一部分并支承金属翅片。
Description
技术领域
本发明的一个主题是催化反应器,该催化反应器包括特别是催化陶瓷或金属泡沫的多孔催化结构以及优化与反应器内壁的接触的成分。
背景技术
公知由陶瓷或甚至金属合金制成的泡沫被用作化学反应、更具体地用作多相催化反应中的催化剂支承物。这些泡沫特别有益于高放热或吸热反应(例如,放热费托反应、水-气转化反应、部分氧化反应、甲烷化反应等),和/或需要高空间速度的催化反应器(天然气、石脑油、LPG等的蒸汽重整)。
最普遍的用于形成具有开口宏观孔隙的陶瓷泡沫的方法包括使用陶瓷颗粒在水溶液或有机溶剂中的悬浮液浸润聚合物泡沫(通常为聚氨酯或聚酯泡沫),并切割成所需的几何形状。通过重复地施加压缩或通过离心旋转而从聚合物泡沫去除多余的悬浮液,以便仅在聚合物上留下一薄层悬浮液。在利用该方法对聚合物泡沫进行一次或多次浸润之后,使泡沫干燥以去除溶剂同时维持沉积的陶瓷粉末层的物理完整性。然后通过两个阶段将泡沫加热至高温。被称为粘合剂去除阶段的第一阶段在于通过缓慢和受控度升高温度来降解悬浮液中可能存在的聚合物和任何其它有机化合物,直到挥发性有机化合物被彻底去除(通常为500-900℃)。被称为烧结的第二阶段包括使用高温热处理强化残余的无机结构。
这种制造方法因此可以获得作为初始聚合物泡沫的替代品的无机泡沫,除了由于烧结造成的收缩。可通过该方法实现的最终孔隙度为:对于范围为从0.2mm至5mm的孔隙大小能够覆盖从30%至95%的范围。最终孔隙大小(或开口宏观孔隙)取决于初始有机“模板”(聚合物泡沫,通常为聚氨酯泡沫)的宏观结构。所述宏观结构通常从60ppi至5ppi变化(ppi代表每英寸的孔隙,孔隙的尺寸为从50μm到5mm)。
泡沫也可为具有允许组织结构在操作条件(温度、压力、气体组分等)下具有化学稳定性的化学成分的金属性质。在应用于天然气的蒸汽重整的情况下,金属多孔组织结构将包括基于表面氧化的NiFeCrAl的化学成分,该表面氧化可以形成保护金属合金免于任何腐蚀现象的微米尺度的氧化铝层。
多孔组织结构(陶瓷和/或覆盖有陶瓷的金属)在很多方面是用于催化剂的良好支承物:
-它们具有最大的表面积/体积(m2/m3)比,以便增加用于交换反应的几何面积并因此间接提高了催化效率,
-它们使沿催化床(在催化反应器的入口与出口之间)的压降最小,
-它们具有轴向和/或径向效率改善的热传递。轴向是指沿催化反应器的轴线,径向是指从催化反应器的内壁或外壁朝催化床的中心,
-它们改善了催化床所承受的热机械应力和/或热机械应力,
-它们与通过常规结构(球体、球丸、圆柱体、筒体等)造成的随机填充相比提高了管的填充密度,
-填充的控制可以确保从一个管到另一个管的填充均匀性。
不过,所面临的一个问题是多孔组织结构与反应室内壁之间的“物理”接触在操作期间的低质量。对于在高温下操作的反应器尤其如此,其中特别是金属管的膨胀将大于陶瓷性质的多孔组织结构的膨胀。在金属多孔性质的组织结构的情况下,两个元件(催化床、容纳催化床的反应室)的膨胀可更容易地协调。
多孔组织结构与反应室内壁之间的这种不良接触可能造成两个难点:
-在壁处形成优先流动,于是反应物不与催化剂相接触,
-不良的径向热传递。
发明内容
本发明的一种方案是催化反应器,该催化反应器包括:
-反应室;
-至少一个催化结构,所述催化结构由至少一个催化多孔组织构成,所述催化多孔组织的外部尺寸比反应室的内部尺寸最多小10%;
-反应室的内壁与多孔组织之间的环形空间;
-定位在环形空间中的至少一个第二结构,该第二结构选自:
a)纤维结构,或
b)包括至少一个金属套环的结构,该金属套环紧密地包围多孔组织的至少一部分并支承金属翅片,或
c)金属和/或陶瓷粉末或粉末的混合物。
可选地,纤维结构被覆盖有活性催化相。
用语多孔组织的“外部尺寸”应理解为是指:
-在该组织为块状的情况下是指长度、宽度和高度;或
-在该组织为圆柱体的情况下是指外径和高度;等等。
用语反应室的“内部尺寸”通常应理解为是指内径和长度,因为反应室通常是管,但如果反应器具有不同形状,则“内部尺寸”可以是其它尺寸。
如果催化结构包括若干个多孔组织,则该催化结构由多孔组织连续堆叠构成。
