CN106475069A - 用于处理压缩气体的吸附试剂及其制造方法和提供有这样的吸附试剂的吸附装置 - Google Patents

用于处理压缩气体的吸附试剂及其制造方法和提供有这样的吸附试剂的吸附装置 Download PDF

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CN106475069A
CN106475069A CN201610587117.3A CN201610587117A CN106475069A CN 106475069 A CN106475069 A CN 106475069A CN 201610587117 A CN201610587117 A CN 201610587117A CN 106475069 A CN106475069 A CN 106475069A
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aforementioned
support structures
adsorbent
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adsorptive agent
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CN106475069B (zh
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C·拉梅尔斯
S·H·R·W·穆勒
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Atlas Copco Airpower NV
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Abstract

用于处理压缩气体的吸附试剂的制造方法，其中该方法包括以下步骤：‑提供整块状支持结构；‑生产包含吸附剂的涂层悬浮液；‑将前述涂层悬浮液施加至前述支持结构上，以形成涂层；‑对具有涂层的支持结构施加热处理，从而烧结所述涂层。

Description

用于处理压缩气体的吸附试剂及其制造方法和提供有这样的 吸附试剂的吸附装置
技术领域
本发明涉及用于处理压缩气体的吸附试剂的制造方法，更具体地，可用于干燥压缩气体，例如压缩空气的吸附试剂的制造方法。
背景技术
呈用于压缩气体的干燥装置形式的吸附装置已经是已知的，其中这些干燥装置包括容器，在所述容器中放置干燥试剂或干燥剂。有关的容器提供有用于供应待干燥的压缩气体的入口和用于除去经干燥的气体的出口。
有关的干燥试剂通常以可再生的干燥试剂形式，或换言之以在达到一定饱和程度之后可再生的干燥试剂形式实现。当干燥试剂从待干燥的气体中提取水分时确实是这样，该干燥试剂将会逐渐被吸附的水分饱和。因此，在将所述干燥试剂用于干燥压缩气体一段时间之后，普遍的是再生该干燥试剂，例如通过使其经受再生气流，所述再生气流从所述干燥试剂中提取水分。这样的再生气流可以由例如其相对湿度足够低，使得能实现干燥试剂再生的热气体和/或经干燥的气体的级分组成。
在用于压缩气体的干燥装置的一些实施方案中，使用两个或更多个干燥试剂的容器。在采用两个容器的情况下，干燥装置的该原理也被称为双塔干燥器。在这种类型的干燥装置中，可以使压缩气体，例如源自压缩机的压缩气体穿过例如前述容器的第一个，其中在穿过下游冷却器和冷凝物分离器(它们可以或者可以不形成有关的下游冷却器的一部分)之后，它将被有关的容器中的干燥试剂干燥。该容器因此充当干燥容器。
与此同时，可以引导再生气流通过第二个前述容器，从而在所述第二个容器中通过从该干燥试剂中提取水分而再生所述干燥试剂。这可以通过使用已经干燥的气体，例如从干燥容器下游流出的已经干燥的气体和/或通过供应已经加热的气流来完成，所述加热例如通过在压缩过程中回收在压缩机中产生的热而进行。在该后一情况下，它被称为“压缩热”或HOC干燥器。
