CN1860207A - 制氢用自热转化器－转化交换器布置 - Google Patents

制氢用自热转化器－转化交换器布置 Download PDF

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CN1860207A
CN1860207A CNA2004800070761A CN200480007076A CN1860207A CN 1860207 A CN1860207 A CN 1860207A CN A2004800070761 A CNA2004800070761 A CN A2004800070761A CN 200480007076 A CN200480007076 A CN 200480007076A CN 1860207 A CN1860207 A CN 1860207A
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A·马尔霍特拉
J·H·戈斯内尔
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Abstract

本发明涉及制氢方法和设备。所述设备包括与自热转化器(10)(供入经预热的蒸汽－烃混合物)并行布置的转化交换器(14)，空气－蒸汽混合物供入自热转化器(10)的燃烧器/混合器以制得650°－1050℃的合成气排放物。得自自热转化器(10)的排放物用于加热转化交换器(14)，合并的转化器排放物被导入变换反应器(30)和分离器(32，34)以分离成混合气流和富含氢的产物气流。

Description

制氢用自热转化器-转化交换器布置
                      发明背景
本发明涉及使用自热反应器(ATR)和转化交换器制备合成气(syngas)。
烃的转化是一种应用多个通常为吸热的反应来制备含氢合成气的标准方法，其中所述合成气用于制备例如氨或甲醇。常规的自热转化反应器(ATR)为一种包含带有特殊设计的燃烧器/混合器的催化气体生成器床的蒸汽转化装置，其中往所述燃烧器/混合器中供入预热的烃气体、空气或氧气和蒸汽。烃在燃烧器中的部分燃烧为发生于燃烧器下方催化床的转化反应提供了所需的热量以生成主要为蒸汽、氢、一氧化碳(CO)和二氧化碳(CO2)等的混合物。蒸汽转化器的排放物随后在变换器中进一步转化，其中CO和蒸汽反应生成另外的氢和CO2，这些气体特别用于氢为主要需求的合成气组分的氨和其他合成。
ATR相对常规催化蒸汽转化器的优点在于例如成本较低且容易操作。工业上采用的ATR方法的缺点是伴随空气分离单元(ASU)所带来的资金成本、操作困难和占用区要求等问题，特别是操作人员和占用区受限等因素致使ASU不合需要。在合成气用于制备氨时，采用低温蒸馏以脱除过量的氮和其他杂质以获得99.9％的纯度水平。
本发明解决无须使用ASU和/或低温蒸馏而从ATR制备氢的需要，通过用过量的空气运转ATR，将ATR过程的排放物供应到转化交换器为制备另外的合成气提供热量，并在无须低温除氮的情况下部分纯化产物氢流。例如从LeBlanc的美国专利5,011,625和5,122,299以及Cizmer等的美国专利5,362,454中已知与自热转化器联用的转化交换器。所有这些专利文献通过引用结合到本文中。这些转化交换器可从市场上购得，商品名为KRES或Kellogg，Brown and Root(KBR)转化交换器系统。
                      发明概述
本发明于新的氢装置中并行使用转化交换器和自热反应器(ATR)，由此降低资金成本、减少能源要求、极大简化操作并减少NOx和CO2的排放，或于现有的氢装置并行使用所述转化交换器和自热反应器而将氢生产量提高40-60％并降低氢装置的蒸汽输出。所得的方法具有非常低的能耗。
本发明在一个实施方案中提供了一种制氢的方法。所述方法包括：(a)在自热反应器中，用蒸汽和空气将第一烃部分催化转化制备温度为650°到1050℃、优选650°到1000℃的第一合成气排放物；(b)将第一合成气排放物供入转化交换器；(c)将第二烃部分和蒸汽通过转化交换器的催化剂区制备第二合成气排放物；(d)从邻近入口的催化区排放第二合成气排放物，与第一合成气排放物形成合成气混合物；(e)将该混合物通过催化剂区并与其间接热交换而冷却混合物并加热催化剂区；(f)从转化交换器的出口收集经冷却的混合物；(g)变换所述混合物以制得富含二氧化碳而一氧化碳贫乏的气流；并(h)分离所述富含二氧化碳的气流以形成包含氮气和二氧化碳的氢贫乏的混合气流和富含氢的产物流。
