CN1791459A - 化学反应器 - Google Patents

化学反应器 Download PDF

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CN1791459A
CN1791459A CN200480013475.9A CN200480013475A CN1791459A CN 1791459 A CN1791459 A CN 1791459A CN 200480013475 A CN200480013475 A CN 200480013475A CN 1791459 A CN1791459 A CN 1791459A
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埃尔曼诺·菲利皮
恩里科·里奇
米尔科·特罗佐
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Casale SA
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Abstract

一种用于催化反应的化学反应器,其包括:通过各自的盖(3和4)在相对端封闭的基本上圆柱形外壳(2);至少一个反应区域(7、8),其中支持各自的催化床(9、10);和设置于所述至少一个反应区域(7、8)中的多个热交换器(25)。

Description

化学反应器
技术领域
本发明涉及用于催化反应的化学反应器。
具体地,本发明涉及一种类型的化学反应器,包括通过各自的盖在相对端封闭的基本上圆柱形外壳和在所述外壳中限定的反应区域,所述反应区域中支持至少一个催化床。
更具体地,本发明涉及上面类型的化学反应器,其中所述至少一个催化床是“伪等温类型”的,也就是其中反应温度被控制在预定最佳值周围值的有限范围中。
背景技术
如已知的,在催化反应领域中,增大生产能力和反应产量、同时减小能量消耗和为实施所述催化反应而设计的化学反应器的安装和操作成本的需要越来越大。
为此,在现有技术中,已经提出伪等温化学反应器的多种类型和结构。
术语“伪等温反应器”,我们希望表示这样一种用于化学反应的反应器,其中通过比如管热交换器或板热交换器的热交换部件将反应温度控制在预定最佳值周围值的有限范围中。
然而,尽管在相同方面是有利的,但根据现有技术的反应器没有一个能同时满足全部需要。
事实上,当它们部分适用于高生产能力和反应产量时,它们通常具有结构上复杂和需要高能量损耗以及高操作和维修成本的缺陷,并且反之亦然。
发明内容
基于本发明的技术问题是提供具有结构和功能特性的前述类型的化学反应器,从而允许高生产能力和转换产量,并同时需要低能量消耗以及低安装和操作成本。
如通过附加权利要求中描述和要求的,通过用于催化反应的化学反应器解决前述技术问题。
本发明的进一步的特征和优点将从参照相关附图在下文中给出的根据本发明的化学反应器的实施例的详细说明显而易见,其用于陈述而非限制用途。
附图说明
图1示意性示出了根据本发明的优选实施例的化学反应器的横截面图。
图2和3的每一个示意性示出了分别沿着虚线B-B和C-C的图1的反应器的横截面图。
具体实施方式
参照图1,以1整体和示意性地示出具有垂直轴A-A的伪等温化学反应器,在用于氨、甲醇或甲醛合成的具体(不局限于此)情况中,所述伪等温化学反应器通常用于实现通过催化剂的活化的化学反应。
所述反应器1包括圆柱形外壳2和相对的下部盖3和上部盖4。上部盖4配备有用于反应物输入的三个开口5、5′和5″,而下部盖3配备有用于反应产品排出的开口6。
根据本发明的第一方面,所述外壳2包括两个反应区域7和8,其中支持各自的催化床9和10,被用于充满合适的催化剂(未示出)。
上部催化床9在上部开口,并被限定于上线11和下、有孔的底部12之间,从而允许通过催化床9反应物的轴向通道。