当干燥容器中的干燥试剂已达到一定的饱和程度时，可以调换通过第一和第二容器的气流，使得在第一容器中的干燥试剂现在将会通过再生气流再生，同时第二容器将会承担干燥容器的作用。以该方式，两个或更多个容器将作为干燥压力容器和再生压力容器交替运行，从而实现干燥工艺的连续性。采用多个容器的这样的干燥装置的实例例如描述于US 2003/023,941，US 4,783,432，US 6,375,722，EP 1,776,171和WO 2006/050,582中。
用于这样的具有多个容器的干燥装置中的干燥试剂经常由硅胶、活性氧化铝或分子筛材料或其组合的颗粒组成。已知活性氧化铝通过热脱水或活化氢氧化铝Al(OH)3来生产，而分子筛由合成沸石(结晶硅铝酸盐)组成。
包括颗粒形式的干燥试剂的这种类型的干燥装置的限制在于通过容器的气体速率必须受到限制，从而抵抗相对于彼此移动或甚至流化的颗粒。确实，由于在所述颗粒之间会发生颗粒处于运动摩擦的状况，这又导致粉尘形成和降低的干燥能力。这样的粉尘形成的其它原因例如是压力变化和/或热冲击。此外，横跨双塔干燥器的压降相对高，并且干燥剂颗粒具有相当高的热质量。
对于压缩气体而言，备选的干燥装置是已知的，其中将干燥试剂放置在转鼓中，同时干燥区和再生区在该容器中延伸。在这样的干燥装置的运行过程中，将通过为此提供驱动机构使干燥转鼓旋转，使得在该干燥转鼓中的干燥试剂将会交替地被带动通过干燥区和再生区。待干燥的压缩气体将会被引导通过所述干燥区，同时将再生气流引导通过再生区，从而实现同时在干燥区中干燥压缩气体和在再生区中再生干燥试剂。
提供有旋转干燥转鼓的这样的干燥装置的实例例如描述于WO 00/033,943，WO00/074,819，WO 01/078,872，WO 01/087,463，WO 02/038,251，WO 2007/079533，WO 2005/070,518，WO 2006/012,711，GB 1,226,348，GB 1,349,732，GB 1,426,292，US 3,490,201，US 5,385,603和US 8,349,054中。
用于干燥压缩气体的已知干燥装置中的干燥试剂或干燥剂例如由硅胶、分子筛、活性氧化铝或其组合组成。已知的是，可以将干燥试剂固定在载体，例如卷起的玻璃纤维或陶瓷纤维的波纹结构上，例如以在容器中形成蜂窝结构，例如如US 5,683,532中所描述。
在实践中，证明采用用于干燥压缩气体的已知干燥装置，在某些条件下，如在干燥试剂的再生不足及其过饱和情况下，干燥试剂经历复杂的分解过程，所述分解过程在一些情况下可以最终导致干燥装置失效，例如在硅胶在滚筒(rotor)内作为干燥试剂的情况下，因为所述硅胶的粘结功能下降，这导致支持性玻璃纤维基体的结构强度损失，且还由于硅胶结构的水解和分解，硅胶的吸附功能下降。
因此，在高湿度和高温的激烈条件下，硅胶滚筒的吸附行为和吸附能力在滚筒的使用寿命期间将显著变化。
发明内容
本发明的目的在于提供用于处理压缩气体的改进的吸附试剂的制造方法，其中该吸附试剂提供与常规的已知吸附试剂相关的一个或多个缺点的解决方案。
为此，本发明涉及用于处理压缩气体的吸附试剂的制造方法，其中该方法包括以下步骤：
-提供整块状支持结构；
-生产包含吸附剂的涂层悬浮液；
-在前述支持结构上施加前述涂层悬浮液，以形成涂层；
-对具有涂层的支持结构施加热处理，从而烧结所述涂层。
采用该方法获得的吸附试剂的优点在于在用于处理压缩气体的吸附装置中的使用过程中，不存在颗粒相对于彼此移动或甚至流化这样的吸附试剂的风险，因为没有使用松散的吸附试剂颗粒。结果防止了粉尘形成，同时相对高流速的待干燥的压缩气体穿过干燥装置是可能的。
另外，如此获得的干燥试剂使得它能够在使用过程中以任何空间取向，例如垂直、倾斜或甚至水平固定在干燥装置中，而这在采用颗粒状的常规干燥试剂的情况下是不可能的，因为水平使用这样的颗粒干燥试剂可能导致颗粒重排并且形成内部泄露路径和因此降低干燥器性能。
根据本发明的优选特征，前述整块状支持结构包括一种或多种以下材料：陶瓷材料、金属箔、纤维结构和聚合物。采用含有堇青石的陶瓷结构获得了尤其良好的结果。