如果需要，所述转化、变换和混合气分离可在10到200巴，例如30巴以上的工艺压力下进行。氮和二氧化碳的脱除可由膜分离法或变压吸附分离法或类似的单元操作组成，这些单元可同时在工艺压力下从氢中脱除气体混合物并优选不需要脱除二氧化碳和氮的独立后续步骤。该方法优选包括用燃气轮机传动将空气压缩到催化转化器并从燃气轮机的废气中回收热量。催化剂区可包含催化剂管，且该方法还可以包括：将第一合成气排放物供入转化器的壳侧；将第二烃部分和蒸汽通过催化剂管；以及从邻近壳侧入口的催化剂管中卸载第二合成气排放物以形成合成气混合物。自热转化器可用过量的空气运行。得自变换的富氢气流的氢/氮摩尔比小于3。氮和二氧化碳的脱除优选不需低温蒸馏，且该方法优选不需空气分离。第一烃部分占第一和第二烃部分的比例优选为55到85％。第一烃部分占第一和第二烃部分的比例更优选为60到80％。氢产物流的纯度至少为70％到99.5％，优选至少90％，更优选至少95％，甚至更优选至少97％且特别为至少98.5％，其中百分数按体积计。该方法可包括将氢产物流供入燃料电池以产生电流，或供入例如加氢处理装置以提炼原油，或供入其他精炼过程。
在另一个实施方案中，本发明提供了一种制备合成气的设备。该设备包含：(a)用于用蒸汽和空气催化转化第一烃部分以制备温度为650°到1050℃的第一合成气排放物的自热反应器装置；(b)用于将第一合成气排放物供入转化交换器的入口的装置；(c)用于将第二烃部分和蒸汽通过转化交换器中的催化剂区以形成第二合成气排放物的装置；(d)用于从邻近入口的催化剂区排放第二合成气排放物以与第一合成气排放物形成合成气混合物的装置；(e)用于将所述混合物通过催化剂区并与其间接热交换而冷却所述混合物并加热催化剂区的装置；(f)用于从转化交换器的出口收集经冷却的混合物的装置；(g)用于变换所述混合物以制得富含二氧化碳而一氧化碳贫乏的气流的装置；和(h)用于分离富含二氧化碳的气流以形成包含氮气和二氧化碳的氢贫乏的混合气流和富含氢的产物流的装置。所述设备的分离装置可以包括变压吸附单元或膜分离器。
                       附图简述
图1为本发明的一个实施方案的ATR-转化交换器法的工艺流程简化示意图。
                       发明详述
本发明方法的一个实施方案的主要流程如图1所示。管线2供应的经脱硫的天然气或其他烃与管线4供应的工艺蒸汽混合且该混合物在原料预热交换器6中预热。混合物的蒸汽/碳比率优选为2.0到4.0，例如为约3。经预热的蒸汽-烃混合物的第一部分通过管线8导入自热转化器(ATR)10的燃烧器中，而第二部分则通过管线12导入转化交换器14的管侧入口。如果需要，可以通过管线36将另外的蒸汽加入管线8。
空气通过管线16供入并与管线18的蒸汽混合，且蒸汽-空气混合物在预热器38中预热，例如加热到200℃到650℃的温度，并通过管线20传送到燃烧器，注意维持燃烧器的火焰温度低于1500℃。所述空气优选为过量的空气，即意味着所得的合成气的氢/氮摩尔比(变换后)小于约3(氨合成气组成的常见化学计量比率)。在合成气的氮含量和/或氢纯度不是关键要素的情形，例如在燃料电池、原油或其重馏分的加氢处理或在氮为惰性且其存在不会显著影响合成气使用方法的经济性的应用中，使用空气代替氧气或富氧空气具有经济上的益处。在经济或空间考虑限制了常规空气分离单元(ASU)的使用的情形，例如当ATR/转化交换器用于制备氢(用于浮动产物存储和排出(FPSO)设施)，空气可用作纯氧的替代物。如果需要，空气可通过燃气轮机驱动的压缩机供入，而从燃气轮机废气中回收的热量例如可用于预热工艺原料流、产生工艺蒸汽等。
空气-蒸汽混合物中蒸汽/分子氧的摩尔比优选为约0.8到约1.8，更优选为约1到约1.6，而导入ATR的烃原料的氧/碳摩尔比可为约0.5到约0.8，优选约0.6到0.7。导入ATR 10(管线8)的烃分流占导入ATR 10和转化交换器14(管线2)的烃总量的比例优选为ATR的55到85％，更优选为60到80％，且特别为65到75％。一般优化运行条件和流量使其达到最大氢产量。
来自ATR 10的管线22中的合成气排放物可供入转化交换器14的壳侧入口。来自催化剂管24的出口端的经转化的气体与ATR的排放物混合，且该混合物通过催化剂管24的外部到达壳侧出口，在此处它被收集于管线26。管线26中的合并合成气在交叉换热器6和废热锅炉28中冷却以制备排出蒸汽并被供入下游加工，所述下游加工包括变换段30(可包括高温、中温和/或低温变换器)、热回收32、混合气分离34(例如CO2脱除(例如变压吸附法(PSA)或膜分离法))等，其所有单元操作为本领域技术人员所熟知。分离34优选不包括用于脱除氨合成气产物中过量的氮的低温或深冷分离工艺，所述工艺要求独立的上游脱除系统以使二氧化碳在脱除氮所需的低温下凝固。
转化交换器14的热量要求是由ATR排放物的量和温度来满足。一般来说，向转化交换器供入越多原料，则需要从ATR排放物中获得越多热量。管线22中的ATR排放物的温度应为650°到1000℃或1050℃，且可优选高达转化交换器18的结构材料所允许的温度。如果温度太低，转化交换器14中将发生不完全转化，然而如果温度太高，则应考虑冶金学问题。也应该注意确保所选择的运行条件能使得金属粉尘降低到最少。运行压力优选10到200巴或更高，特别为至少25或30巴，且可方便地选为在所需的压力下供入氢产物流，因此无须使用氢气压缩机。
以下通过实施例对本发明进行阐述。将转化交换器如图1所示与ATR联合安装，其中空气代替氧气用于50MMSCFD氢的制备，在燃烧的加工加热器中具有总吸附负荷为38.94Gcal/hr，且具有如下表1所示的关联参数：
