CN105722587B - 用于制备吸着剂的方法 - Google Patents

用于制备吸着剂的方法 Download PDF

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CN105722587B
CN105722587B CN201480062717.7A CN201480062717A CN105722587B CN 105722587 B CN105722587 B CN 105722587B CN 201480062717 A CN201480062717 A CN 201480062717A CN 105722587 B CN105722587 B CN 105722587B
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sorbent
agglomerate
copper
method described
copper sulfide
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CN105722587A (zh
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M·J·伊万斯
M·D·G·卢恩
M·G·帕特瑞治
C·J·杨
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Johnson Matthey PLC
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Abstract

描述了用于制备吸着剂的方法，其包括以下步骤：(i)将惰性粒状载体材料和一种或多种粘结剂混合在一起，以形成载体混合物，(ii)通过在造粒机中造粒使载体混合物成型，以形成附聚物，(iii)用包含粒状铜硫化物和一种或多种粘结剂的涂层混合物粉末涂覆所述附聚物，以形成经涂覆的附聚物，和(iv)干燥所述经涂覆的附聚物，以形成经干燥的吸着剂。

Description

用于制备吸着剂的方法
本发明涉及用于制备吸着剂的方法，尤其是用于制备包含铜硫化物的吸着剂的方法。
包含铜硫化物的吸着剂可被用于从流体料流中除去重金属。在流体料流如烃或其它气体和液体料流中发现少量重金属如汞。在烃料流中还可以发现少量砷和锑。除了其毒性之外，汞还可以导致铝换热器和其它处理设备失效。因此存在对从流体料流有效除去这些金属，优选在工艺流程中尽早除去的需求。
铜吸着剂常规地为由包含铜的经沉淀的组合物形成的粒状组合物或粒料。
WO2011/021024公开了用于制备吸着剂的方法，包括以下步骤：(i)从溶液或浆料将铜化合物的层施加至载体材料的表面上，和(ii)干燥经涂覆的载体材料，其中在经干燥的载体上的铜化合物层的厚度为1-200μm的范围内。在实施例中，铜化合物的层由铜氨碳酸盐溶液或由碱性碳酸铜的浆料形成。将前体转化为适合于通过施用一种或多种硫化合物以使铜化合物硫化并形成CuS从液体或气体除去重金属的吸着剂。
虽然该方法提供了铜吸着剂，但存在对避免必须使用单独的硫化步骤的需求。
因此，本发明提供了用于制备吸着剂的方法，包括以下步骤：
(i)将惰性粒状载体材料和一种或多种粘结剂混合在一起，以形成载体混合物，
(ii)通过在造粒机中造粒使载体混合物成型，以形成附聚物，
(iii)用包含粒状铜硫化物和一种或多种粘结剂的涂层混合物粉末涂覆所述附聚物，以形成经涂覆的附聚物，和
(iv)干燥所述经涂覆的附聚物，以形成经干燥的吸着剂。
本发明还提供了通过所述方法可获得的吸着剂和所述吸着剂在从含重金属的流体料流中除去重金属的用途。
“吸着剂”包括吸收剂和吸附剂。
“惰性粒状载体材料”是指不包含粒状铜化合物的载体材料。这样的载体材料包括氧化铝、金属铝酸盐、二氧化硅、二氧化钛、氧化锆、氧化锌、铝硅酸盐、沸石、金属碳酸盐、碳化硅、碳，或其混合物。所述载体材料提供使吸着剂的物理性质适应任务的手段。因此，可以使得吸着剂的表面积、孔隙率和压碎强度适宜地适合其用途。载体材料期望地是氧化物材料如氧化铝、二氧化钛、氧化锆、二氧化硅和铝硅酸盐，或这些的两种或多种的混合物。也可以使用水合的氧化物，例如三水合氧化铝或勃姆石。尤其合适的载体是氧化铝和水合氧化铝，特别是三水合氧化铝。颗粒状载体材料期望地为粉末形式，更优选D50粒度在1-100μm，特别是5-20μm范围内的粉末。