优选地,第二结构的特征接近反应室的特征(组分、热膨胀系数、导热率等),且第二结构具有柔性特征。
用语“纤维结构”应理解为基于硅钙氧化物、硅铝氧化物等的陶瓷纤维类型的结构,或者金属性质的纤维结构(例如,钢丝棉等)。与纤维结构的化学性质(成分)有关的约束就反应混合物而言是构成该纤维结构的材料的化学稳定性以及化学惰性。这一点对于结构b)和c)也是有效的。
这三种结构a)或/和b)或/和c)具有以下优点:灵活并因此能够适应由于反应室和多孔结构的膨胀不同而可能引起的反应器的环形空间的多孔结构内壁的尺寸变化。
翅片(结构b)还具有增加热传递的作用。反应器的内壁、翅片和催化结构之间的热传递主要通过热传导发生。
金属和/或陶瓷粉末或粉末的混合物(结构c)还具有改善热传递的作用。反应器的内壁、翅片和催化结构之间的热传递主要通过热传导发生。粉末或粉末混合物具有介于1μm与5000μm之间的颗粒大小。
附图说明
图1示出了连续堆叠并由纤维结构包围的催化陶瓷或金属泡沫的外围。
图2示出了被“套环或环以及翅片”型结构紧密包围的催化陶瓷或金属泡沫。
图3示出了被陶瓷和/或金属粉末型催化床结构紧密包围的催化陶瓷或金属泡沫。
具体实施方式
在这些图中,比例尺不具有代表性。具体而言,环形空间通常具有小于20mm、优选地小于10mm的尺寸。
根据情况而定,根据本发明的反应器可具有以下特征中的一个或多个:
-多孔组织结构是陶瓷泡沫,或者对于高温应用——即高于500℃的应用——是表面上覆盖有陶瓷性质的保护层的金属泡沫;
-第二结构是由陶瓷(氧化铝纤维、硅钙纤维、硅铝纤维等)制成或由金属制成的纤维结构;该金属纤维结构可以由包含镍和铬的合金或与预期反应的条件相适应的任何合金例如铬镍铁合金构成;
-陶瓷纤维结构包括从以下选择的至少一种成分:(i)氧化物:氧化铝、硅铝氧化物(SiO2-Al2O3)、硅钙氧化物(CaO-SiO2)、硅镁氧化物(MgO-SiO2)或这些成分的结合,或(ii)非氧化物:碳化物或氮化物;
-金属性质的纤维结构包含镍,优选地基于NiCrO、NiCrAlO或NiFeCrAlO的合金;
-第二结构是由至少一个套环构成的结构,所述套环由主要包含镍和铬的合金构成并紧密地环绕多孔组织结构的至少一部分,并且支承主要由镍和铬的合金构成的翅片。优选地,对于蒸汽重整应用,金属套环和翅片由铬镍铁合金制成;
-第二结构是由金属和/或陶瓷粉末或粉末的混合物构成的结构,粉末的混合物包括至少50%的从以下选择的氧化物或非氧化物无机材料的至少一种成分:(i)氧化物:氧化铝、硅铝氧化物(SiO2-Al2O3)、硅钙氧化物(CaO-SiO2)、硅镁氧化物(MgO-SiO2)或这些成分的结合,或(ii)非氧化物:碳化物或氮化物;和/或包含镍的金属材料,优选地基于NiCrO、NiCrAlO或NiFeCrAlO的合金;
-第二结构稳定并且相对于反应室中存在的气态气氛呈化学惰性。
多孔催化组织结构由从聚氨酯(PU)、聚氯乙烯(PVC)、聚苯乙烯(PS)、纤维素和胶乳中选择的聚合材料制成的基质制成,但泡沫的理想选择受严格的要求限制。
聚合材料必需不释放有毒混合物,例如避免使用PVC,因为其可导致氯化氢的释放。
当具有陶瓷性质时,多孔催化组织结构通常包括从氧化铝(Al2O3)和/或掺杂氧化铝(La(按重量计算1%至20%)-Al2O3、Ce(按重量计算1%至20%)-Al2O3、Zr(按重量计算1%至20)-Al2O3)、氧化镁(MgO)、尖晶石(MgAl2O4)、水滑石、CaO、硅钙氧化物、硅铝氧化物、氧化锌、堇青石、多铝红柱石、钛酸铝和锆石(ZrSiO4)中选取的无机颗粒;或从以下选择的陶瓷颗粒:铈土(CeO2)、氧化锆(ZrO2)、稳定铈土(铈土中的Gd2O3介于3mol%与10mol%之间)和稳定氧化锆(氧化锆中的Y2O3介于3与10mol%之间),以及配方(I)的混合氧化物:
Ce(1-x)Zrx O(2-δ)(I),
其中0<x<1且δ确保氧化物的电中性,
或配方(II)的掺杂混合氧化物:
Ce(1-x-y)Zrx Dy O2-δ(II),
