CN105706281A - 具有用于管理去往化学反应器的气态反应介质流的歧管的化学反应器 - Google Patents
具有用于管理去往化学反应器的气态反应介质流的歧管的化学反应器 Download PDFInfo
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- CN105706281A CN105706281A CN201480061178.5A CN201480061178A CN105706281A CN 105706281 A CN105706281 A CN 105706281A CN 201480061178 A CN201480061178 A CN 201480061178A CN 105706281 A CN105706281 A CN 105706281A
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Abstract
化学反应器(例如重整器反应器)系统包括用于管理去往其的气态反应介质流的歧管(126)。歧管(126)包括歧管壳(128),所述歧管壳(128)限定歧管室(129)并且具有选自如下的至少一个另外的部件:气体分布器(127);加热器;具有在其内或与其邻近的密封的空穴。
Description
相关申请的交叉引用
本申请要求均在2013年11月6日提交的美国专利申请序号61/900,510和61/900,543的权益,将其全部内容引入本文作为参考。
技术领域
本教导涉及化学反应器并且更具体地涉及其中使气态反应介质进行向期望产物的转化的化学反应器。
背景技术
气态的或气化的液体可重整燃料向富含氢气的包含一氧化碳的气体混合物(通常被称为“合成气体”或“合成气”的产物)的转化可根据任意这样的公知气相燃料重整操作例如蒸汽重整、干重整、自热重整、和催化部分氧化(CPOX)重整进行。这些燃料重整操作各自具有其与众不同的化学和要求并且各自的特点是其相对于其它而言有优点和缺点。
改进的燃料重整器、燃料重整器部件、和重整工艺的发展由于燃料电池(即,用于将可电化学氧化的燃料例如氢气、氢气与一氧化碳的混合物等电化学转化为电力的装置)的潜力而依旧是相当多的研究的焦点,对于包括主动力设备(MPU)和辅助动力设备(APU)在内的通常应用依旧起到极大扩展的作用。燃料电池也可用于专业化应用例如作为用于电动车的机载发电装置,用于住宅用装置的备用电源,用于在离网场所中的休闲用途、户外和其它耗电装置的主电源,和用于便携式电池组的更轻质、更高功率密度、不依赖环境温度的替代品。
由于氢气的大规模的经济的生产、其分销所需要的基础设施、以及用于其存储(尤其是作为运输燃料)的实用手段普遍被认为还有长的路要走,因此很多当前的研究和开发涉及改进作为可电化学氧化的燃料(特别是氢气与一氧化碳的混合物)的来源的燃料重整器和作为这样的燃料到电力的转化器的燃料电池组件(通常被称为燃料电池“堆”)两者,以及将燃料重整器和燃料电池集成到用于产生电能的更紧凑、可靠和有效率的装置中。
发明内容
本教导虽然总体上适用于用于进行所有方式的气相反应的所有类型的气相反应器,但是在本文中将通过用于液态(液体)和气态可重整燃料的气相重整以制造富含氢气的重整物的气相重整器和方法具体地示例。这样的重整物可用于各种各样的用途,例如,作为化学反应物和作为用于在燃料电池内转化为电力的燃料。
本教导的化学反应器系统可包括具有入口的化学反应器;以及与所述化学反应器的入口流体连通的歧管。所述歧管可包括歧管壳(housing),所述歧管壳限定歧管室。所述歧管可包括选自如下的至少一个另外的部件:气态反应物分布器,其设置在所述歧管室内并且延伸达所述歧管室的至少大部分长度,其中所述气态反应物分布器与气态反应物导管流体连通,且所述气态反应物分布器包括与所述化学反应器的入口相反定位的一个或多个出口;与所述歧管室热连通的加热器;和空穴(cavity),其中所述歧管壳限定所述空穴,并且可在所述空穴内或者邻近于所述空穴设置密封。所述密封可接合所述化学反应器的入口,从而在所述歧管壳和所述入口之间提供气密密封。所述密封可为垫圈。
所述化学反应器可为固定床反应器、流化床反应器、微通道反应器、管壳式(shell-and-tube)反应器、管式反应器、多管式反应器、或其组合。
所述化学反应器可适合于进行选自如下的气相反应:乙酰化、加成反应、烷基化、脱烷基化、加氢脱烷基化、还原烷基化、胺化、芳构化、芳基化、重整、羰基化、脱羰、还原羰基化、羧化、还原羧化、还原偶联、缩合、裂化、加氢裂化、环化、环化低聚、燃烧、脱卤、二聚、环氧化、酯化、交换、费-托、气化、卤化、氢卤化、同系化、水合、脱水、加氢、脱氢、加氢羧化、加氢甲酰基化、氢解、加氢金属化、水解、加氢处理(hydroprocessing)、加氢精制(hydrotreating)、异构化、甲基化、脱甲基化、易位、硝化、氧化、部分氧化、聚合、还原、磺化、调聚、酯交换、三聚和水煤气变换。
