CN110799452B - 用于制备合成气的方法 - Google Patents

用于制备合成气的方法 Download PDF

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CN110799452B
CN110799452B CN201880042888.1A CN201880042888A CN110799452B CN 110799452 B CN110799452 B CN 110799452B CN 201880042888 A CN201880042888 A CN 201880042888A CN 110799452 B CN110799452 B CN 110799452B
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K·阿斯伯格-彼得森
P·A·汉
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Abstract

本发明涉及用于制备合成气的方法，其基于ATR工艺或使用来自水电解和空气分离单元的氧气使烃原料进行部分氧化的组合来生产合成气。

Description

用于制备合成气的方法
本申请涉及合成气的制备。更具体地，本发明在制备包含氢和碳氧化物的合成气时结合了空气分离、水的电解和烃原料的部分氧化。
用天然气进料生产例如用于甲醇合成的合成气通常通过蒸汽重整来进行。
蒸汽重整的主要反应是(针对甲烷)：
其他碳氢化合物发生类似的反应。蒸汽重整通常伴随着水煤气变换反应：
蒸汽重整可以例如通过管式重整器(也称为蒸汽甲烷重整器，SMR)和自热重整(ATR)的组合来完成，其也称为初级和次级重整或两步重整。或者，可以使用独立的SMR或独立的ATR来制备合成气。
ATR反应器的主要元件是耐火衬里压力外壳内包含的燃烧器、燃烧室和催化剂床。在ATR反应器中，亚化学计量量的氧气使烃进料进行部分氧化或燃烧，然后在蒸汽重整催化剂的固定床中发生部分燃烧的烃进料流的蒸汽重整。由于高温，燃烧室中也发生一定程度的蒸汽重整。蒸汽重整反应伴随着水煤气变换反应。通常，就蒸汽重整和水煤气变换反应而言，气体在ATR反应器出口处处于或接近平衡状态。出口气体的温度通常为850至1100℃。ATR的更多细节和完整描述可以在现有技术中找到，例如“Studies in Surface Scienceand Catalysis,Vol.152,“Synthesis gas production for FT synthesis”；Chapter 4,p.258-352,2004”。在同一参考文献中，可以找到有关蒸汽重整(SMR)和两步重整的其他信息。
无论使用独立的SMR、两步重整还是独立的ATR，产品气体都将包含氢、一氧化碳和二氧化碳以及通常包括甲烷和蒸汽的其他组分。
用于生产合成气的替代方法是单独进行部分氧化，也称为POX。POX反应器的主要元件是耐火衬里压力外壳内包含的燃烧器和燃烧室。在POX反应器中，通过亚化学计量量的氧气发生烃进料的部分氧化或燃烧。还发生一些蒸汽重整，并且水煤气变换反应是活跃的。反应器的出口温度通常为1100-1500℃。在反应器中可能会发生一些烟灰形成，并且可能需要在POX反应器的下游除去烟灰。
甲醇合成气优选的组成对应于所谓的模数(M＝(H2-CO2)/(CO+CO2))为1.90-2.20或更优选略高于2(例如2.00-2.10)。
SMR中的蒸汽重整通常导致较高的模数，即过量的氢气，而两步重整可以提供所需的模数。在两步重整中，通常调节蒸汽重整器的出口温度，以便在ATR的出口处获得所需的模数。对于独立的ATR，当合成气用于甲醇生产时，ATR出口气体中的模数通常低于期望值。这可以例如通过从来自甲醇合成回路的吹扫气体中除去二氧化碳或回收氢来进行纠正。在这两种情况下，甲醇回路效率均低于两步重整所获得的效率。
在两步重整中，蒸汽甲烷重整器(SMR)必须很大，并且需要大量热量来驱动吸热的蒸汽重整反应。因此，期望能够减小蒸汽重整器的尺寸和负荷。此外，两步重整概念中的ATR需要氧气。如今，这通常是在低温空气分离单元(ASU)中生产的。该ASU的尺寸和成本很大。如果可以通过其他方式产生一部分或全部氧气，则将是理想的。
因此，本发明提供了一种用于制备合成气的方法，该方法包括以下步骤：
(a)将大气分离成单独的含氧流和单独的含氮流；
(b)通过水和/或蒸汽的电解制备单独的含氢流和单独的含氧流；
(c1)用在步骤(a)中通过分离大气而获得的含氧流的至少一部分和在步骤(b)中通过水的电解而获得的含氧流的至少一部分将至少一部分烃原料部分氧化或自热重整为包含氢气、一氧化碳和二氧化碳的工艺气体；或
(c2)用水和在步骤(a)中通过分离大气而获得的含氧流的至少一部分和在步骤(b)中通过水的电解而获得的含氧流的至少一部分将煤或生物质气化为包含氢气、一氧化碳和二氧化碳的工艺气体；和