                                 表1  使用过量空气的ATR-转化交换器工艺
  流编号   催化剂管入口，管线12   ATR原料，管线8   ATR排放物，管线22   壳侧出口，管线26  ATR供入空气-蒸汽，管线20
  干摩尔分数
  H2   0.0200   0.0200   0.3578   0.4492
  N2   0.0190   0.0190   0.4628   0.3561  0.7804
  CH4   0.9118   0.9118   0.0013   0.0036
  AR   0.0000   0.0000   0.0055   0.0042  0.9400
  CO   0.0000   0.0000   0.0835   0.1026
  CO2   0.0000   0.0000   0.0891   0.0843  0.0300
  O2   0.0000   0.0000   0.0000   0.0000  0.2099
  C2H6   0.0490   0.0490   0.0000   0.0000
  C3H8   0.0002   0.0002   0.0000   0.0000
  总流量KMOL/HR(干)   312.6   713.9   4154.2   5414.7  2446.2
  H2OKMOL/H   947.7   2164.0   2827.0   3380.6  728.9
  总流量KMOL/HR   1260.3   2878.0   6981.2   8795.3  3175.1
  总流量KG/HR   22288   50896   134887   156700  83990
  压力(kg/cm2abs)   25.9   25.9   22.4   22.1  24.0
  温度(℃)   601   601   1011   747  621
此外，表1的数据为代表低资金成本、低能耗、运行方便以及减少的NOx和CO2排放(与具有相同产能的相当的蒸汽转化氢装置相比减少56％)的一个实施例。该方法对建造新的制氢设施而言是有吸引力的选择，其中过量的氮气是所需要的、可以容许的或可经济地从合成气中脱除。
在另一个实施例中，转化交换器如图1所示与ATR联合安装，其中空气用作氧气来源用于50MMSCFD氢制备。本实施例的常见的压力和温度见图1所示，其他关联参数见下面表2所示：
                           表2使用过量空气氧化剂的ATR-转化交换器工艺
  流编号   催化剂管入口12   ATR原料管线8   ATR排放物，管线22   壳侧出口，管线26  ATR供入空气-蒸汽，管线20
  干摩尔分数
  H2   0.0200   0.0200   0.4115   0.4792
  N2   0.0023   0.0023   0.4020   0.3089  0.7804
  CH4   0.9612   0.9612   0.0026   0.0227
  AR   0.0000   0.0000   0.0048   0.0037  0.0094
  CO   0.0000   0.0000   0.0803   0.0875
  CO2   0.0150   0.0150   0.0987   0.0980  0.0003
  O2   0.0000   0.0000   0.0000   0.0000  0.2099
  C2H6   0.0013   0.0013   0.0000   0.0000
  C3H8   0.0002   0.0002   0.0000   0.0000
  总流量KMOL/HR(干)   371.5   754.3   4069.7   5299.5  2094.1
  H2OKMOL/HR   1074.8   2182.2   2610.9   3325.1  656.2
  总流量KMOL/HR   1446.3   2936.5   6680.5   8624.6  2750.3
  总流量KG/HR   25395   51557   124039   149434  72482
  压力(kg/cm2abs)   25.5   23.6   22.8   22.5  23.6
  温度(℃)   601   601   884   659  621
表2中的数据同样为代表低资金成本、低能耗、运行方便以及减少的NOx和CO2排放的一个实施例。从转化交换器中回收的排放物包含47.9％的H2、30.9％的N2、8.8％的CO和9.9％的CO2。转化交换器的排放物经过变换(如图1所示)产生组成为51.9％的H2、28.6％的N2、0.5％的CO和16.6％的CO2的排放物。通过PSA的纯化产生组成为98.0％的H2、0.80％的N2和1.0％CH4的纯化产物。
本发明以上的描述是对本发明的举例说明和解释。本领域技术人员将理解有关材料、装置和所采用工艺的各种变化。在附加的权利要求书的范围和精神以内的所有这类变化都是可以接受的。