所述化学反应器可包括多个管式反应器单元。
所述歧管壳可由在所述化学反应器的操作温度下保持热和机械稳定的材料制造。
所述加热器可为设置在所述歧管室内的电阻加热器和/或与所述歧管以及化学反应器的反应区热连通的至少一个热传导元件。
用于将至少一种可重整燃料重整以制造富含氢气的重整物的重整器系统,其中所述重整器系统可包括具有入口的重整器反应器单元;以及与所述至少一个重整器反应器单元的入口流体连通的歧管。所述歧管可包括歧管壳,所述歧管壳限定歧管室。所述歧管可包括选自如下的至少一个另外的部件:气态重整反应物分布器,其设置在所述歧管室内并且延伸达所述歧管室的至少大部分长度,其中所述气态反应物分布器与反应物导管流体连通,并且所述气态反应物分布器包括与所述重整器反应器的入口反向定位的一个或多个出口;与所述歧管室热连通的加热器;和空穴,其中所述歧管壳限定所述空穴,并且在所述空穴内或者邻近于所述空穴设置密封。所述密封可接合所述重整器反应器的入口,从而在所述歧管壳和所述入口之间提供气密密封。
所述重整器系统,其中所述歧管壳可由在所述至少一个重整器反应器的操作期间在重整反应区的温度下保持热和机械稳定的材料制造。
根据本教导,化学反应器系统可包括:
(a)至少一个反应器单元,其具有:用于接纳气态反应介质的入口端和相关的入口,其中气态反应介质进行气相反应以产生反应产物的气相反应区,用于这样的反应产物的流出的出口端和相关的出口;
(b)歧管,其与所述至少一个反应器的入口气流连通,所述歧管包括具有壁厚度的壳,所述壳限定歧管室并且具有选自如下的至少一个另外的部件:
(i)气态反应介质分布器,其设置在所述歧管室内并且延伸达所述歧管室的至少大部分长度,所述分布器与用于将气态反应介质流输送至所述分布器的导管气流连通,所述分布器具有一个出口或多个出口并且排列成将在所述分布器内流动的气态反应介质以初始远离所述至少一个反应器的入口并且之后朝着所述至少一个反应器的入口的路径排入到所述歧管室中,
(ii)加热器,其用于维持所述歧管室的温度高于所述气态反应介质或其组分(一种或多种)的冷凝温度和/或用于使在其中的所述气态反应介质在所述气态反应介质进入所述至少一个反应器的入口之前在温度方面更均匀,和
(iii)限定在所述壳的壁段内的空穴和设置在所述空穴内的垫圈,所述垫圈接合所述至少一个反应器单元的入口端,从而在所述壳的壁和所述反应器的入口端之间提供气密密封。
本文中的化学反应器系统的歧管部件可为反应器操作的管理提供若干好处。一种这样的好处可为气态反应介质遍及所述反应器入口的整个截面的基本上均匀的分布,或者在具有反应器单元的阵列的反应器(例如以下描述的气相重整器的实施方式)的情况下,去往所述阵列中的各反应器单元的入口的气态反应的基本上均匀的分布,由此没有一个反应器单元收到与另外的反应器单元相比明显更大量的气态反应介质。
所述歧管部件的另一好处可为其限制或者抑制在所述歧管室内发生湍流的能力,这是也可对遍及所述反应器和反应器系统的低背压的维持有贡献的好处。
所述歧管部件的又一好处可为其在所述反应器入口处提供气态反应介质的基本上层流的能力,这是可有利于遍及所述反应器和反应器系统的低背压的维持的另一因素。
附图说明
应理解,以下描述的附图仅用于说明目的。附图未必是按比例的,重点通常放在说明本教导的原理上。附图绝不意图限制本教导的范围。相似的附图标记通常是指相似的部分。
图1A为引入根据本教导的歧管部件的气态燃料CPOX重整器的一种实施方式的纵截面图。
图1B为图1A中所示的气态燃料CPOX重整器的横向(垂直于纵轴)截面图。
图1C和1D为图1A和2A中所示的管式CPOX反应器单元之一分别的放大的纵截面图和横截面图。
图1E和1F为本教导的CPOX重整器的管式CPOX反应器单元的两种实施方式的放大的横截面图。
图1G为图1A、1B和2A中所示的气态燃料CPOX重整器的一部分歧管和相关的管式CPOX反应器单元的放大的纵截面图。
图2A为引入根据本教导的歧管部件的液体燃料CPOX重整器的一种实施方式的纵截面图。
图2B为图2A中所示的液体燃料CPOX重整器的横向(垂直于纵轴)截面图。
具体实施方式
应理解,本文中的本教导不限于所描述的具体程序、材料和改动并且因此可变化。还应理解,所使用的术语仅用于描述具体实施方式的目的并且不意图限制本教导的范围,本教导的范围将仅由所附权利要求限制。
为了简要起见,本文中的讨论和描述将主要关注于部分氧化重整反应和反应物,包括催化部分氧化重整反应和反应物(可重整燃料和包含氧气的气体)。然而,本文中描述的装置、组件、系统和方法可应用于其它重整反应例如蒸汽重整和自热重整以及它们各自的反应物(分别地,可重整燃料和蒸汽,以及可重整燃料、蒸汽和包含氧气的气体)以及本文中描述的其它气相反应。因此,当在本文中结合装置或方法提及包含氧气的气体时,本教导应被认为包括组合的或单独的蒸汽,即,包含氧气的气体和/或蒸汽,除非明确地另有叙述或者通过上下文理解。此外,当在本文中结合装置或方法提及可重整燃料时,本教导应被认为包括组合的或单独的蒸汽,即可重整燃料和/或蒸汽,除非明确地另有叙述或者如通过上下文理解。