(d)将来自步骤(b)的单独的含氢流的至少一部分引入到来自步骤(c1)或(c2)的工艺气体中。
在根据本发明的方法中采用的用于空气分离的方法优选是在低温空气分离单元中的分馏，以提供用于步骤(c1)或(c2)的一部分氧气。或者，可以使用其他方法，例如膜分离、变压吸附(PSA)和真空变压吸附(VPSA)。
除了至少一部分烃原料的部分氧化或自热重整以外，还可以通过利用在空气分离中形成的氧气流和来自水和/或蒸汽的电解的氧气使固体碳质原料(优选煤或生物质)气化来生产包含氢气、一氧化碳和二氧化碳的工艺气体。
在本发明的一个实施方案中，步骤(c1)中的烃原料在自热重整器上游的初级重整器(SMR)中进行部分蒸汽重整。
在使用烃原料的一个实施方案中，操作电解单元，使得在该单元中产生的所有氢气在步骤(d)中被添加到来自步骤(c1)的工艺气体中，并且所得的该氢气和来自步骤(c1)的工艺气体的混合物的模数为1.9至2.2或优选2至2.1。
在该实施方案中，在步骤(c1)中将来自电解单元的一些或优选所有的氧气添加至自热重整器。
此外，可以通过与ATR串联或并联布置的热交换重整器来补充ATR。
热交换重整器可替代地被称为气体加热重整器，而热交换重整可以被称为气体加热重整。
在串联概念中，将一部分或全部烃原料引导至进行蒸汽重整的热交换重整器。剩余部分的烃原料可以绕过热交换重整器，然后被引入到自热重整器中。
因此，在本发明的一个实施方案中，该方法还包括以下步骤：使与离开自热重整步骤(c1)的一部分或全部工艺流为间接传热关系的一部分或全部烃原料进行蒸汽重整。
通常，离开串联的热交换重整器的气体将在650-800℃的温度下处于或接近平衡。然后将来自串联的热交换重整器的出口气体与未在热交换重整器中进行蒸汽重整的任何烃进料一起引导到ATR。来自ATR的一部分或全部出口气体在热交换重整器中用作热源，其通过热交换驱动吸热的蒸汽重整反应。
在热交换重整的并联概念中，将一部分烃原料引导至ATR，并且将剩余部分的烃原料和/或第二烃原料引导至热交换重整器。
进入ATR和进入热交换重整器的原料可以具有不同的组成，例如不同的蒸汽/碳比。
在并联概念的热交换重整器中，进行蒸汽重整。来自ATR的一部分或全部出口气体在热交换重整器中用作热源，其通过热交换驱动吸热的蒸汽重整反应。
在热交换重整器中离开催化剂的气体可以任选地与来自ATR的一部分或全部出口气体混合，然后将后者用作热源。或者，可以将来自热交换重整器的出口气体和来自ATR的出口气体在热交换重整器的下游混合。
因此，在本发明的另一个实施方案中，该方法还包括以下步骤：使与离开自热重整步骤(c1)的一部分或全部工艺流为间接传热关系的一部分烃原料和/或第二烃原料进行蒸汽重整，并使热交换的蒸汽重整的工艺气体与自热重整的工艺气体混合。
根据合成气的最终用途，也可以不混合两种气体。
无论使用并联还是串联概念的热交换重整器，原则上都可以调节操作参数和热交换重整器的设计，以获得模数M的期望值1.9-2.2，或者优选2.0-2.1，特别是在使用合成气来制备甲醇时。
但是，热交换重整器的尺寸可能使这种解决方案不经济。在这种情况下，如上所述使用来自电解的氢气可能证明是有益的。这允许较小的热交换重整反应器。
可以调节氢气的量，使得当将氢气与由重整步骤产生的工艺气体混合时，获得期望的M值(1.90至2.20，或者优选2.00至2.10)。
通过向烃原料和/或合成气和/或自热重整器的上游添加基本上纯的二氧化碳，可以将模数另外调节至期望的值。
因此，在本发明的一个实施方案中，其中将基本上纯的二氧化碳在自热重整上游添加到烃原料中。
电解同时产生氧气，该氧气被进料至ATR或POX。这减小了二级氧气供应例如空气分离单元(ASU)的尺寸。
如果用于电解的动力(至少部分地)由可持续来源产生，则单位生产的产品产生的二氧化碳排放量将减少。
在上述所有情况下，原料都可以首先进行纯化(包括脱硫)和绝热预重整的步骤。
优选地，烃原料包括原样的或经预重整和/或脱硫的天然气、甲烷、LNG、石脑油或它们的混合物。
烃原料可进一步包含氢气和/或蒸汽以及其他组分。
本发明可进一步用于生产用于其他应用的合成气，其中期望增加进料气体中的氢气浓度并且其中通过电解有利地生产合成气生产所需的一部分氧气。
可以通过本领域已知的各种方式来进行电解，例如通过基于固体氧化物的电解或通过碱性电池或聚合物电池(PEM)进行的电解。
实施例
常规ATR和根据本发明的ATR+电解的比较
比较表
*包含在产物气体中
**包含在进入ATR的氧化剂中
从上面的比较表可以明显看出，当施加电解时，来自ATR的入口和出口流量较少。也就是说，在根据本发明的方法中，ATR反应器更小。对于ASU，也是如此。
根据本发明的方法的另一个优点是，在根据本发明的方法中，如果将合成气用于甲醇生产，则进入ATR的所需进料量更少并且合成气的模数得到改善。

