CN1458060A - 气体回收方法 - Google Patents

气体回收方法 Download PDF

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CN1458060A
CN1458060A CN03123848A CN03123848A CN1458060A CN 1458060 A CN1458060 A CN 1458060A CN 03123848 A CN03123848 A CN 03123848A CN 03123848 A CN03123848 A CN 03123848A CN 1458060 A CN1458060 A CN 1458060A
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carbon monoxide
hydrogen
gas
pipeline
hydrocarbon conversion
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N·纳拉辛汉
R·拉马钱德兰
S·S·塔哈卡
江伟斌
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BOC Inc
Linde LLC
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Abstract

提出了一种从烃类转化过程中回收氢气和一氧化碳的改进方法。使用单块催化剂反应器装置来处理来自烃类转化过程的废气流，以帮助从废气流中回收氢气和一氧化碳。本发明还提供了一种使用单块催化剂反应器装置提高烃类转化过程中的氢气和一氧化碳收率的方法。

Description

气体回收方法
技术领域
本发明涉及用于制备氢气、一氧化碳和合成气过程的改进方法。更具体地说，本发明提供了通过使用催化部分氧化反应方法提高烃类转化过程中氢气和一氧化碳收率的方法。
背景技术
在许多精炼和石化工厂中，产生了废气；通常包含未转化的烃、氢气、一氧化碳和惰性气体。这些废气通常在低压下存在，一般可用作联合企业(complex)中其它过程的燃料。如果这些废气可经济地转化成高价值的产品和用作化学原料(feedstock)，那么就能实现更好的利润。因此，能达到这个目标的方法是非常有利的。有可能得到改进的这样一种方法是把烃转化成氢气和一氧化碳。
把烃转化成含氢气和一氧化碳的气体在现有技术中是众所周知的。这些方法的例子包括催化蒸汽重整、自热(autothermal)催化重整、催化部分氧化和非催化部分氧化。这些方法都各有优缺点，且能制备各种比例的氢气和一氧化碳，也就是已知的合成气。
制造氢气作为主要产物的大部分车间是用蒸汽甲烷重整(SMR)方法。SMR车间由装有重整催化剂的管式炉组成。经预热的蒸汽混合物和甲烷原料(source)(如天然气)被输入反应器管子中，它们在超过约800℃的温度下反应，通过高吸热重整反应形成H2、CO和CO2混合物。该反应所需的热量是通过燃料在炉管周围的空气中燃烧提供的。离开SMR反应器的气体混合物穿过另一个反应器，大部分CO在那里与蒸汽反应，形成H2和CO2。在大部分氢气和合成气发生设备中，变压吸附(pressure swing adsorption)即PSA可用来最终纯化氢气或把粗制气流分成指定的合成气产品。PSA加工步骤通常产生了携带未回收氢气(它占输入PSA步骤中的氢气的10-20％)、一氧化碳和来自原料的未转化烃的废气流。
通常，来自PSA的这种废气只获得在生产氢气、一氧化碳和合成气中的作为燃料的价值，因为它被循环输入SMR炉中。在一些例子中，如在甲醇生产过程中，通过轻烃(primary hydrocarbon)转化方法产生的合成气被送入甲醇生产设备中，然后生产出包含H2、CO、CH4和CO2的废气流。这种废气流也通常用作该过程的一些部分中的燃料。