此外,本教导的包括歧管的液态(液体)和气态可重整燃料重整系统和方法应被理解为适合于与液态(液体)和/或气态反应物一起使用以进行蒸汽重整和自热重整。例如,蒸汽或自热重整系统的输送、控制和管理可在与本文中描述的相同结构体和部件内和/或用与本文中描述的相同的总体方法发生。即,本教导的重整系统和方法可将合适的液体反应物例如液体可重整燃料和/或液体水从液体可重整燃料储器输送至气化器以分别产生气化的液体可重整燃料和蒸汽,并且将合适的气态反应物,例如,包含氧气的气体、气态可重整燃料和蒸汽的至少一种,从它们各自的来源输送(其中所述气化的液体可重整燃料、蒸汽和其它气态反应物可通过本教导的歧管输送)至燃料电池单元或系统的期望部件,例如重整器。
当在输送系统中使用水时,可使用来自燃料电池单元或系统的重整器、燃料电池堆和后燃烧器的一个或多个的再循环热使所述水气化以产生蒸汽,其可存在于所述输送系统中和/或从独立的来源引入到所述输送系统中。
在整个说明书和权利要求中,当结构(体)、装置、设备、组成(组合物)等被描述为具有、包括或包含特定部件(组分)时,或者当方法被描述为具有、包括或包含特定方法步骤时,所思虑到的是,这样的结构(体)、装置、设备、组成(组合物)等还基本上由所列举的部件(组分)构成或者由所列举的部件(组分)构成,和这样的方法还基本上由所列举的方法步骤构成或者由所列举的方法步骤构成。
在本说明书和权利要求中,当一个要素(元件)或部件(组分)被认为包括在所列举的要素(元件)或部件(组分)的列表中和/或选自所列举的要素(元件)或部件(组分)的列表时,应理解,所述要素(元件)或部件(组分)可为所列举的要素(元件)或部件(组分)的任一个,或者所述要素(元件)或部件(组分)可选自所列举的要素(元件)或部件(组分)的两个或更多个。进一步地,应理解,在不背离本教导的焦点和范围的情况下。本文中所描述的结构(体)、装置、设备或组成(组合物)或方法的要素和/或特征可以多种方式组合,无论是在其中明示的还是暗示的。例如,当介绍具体的结构(体)时,该结构(体)可在本教导的设备和/或方法的多种实施方式中使用。
术语“包括”、“包含”、“具有”、“含有”、或“含”(包括其语法等同物)的使用应通常被理解为是开放式的和非限制性的,例如,不排除另外的未列举的要素(元件)或步骤,除非另有具体叙述或者由上下文理解。
本文中单数例如“一个(种)(a,an)”和“该(所述)”的使用包括复数(并且反过来也成立),除非另有具体叙述。
当在数量值之前使用术语“约”时,本教导也包括所述具体数量值本身,除非另有具体叙述。如本文中使用的,术语“约”指的是与标称值的±10%变化,除非另有指示或暗示。
应理解,步骤的顺序或者用于进行某些动作的顺序是不重要的,只要本教导仍然是可操作的。例如,此处描述的方法可以任何合适的顺序进行,除非本文中另有指示或者明显与上下文矛盾。此外,除非步骤本来就必须依序进行,否则它们可同时进行。
在本说明书中的多个位置处,数值是以值的范围公开的。具体意图是,本文中公开的数值的范围包括在所述范围内的每一个值以及其任意子范围。例如,在0-20范围内的数值具体地意图单独地公开0、1、2、3、4、5、6、7、8、9、10、11、12、13、14、15、16、17、18、19和20,以及其任意子范围,例如,0-10、8-16、16-20等。
本文中提供的任意和全部实例、或示例性语言例如“例如”的使用仅意图更好地阐明本教导且不对本发明的范围加以限制,除非有声明。本说明书中的语言均不应被理解为将任何未声明的要素指示为对于本教导的实践是必要的。
指示空间方位或高度的术语和表述例如“上部”、“下部”、“顶部”、“底部”、“水平(的)”、“竖直(的)”等除非它们的上下文用法另有指示,否则在本文中应被理解为不具有结构、功能或操作意义并且仅反映附图的某些中所说明的本教导的液体燃料CPOX重整器的多种视图的任意选择的方位。
如本文中使用的,“可重整燃料”指的是液体可重整燃料和/或气态可重整燃料。
表述“液体可重整燃料”应被理解为包括在经历重整时进行向富含氢气的重整物的转化的在标准温度和压力(STP)条件下为液体的可重整的包含碳和氢的燃料,例如,甲醇、乙醇、石脑油、馏出物、汽油、煤油、喷气发动机燃料、柴油、生物柴油等。表述“液体可重整燃料”应进一步理解为包括这样的燃料,无论它们处于液态还是气态即蒸气。
如本文中使用的,“气态重整反应混合物”指的是包括如下的混合物:气态的液体可重整燃料(例如,气化的液体可重整燃料)、气态可重整燃料或其组合,以及包含氧气的气体(例如,空气)和/或水(例如,以蒸汽形式)。气态重整反应混合物可经历重整反应以产生富含氢气的产物(“重整物”),其也可包含一氧化碳。当要进行催化部分氧化重整反应时,所述气态重整反应混合物可被称为“气态CPOX重整反应混合物”,其包括可重整燃料和包含氧气的气体。当要进行蒸汽重整反应时,所述气态重整反应混合物可被称为“气态蒸汽重整反应混合物”,其包括可重整燃料和蒸汽。当要进行自热重整反应时,所述气态重整反应混合物可被称为“气态AT重整反应混合物”,其包括可重整燃料、包含氧气的气体和蒸汽。。