Claims (10)

1.用于制备合成气的方法，其包括以下步骤：
(a)将大气分离成单独的含氧流和单独的含氮流；
(b)通过水和/或蒸汽的电解制备单独的含氢流和单独的含氧流；
(c1)在自热重整器中，用在步骤(a)中通过分离大气而获得的含氧流的至少一部分和在步骤(b)中通过水和/或蒸汽的电解而获得的含氧流的至少一部分将至少一部分烃原料部分氧化或自热重整为包含氢气、一氧化碳和二氧化碳的工艺气体；和
(d)将来自步骤(b)的单独的含氢流的至少一部分引入到来自步骤(c1)的工艺气体中，其中操作电解，使得在步骤(b)中产生的所有单独的含氢流被添加到来自步骤(c1)的工艺气体中，并且所得的氢气和来自步骤(c1)的工艺气体的混合物的模数M为1.9至2.2，其中M＝(H2-CO2)/(CO+CO2)。
2.根据权利要求1所述的方法，其中模数M为2至2.1。
3.根据权利要求1所述的方法，其进一步包括以下步骤：使与离开自热重整步骤(c1)的一部分或全部工艺流为间接传热关系的一部分或全部烃原料进行蒸汽重整。
4.根据权利要求1所述的方法，其进一步包括以下步骤：使与离开自热重整步骤(c1)的一部分或全部工艺流为间接传热关系的一部分烃原料和/或第二烃原料进行蒸汽重整，并使热交换的蒸汽重整的工艺气体与自热重整的工艺气体混合。
5.根据权利要求1或2所述的方法，其进一步包括使一部分或全部烃原料在步骤(c1)的上游进行初级蒸汽重整的步骤。
6.根据权利要求1或2所述的方法，其中在部分氧化或自热重整的上游和/或步骤(c1)的下游，将基本上纯的二氧化碳添加到烃原料中。
7.根据权利要求1或2所述的方法，其中烃原料包括原样的或经预重整和/或脱硫的天然气、甲烷、LNG、石脑油或它们的混合物。
8.根据权利要求1或2所述的方法，其中步骤(a)中的大气的分离和/或步骤(b)中的水和/或蒸汽的电解至少部分地由可再生能源提供动力。
9.根据权利要求1或2所述的方法，其中步骤(a)中的大气的分离通过低温分离进行。
10.根据权利要求1或2所述的方法，其中在步骤(d)中制备的合成气在进一步的步骤中被转化为甲醇产物。
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