CN100398439C - 一氧化碳的高得率生产方法 - Google Patents
一氧化碳的高得率生产方法 Download PDFInfo
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- CN100398439C CN100398439C CNB2004100826520A CN200410082652A CN100398439C CN 100398439 C CN100398439 C CN 100398439C CN B2004100826520 A CNB2004100826520 A CN B2004100826520A CN 200410082652 A CN200410082652 A CN 200410082652A CN 100398439 C CN100398439 C CN 100398439C
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Abstract
本发明提供了以烃和氧气为原料生产合成气的整体反应方法。合成气冷却、分离后,得到一氧化碳和氢气,在此分离过程中采用的纯化设备将尾气和进料气循环返回到合成气进气管线中,将来自一氧化碳分离系统的甲烷循环返回到整体反应器中。此方法能使几乎所有的碳都转化为一氧化碳,使得一氧化碳和氢气的得率非常高。
Description
发明领域
本发明提供了以烃和氧气为原料生产合成气的整体反应方法。
合成气经冷却和纯化后产生纯一氧化碳和纯氢气流。纯化设备经适当设计,在合适的操作方式下可使废气流循环回流到生产过程中,从而保证几乎所有的碳都转化为一氧化碳,使得一氧化碳和氢气的得率非常高。
发明背景
将烃转化为含氢和一氧化碳的气体在本领域是广为人知的。这些方法的实例包括催化气流重整、自热催化重整、催化部分氧化和非催化部分氧化。这些方法都既有优点也有缺点,得到的是不同比例的氢气和一氧化碳,即合成气。
催化部分氧化是放热反应,气体烃(如甲烷)和含氧气体(如空气)在高温下与催化剂接触,生成含氢和一氧化碳浓度高的反应产物。这些方法中所用的催化剂通常为负载在合适载体上的贵金属(如铂或铑)和过渡金属(如镍)。
部分氧化方法将含烃气体,如天然气或石脑油气体转化为氢(H2)、一氧化碳(CO)和其他痕量组分如二氧化碳(CO2)、水(H2O)和其他烃。这些方法一般这样进行,即在燃烧室中注入预热过的烃和含氧气体,氧低于化学计量含量,使烃发生不完全燃烧。此反应在非常高的温度下进行,例如超过700℃,通常超过1000℃,压力达到150大气压。在某些反应中,燃烧室中也可以注入水蒸汽或CO2,对合成气产品进行改性,并调整H2与CO的比例。
在最近公开的部分氧化方法中,在催化剂(如沉积在整体载体上的金属)存在条件下,气态烃与含氧气体以高空速接触。整体载体浸渍有贵金属如铂、钯或铑,或者其他过渡金属如镍、钴、铬等。这些载体一般由固体难熔材料或陶瓷材料如氧化铝、氧化锆、氧化镁等制备。
对于低温一氧化碳的回收一般有两个主要方法过程:甲烷清洗过程和部分冷凝循环。第一个方法一般可获得更高的一氧化碳收率和氢气纯度,但需要更多的动力和投资。第二个方法对于动力和投资的要求较少,但氢气纯度和一氧化碳收率低。本发明认识到这个问题,本发明方法既能获得较高的一氧化碳收率和氢气纯度,又不会增加动力或投资的需求。
发明概述
本发明改进了由整体反应器生产一氧化碳的方法。该方法包含如下步骤:从一个整体反应器中将包含一氧化碳、二氧化碳、甲烷和氢气的合成气通入一个二氧化碳分离系统中。二氧化碳分离系统包含一个压缩机,它能提高进入二氧化碳分离系统的合成气的压力,从而将二氧化碳从进料气流中分离出来。然后将合成气流通入一个预纯化单元(PPU)(除去痕量CO2和水),接着通入一氧化碳分离系统,它是一个冷箱,剩余的一氧化碳、甲烷和氢气组分在此分离。
由整体反应器生产的合成气中,甲烷含量通常接近1%。因此采用部分冷凝过程,以最大程度降低一氧化碳冷箱的动力和投资费用。