下部催化床10通过被穿孔的基本上环状圆柱形的篮15的各自的内部和外部壁13和14沿着平行于轴A-A的方向被限定范围,从而允许反应物通过催化床10径向通过。
下部催化床10在上部开口,并被限定于上线16和在下线17之间。在下线17下、盖3中提供空间18,用于充满惰性材料(未示出)的合适颗粒层,以支持催化床10中的催化剂。
在所述篮15和外壳2之间是用于催化床10内部反应物分配的间隙19。该间隙19和催化床10的上部部分(线16)通过有孔的底部12和收集从催化床9出来的反应物/产品混合物的收集腔室20与催化床9联系。
在所述篮15和外壳2的轴A-A之间是收集从催化床10出来的产品流的收集腔室21,其通过排出管22与盖3的出口开口6流体联系。
以本质上已知的方式在外壳中支持催化床9和10,并因此不再下面的说明中作进一步详的细描述。
有利地,在外壳2的中部和下部中配备排出开口23和24,以用于分别排出容纳于催化床9和10中的催化剂。
根据本发明的进一步的方面,在催化床9和10中沉入和支撑多个热交换器25。优选地,所述热交换器25是板形、矩形和箱形。这些板热交换器通常包括一对并置的金属板,通过焊接以预定的空间关系相互邻接,从而在它们之间限定用于操作热交换流体的流体的预定宽度的间隙。
优选地,利用平行于外壳2自身的轴A-A的长侧26径向设置交换器25。仍优选地,交换器25具有小于通常存在于反应器的下和/或上盖中比如人孔(manhole)开口(本质上传统的,并因此不再示出)的开口的横截面尺寸的横截面尺寸。这样做,有利地可以采用这些开口,其具有远小于外壳直径的横截面,以安装于热交换器25中,或从催化床拆除,以及用于实现相同的维修操作。
有利地,根据非限制性的实施例,在与所述外壳2同轴的多个同心行(在例子中为两个)上设置(分组)所述热交换器25(见图2和图3),从而形成如在下面的说明中更加详细描述的关于彼此串联和/或平行设置的环形结构的独立热交换器单元。
每一热交换器25包括进口连接器27和出口连接器28,以用于操作热交换流体。在所述热交换器25的相对短侧上定位所述连接器。
具体地,在上催化床9中设置的热交换器25通过管状配件29和连接器27与进口开口5和5′流体联系。在相对侧上,这些热交换器25通过连接器28、管状配件30、中心管31和收集腔室32与催化床9(线11)的进口流体联系。
中心管31是圆柱形的,并与所述外壳2同轴,并延伸通过上催化床9。它通过没有穿孔的底板33在底部封闭,并通过有孔的上板34与收集腔室32流体联系。
优选地,中心管31也借助经过有孔的上板34的连接管35与进口开口5流体联系,以用于反应气体的附加输入。
相反,在下催化床10中设置的热交换器25与进口和出口开口流体联系,以用于操作支持于下部盖3中的热交换流体。就这方面,下部盖3包括进口开口36和37以及出口开口38,以用于操作热交换流体。
催化床10中的交换器25的底侧然后通过连接器27和管状配件39与进口开口36和37流体联系。这些热交换器也通过连接器28和管状配件40与出口开口38流体联系。此外,根据本发明的特别有利的特征,下催化床10中的热交换器25通过连接器28和管状配件41在它们之间流体联系。
在图1-3中示出的例子中,在每一催化床9和10中限定热交换器25的两个独立单元U1和U2。在上部床9中,所述单元平行连接,同时在下部床10中,所述单元串联连接。
根据本发明的进一步优选方面,热交换器25不对于全部它们的轴向长度延伸于催化床9和10中,并且有利地,床9和10的上部42是绝热类型的,也就是无热交换部件。
参照前述设备,反应物的流通过开口5、5′和5″被连续地供给至反应器1。
这种流通过管状配件29和连接器27被同时供给至在上催化床9中设置的两个单元U1和U2的热交换器25的内部,在这种情况中,它与第一反应区域7热交换。
在所述热交换器25内部,反应物的流具有操作热交换流体的功能(第一)。