本发明的发明人已经发明了一种方法，来自PSA或其它过程的废气流再在部分氧化反应器中反应，并进行纯化，这样可得到非常高的整个烃转化过程的氢气和一氧化碳收率。
部分氧化方法把含烃气体(如天然气或石油脑)转化成氢气、一氧化碳和其它微量组分(如二氧化碳、水和其它烃类)。该方法通常是通过把经预热的烃类和含氧气体喷到燃烧室中进行的，在燃烧室中，使用少于完全燃烧所需的化学计量量的氧气与烃类发生氧化反应。该反应在非常高的温度(如大于1000℃，通常超过1300℃)和直至150大气压的压力下进行。在一些反应中，蒸汽或二氧化碳也可注入到燃烧室中，以改变合成气产物和调节氢气与一氧化碳之比。
催化部分氧化比非催化部分氧化更有效，因为它使用了较少的氧气。在这样情况下，放热的部分氧化反应在催化剂上发生了，其温度为约700-约1100℃，生成了含高浓度氢气和一氧化碳的反应产物。用在这些方法中的催化剂通常是位于合适载体结构上的贵金属(如铂或铑)和其它过渡金属(如镍)。
最近，已经提出了一些部分氧化方法，其中烃类气体在催化剂(如沉积在陶瓷多孔单块载体上的金属)存在下以高空速(space velocity)与含氧气体接触。单块载体用贵金属(如铂、钯或铑)或其它过渡金属(如镍、钴、铬等)进行浸渍。通常，这些单块载体由固体耐火材料或陶瓷材料(如氧化铝、氧化锆、氧化镁等)制成。在这些反应的进行中，烃类原料气和含氧气体与催化剂接触，其温度足以引发反应，标准的气体小时空速(GHSV)为超过10000小时-1，通常超过100000小时-1。
发明内容
本发明提供了从包含这些气体和未转化烃类的废气(如来自烃类转化过程的PSA废气流)中回收氢气和一氧化碳的改进方法。改进包括使废气流和含氧废气流一起通过整体式催化剂反应器，从反应器中收回氢气和一氧化碳作为合成气产物，或者进一步分离氢气和一氧化碳作为各自的产物。在另一个实例中，生成的气体混合物循环返回到过程中，或者作为最终产品储存起来。
本发明也提供提高烃类转化过程中氢气和一氧化碳收率的方法，这种方法是使来自烃类转化过程的PSA步骤的废气流和含氧气流与整体式催化剂接触，从而把剩余的烃类转化成氢气和一氧化碳，并从产物气流中分离出氢气和一氧化碳。
在制造氢气、一氧化碳或合成气的典型方法中，一种烃(如甲烷)与蒸汽和任选的含氧气体一起输送给烃类转化反应器，并在约800-1000℃的温度下反应。然后，得到的氢气、一氧化碳、二氧化碳和未反应烃类的产物通过变换反应器(shiftreactor)，在那里进一步发生未反应烃类的反应。接着这种气流被送入变压吸附单元，在那里氢气作为产物从气体混合物中分离出来。剩余的气体(它包括一些氢气、二氧化碳、一氧化碳、甲烷和氮气)处于低压状态，并被输送到单块催化剂反应器。氧气也被输送到单块催化剂反应器，且氢气、一氧化碳和二氧化碳作为产物被除去。如果需要的话，可在原料中加入一些烃类燃料，以维持自热反应器运行。接着可从系统中除去氢气和一氧化碳用于其它过程。
另外，本发明也提供了二氧化碳的回收，它也可用于其它过程。因此，相比常用类型转化方法，本发明提供了烃类原料更完全地转化为氢气和一氧化碳，更高的回收这些有价值的产物。当重整和转化催化剂开始老化时，在烃利用方面由于方法的创造性也可保持本发明方法的加工性能。因此，不管重整和转化催化剂的老化，也都能保持氢气或合成气设备的满负荷生产。
另外，本发明还提供共生产氢气、一氧化碳和二氧化碳的改进方法。
附图简述
图1是烃类转化过程的示意图，它使用了本发明单块催化剂反应器方法。
图2是烃类转化过程的示意图，它使用了本发明单块催化剂反应器方法，且二氧化碳作为产物被回收。
图3是使用了单块催化剂反应器方法的烃类转化过程的示意图，它回收了一氧化碳和氢气，且除去并回收了二氧化碳。
具体实施方式