表述“气态可重整燃料”应被理解为包括在经历重整时进行向富含氢气的重整物的转化的在STP条件下为气体的可重整的包含碳和氢的燃料,例如,甲烷、乙烷、丙烷、丁烷、异丁烷、乙烯、丙烯、丁烯、异丁烯、二甲基醚、它们的混合物,例如天然气和液化天然气(LNG)(其主要为甲烷)、以及石油气和液化石油气(LPG)(其主要为丙烷或丁烷,但是包括主要由丙烷和丁烷组成的所有混合物)、和氨等。
术语“重整反应”应被理解为包括在气态反应介质转化为富含氢气的重整物期间发生的放热和/或吸热反应。本文中的表述“重整反应”因此包括,例如,CPOX、自热和蒸汽重整。
再则如之前所述,为了简要起见,本文中的讨论和描述将关注于部分氧化重整反应和反应物,包括催化部分氧化重整反应和反应物(可重整燃料和包含氧气的气体)。然而,本文中描述的装置、组件、系统和方法可同等地适用于其它重整反应例如蒸汽重整和自热重整和它们各自的反应物以及本文中描述的其它气相反应。例如,对于蒸汽重整,在本文中的描述中,蒸汽可代替包含氧气的气体。对于自热重整,在本文中的描述中,蒸汽可与包含氧气的气体和/或可重整燃料一起引入。
如本文中使用的,术语“反应器”、“反应器单元”、“化学反应器”和“化学反应器单元”应被理解为包括化学转化反应器和电化学转化反应器,例如,燃料电池,以及这两者的组合,特别是集成的重整器-燃料电池系统。
本教导的化学反应器(具有用于将气态反应介质分布至其至少一个反应器单元的入口的其歧管部件)适用于其中使气态反应介质进行向期望产物的转化的所有化学反应器。例如,并且没有限制,本教导广泛地适用于所有类型的气相反应器例如用于进行例如如下的众多气相反应的任意者的固定床、流化床、微通道、管壳式、管式、多管式等反应器:乙酰化、加成反应、烷基化、脱烷基化、加氢脱烷基化、还原烷基化、胺化、芳构化、芳基化、重整、羰基化、脱羰、还原羰基化、羧化、还原羧化、还原偶联、缩合、裂化、加氢裂化、环化、环化低聚、燃烧、脱卤、二聚、环氧化、酯化、交换、费-托、气化、卤化、氢卤化、同系化、水合、脱水、加氢、脱氢、加氢羧化、加氢甲酰基化、氢解、加氢金属化、水解、加氢处理、加氢精制(HDS/HDN)、异构化、甲基化、脱甲基化、易位、硝化、氧化、部分氧化、聚合、还原、磺化、调聚、酯交换、三聚、水煤气变换等。
现在将具体地结合图1A和1B的气态燃料催化部分氧化(CPOX)重整器以及图2A和2B的液体燃料CPOX重整器的实施方式详细地具体描述本教导的化学反应器。
如图1A和1B中所示,将典型地处于环境温度的作为包含氧气的气体的空气经由离心式鼓风机102以预设的质量流速通过导管104的入口103引入到气态燃料CPOX重整器100中。将丙烷经由燃料管线111和燃料入口112引入到导管104中。丙烷和空气开始在导管104的混合区120中合并以提供气态CPOX反应混合物。可包括任何合适种类的混合器,例如,设置在混合区120内的静态混合器和/或导管104的螺旋形凹槽化内壁表面,以提供与否则在混合区120中将形成的相比具有更高组成均匀性的气态CPOX反应混合物。
在其穿过该任选的静态混合器和/或与设置在混合区120内的螺旋形凹槽接触之后,气态CPOX反应混合物通过出口125离开导管104并且进入其作用是提供去往管式CPOX反应器单元108的和在管式CPOX反应器单元108内的气态反应介质的均匀分布的歧管126的气态反应介质(气体)分布器127。这样的排列或者本教导内的其它排列可提供气态CPOX反应混合物的如下分布:其中任意两个CPOX反应器单元内的气态CPOX反应混合物的流速的差异不大于约20%,例如不大于约10%或者不大于约5%。
歧管126包括限定歧管室129的歧管壳或围壳128,在歧管室129内气体分布器127连接至导管104的出口125。通过出口125离开导管104的气态CPOX反应混合物进入气体分布器127,之后向外穿过位于所述气体分布器的底部或下部部分处的孔洞(aperture)(例如,孔(hole)或缝)130,所述气体然后围绕所述分布器的外表面流动至其顶部或上部部分并且从那里进入管式CPOX反应器单元108的入口131中。所述气态CPOX反应混合物在其穿过孔洞130和进入入口131中时的路径示于图1B中。
可瞄准歧管126的设计的优化以实现其将气态CPOX反应混合物均匀地分布至CPOX反应器单元108的功能的一些具体因素包括其壳128的构型、其室129的容积、和气体分布器127的尺度(包括其孔洞130的数量、设计和安排)。这样的因素本身又取决于如导管内气态CPOX反应混合物的目标流速、CPOX反应器单元108的数量和排列、CPOX反应器单元108的入口131的形状和尺度、和类似考虑因素这样的重整器设计和操作因素。根据本教导的用于具体的气态燃料CPOX重整器的最优燃料-空气分布性能的歧管可由本领域技术人员采用惯常的试验方法而容易地构造。