可用于制备所述附聚物的粘结剂包括粘土粘结剂如膨润土、海泡石、minugel和绿坡缕石粘土；水泥粘结剂，尤其是氧化铝水泥如ciment fondu；和有机聚合物粘结剂如纤维素粘结剂，或其混合物。尤其是可以形成强附聚物，其中粘结剂是水泥粘结剂与粘土粘结剂的组合。在这样的材料中，水泥与粘土粘结剂的相对重量可以在1:1至3:1的范围(第一粘结剂比第二粘结剂)。附聚物中的粘结剂的总量可以在5-30重量％，优选5-20重量％范围内。一种或多种粘结剂期望地呈粉末，更优选D50粒度在1-100μm，特别是1-20μm范围内的粉末形式。
将粒状载体材料和一种或多种粘结剂混合以形成载体混合物，这可以通过常规共混技术实现。然后将所述混合物在造粒机中造粒，以形成附聚物，其提供基本上不含铜化合物的核心。所述附聚物可以通过在造粒机中将粉末组合物与不足以形成浆料的少许液体如水混合，然后导致所述组合物附聚成大体上球形的粒料而形成。所添加的液体的量将取决于组分的孔隙率和润湿性而变化，但是可以为0.1至0.5ml/g载体混合物。可以使用水性或非水性液体，但是优选水。造粒机设备是商购可得的。所述附聚物优选具有在1-15mm范围内的直径。
可以在涂覆之前将所述附聚物老化和/或干燥，以增强它们的强度。老化和/或干燥优选在20-50℃进行1-10小时，更优选5-8小时。
在优选的实施方案中，所述附聚物包括三水合氧化铝、水泥粘结剂和粘土粘结剂。在所述附聚物中，水泥和粘土粘结剂的优选的量为各自5-15重量％。这样的附聚物提供了高强度的核心，在所述核心上布置所述粒状铜化合物。
用于制备吸着剂的粒状铜硫化物可以是市售来源的或者可以通过许多方法制备。合适的方法包括焙烧铜或铜化合物与单质硫，溶剂热工艺，水热工艺(例如微波辐照)，电沉积技术，从溶液中沉淀铜硫化物，使用硫化氢使铜化合物硫化，通过电子辐照，或通过其中将粉末化的铜金属与单质硫在导致单质铜与单质硫反应以形成一种或多种铜硫化物的条件下混合的机械化学工艺。这样的方法描述于Materials Research Bulletin,vol 30,no12,p1495-1504,1995中。
可以使用的铜硫化物包括硫化铜(II)(CuS)、(铜蓝)和/或亚化学计量的铜硫化物，例如式Cu2-xS的铜硫化物，其中x为0-1，如Cu9S5(蓝辉铜矿)。可以使用一种或多种铜硫化物。优选的是CuS含量高的铜硫化物，并且粒状铜硫化物的总体S:Cu原子比优选为≥0.8，更优选≥0.9，最有选≥0.95。期望地，吸着剂中的基本上全部经硫化的铜呈硫化铜(II)(CuS)的形式。所述粒状铜硫化物可以成粉末，优选平均粒度，即D50在5-100μm，特别是5-50μm范围内的粉末形式。
吸着剂的铜硫化物含量可以在0.5-75重量％(以经干燥的材料中的CuS表示)，但我们已发现具有低水平的铜硫化物的材料在捕获重金属方面与常规吸着剂材料一样有效。因此，吸着剂的铜硫化物含量优选为5-45重量％(以经干燥的材料中的CuS表示)。
涂层混合物包括粒状铜硫化物和一种或多种粘结剂。可以使用与附聚物中所使用的相同或不同的粘结剂。涂层混合物的总粘结剂含量可以在5-20重量％范围内，但优选5-15重量％。尤其是我们已发现包括粒状铜硫化物和作为仅有的粘结剂的粘土粘结剂的涂层混合物在制备耐磨吸着剂方面尤其有效。因此，涂层混合物可以不含水泥粘结剂。
其它组分也可以存在于涂层混合物中，以增强吸着剂的物理性质或性能。涂层混合物中可以包括氧化铝，如过渡型氧化铝(包括γ氧化铝)和/或水合氧化铝(如三水合氧化铝或勃姆石)。所述氧化铝或水合氧化铝的量可以在涂层混合物的1-15重量％范围内。其它的这样的添加剂包括锌化合物如氧化锌、碳酸锌或碱式碳酸锌，或可以包括其它过渡金属化合物。然而，当需要吸着剂的高耐水性时，吸着剂中除铜硫化物以外的金属硫化物含量优选为≤5重量％，更优选≤1重量％，最优选≤0.5重量％，特别是≤0.1重量％(基于经干燥的吸着剂计)。