在热交换器25的出口处,通过连接器28和管状配件30向该处抽取反应物的流,并将其传送进入中心管31。
中心管31也被供给通过管35来自开口5″的“新鲜”反应物的附加流,其与来自交换器25的反应物的流混合,并运载全部反应物流向上至收集腔室32,从所述收集腔室32,它在基本上轴向方向上向下流过催化床9,在这种情况中,它部分反应。
在收集腔室20中收集通过有孔的底部12从反应区域7出来的反应物/产品混合物,从所述收集腔室20,它轴向(通过线16)和径向(通过间隙19)分布于第二反应区域8内部。
在第二反应区域8中,通过在轴向/径向方向上反应物/产品混合物的混交(crossed),完成反应。
在来自第二反应区域8的出口处,产品流进收集腔室21,从所述收集腔室21,它们通过排出管22被输送至出口开口6。
使比如水、沸水或熔融盐等的第二操作热交换流体流进设置于下催化床10中的热交换器25中,获得第二交换区域9中的温度控制。在这种情况中,在反应区域8和第二操作热交换流体之间交换热,其是第一供给-通过开口36、管状配件39和连接器27至外部单元U2的交换器25。从这些交换器,将第二操作热交换流体通过连接器28、管状配件41和连接器27进一步供给至内部单元U1的交换器25。最后,通过连接器28、管状配件40和出口开口38从交换器25的单元U2抽取第二操作热交换流体。
在此方面,需要指出,根据本发明的进一步优选实施例,将第二操作热交换流体的一部分直接供给至内部单元U1的交换器25。在这情况中,它通过开口37和管状配件39与从外部单元U2出来的流体混合。
从上面的描述显而易见,有利地平行操作第一反应区域7中交换器25的单元U1和U2,同时串联操作第二反应区域8的单元U1和U2。此外,由于绝热类型的其较小的上部42,两个催化床9和10级本上是“伪等温”类型的,也就是无热交换部件,并因此没有温度控制地操作。
在确定的具体环境中,可以在外壳2中配备附加的合适催化床(未示出),其完全是绝热类型的。
可以非重新地(ex novo)设计根据本发明的反应器,或者根据本发明的反应器可以由已经存在的伪等温反应器组成,其基于内部设备(试图被废弃的反应器的修补)的去除已被恢复。或者,根据本发明的反应器可以由已经存在的绝热反应器组成,其也已经被清除内部设备(从绝热至伪等温反应器的转换)。
由于上面所述的结构,可以获得能够确保高生产能力和反应产量、同时简单制造、利用低能量消耗、并且不需要高安装和操作成本的化学反应器。
分别基本上在轴向/径向方向上被反应物气体混交的催化床的存在允许改进热交换效率和更好控制气压下降,从而实现上面的优点。
单独反应器外壳的存在允许减小安装成本和设备的结构复杂性。
此外,如本发明提出的,这种单独的反应器外壳中不同的操作热交换流体的使用允许进一步增大反应的转换产量(由于反应温度的更好控制)和改进热回收,从而减小能量消耗。
尽管可以把在图1-3中示出的反应看作本发明的优选实施例,但后者易于进行进一步的实施例和修改,以解决上面识别的技术问题,通过如在附加权利要求中限定的保护范围将其全部覆盖。
具体地,根据反应器1(未示出)的进一步的实施例,伪等温催化床10包括热交换器25的单元U1和U2,平行设置所述热交换器25的单元U1和U2,并对其供给操作热交换流体的不同、独立的流。为此,不需管状配件41,并且通过相应的连接器27和29以及管状配件39、40,每一单元的热交换器25合适地连接至操作热交换流体的各自的外部源。也在这种情况中,操作热交换流体的一个能够有利地包括反应物气体。
由于根据本发明的反应器,可以获得用于实施催化化学反应的方法,例如用于氨、甲醇或甲醛的合成,其包括供给反应物至至少一个反应区域的步骤,所述至少一个反应区域包括催化床和在所述催化床中设置的多个热交换器,所述热交换器集合成结构上独立的热交换单元,并且供给各自不同的操作热交换流体至所述热交换器单元,以用于在伪等温的环境中控制反应温度。