本发明提供了从烃类转化过程的PSA废气流中回收氢气和一氧化碳的改进方法。该改进包括使废气流和含氧气流通过单块催化剂反应器，从而回收氢气和一氧化碳。本发明还提供了提高从烃类转化过程中回收氢气和一氧化碳收率的方法，它包括使得自烃类转化过程的废气和含氧气流与反应器中的单块催化剂接触，从而在通过烃类转化过程的基础上再次回收一定量的氢气和一氧化碳。这些方法都包括单体反应器装置、压缩机装置、骤冷或加回收装置和一氧化碳、二氧化碳和氢气回收装置的系统。
在本发明的方法中，含烃原料气(它通常包含C1-C8烷或烯，且C1-C5烷是优选的，最优选是甲烷)被输送到烃类转化反应器。也可使用其它燃料源，包括天然气和包含甲烷或更长链的烃类的炼油厂废气。汽油、柴油、甲醇和其它燃料源也可用在烃类转化反应器中。含氧气体(它通常是空气，但可包括富氧空气、氧气与其它气体的混合物以及纯氧)也可任选输送到烃类转化反应器中。在反应器中，使用850-900℃的温度来生产气体混合物，它包括氢气、一氧化碳、二氧化碳和未反应的烃类。这种气流被输送到变换反应器，在那里再次发生烃类的反应。在本发明优选的实例中，离开变换反应器的气流优选先在酸性气体去除单元(AGR)中进行处理，以回收大部分的二氧化碳作为有价值的副产物。然后，除去二氧化碳的气流输送到变压吸附单元。
变压吸附单元是依靠气体混合物中特定组分相对气体混合物中其它组分的选择性吸附的，通过使气体混合物接触适当吸收剂从这些其它组分中分离出特定的组分，接触的条件能促进含被强烈吸附的组分的吸附。通常，这些过程在大气压下进行。吸附能发生的上限温度通常约400℃，优选的范围是不高于50-70℃。
通常，吸附步骤进行的的最小绝对压力为50bara(巴绝对值)或更高，但是优选在不超过20bara的绝对压力下进行，更优选不超过约15bara。在典型的PSA方法中，再生步骤的压力通常减小到约0.1-约5巴的绝对压力，优选为约0.2-约2bara的绝对压力。氢气在这种条件下是不被吸附的，因此会在接近输送压力的条件下离开PSA单元，而剩余气体(它包括一氧化碳、二氧化碳、烃类和氮气，以及一些来自吸附床空隙的未回收氢气)在低压条件下离开PSA单元。包含这些组分的低压气流接着被输送到单块催化剂反应器单元。如果需要的话，在原料气中可另外加入燃料，以维持所需的反应和保持反应器温度(自热操作)。
单块催化剂反应器单元是具有耐火材料衬里的容器或管子一段，其中放有单块催化剂。单块催化剂通常是一个或多个由耐热陶瓷材料(如氧化铝、氧化锆、氧化镁、铈土等)制成的圆盘的形式，该圆盘用贵金属(如铑、铂、钯和铱)以适当的担载量进行浸渍。圆盘是多微孔、泡沫样结构。反应器具有入口和出口管，分别用来输入到反应器和移出产物气体。在原料进入反应器之前可进行加热。通常，单块催化剂夹在空白单块盘(它们用作挡热层)之间，以把反应器中产生的热量保留在单块催化剂中。
单块催化剂反应器单元中的反应通常在约0.2-3巴的压力和大于700℃的温度下进行。废气中的剩余烃类在该过程中被部分氧化，以非常高的收率(通常大于90％)产生另外的一氧化碳和氢气。已经存在于原料废气中的氢气和一氧化碳通常都没有变化。单块催化剂反应器单元所需的短停留时间使之产生清洁的气体，只产生最少量的炭黑。伴随小压降产生的高产量可实现很高的投资成本节约。单块催化剂反应器单元流出的气流主要由氢气和一氧化碳组成。在骤冷或热回收单元中回收热量之后，氢气和一氧化碳可在过程中的适当位置循环回烃类转化过程，或者单独处理以回收氢气、一氧化碳或其混合物。对于本发明的更详细描述，将参考图1-3完成。
现在参考图1，管道20提供了进入烃转化反应器装置A的入口。通常，烃转化反应器装置包括催化蒸汽重整、自热催化重整、催化部分氧化过程和非催化部分氧化过程。烃流、蒸汽和任选的含氧气流会在烃转化反应器装置中反应，范围温度约700-约1300℃。反应产物通过管道1离开烃类转化反应器装置。通常，这种气流包括氢气、一氧化碳、二氧化碳和未反应的烃(如甲烷)。这种气流被输送到变换反应装置，但是也可经过管道2，通过阀门3，越过变换反应装置输送到管道4，管道4是进入变压吸附过程装置C的管道。通常，变压吸附过程装置包含吸收剂材料，它可用来分离气流中的氢气。通常，这种吸附剂材料是活性炭或5A沸石吸附剂。变压吸附过程的产物是高压氢气，它通过管道5离开PSA单元。在这种气流中的气体剩余物作为废气通过管道8离开PSA单元。