所述冷箱的操作包括以下几步:通过对进料气流部分冷凝除去其中的H2气,残余H2从冷凝气流中转移到燃料气流中,最后分离剩下的一氧化碳和甲烷,得到纯一氧化碳产物气流和甲烷气流。
冷箱中的原料氢在变压吸附(PSA)单元中纯化,得到纯氢气产品流和尾气流。
但是,部分冷凝过程的一个局限是,它得到的一氧化碳收率和氢气纯度低于甲烷清洗冷箱过程。提高部分冷凝过程中一氧化碳收率和氢气纯度的一个典型方法是增加冷箱过程的复杂程度,这就导致额外的动力和投资费用消耗。本发明则通过将气流进行循环解决了这一问题,即在进入二氧化碳分离过程之前,而且是在用压缩机将合成气压入二氧化碳分离系统之前,来自变压吸附过程的尾气和上面的燃料气流回到进料气流中,最终使一氧化碳在循环气流中消失。这当然是在低压下进行的,因而这两股气流在循环时不需要额外的设备,可以采用低成本冷箱。尽管此过程从冷箱中得到的一氧化碳收率较低,但整个方法能得到非常高的一氧化碳收率,同时使氢气的总体收率达到很高的水平。
本发明的改进是,使PSA氢气分离系统中含H2和CO的尾气与一氧化碳清除系统中同样含H2和CO的燃料气循环到二氧化碳清除系统的压缩机中。
冷箱中的其他废气是来自一氧化碳-甲烷分离柱的甲烷。此甲烷气流可循环返回到反应器的进料中,从而将进料中烃的整体转化率从相对于反应器的大约97%提高到相对于整个系统的约100%。当将二氧化碳循环返回到反应器中时,系统中几乎没有碳的损失,烃进料中的所有碳几乎100%转化为一氧化碳。此方法的其他优点包括在整个过程中没有CO2和其他废气释放出来,如果它们释放出来,就需要进行处置和/或在处置之前要纯化。
另外,本发明方法的实施方法既可以是将氢气分离系统中的尾气循环返回到二氧化碳分离系统的压缩机中,也可以是将一氧化碳分离系统中的燃料气循环返回到二氧化碳分离系统的压缩机中。
附图简述
附图是基于整体反应器的一氧化碳生产工厂的示意图。
发明详述
现在看一种实施方式的示意图,它展示了本发明的基本操作流程。氧从管线1进入整体反应器A。整体反应器包含金属催化剂,它基本上是负载在陶瓷块的二氧化铈涂层上的金属。所述金属选自镍、钴、铁、铂、钯、铱、铼、钌、铑和锇。所述陶瓷材料选自氧化锆、氧化铝、氧化钇、氧化钛、氧化镁、氧化铈和堇青石。氧化铈涂层约占陶瓷块重量的5-30%。在一种实施方式中,陶瓷选自氧化锆、氧化钇、氧化钛、氧化镁、氧化铈和堇青石。对这种金属催化剂整体陶瓷的其他介绍可参见公布于2003年1月9日的待审申请10/143705,即现在Jiang等人的美国专利2003/0007926A1。
天然气通过脱硫单元B1后,通过管线1A也进入反应器A。氧和天然气的进料压力通常是约1巴的低压。管线23也接入反应器A,它提供二氧化碳。包含一氧化碳、二氧化碳、甲烷和氢以及氮、氩和水分的产物气离开反应器A后,经由管线2进入骤冷室B,管线3向骤冷室B提供骤冷水。从约1025℃骤冷到约800℃后,此产物气通过管线4进入蒸汽超过热器C1、废气加热锅炉C2和锅炉进水交换器C3,然后进入容器D。锅炉进水由管线5提供,在蒸汽冷凝涡轮C4中冷凝,冷凝水通过管线6离开蒸汽冷凝涡轮。管线7向冷凝单元6A提供循环冷却水。
冷凝水也通过管线11离开容器D,可以进行回收。进流经过管线9和空气冷却器8进入水冷却器E,它利用管线10实现冷水循环。现在进气流的温度约等于室温。进气流经管线9进入容器F,其他冷凝物通过管线12进入管线11,而上面的气体通过管线13进入合成气压缩机G,合成气在这里压缩到约10-50巴(表压)。压缩的合成气流经过管线14进入容器H,其他冷凝物经管线15进入管线11。上面经压缩的气流经过管线16进入二氧化碳分离柱I,此分离柱在10-约30巴的压力(表压)操作。