Claims (16)

1、用于催化反应的化学反应器,其包括:通过各自的盖(3和4)在相对端封闭的基本上圆柱形外壳(2);至少一个反应区域(7、8),其中支持各自的催化床(9、10);和设置于所述至少一个反应区域(7、8)中的多个热交换器(25),其特征在于,所述热交换器(25)被分组为结构上独立的热交换单元(U1、U2),以及包括用于供给至所述单元(U1、U2)操作热交换流体的各自流的装置(27、29、39)的事实。
2、根据权利要求1所述的反应器,其特征在于,它包括:至少两个反应区域(7、8),每一个区域支持各自的催化床(9、10);至少一个热交换单元(U1、U2);以及用于供给至所述单元(U1、U2)操作热交换流体的各自流的装置(27、29、39)。
3、根据权利要求1所述的反应器,其特征在于:所述多个热交换器(25)的至少一个交换器是板状、矩形和箱形。
4、根据权利要求3所述的反应器,其特征在于:所述交换器(25)径向设置,长侧(26)平行于外壳2的轴(A-A)。
5、根据权利要求3所述的反应器,其特征在于:所述交换器(25)具有小于存在于反应器的下和/或上盖(3、4)中的比如人孔开口的开口的横截面尺寸的横截面尺寸,其具有远小于所述外壳(2)的直径的横截面。
6、根据权利要求3所述的反应器,其特征在于;用于供给至所述单元(U1、U2)操作热交换流体的各自流的所述装置(27、29、39)包括在其相对短侧连接至所述热交换器(25)的进口和出口连接器(27、28)。
7、根据权利要求1所述的反应器,其特征在于:所述热交换器(25)部分延伸于各自的催化床(9、10)中。
8、根据权利要求1所述的反应器,其特征在于:所述单元(U1、U2)具有环形结构,并包括在与所述外壳(2)同轴的至少一个同心行上设置的多个交换器(25)。
9、根据权利要求8所述的反应器,其特征在于:所述单元(U1、U2)包括与所述外壳(2)同轴的交换器(25)的两个同心行。
10、根据权利要求1所述的反应器,其特征在于:所述各自的催化床(9、10)包括关于彼此串联和/或平行设置的热交换器单元(25)的至少两个单元(U1、U2)。
11、根据权利要求2所述的反应器,其特征在于:它包括上部和下部反应区域(7、8),每一反应区域支持各自的催化床(9、10)和被分组为与所述外壳(2)同轴的两个环形单元(U1、U2)的多个热交换器(25),关于彼此地平行设置上部反应区域(7)中的环形单元(U1、U2),并且关于彼此地串联设置下部反应区域(8)中的环形单(U1、U2)。
12、根据权利要求11所述的反应器,其特征在于:在上部反应区域(7)中支持的各自的催化床(9)具有有孔的底部(12),以允许通过反应物气体由此轴向混交,同时下部反应区域(8)中支持的各自的催化床(10)具有有孔的侧壁(13、14),以允许通过反应物气体由此径向混交。
13、根据权利要求2所述的反应器,其特征在于:所述外壳包括与所述各自的催化床(9、10)联系的至少两个催化剂排出开口(23)。
14、用于实施催化化学反应的方法,其包括下面的步骤:
-供给反应物至化学反应器的至少一个反应区域,所述化学反应器包括催化床和在所述催化床中设置多个热交换器,所述热交换器被分组为结构上独立的热交换单元;以及
-供给各自的不同操作热交换流体至所述热交换单元,以用于在伪等温条件下控制反应温度。
15、根据权利要求14的方法,其特征在于:在下面的组中选择所述不同的操作热交换流体:反应物气体、水、沸水或熔融盐。
16、根据权利要求14的方法,其特征在于:将所述反应物供给至化学反应器的至少一个区域,所述化学反应器包括每一个支持各自的催化床的至少两个反应区域和至少一个热交换单元,以及分别供给所述不同的操作热交换流体至所述反应区域中的热交换单元。
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