在这个实例中，在循环部分中，二氧化碳通过管道6离开变压吸附单元，且被输送到富二氧化碳废气储罐(holder)D中。富二氧化碳气体接着通过管道7离开气体储罐输送到二氧化碳回收装置(recovery)，或者通过管道19输送回烃转化反应器装置A。离开PSA单元C的废气流通过管道8到达平衡废气储罐(holder)E，并通过管道9输送废气流到废气原料压缩机F。压缩的废气流通过管道10输送到单块催化剂反应器装置G。含氧气流通过管道18输送到单块催化剂反应器装置。
包含氢气、一氧化碳和二氧化碳的反应产物通过管道11离开单块催化剂反应器装置，进入骤冷或热回收装置H。这种被骤冷的气流接着通过管道12输送到产物废气压缩机I。这种冷却和压缩的气流被输送到一氧化碳回收单元J。一氧化碳回收单元是胺洗、干燥塔、冷箱、膜分离过程或一氧化碳选择性吸收溶剂系统，在那里一氧化碳从废气流的其它组分中分离出来。氢气通过管道17从一氧化碳回收单元除去，该氢气可在原始烃类转化反应装置气体产物进入PSA单元C之前输送回管道4，或者该氢气可与来自PSA的氢气产物在管道5中混合。剩余废气通过管道16输送，它被送入管道19，以重新返回到用在烃转化反应装置单元中的炉中。管道15使回收的二氧化碳输送到管道7以回收二氧化碳，或者通过管道14进入原料二氧化碳液化工段。
现在参考图2，在这里描述了本发明的另一个实例。管道20输送烃原料到烃转化反应器装置A中。反应产物通过管道21离开，并进入变换反应器B，但反应产物也可通过管道23、阀门24从旁路绕开变换反应器到达管道25。离开变换反应器B的气体混合物通过管道25和阀门26输送到变压吸附单元C。在进入PSA单元C之前，离开变换反应器B的气体任选通过管道38输送到CO2回收单元K。然后管道39把去除了二氧化碳的气流送入PSA单元C。二氧化碳通过管道40离开单元K。离开变压吸附单元的废气通过管道27离开，并进入平衡废气储罐E。然后废气通过管道28离开，并进入废气原料压缩机F，它使压缩了的废气通过管道29进入单块催化剂反应器单元装置G。管道30提供了含氧气体的输入。离开单块催化剂反应器单元装置G的气流主要由氢气、一氧化碳和二氧化碳组成，它通过管道31输入到H，即骤冷或热回收装置。
骤冷了的气流沿着管道32输送到产物气体压缩机单元装置I，它把压缩的气体沿着管道33输送到一氧化碳回收装置J。回收的一氧化碳产物通过管道36离开回收单元J。在CO回收过程中剩下的废气通过管道34离开，在那里被重新输送回烃转化反应器装置A。另外，二氧化碳通过管道37离开，并在那里被回收，用于该过程的其它方法或用于其它过程。在单元J中回收的氢气通过管道35离开，并返回到管道25，以进入PSA单元C。
现在参考图3，在这里描述了本发明的另一个实例。作为原料的烃类通过管道20输送到烃转化反应器装置A。燃料通过管道41也被输送到烃转化反应器装置A。反应产物通过管道42输送到变换反应单元B。离开变换反应器的气流通过管道48和旁路阀门50进入变压吸附单元C。来自变换反应器B的在管道48中的产物气可任选通过管道49输入二氧化碳回收装置K。来自这个单元的去除了二氧化碳的气流51接着被返回加到原料管道，进入PSA单元C。氢气产物通过管道52离开PSA单元。废气流通过管道53离开PSA单元进入废气储罐单元E。一部分废气通过管道55至62返回到烃转化反应器装置A的炉中作为燃料，或者通过管道61作为燃料副产物用于其它过程。