当CPOX反应器单元的CPOX反应区基本上与所述反应器单元的长度共同延伸时,歧管壳128可由在CPOX重整所典型的高温下保持热和机械稳定的材料制造。在这些实施方式中,多种种类的难熔的材料,包括难熔的复合材料例如碳纤维-和/或玻璃纤维-增强的陶瓷适合用于制造所述歧管壳。合适的构造材料包括致密的陶瓷例如多种已知类型的氧化铝、重结晶氧化铝、铝硅酸盐、氮化硼、玻璃-陶瓷、氧化镁、磷酸锆等,金属例如基于镍-铬的超合金、哈斯特洛依超合金等。然而,这些和其它难熔的材料往往成本相对高并且对于加工而言也可为挑战性的,尤其是在制造具有相对复杂构型的制品的情况下。
如示于图1C中的示例性的CPOX反应器单元108的放大的纵截面图中所示,CPOX反应器单元108的透气性壁151可沿着其长度划分为:在其燃料-空气混合物入口131处开始的第一或上游区域152,其基本上没有CPOX催化剂;和在第一区域152的末端处开始并且在所述反应器单元的产物重整物流出物出口154处或者附近结束的第二或下游区域153,其包含催化有效量的CPOX催化剂164。在图1A的CPOX重整器100的稳态操作期间,CPOX反应器单元108的该实施方式很大程度上将热的CPOX反应区109局限于它们的第二区域153,让其基本上没有CPOX催化剂的第一区域152保持在(例如,在从环境到最高达约350℃的区域中的)明显较低的温度下,特别是在CPOX反应器单元108的燃料-空气混合物入口131和歧管壳128的接合点处。
没有CPOX催化剂的壁段区的较低的温度(该温度低于许多热塑性树脂的熔融温度并且低于许多热固性树脂的热降解温度)使得使用若干家族的热塑性和热固性树脂的任意者来制造歧管壳128成为实际的和有利的。可用于制造歧管壳的热塑性和热固性树脂的具体类型包括聚醚酰亚胺(PEI)、聚芳基醚酮(PAEK)例如聚醚醚酮(PEEK)、酚醛树脂等。这些和其它热稳定树脂除了它们相对低的材料成本之外还具有如下的附加优点:能采用低成本制造程序例如挤出模塑、真空模塑、注射模塑、反应注射模塑、旋转模塑等容易地成型为复杂形状并且因此很好地适合于制造具有相对复杂的几何结构的歧管壳。
CPOX反应器单元108除了图1D中所示的环形截面之外还可采用其它截面构型例如示于图1E和1F中的那些。因此,例如,图1E说明具有交替的凹面-凸面或双叶截面的CPOX反应器单元。具有这样的截面构型的CPOX反应器单元可为尤其有利的,其中它们的出口段将如在Finnerty等的共同待审的、共同转让的美国专利申请公布No.2013/0230787(其全部内容引入本文作为参考)的SOFC燃料电池组件中那样与类似地配置的管式固体氧化物燃料电池(SOFC)单元接合或者配对。
气态CPOX反应混合物从歧管126进入CPOX反应器单元108的入口131并且进入到CPOX反应区109中,在CPOX反应区109中所述反应混合物经历气相CPOX反应以产生富含氢气的、包含一氧化碳的重整物。在启动模式中,一个或多个点火器135引发CPOX。在CPOX变成自持的之后,例如,当所述反应区的温度达到约250℃-约1100℃时,可将所述点火器关掉,因为不再需要外部点火来维持现在自持的CPOX反应。热绝缘体110(例如,微孔的或者基于氧化铝的难熔类型的)包围所述CPOX重整器的那些部分以减少来自这些部件的热损失。
如示于图1C和1D中的管式CPOX反应器单元108的分别的放大的纵截面图和横截面图中所示,反应器单元108的透气性壁151包括:内表面161;外表面162;由透气性壁151限制的开放的气流通道(气体流动通道)163,其一部分构成CPOX反应区109;氢气阻挡物165,其附着至外表面162;和催化有效量的CPOX催化剂164,其担载于如下的结构体内和/或包括如下的结构体:透气性壁151的至少的与第二区域153和CPOX反应区109对应的段。
如图1G中所示,图1A和1B中所示的重整器100的歧管126的歧管部分150的放大的纵截面图包括上部壳结构155、下部壳结构156、歧管室129、气态CPOX反应混合物分布器127以及与管式CPOX反应器单元108的入口131气流连通的气体分布器出口130。管式CPOX反应器单元108的入口端157牢固地座落于形成于上部壳结构155内的空穴158内并且通过O-环垫圈159与其以气密关系接合。形成于上部壳结构155内的空穴158以及保持在其中的O-环垫圈的提供使对于上部壳结构155和管式CPOX反应器单元108的入口端157之间的气密连接的要求简化并且,此外,大大地便利于将无效的或者有缺陷的反应器从歧管壳156分离以及插入代替反应器单元。