Claims (23)

1.一种制氢方法，所述方法包括：
在自热反应器中，用蒸汽和空气将第一烃部分催化转化制备温度为650°到1050℃的第一合成气排放物；
将第一合成气排放物供入转化交换器；
将第二烃部分和蒸汽通过转化交换器的催化剂区制备第二合成气排放物；
从邻近入口的催化剂区排放第二合成气排放物，与第一合成气排放物形成合成气混合物；
将该混合物通过催化剂区并与其间接热交换而冷却混合物并加热催化剂区；
从转化交换器的出口收集经冷却的混合物；
变换所述混合物以制得富含二氧化碳而一氧化碳贫乏的气流；并
分离富含二氧化碳的气流以形成包含氮气和二氧化碳的氢贫乏的混合气流和富含氢的产物流。
2.权利要求1的方法，其中所述混合气分离包括膜分离法。
3.权利要求1的方法，其中所述混合气分离包括变压吸附法。
4.权利要求1的方法，其中所述催化剂区包括催化剂管，所述方法还包括：
将第一合成气排放物供入转化器的壳侧；
将第二烃部分和蒸汽通过催化剂管；
从邻近壳侧入口的催化剂管排放第二合成气排放物，形成合成气混合物。
5.权利要求1的方法，其中所述自热转化器使用过量空气运行。
6.权利要求1的方法，其中所述经变换得到的富含二氧化碳的气流的氢/氮摩尔比小于3。
7.权利要求1的方法，其中所述混合气分离不包括深冷分离。
8.权利要求1的方法，其中所述方法不包括空气分离。
9.权利要求1的方法，其中所述第一烃部分占第一和第二烃部分总量的比例为55到85％。
10.权利要求1的方法，其中所述第一烃部分占第一和第二烃部分总量的比例为60到80％。
11.权利要求1的方法，其中所述氢产物流的纯度为至少70％体积。
12.权利要求11的方法，其中所述氢产物流的纯度为90到99.5％体积。
13.权利要求1的方法，其中所述氢产物流的纯度为至少95％体积。
14.权利要求1的方法，其中所述氢产物流的纯度为至少97％体积。
15.权利要求1的方法，其中所述氢产物流的纯度为至少98.5％体积。
16.一种产生电流的方法，所述方法包括权利要求1的方法并将富含氢的产物流供入燃料电池。
17.一种加氢处理方法，所述方法包括权利要求1的方法并将富含氢的产物流供入加氢处理装置。
18.一种制备合成气的设备，所述设备包括：
用于用蒸汽和空气催化转化第一烃部分以制备温度为650°到1050℃的第一合成气排放物的自热反应器装置；
用于将第一合成气排放物供入转化交换器的入口的装置；
用于将第二烃部分和蒸汽通过转化交换器中的催化剂区以形成第二合成气排放物的装置；
用于从邻近入口的催化剂区排放第二合成气排放物以与第一合成气排放物形成合成气混合物的装置；
用于将所述混合物通过催化剂区并与其间接热交换而冷却混合物并加热催化剂区的装置；
用于从转化交换器的出口收集经冷却的混合物的装置；
用于变换所述混合物以制得富含二氧化碳而一氧化碳贫乏的气流的装置；和
用于分离富含二氧化碳的气流以形成包含氮气和二氧化碳的氢贫乏的混合气流和富含氢的产物流的装置。
19.权利要求18的设备，其中所述分离装置包括一个变压吸附单元。
20.权利要求18的设备，其中所述分离装置包括一个膜分离器。
21.权利要求1的方法，其中所述转化、变换和混合气分离的工艺压力为10到200巴。
22.权利要求21的方法，其中所述转化、变换和混合气分离的工艺压力为至少30巴。
23.权利要求1的方法，所述方法还包括用燃气轮机传动将空气压缩到催化转化器并从燃气轮机的废气中回收热量。
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