剩下的废气通过管道54离开废气储罐E，进入废气压缩机单元F，它通过管道56把压缩了的气流输送到单块催化剂反应器单元G。管道57为单块催化剂反应器单元装置提供了含氧气体。然后，反应产物通过管道58输送到骤冷或热量回收单元装置H，然后把骤冷了的反应产物气流通过管道59输送到循环压缩机I中。氢气/一氧化碳混合物接着通过管道60除去，或者通过管道61与来自烃转化单元A的产物气体在管道42中混合。来自烃转化反应器A且流过管道42的产物气体任选通过管道43输送到一氧化碳回收单元L。一氧化碳回收单元把一氧化碳作为产物通过管道44，并沿着管道45-46返回氢气联产品进入变压吸附单元C。在管道45中的氢气副产物任选通过管道47输送到氢气产物管道52。
实施例
下述实施例用来说明本发明，但是并没有限制本发明。
A.催化剂制备
通过用硝酸铑的饱和水溶液浸渍多孔单块载体制备催化剂。在单块载体被饱和且在空气中干燥之后，在550℃的空气中煅烧5小时，并在550℃的纯氢气中还原6小时。这种方法导致金属担载量约2-5重量％。所用的单块载体为0.73英寸直径、0.93英寸长，是用多孔氧化锆制成，上面有或没有10％CeO2涂层，它具有表示为每线性英寸45孔(45ppi)的标称尺寸的大孔。
B.实验测试方法
这些装置包括不锈钢反应器管，该管5英寸长，0.9英寸的内径。上述催化剂与氧化锆绝缘体薄层包在一起，以防止气体绕过催化剂。催化剂前后放置的惰性A12O3多孔单块载体可在轴向上使热辐射损失降到最小。在进入反应区之前气体进行预混合。产物管道用水骤冷，以防止碳沉积。使用联机GC和NOVA气体分析仪来分析反应产物。总气体流量为10-20SLPM。使用位于下游辐射屏障和单块催化剂之间的热电偶来测量反应温度。系统的总压力保持在1.6ATM，以克服系统中的压降。
为了开始实验，通过电加热装有催化剂的反应器管子在氮气流中预热催化剂。在到达所需温度之后，停止氮气流，然后含有CH4、H2、CO和O2的所需气体混合物开始流动。上述混合物的点火发生在催化剂表面，温度根据原料组合物在100-200℃之间变化，温度快速上升到600-1100℃之间表明点火成块。为了关闭反应器，首先关掉O2，然后关掉其它气体。应当注意确定在系统中没有可燃的条件存在。
计算转化率和选择性
因为氮气在反应中没有消耗或产生，所以N2峰被用作质量平衡的校准。CH4转化率、H2转化率、CO和H2选择性(以碳和氢原子计)的定义如下：
Figure A0312384800101
Figure A0312384800102
S C 0 = F CO F CO + F C O 2
Figure A0312384800104
其中FH2 *指形成水的氢气输入量。它用水的总量减去由甲烷氧化形成的水的量进行计算。水的数量是根据氧和氢原子的平衡决定的。碳和氢原子的平衡都接近±5％。
                   表1
            PSA废气的部分氧化
    载体     45ppi，单块氧化锆
    尺寸     0.73×0.39英寸
    PSA废气组分     48％H2；20％CO；29％CH4
    温度     25℃
    压力     10psig
  催化剂 总流速 CH4/O2比                             产物组分     CH4转化率      H2选择性      CO选择性
  CH4   O2   H2   CO   CO2   H2O   实验值   计算值   实验值   计算值   实验值   计算值
SLPM   ％   ％   ％   ％   ％   ％   ％   ％   ％   ％   ％   ％
  5％Rh/ZrO2 7.5 1.48   4.8   0   59   28.4   1.7   4.1   77.9   97.5   65.4   87.4   94.3   92.6
  两个5％Rh/ZrO2 7.5 1.48   3.6   0   59.4   28.1   2.2   4.9   82.7   97.5   71.3   87.4   92.7   92.6