气态CPOX反应混合物流动通过气体分布器127的出口130,通过管式CPOX反应器单元108的入口131并且进入CPOX反应区109中,在CPOX反应区109中所述气态CPOX反应混合物进行向富含氢气的、包含一氧化碳的流出物重整物的气相CPOX转化,所述重整物在所述反应器单元的出口端160处通过相关的出口154离开所述反应器单元。
现在参照图2A和2B,将作为包含氧气的气体的空气在环境温度下并且经由离心式鼓风机202以预设的质量流速通过导管204(其包括有利于紧凑设计的通常U形的导管段)的入口203引入到液体燃料CPOX重整器200中。所述环境温度空气初始在重整器200的启动模式操作中通过穿过被供应有来自第一加热器单元206的热的第一加热区205而被加热至预设的升高的温度范围内。第一加热器单元206和在其下游的第二加热器单元213可为额定为例如10-80瓦或者甚至更大(取决于所述重整器的燃料处理本领的设计范围)的常规的或以其它方式知晓的电阻型。这样的加热器能够将引入到导管204中的环境空气的温度升高至对于相对宽范围的CPOX重整器构型和操作本领而言期望的水平。在重整器200的操作的稳态模式期间,可关掉第一加热器单元206,引入到导管204中的空气于是初始在热传递区207内通过从伸长管式透气性CPOX反应器单元208的CPOX反应区209回收的放热热而被加热。以此方式,引入到导管204中的空气的温度可从环境升高至某一预设的温度升高范围内并且如本领域技术人员将容易认识到的,具体温度受多种设计(即结构和操作)因素影响。
热绝缘体210(例如,微孔的或者基于氧化铝的难熔类型的)包围大部分的导管204以及CPOX反应器单元208的与它们的CPOX反应区209对应的那些部分以减少来自这些部件的热损失。
为了提高已经初始通过穿过第一加热区205和/或第二加热区207而被加热的空气的温度,在该经初始加热的空气继续在导管204中向下游流动时,其穿过被供应有来自第二加热器单元213的热的第二加热区212。由于所述第二加热器单元仅需要将所述经初始加热的空气的温度提高相对小的程度,因此其可起到能够进行有益于所述重整器的精确和快速的热管理(关于本文中描述的其燃料气化系统和其管式CPOX反应器单元的运行两者)的在空气温度方面的典型地小的调节的增量加热器的作用。
将液体可重整燃料(例如以上提及的任意那些以及在本教导的该和其它实施方式中示例为汽车柴油的)经由在主导管204内终止的燃料管线214引入液体燃料撒布器装置215例如虹吸油芯或者喷射装置中。
可使用用于使流体穿过液体燃料CPOX重整器的通道和导管例如将液体燃料通过燃料管线214引入到导管204中的任何常规的或者以其它方式知晓的泵装置218。例如,计量泵、旋转泵、叶轮泵、隔膜泵、蠕动泵、正位移泵例如内齿轮油泵、齿轮泵、压电泵、电动泵、电渗泵、毛细泵等可用于此目的。如上所示,可将经加压的液体燃料通过虹吸油芯、或者通过任何像燃料注射器、加压喷嘴、雾化器(包括超声类型的那些)、喷雾器等这样的常规或者以其它方式知晓的喷射装置作为细的喷雾或者以液滴形式在导管内撒布。第二加热器单元和燃料撒布器装置可协调运行以使引入到所述导管中的液体燃料气化并且一起构成重整器的燃料气化器系统的主要部件。在一些实施方式中,泵或等效装置可基于间歇或者脉冲流动输送燃料。在某些实施方式中,泵或等效装置可将燃料作为基本上连续的流输送。在具体实施方式中,泵或等效装置可响应于变化的CPOX重整器操作要求而在燃料流速方面进行快速调节。
虽然重整器200可使用任何热源来驱动在操作的启动模式期间液体燃料的气化(例如,电阻型的加热器(如在加热器206和213的情况中那样),尤其是当使燃料的气化在导管204外发生时),但是使用加热器213以不仅渐增地提高所述经初始加热的环境温度空气的温度,而且在液体燃料引入到导管204中之前对其进行加热并且提供足够的热用于一旦所述燃料进入所述导管就将其气化。该任选的在液体燃料引入到导管204中之前对其进行加热的措施可使如下成为可能:与对在其进入所述导管时处于环境温度的可重整燃料进行操作的相同的气化器系统相比,更快地将给定量的液体可重整燃料或者在给定时期内将更大量的液体燃料气化。
为了保证液体燃料在其进入导管204之前的加热,燃料管线214来回穿行(横穿,traverse)导管204的壁(其中燃料管线的段219在长度上延伸以延长在其中流动的燃料在所述燃料管线穿过之处的停留时间),或者接近于主导管204的第二加热区212。为此目的,延伸的燃料管线段可呈现各种各样的构型,例如,设置在导管的与第二加热区对应的外表面上或者与导管的与第二加热区对应的外表面接近的线圈状或者螺旋的绕组(如所示的)或一系列的纵向折叠体或者设置在所述导管的内部在所述第二加热区处或附近的任何类似的这样的构型。不管其精确的构型和/或布置为何,延伸的燃料管线段219必须是在第二加热区212的有效热传递附近以接收足以将其中的燃料的温度升高至某一预设温度范围内的量的热。因此,在导管204的第二加热区212内的加热器213的热输出的一部分,除了进一步加热在该区内流动的空气之外,还将传递至在燃料管线214的远侧段219内流动的燃料例如柴油燃料(燃料管线214的该远侧段可如附图标记219所示那样延长或延伸),从而将其温度升高至预设的范围。对于所述燃料管线内的燃料无论选择哪个范围的温度值,如果要避免重整器200的气阻和因之而来的关停,则其均不应超过所述燃料的沸点(在柴油的情况下150℃-350℃)。