优选地，前述吸附剂含有一种或多种以下材料：沸石、硅胶、活性氧化铝、活性炭、金属有机框架、碳分子筛(CMS)、经浸渍的吸附剂和混杂物(hybrid)。特别优选亲水性沸石载体。通过使用其中硅/铝之比为2至3的X型八面沸石，获得良好结果。
本发明还涉及采用权利要求1的方法获得的吸附试剂，不管是否与随后的一个或多个权利要求的特征组合。
本发明还涉及用于干燥压缩气体的吸附装置，其中该吸附装置包括采用根据本发明的方法获得的吸附试剂。
附图说明
为了更好地显示本发明特征的意图，参考附图在没有任何限制特性的情况下，下文借助实施例描述制造用于处理压缩气体的吸附试剂的根据本发明的方法的若干优选变体，其中：
图1示意性示出了制造吸附机构的根据本发明的方法的可能的实施方案；
图2示出了可以应用于根据本发明的方法中的可能的温度变化。
具体实施方式
图1示出了方框图，其中每个方框列出了根据本发明的方法的步骤，和其中在一些方框中，在其间区分了许多子步骤。
用于制造处理压缩气体的吸附试剂的根据本发明的方法基本上由步骤1A和步骤1B组成，其中步骤1A提供整块状支持结构，和步骤1B包括生产含有吸附剂的涂层悬浮液。
在下一步骤2中，将前述涂层悬浮液施加至前述支持结构上，以形成涂层，和最后在步骤3中，对在步骤2之后获得的具有涂层的所得支持结构施加热处理，从而烧结前述涂层而最终获得改进的吸附试剂。
根据优选、但非必须的本发明的特征，为整块状支持结构选择含有堇青石的陶瓷结构，例如Corning的
或者，根据本发明，也可以将其它材料用于制造有关的支持结构，例如：
-其它陶瓷材料，如莫来石，γ-氧化铝或α-氧化铝或碳化硅(SiC)；
-金属箔；
-纤维结构，例如基于玻璃纤维、陶瓷纤维或其它纤维，或不同类型纤维的混合物的纤维结构；或
-聚合物。
毋庸置疑，前述列举不是穷举，且不排除使用其它材料。
根据本发明，也并不排除整块状支持结构由两种或更多种前述和/或其它材料的组合制成。
根据本发明的优选特征，由其制造支持结构的材料优选包含200至1200CPSI(孔/平方英寸)和更优选350至450CPSI。
支持结构的壁厚优选为2至11密耳(毫英寸)，和更优选3至9密耳，和甚至更优选5至7.5密耳。在最优选的实施方案中，壁厚为6至7密耳，优选约6.5密耳。
支持结构的壁的孔隙率优选大于5％，和更优选大于10％，和甚至更好地大于20％。
所形成的孔优选具有正方形形状，但可存在其它形状，如三角形、正弦、圆形、六边形和类似形状。
生产涂层悬浮液的步骤1B优选包括以下子步骤：
-第一子步骤1BX：提供溶剂；
-第二子步骤1BY：将吸附剂添加至前述溶剂中，以形成混合物；和
-第三子步骤1BZ：将粘结剂材料添加至前述混合物中。
在子步骤1BY中，优选选择一种或多种以下和/或其它材料作为吸附剂：
-沸石，优选亲水性沸石，但疏水沸石也是可能的–该沸石可以是例如X型八面沸石，例如Tosoh的Zeolum F9，或者X和A型沸石的混合物；
-硅胶；
-活性氧化铝；
-活性炭；
-金属-有机框架；
-碳分子筛(CMS)；
-经浸渍的吸附剂；和
-混杂(hybrid)的吸附剂。
上述列举不是穷举，并且根据本发明，其它材料也是可能的。吸附剂的选择取决于待处理的气体必须经历什么处理，例如干燥或选择性除去其它分子，如氧气或二氧化碳，例如当在氮气发生器或类似装置中使用吸附机构时，其中待处理的气体可以例如是压缩空气。
吸附剂的粒度分布优选使得D50小于10μm和更优选小于4μm。
在第三子步骤1BZ中添加的前述粘结剂材料优选含有无机粘结剂材料，如：
-胶体二氧化硅，例如Grace Davison的Ludox-AS 40；
-氧化铝；和/或
-粘土。
此外，如果需要的话，可使用有机粘结剂材料，如：
-甲基纤维素；
-聚合物，如丙烯酸类树脂、乙烯基树脂和类似物；和/或
-来自纤维素组中的材料。
根据本发明的可能特征，生产涂层悬浮液的步骤1B包括添加一种或多种添加剂，如影响酸度(pH值)的添加剂，例如降低pH的氯化氢(HCl)，或升高pH的氨(NH3)，和/或抵抗泡沫形成的添加剂。例如，但并不严格地必需的是使pH值为9至11，和更优选9.5至10.5。