可以使用常规共混技术通过简单混合所述粒状铜硫化物和一种或多种粘结剂和任选的其它组分制备涂层混合物。
将涂层混合物与附聚物合并，以形成在它们的表面上具有粒状铜硫化物的层的经涂覆的附聚物。这可以通过在造粒机中翻腾时将涂层混合物简单地添加至附聚物来实现。在添加或不添加另外的液体的情况下可以形成经涂覆的附聚物。使所使用的液体的量最小化有利地缩短它们的干燥时间并且降低形成不期望的涂层混合物本身的附聚物的可能性。此外，使水的添加最小化可以减少不期望的铜硫酸盐的形成。类似地，在干燥和/或非氧化性气氛如不含氧的氮气下将涂层混合物施加至所述附聚物也可以有助于减少硫酸盐的形成。然而，当干燥和/或老化附聚物时可能需要另外的液体。所使用的液体的量可以为0.1至0.5ml/g涂层混合物。可以使用水性或非水性液体，但优选水。可以通过喷雾而常规地添加液体。
经涂覆的附聚物的尺寸极大地由附聚物的尺寸决定。因此，经涂覆的附聚物优选具有在1-15mm范围内的直径。
铜硫化物存在于在附聚物的表面上的层中。经干燥的材料中的层的厚度可以在1至1000μm(微米)范围内，但是优选在1-500微米，更优选1-250微米范围内。较薄的层使得更有效地使用所施加的铜。
尤其优选的吸着剂包括作为在附聚物的表面上的1至1000μm厚度的表面层涂覆的粒状铜硫化物连同粘土粘结剂和任选的氧化铝或三水合氧化铝，所述附聚物由与水泥粘结剂和粘土粘结剂结合在一起的粒状水合氧化铝载体材料形成。
将经涂覆的附聚物干燥。干燥温度优选保持在≤200℃，更优选≤150℃，以避免铜硫化物的本体分解。最高120℃的干燥温度是优选的，例如可以便利地在约70-120℃干燥经涂覆的附聚物。干燥时间可以在0.25-16小时范围内。在非氧化性气氛如干燥的氮气下干燥可以减少硫酸盐形成。
可以筛分经干燥的吸着剂前体，以产生期望的粒度级分。
可以将吸着剂用于处理包含重金属的液态流体料流和气态流体料流二者，尤其是包含汞和/或砷的流体料流。在一个实施方案中，所述流体料流为烃料流。所述烃料流可以为精炼厂烃料流如石脑油(例如包含5个或更多个碳原子且最终常压沸点高达204℃的烃)、中间馏分或常压瓦斯油(例如具有177℃至343℃的常压沸程)、真空瓦斯油(例如常压沸程343℃至566℃)或渣油(常压沸点高于566℃)，或通过例如催化重整由这样的原料生产的烃料流。精炼厂烃料流还包括载体料流如FCC工艺中所使用的“循环油”和溶剂萃取中所使用的烃。所述烃料流还可以是原油料流，特别是当原油相对轻质时，或是例如从焦油或煤提取生产的合成原油料流。气态烃可以使用该方法处理，例如天然气或精制石蜡或烯烃。海上原油和海上天然气料流尤其可以用所述吸着剂处理。也可以处理受污染的燃料如汽油或柴油。或者，所述烃可以是冷凝物如天然气液(NGL)或液化石油气(LPG)，或者气体如煤层甲烷、掩埋气或生物气。气态烃，如天然气和伴生气是优选的。
可以使用所述吸着剂处理的非烃流体料流包括可以用于强化采油工艺或碳捕获及封存中的二氧化碳，用于除去咖啡中的咖啡因、香味和香气提取、煤的溶剂萃取等的溶剂。诸如在洗涤工艺或干燥工艺中所使用的醇(包括二醇)和醚(例如三乙二醇、单乙二醇、RectisolTM、PurisolTM和甲醇)的流体可以通过本发明方法进行处理。还可以从酸性气体脱除装置内所使用的胺料流中除去汞。任选地在例如为了形成生物柴油的进一步加工如氢化或酯交换之后，天然油类和脂肪如植物油和鱼油可以通过本发明的方法进行处理。
可以进行处理的其它流体料流包括来自脱水装置的再生气体，如分子筛废气或来自二元醇干燥器再生的气体。
当流体料流包含水、优选以0.02至1体积％的低水平包含水时，所述吸着剂有用。至多5体积％的更高水平在短时间内可以容忍。在长时间暴露于水之后，简单地通过用干燥气体、优选干燥的惰性气体如氮气吹扫，可以使所述吸着剂简单地再生。
优选地，在低于150℃的温度、优选在120℃或以下进行重金属的吸收，因为在这样的温度，重金属吸收的总体能力提高。可以使用低至4℃的温度。优选温度范围是10至60℃。穿过所述吸着剂的气时空速可以在正常使用的范围内。