液体燃料撒布器215设置在导管204内在第二加热区212和相关的加热器213的下游并且在混合区220的上游。在导管204内在所述气化器的下游设置热电偶223以监测其中开始形成的气化的燃料-空气混合物的温度。
在其穿过设置在混合区222下游的静态混合器221之后,气态CPOX反应混合物通过出口225离开导管204并且进入与图1A和1B的气态燃料CPOX重整器100的歧管126的结构和操作两者相同或相似的歧管226的气体分布器227。歧管226包括限定歧管室229的歧管壳或围壳228,在歧管室229内经加热的气态CPOX反应混合物(气体)分布器227连接至导管204的出口225。通过出口225离开导管204的经加热的气态CPOX反应混合物进入气体分布器227,之后向外穿过位于所述气体分布器的底部或下部部分处的孔洞(例如,孔或缝)230,所述气体然后围绕所述分布器的外表面流动至其顶部或上部部分并且从那里进入管式CPOX反应器单元208的入口231中。所述气态CPOX反应混合物在其穿过孔洞230和进入入口231中时的路径示于图2B中。
为了消除或者减少歧管室229的一些区域和/或表面内的温度下降至等于或低于其中存在的气态CPOX反应混合物的气化的液体可重整燃料的冷凝温度的可能性,可将电阻加热器232和热电偶233设置在歧管室229内,例如,在其内表面的一个或多个上或者嵌入其壁的一个或多个内,以提供用于维持所述室内的温度高于燃料冷凝温度的主动加热器系统。除了主动加热器系统(例如,如以上描述的)之外,或者作为其替代物,可在重整器200内布置将管式CPOX反应器单元208的CPOX反应区209与歧管室229热关联的被动加热器或热传递系统(包括热传导元件234(例如由热的良导体例如铜制造))以将来自CPOX反应区209的放热热传送至歧管室229内的区域和/或表面以便将其中的气化的燃料的温度维持为高于其冷凝温度。
除了它们防止或者最少化燃料冷凝的发生的功能之外,这样的主动和/或被动加热器还可在气态CPOX反应混合物被引入到CPOX反应器单元208的入口231中时用于使所述气态CPOX反应混合物的温度更均匀,并且因此对于重整器操作和控制两者均有益。因此,例如,一种或全部两种歧管加热器可起到如下作用:提供遍及歧管室具有一致地均匀的温度的气态CPOX反应混合物,使得在进入任意两个管式CPOX反应器单元的气态CPOX反应混合物的温度方面,将存在不超过约10%差异、例如不超过约5%差异。
如在示于图1A和1B中的歧管126中那样,可瞄准歧管226的设计的优化以实现其促进去往CPOX反应器单元208的气态CPOX反应混合物的更均匀分布的功能的一些具体因素包括其壳228的构型、其室229的容积、和所述气体分布器227的尺度(包括其孔洞230的数量、设计和安排)。这样的因素本身又取决于如导管内气态CPOX反应混合物的目标流速、CPOX反应器单元208的数量和排列、CPOX反应器单元208的入口231的形状和尺度、和类似考虑因素这样的重整器设计和操作因素。用于根据本教导的具体的液体燃料CPOX重整器的最优燃料-空气分布性能的歧管可由本领域技术人员采用惯常的试验方法而容易地构造。
经加热的气态CPOX反应混合物从歧管226进入CPOX反应器单元208的入口231并且进入到CPOX反应区209中,在CPOX反应区209中所述反应混合物经历气相CPOX反应以产生富含氢气的、包含一氧化碳的重整物。如在图1A和1B的气态燃料CPOX重整器100中那样,在液体燃料CPOX重整器200的启动模式中,一个或多个点火器235引发CPOX。在CPOX变成自持的之后,例如,当所述反应区的温度达到约250℃-约1100℃时,可将所述点火器关掉,因为不再需要外部点火来维持现在自持的CPOX反应。
进一步地,根据本教导,可将蒸汽引入到所述重整器中,使得所述重整器可操作以进行自热和/或蒸汽重整反应。
在一种实施方式中,所述重整器可初始地操作以进行液态或气态可重整燃料的CPOX转化,从而提供放热热,所述放热热,在有或者没有由例如由电加热器供应的另外的热的情况下,可被回收以在蒸气发生器中产生蒸汽。由此产生的蒸汽可引入到所述重整器中的其中的一个或多个位置中。一个合适的位置是蒸发器,在所述蒸发器中所述蒸汽可提供热以使液体燃料气化。例如,引入到图5中所示的重整器500中的虹吸油芯515中的蒸汽可提供热用于使虹吸油芯表面上的液体燃料气化,同时帮助消除或抑制这样的表面的堵塞。