将吸附剂添加至前述溶剂中，以形成混合物的第二子步骤1BY优选包括：
-将粉末形式的吸附剂引入溶剂，
-在将吸附剂引入溶剂期间或之后，混合吸附剂和溶剂。
根据本发明的额外的优选方面，在将吸附剂混合到溶剂中之后，减小吸附剂颗粒的尺寸，从而获得前述优选的粒度，例如通过湿法研磨减小。湿法研磨的实例是砂磨，辊磨或浸渍研磨。
在步骤1B之后获得的涂层悬浮液优选是剪切变稀的液体，当剪切应力作用时，所述液体呈现出降低的粘度。
根据本发明的方法的步骤2由将前述涂层悬浮液施加至前述支持结构上组成，优选由采用有关的涂层悬浮液冲刷或灌注所述支持结构组成。
优选地，支持结构的灌注从顶部到底部进行，或换言之，在与重力相反的方向上，例如通过为此提供的泵送机构进行，所述泵送机构或者泵送涂层悬浮液向上通过支持结构，或者抽吸涂层悬浮液向上通过支持结构，优选直到穿过支持结构的所有通道已经被涂层材料填充。
然后可关闭泵送机构，从而让多余的涂层材料流出所述通道。或者，有关的泵送机构的运行方向可以反转，使得实现多余的涂层材料从所述通道中主动排出。
根据本发明的特别优选的方面，可以通过施加吹扫气体的一个或多个压力脉冲通过支持结构的通道，从支持结构中排出多余的涂层材料的一部分。这样的吹扫气体的实例是空气。
尤其在支持结构内的通道采用这样的主动排出的情况下，当使用剪切变稀的涂层悬浮液时，获得良好结果。
在任何除去多余涂层材料之后，可以让涂布的支持结构干燥，例如在环境条件下干燥，直至溶剂大部分蒸发。当将水用作溶剂时，例如可以在周围空气中进行该干燥。
在根据本发明的方法的最后的步骤3中，使在步骤2之后获得的具有涂层的所得支持结构经受热处理，从而烧结所述涂层。
在该热处理期间，将前述所得支持结构暴露于优选大于400℃的温度，且甚至更优选大于500℃，且在最优选的实施方案中，550℃的温度。
当然在该热处理期间可以应用许多变化的温度变体。在图2中示出了非限制性实施例，其中横轴示出了以小时表达的时间，而纵轴表示以℃表达的温度。
在步骤3的起始时间t0处，温度等于环境温度，在该实施例中为20℃。缓慢地升高温度，在该情况下，速率为50℃/h，和在该实施例中，时间段为10小时36分钟。在时间t1，即在时间t0之后的10小时36分钟处，在该情况下，温度将因此升至550℃。
优选地，升高温度的时间段之后是其中温度保持恒定地高，优选高于400℃，和更佳地高于500℃的时间段。在该非穷举性实施例中，其中温度保持高的时间间隔为1小时。在其中在该实施例中将温度于550℃保持1小时的该时间间隔末时，将再次降低温度，在该实施例中以比热处理开始时温度升高时更高的速率降低。例如所述温度可以以150℃/h的速率降低，在所示的实施例中，这意味着在其中温度保持实践中恒定地高的时间段末的t2与在温度降低到环境温度(在该实施例中为20℃)的末处的t3之间的时间间隔仅为3小时32分钟。
从20℃的环境温度开始，和作为非限制性实施例，遵照图2中所示的温度变化，热处理的整个步骤3因此将花费15小时8分钟。
由于根据本发明的方法产生具有非常高的质量密度的吸附剂材料和对支持结构具有非常好的粘附性(大于或等于250kg/立方米)的涂层材料，因此采用根据本发明的方法获得的这样的吸附试剂极其适合于应用于干燥装置中用于干燥压缩气体，因为增加的干燥器效率甚至能够使被引导通过干燥装置的待干燥的气体流速增至三倍。换言之，对于相同的待干燥的气体的流速而言，可以使用明显较小的干燥装置，这呈现出重要的生态和经济优势。
为了能够使层厚更大，根据本发明的优选方面，施加涂层悬浮液和热处理在其上具有涂层的整个支持结构的步骤反复一次或多次，直到达到在支持结构上所需的涂层厚度。
本发明涉及呈用于吸附水分的干燥试剂形式或呈可用于选择性吸附，例如在氮气发生器或类似装置内的不同吸附试剂形式的吸附试剂的制造方法，因为该吸附试剂能吸附某些气体分子，例如氧气、二氧化碳和类似物。已知的是，例如通过从压缩空气中除去这样的气体分子，可产生氮气。
绝不将本发明以任何方式限制到作为实施例描述和在附图中显示的实施方案，而是可以以许多方式，实现用于制造吸附试剂的根据本发明的方法，而不脱离本发明的范围。