  两个2％Rh/10％CeO2/ZrO2 7.5 1.48   2.7   0   60.5   28.2   1.7   5   86.2   97.5   78.5   87.4   94.3   92.6
  两个5％Rh/ZrO2 7.5 1.34   2.1   0   60.1   29.4   2.3   4.4   90.3   99.0   66.9   81.6   92.7   93.0
  两个5％Rh/ZrO2 15.1 1.34   5.1   0   57.9   29.3   2.1   3.6   77.3   99.9   55.3   81.6   93.3   93.0
  两个2％Rh/10％CeO2/ZrO2 7.5 1.34   0.7   0   61.7   29.4   2.3   4.3   96.5   99.9   74.7   81.6   92.7   93.0
  两个2％Rh/10％CeO2/ZrO2 15.1 1.34   0.9   0   61.2   29.5   1.9   4.8   95.3   99.9   71.0   81.6   93.9   93.0
1.计算值是基于Gibbs自由能方程。2.H2转化率是通过H、C和O物料平衡计算的。3.没有原料氢气有效地消耗掉，H2选择性仅指由CH4形成H2。4.原料和产物组合物都是用N2平衡的。
本发明的发明人预期，也可使用本发明的方法来回收和转化过程吹扫气体(process purge gas)，这些吹扫气体来自羰基合成过程、甲醇、氨、乙酸、有机氧化过程、石油脑的催化重整、高级芳香族汽油或高辛烷值汽油产品、甲苯加氢脱烃基和甲烷加工过程。另外，本发明的发明人发现，本发明可经济有效地回收二氧化碳产物，该二氧化碳产物是在烃类转化过程中产生的和通过PSA以及单块催化剂反应器单元装置分离出来的。
例如，在甲醇合成方法中，氢气和一氧化碳构成了用来合成甲醇的试剂。它们也随着未转化的烃类和一些甲醇作为未反应的气体流离开甲醇反应室，然后可使用本发明方法进行处理，返回到甲醇合成反应室中。
虽然本发明使用了具体的实例来进行描述，它们本领域的技术人员可容易地作出许多变化和改进。本发明的所附权利要求书通常覆盖了所有的这些明显变化和改进，这些变化和改进在本发明的精神和范围内。

Claims (11)

1.一种从烃类转化方法的变压吸附过程的废气流中回收氢气和一氧化碳的改进方法，其改进包括使所述废气流和含氧气流通过单块催化剂反应器。
2.一种提高烃类转化法中的氢气和一氧化碳的收率的方法，它包括使来自所述烃类转化过程的废气流和含氧气流与单块催化剂反应器接触。
3.如权利要求1或2所述的方法，其特征在于所述废气流包括氢气、一氧化碳、二氧化碳、烃类和氮气。
4.如权利要求1或2所述的方法，其特征在于所述含氧气流选自氧气、空气和富氧空气。
5.如权利要求1或2所述的方法，其特征在于所述单块催化剂是含有贵金属的耐热陶瓷材料。
6.如权利要求1或2所述的方法，其特征在于在所述单块催化剂反应器中发生烃类部分氧化反应，形成氢气和一氧化碳。
7.如权利要求1或2所述的方法，它还包括压缩反应产物气流；骤冷反应产物气流；回收所述一氧化碳和回收所述氢气的步骤。
8.如权利要求1或2所述的方法，它还包括回收二氧化碳的步骤。
9.如权利要求1或2所述的方法，其特征在于所述一氧化碳是通过胺洗、干燥塔、冷箱、膜分离法过程或一氧化碳选择性吸收溶剂系统回收的。
10.如权利要求1或2所述的方法，其特征在于所述氢气和所述一氧化碳再循环到所述变压吸附过程中。
11.一种如权利要求1-10中任何一项所述的用于从烃类转化方法的变压吸附废气流中回收氢气和一氧化碳的系统，它包括使所述废气流和含氧气流通过单块催化剂反应器装置。
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