在另一实施方式中,根据本教导的重整器可连接至燃料电池堆,在燃料电池堆中,来自所述重整器的富含氢气的重整物被转化为电流。所述燃料电池堆以及当存在时,相关的后燃烧器单元的操作可提供废热的来源,再次地,在有或没有例如由电加热器供应的另外的热的情况下,所述废热可被回收和用于蒸汽发生器的操作。来自所述蒸汽发生器的蒸汽然后可被引入到所述重整器中(例如,通过图5的重整器500的虹吸油芯515)以支持自热或蒸汽重整。在集成的重整器和燃料电池堆的该布置中,所提及的废热的来源可供应驱动自热和蒸汽重整过程中涉及的吸热反应所必需的热。
总之,应理解,本教导的输送系统可输送合适的反应物用于进行重整反应,包括部分氧化(“POX”)重整例如催化部分氧化(“CPOX”)重整、蒸汽重整、和自热(“AT”)重整。液体反应物例如液体可重整燃料和水可从如下和通过如下输送:所述输送系统的“液体可重整燃料”输送部件、导管、和组件。气态反应物例如气态可重整燃料、蒸汽、和包含氧气的气体例如空气可从如下和通过如下输送:所述输送系统的“气态可重整燃料”输送部件、导管、和组件。某些气态反应物例如蒸汽和包含氧气的气体可从如下和通过如下输送:在本教导的输送系统外围或者对于本教导的输送系统次要的部件和组件,例如,包含氧气的气体可从独立地与气化器、重整器、和燃料电池单元或系统的燃料电池堆的至少一个可操作地流体连通的包含氧气的气体的来源输送,例如,以与重整之前的液体可重整燃料和/或气化的液体可重整燃料混合。
本教导涵盖其它具体形式的实施方式而不背离其精神或本质特性。前述实施方式因此应被认为在所有方面都是说明性的,而不是限制本文中描述的本教导。本发明的范围因此由所附权利要求而不是由前述描述指示,并且其中意图包含进入权利要求内的等同含义和范围内的所有变化。
Claims (12)
1.化学反应器系统,其包括:
具有入口的化学反应器;和
与所述化学反应器的入口流体连通的歧管,所述歧管包括歧管壳,所述歧管壳限定歧管室并且具有选自如下的至少一个另外的部件:
气态反应物分布器,其设置在所述歧管室内并且延伸达所述歧管室的至少大部分长度,其中所述气态反应物分布器与气态反应物导管流体连通,并且所述气态反应物分布器包括与所述化学反应器的入口反向定位的一个或多个出口;
与所述歧管室热连通的加热器;和
空穴,其中所述歧管壳限定空穴,在所述空穴内或者邻近于所述空穴设置密封,并且所述密封接合所述化学反应器的入口,从而在所述歧管壳和所述入口之间提供气密密封。
2.权利要求1的化学反应器系统,其中所述化学反应器为固定床反应器、流化床反应器、微通道反应器、管壳式反应器、管式反应器、多管式反应器、或其组合。
3.权利要求1或2的化学反应器系统,其中所述密封为垫圈。
4.权利要求1-3任一项的化学反应器系统,其中所述化学反应器适合于进行选自如下的气相反应:乙酰化、加成反应、烷基化、脱烷基化、加氢脱烷基化、还原烷基化、胺化、芳构化、芳基化、重整、羰基化、脱羰、还原羰基化、羧化、还原羧化、还原偶联、缩合、裂化、加氢裂化、环化、环化低聚、燃烧、脱卤、二聚、环氧化、酯化、交换、费-托、气化、卤化、氢卤化、同系化、水合、脱水、加氢、脱氢、加氢羧化、加氢甲酰基化、氢解、加氢金属化、水解、加氢处理、加氢精制、异构化、甲基化、脱甲基化、易位、硝化、氧化、部分氧化、聚合、还原、磺化、调聚、酯交换、三聚和水煤气变换。
5.权利要求1-4任一项的化学反应器系统,其中所述化学反应器包括多个管式反应器单元。
6.权利要求1-5任一项的化学反应器系统,其中所述歧管壳由在所述化学反应器的操作温度下保持热和机械稳定的材料制造。
7.权利要求1-6任一项的化学反应器系统,其中所述加热器为设置在所述歧管室内的电阻加热器和/或与所述歧管及化学反应器的反应区热连通的至少一个热传导元件。
8.用于将至少一种可重整燃料重整以制造富含氢气的重整物的重整器系统,所述重整器包括:
具有入口的重整器反应器单元;和
与所述重整器反应器单元的入口流体连通的歧管,所述歧管包括歧管壳,所述歧管壳限定歧管室并且具有选自如下的至少一个另外的部件:
气态重整反应物分布器,其设置在所述歧管室内并且延伸达所述歧管室的至少大部分长度,其中所述气态反应物分布器与反应物导管流体连通,并且所述气态反应物分布器包括与所述重整器反应器的入口反向定位的一个或多个出口;
与所述歧管室热连通的加热器;和空穴,其中所述歧管壳限定所述空穴,在所述空穴内或者邻近于所述空穴设置密封,并且所述密封接合所述重整器反应器的入口,从而在所述歧管壳和所述入口之间提供气密密封。
9.权利要求8的重整器系统,其中所述歧管壳由在所述至少一个重整器反应器的操作期间在重整反应区的温度下保持热和机械稳定的材料制造。
10.权利要求8和9任一项的重整器系统,其中所述加热器为设置在所述歧管室内的电阻加热器,和被动加热器组件包括与所述歧管及所述重整器反应器的反应区热连通的至少一个热传导元件。
11.权利要求8-10任一项的重整器系统,其包括多个管式重整反应器单元。
12.权利要求8-11任一项的重整器系统,其为催化部分氧化重整器。
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