Claims (25)

1.用于处理压缩气体的吸附试剂的制造方法，其特征在于，该方法包括以下步骤：
-提供整块状支持结构；
-生产包含吸附剂的涂层悬浮液；
-将前述涂层悬浮液施加至前述支持结构上，以形成涂层；和
-对具有涂层的支持结构施加热处理，从而烧结所述涂层。
2.根据权利要求1所述的方法，其特征在于，对于所述整块状支持结构而言，选择一种或多种以下材料：陶瓷材料、金属箔和纤维结构。
3.根据权利要求2所述的方法，其特征在于，对于所述整块状支持结构而言，选择含有堇青石的陶瓷结构。
4.根据前述权利要求中任一项或多项所述的方法，其特征在于，为了生产涂层悬浮液，对于吸附剂而言，选择一种或多种以下材料：沸石、硅胶、活性氧化铝、活性炭、金属-有机框架、碳分子筛(CMS)、经浸渍的吸附剂和混杂的吸附剂。
5.根据权利要求4所述的方法，其特征在于，前述吸附剂包括亲水性沸石。
6.根据权利要求4所述的方法，其特征在于，前述吸附剂包括X型八面沸石。
7.根据前述权利要求中任一项或多项所述的方法，其特制在于，生产前述涂层悬浮液的步骤包括以下子步骤：
-提供溶剂；
-将前述吸附剂添加至所述溶剂中，以形成混合物；和
-将粘结剂材料添加至该混合物中。
8.根据权利要求7所述的方法，其特征在于，在将所述吸附剂添加至所述溶剂和将所述吸附剂与所述溶剂混合之后，通过湿法研磨减小吸附剂颗粒的尺寸。
9.根据权利要求8所述的方法，其特征在于，将所述吸附剂的粒度降低至D50小于10μm和更优选小于4μm的尺寸。
10.根据权利要求7-9中任一项所述的方法，其特征在于，选择一种或多种以下无机粘结剂材料作为粘结剂材料：
-胶体二氧化硅；
-氧化铝；和/或
-粘土。
11.根据权利要求7-10中任一项所述的方法，其特征在于，选择一种或多种以下有机粘结剂材料作为粘结剂材料：
-甲基纤维素；
-聚合物，如丙烯酸类树脂、乙烯基树脂和类似物；和/或
-来自纤维素组的材料。
12.根据前述权利要求中任一项或多项所述的方法，其特征在于，将前述涂层悬浮液施加至前述支持结构上包括采用有关的涂层悬浮液冲刷或灌注所述支持结构的步骤。
13.根据权利要求12所述的方法，其特征在于，从底部到顶部，或换言之，以与重力相反的方向，进行支持结构的灌注。
14.根据权利要求13所述的方法，其特征在于，通过泵送机构实现灌注，所述泵送机构或者泵送涂层悬浮液向上通过支持结构，或者抽吸涂层悬浮液向上通过支持结构。
15.根据权利要求12至14中任何一项的方法，其特征在于，在用所述涂层悬浮液灌注支持结构之后，除去多余的涂层材料。
16.权利要求14和15的方法，其特征在于，通过反转有关的泵送机构的运行方向，实现多余涂层材料的除去。
17.根据权利要求16所述的方法，其特征在于，通过施加吹扫气体的一个或多个压力脉冲通过支持结构的通道，从支持结构中排出多余的涂层材料的一部分。
18.根据前述权利要求中任一项或多项所述的方法，其特征在于，前述热处理由至少三个阶段组成：
-在第一时间间隔t1-t0期间升高温度；
-在第二时间间隔t2-t1期间将温度恒定地高地保持在高于400℃的值；
-在第三时间间隔t3-t2期间将温度降回至环境温度。
19.根据权利要求18所述的方法，其特征在于，在前述第二时间间隔t2-t1期间，温度保持恒定。
20.根据前述权利要求任一项或多项所述的方法，其特征在于，生产涂层悬浮液的步骤(1B)包括：添加一种或多种添加剂。
21.根据权利要求20所述的方法，其特征在于，前述添加剂含有一种或多种以下试剂：
-影响酸度(pH值)的添加剂；和
-抵抗泡沫形成的添加剂。
22.根据权利要求21所述的方法，其特征在于，前述影响酸度的添加剂由氯化氢或氨组成。
23.采用根据前述权利要求中任一项或多项所述的方法获得的吸附试剂。
24.根据权利要求23所述的吸附试剂，其特征在于，它是干燥试剂。
25.提供有根据权利要求23所述的吸附试剂的吸附装置。
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