其中D选自镁(Mg)、钇(Y)、锶(Sr)、镧(La)、镨(Pr)、钐(Sm)、钆(Gd)、铒(Er)或镱(Yb);其中0<x<1,0<y<0.5,且δ确保氧化物的电中性。
根据本发明的催化反应器可用于生产气态产品,特别是合成气。
优选地,供给气体包含与甲烷混合的氧气和/或二氧化碳和/或蒸汽。然而,这些催化床结构可以配置在所有用于通过重整生产氢气的方法的催化反应器中,即,特别是预重整床、重整床和水-气转化床。
所用的反应温度高且在200℃与1000℃之间、优选在400℃与1000℃之间。
反应物(CO、H2、CH4、H2O、CO2等)的压力可在10bar与50bar之间,优选地在15bar与35bar之间。
本发明的另一主题是在包括反应室和多孔催化结构的催化反应器内使用:
-纤维结构;和/或
-包括至少一个金属套环的结构,所述金属套环紧密地环绕多孔结构的至少一部分并支承金属翅片,以便防止反应室内壁与多孔催化结构之间形成环形空间;和/或
-金属和/或陶瓷粉末或粉末的混合物,
从而防止反应室内壁与多孔催化结构之间形成环形空间。
将纤维结构和/或包括至少一个金属套环——其紧密地环绕多孔组织结构的至少一部分并支承金属翅片和/或金属和/或陶瓷粉末和/或粉末的混合物——的结构安装在反应室内壁与多孔催化结构之间的环形空间中既可以改善径向热传递,又可以限制沿壁的流动。
Claims (10)
1.一种催化反应器,包括:
-反应室;
-至少一个催化结构,所述催化结构由至少一个催化多孔组织构成,所述催化多孔组织的外部尺寸比所述反应室的内部尺寸最多小10%;
-所述反应室的内壁与所述多孔组织之间的环形空间;
-定位在所述环形空间中的至少一个第二结构,所述第二结构从以下结构中选择:
a)纤维结构,或
b)包括至少一个金属套环的结构,所述金属套环紧密地包围所述多孔组织的至少一部分并支承金属翅片。
2.根据权利要求1所述的催化反应器,其特征在于,所述催化结构包括至少两个多孔催化组织的连续堆叠,所述多孔催化组织的外部尺寸比所述反应室的内部尺寸最多小10%。
3.根据权利要求1和2中任一项所述的催化反应器,其特征在于,所述多孔组织结构是陶瓷泡沫或在表面上覆盖有陶瓷保护层的金属泡沫。
4.根据权利要求1和3中任一项所述的催化反应器,其特征在于,所述第二结构是由陶瓷或金属制成的纤维结构。
5.根据权利要求4所述的催化反应器,其特征在于,所述陶瓷纤维结构包括从以下成分中选择的至少一种成分:
-(i)氧化物:氧化铝、硅铝氧化物(SiO2-Al2O3)、硅钙氧化物(CaO-SiO2)、硅镁氧化物(MgO-SiO2)或这些成分的组合,或
-(ii)非氧化物:碳化物或氮化物。
6.根据权利要求4所述的催化反应器,其特征在于,金属性质的纤维结构包含镍,优选地基于NiCrO、NiCrAlO或NiFeCrAlO的合金。
7.根据权利要求1和3中任一项所述的催化反应器,其特征在于,所述第二结构是由至少一个套环构成的结构,所述套环由主要包含镍和铬的合金构成并紧密地环绕所述多孔组织的至少一部分,并且支承由主要包含镍和铬的合金构成的翅片。
8.利用根据权利要求1至7中任一项所述的催化反应器来生产气体的用途。
9.根据权利要求8所述的用途,其特征在于,所述气体为合成气。
10.一种催化反应器,其包括反应室和催化多孔结构,在所述催化反应器内使用:
-纤维结构;和/或
-包括至少一个金属套环的结构,所述金属套环紧密地环绕所述多孔结构的至少一部分并支承金属翅片,以便防止所述反应室内壁与所述催化多孔结构之间形成环形空间,
从而防止所述反应室内壁与所述催化多孔结构之间形成环形空间。
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WO2011067503A1 (fr) | 2011-06-09 |
BR112012013146A2 (pt) | 2017-03-21 |
FR2953151A1 (fr) | 2011-06-03 |
US20120235096A1 (en) | 2012-09-20 |
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