此外，本发明可以用于处理包含一种或多种还原剂如氢气和/或一氧化碳，尤其氢气的液态和气态流体料流。在一个实施方案中，流体料流是包含溶解的氢气和/或一氧化碳的液态烃料流。在另一实施方案中，流体料流是包含氢气和/或一氧化碳的气态料流，即还原性气体料流。可以受益于该方法的气体料流包括来自常规蒸汽重整工艺和/或部分氧化工艺的合成气料流，和来自煤气化器的合成气料流，例如作为IGCC工艺的一部分，其在气体洗涤和热回收(冷却)步骤之后，并且在酸气转换阶段之前。可以受益于本发明的其它料流包括精炼厂排放料流，精炼厂裂解器料流，高炉气，还原性气体、尤其是富含氢气的气体料流，富含乙烯的料流，和液态或气态烃料流，例如石脑油，它们从烃处理工艺如加氢脱硫或加氢脱氮进料或回收。
使用中，可以将所述吸着剂放置在吸收容器中并且使含重金属的流体料流流过。期望地，根据已知方法将所述吸着剂放置在容器中作为一个或多个固定床。可以使用多于一个床并且所述床在组成上可以相同或不同。
通过参考以下实施例进一步描述本发明。
实施例1.
根据以下处方制备附聚物(全部为重量份)。
100份铝三水合物粉末[D5010μm]
7份Ciment Fondu(铝酸钙)
7份Attagel 50(绿坡缕石粘土)
混合干燥的粉末，以确保均质性，然后使用造粒技术，其中将混合的粉末与水合并(0.2ml/g混合物)和混合，在EirichTM造粒机中形成附聚物。将产生的附聚物指定为材料A。
在造粒机中用少许水将市售来源的试剂级硫化铜(II)粉末(99.8重量％CuS，100重量份)(D50 42μm)和Attagel 50(10重量份)的混合物直接施加至材料A上，然后在实验室流化床干燥器中于105℃立即干燥以产生负载有15重量％硫化铜(10重量％铜)的吸着剂B。
重复所述方法，以产生负载有15重量％硫化铜(10重量％铜)的吸着剂C。使用更大量的硫化铜重复所述方法，以产生负载有27重量％硫化铜(18重量％铜)的吸着剂D。
实施例2.
根据实施例1中所描述的方法制备材料A的附聚物。
在造粒机中用少许水将市售来源的试剂级硫化铜(II)粉末(99.8重量％CuS，100重量份)(D50 42μm)、Attagel 50(10重量份)和三水合氧化铝(10重量份)的混合物直接施加至材料A上，然后立即在实验室流化床干燥器中于105℃干燥，以产生负载有15重量％硫化铜(10重量％铜)的吸着剂E。
实施例3.
根据实施例1中所描述的方法制备材料A的附聚物。
通过将铜粉与硫粉(Cu:S原子比为1:0.9)一起研磨直至达到转化成富含铜蓝的硫化铜而制得硫化铜粉末。
在造粒机中用少许水将所述硫化铜粉末(100重量份)(D50 5-10μm)和Attagel 50(10重量份)的混合物直接施加至材料A上，然后立即在实验室流化床干燥器中于105℃干燥，以产生负载有15重量％硫化铜(10重量％铜)的吸着剂G。
实施例4.
根据实施例1中所描述的方法制备材料A的附聚物。
通过将碱性碳酸铜的粒料在氮气中的1体积％H2S的料流中硫化直至完全硫化而制得硫化铜粉末。然后研磨所产生的基本上由CuS组成的硫化铜粒料，以形成细粉末。
在造粒机中用少许水将所述硫化铜粉末(100重量份)和Attagel 50(10重量份)的混合物直接施加至材料A上，然后立即在实验室流化床干燥器中于105℃干燥，以产生负载有15重量％硫化铜(10重量％铜)的吸着剂H。
实施例5：
单独地将吸着剂B、G和H装料(筛分至2.80-3.35mm粒度级分，体积25ml)至不锈钢反应器(21mm ID)。使100体积％天然气的流穿过包含单质汞的鼓泡器，以使所述气体拾取汞。然后在以下条件下使负载汞的气体向下游穿过反应器。
压力：10巴表压
温度：30℃
气流：110.2NL.hr-1
接触时间：8秒
测试时间：690小时
通过原子荧光检测定期分析来自反应器入口和出口的样品的汞含量。入口气体具有约1,100μg/m3的汞浓度。在测试中吸着剂B、G和H自始至终将出口气体的汞含量降低至低于可检测极限。在每个测试结束时，将25ml吸着剂床取出为9份离散的亚床，将其完全研磨并通过酸消化/ICP-OES分析，以测定总汞含量。被每个吸着剂床捕获的汞的量示于表1中。
表1
全部吸着剂对于除去汞有效。通过Cu和S的机械化学混合制备的吸着剂G产生最尖锐的曲线。
实施例6.
测试吸着剂C、D和E的物理强度和耐磨性。使用Engineering Systems C53测量被筛分至3.35–4.00mm粒度级分的每种吸着剂的20个粒料的压碎强度，以基于正态分布计算平均压碎强度。根据ASTM方法D4058-96通过使100g的每种吸着剂在60rpm旋转30分钟的1800的总转数测量磨损损失DrTL。以原始质量的百分比报道所述DrTL。
平均压碎强度，kgF 磨损损失，重量％
吸着剂C 1.64 1.4
吸着剂D 1.66 0.5
吸着剂E 1.85 0.9
全部吸着剂都显示出良好的强度和耐磨性。
较高的硫化铜负载(较厚的层)看起来提供了增加的耐磨性。将三水合氧化铝引入硫化铜层中同样产生了改进的强度和耐磨性。

Claims (15)

1.用于制备吸着剂的方法，其包括以下步骤：
(i)将惰性粒状载体材料和一种或多种粘结剂混合在一起，以形成载体混合物，
(ii)通过在造粒机中使用液体造粒使载体混合物成型，以形成附聚物，所述液体的量为0.1-0.5ml/g载体混合物，
(iii)用包含粒状铜硫化物和一种或多种粘结剂的涂层混合物粉末涂覆所述附聚物而形成经涂覆的附聚物，其中通过在造粒机中将涂层混合物和任选0.1-0.5ml/g涂层混合物的另外的液体添加至附聚物进行，和
(iv)干燥所述经涂覆的附聚物，以形成经干燥的吸着剂。
2.根据权利要求1所述的方法，其中所述惰性粒状载体材料选自氧化铝、金属铝酸盐、碳化硅、二氧化硅、二氧化钛、氧化锆、氧化锌、铝硅酸盐、沸石、金属碳酸盐、碳，或其混合物。
3.根据权利要求1所述的方法，其中所述惰性粒状载体材料选自氧化铝和水合氧化铝。
4.根据权利要求1所述的方法，其中所述惰性粒状载体材料呈D50粒度在1-100μm范围内的粉末的形式。
5.根据权利要求1所述的方法，其中用于制备所述附聚物的粘结剂选自粘土粘结剂、水泥粘结剂和有机聚合物粘结剂。
6.根据权利要求1所述的方法，其中附聚物具有在1-15mm范围内的直径。
7.根据权利要求1所述的方法，其中所述粒状铜硫化物材料通过如下制备：焙烧铜或铜化合物与单质硫，从溶液中沉淀铜硫化物，使用硫化氢使铜化合物硫化，或其中将粉末化的铜金属与单质硫在导致单质铜与单质硫反应以形成一种或多种铜硫化物的条件下混合的机械化学工艺。
8.根据权利要求1所述的方法，其中所述铜硫化物包括硫化铜(II)和/或式Cu2-xS的亚化学计量的铜硫化物，其中x为0-1。
9.根据权利要求1所述的方法，其中所述粒状铜硫化物的S:Cu原子比≥0.8。
10.根据权利要求1所述的方法，其中所述粒状铜硫化物呈具有在5-100μm范围内的平均粒度[D50]的粉末的形式。
11.根据权利要求1所述的方法，其中吸着剂的铜硫化物含量在0.5-75重量％范围内，以经干燥的吸着剂中的CuS表达。
12.根据权利要求1所述的方法，其中吸着剂的铜硫化物含量在5-45重量％范围内，以经干燥的吸着剂中的CuS表达。
13.根据权利要求1所述的方法，其中所述涂层混合物还包括氧化铝和/或水合氧化铝。
14.根据权利要求1所述的方法，其中在70-150℃干燥经涂覆的附聚物。
15.用于从流体料流中除去重金属的方法，包括使所述流体料流与根据权利要求1至14中任一项所述的方法制备的吸着剂接触。
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