柱I底部经管线17与柱J的顶部相通,柱J的再沸器底部经管线18与泵19相通,气流经由管线20进入CO2排出柱工的顶部。然后,气流经管线18进入再沸单元K,然后经管线21流回柱J。管线22为再沸单元K提供低压蒸汽。将气流中含量约为2-3%的二氧化碳排出,经过管线23进入压缩单元24,然后进入干燥单元L,最后回到整体反应器A。管线25将一氧化碳、甲烷和氢送入预纯化单元M,一氧化碳、甲烷和氢气混合物中的水分、痕量二氧化碳和其他杂质气体在这里清除,剩下的气体经管线29进入一氧化碳冷箱装置P。
作为经过管线29从PPU分离出来的气体的一部分,一氧化碳在冷箱中冷却,然后进入分离容器P1。分离容器P1上部约含90%H2和10%CO的原料H2气流经管线30进入再生加热单元0,管线31为再生加热单元提供低压蒸汽,此原料氢将再次进入PPU装置M,为吸附剂提供再生气流。
管线26将主要含氢的再生气(约90%)从预纯化单元M引出,通到氢变压吸附(PSA)单元N中。PSA尾气通过管线27回到管线13中,使分离的一氧化碳回到压缩机G,所述尾气中氢∶一氧化碳的体积比约为2∶1。氢产物通过管线28离开氢PSA单元N,由此提供给终端用户。
PSA单元进行的可以是单步纯化过程,能够从气体混合物中清除一氧化碳、氮气、烃、二氧化碳和水蒸气等杂质气体。用两步PSA过程可获得更高的纯度,用活性炭可吸附清除二氧化碳、水蒸气和烃,然后用沸石层清除一氧化碳、氮气和残余烃。可采用的常规沸石吸附剂包括A型沸石和SiO2/Al2O3的摩尔比约为2.5∶1的八面沸石。
柱P1中的底部物料从管线32排出,进入柱P2,而柱P2的顶部物料从管线34排出。这些顶部物料是氢与一氧化碳的体积比约为2∶1的燃料气,它通向管线27,最终通过管线13进入压缩装置G。柱P2的底部物料经管线33进入柱P3,一氧化碳从其顶部排出,经管线36进入一氧化碳压缩单元Q,一氧化碳产物经管线37提供给终端用户。管线38将部分一氧化碳循环返回到冷箱中,提供热泵功能。柱P1的顶部物料也可经由管线33A排出,进入管线35。来自柱P3底部的甲烷从管线35排出,循环进入整体反应器A,从而提高进料气中烃的转化率。
虽然已结合一些特定实施方式对本发明进行了描述,但很明显,本领域技术人员不难想到本发明的许多其他形式和变体。附带权利要求一般应理解为包含这些显而易见的形式和变体,只要它们符合本发明的主旨并在本发明范围之内。
Claims (11)
1.用整体反应器生产一氧化碳的改进方法,它包括如下步骤:
(a)将包含一氧化碳、二氧化碳、甲烷和氢气的原料气送入含有至少一个压缩机的二氧化碳分离系统中;
(b)将所述分离了二氧化碳的原料气从所述二氧化碳分离系统送入一氧化碳分离系统;
(c)将氢气流从所述一氧化碳分离系统送入氢气分离系统;
(d)改进之处包括将所述氢气分离系统中的尾气循环返回到所述二氧化碳分离系统的所述压缩机中。
2.权利要求1所述的方法,其特征在于所述改进还包括将燃料气从所述一氧化碳分离系统循环返回到所述二氧化碳分离系统的所述压缩机中。
3.权利要求1所述的方法,其特征在于它还包括将甲烷从所述一氧化碳分离系统循环返回到所述整体反应器中。
4.权利要求1所述的方法,其特征在于所述二氧化碳分离系统包含压缩机、CO2排出柱和CO2分离柱。
5.权利要求1所述的方法,其特征在于所述氢气分离系统是变压吸附系统。
6.权利要求1所述的方法,其特征在于所述一氧化碳分离系统包括冷箱,所述冷箱包括分离容器和一氧化碳/甲烷分离柱。
7.权利要求1所述的方法,其特征在于所述整体反应器中有金属催化剂,它基本上是负载在设置于陶瓷块上的二氧化铈涂层上的金属,所述金属选自镍、钴、铁、铂、钯、铱、铼、钌、铑和锇,所述陶瓷材料选自氧化锆、氧化铝、氧化钇、氧化钛、氧化镁、氧化铈和堇青石,所述氧化铈涂层约占陶瓷块重量的5-30%。
8.权利要求1所述的方法,其特征在于它还包括生产高纯氢气。
9.权利要求2所述的方法,其特征在于所述尾气包含约2∶1体积比的氢气和一氧化碳,所述燃料气包含约2∶1体积比的氢气和一氧化碳。
10.权利要求1所述的方法,其特征在于二氧化碳在步骤(a)中从所述原料气中清除,而一氧化碳在步骤(b)中从所述原料气中清除。
11.权利要求1所述的方法,其特征在于氢气在步骤(b)中从所述分离了二氧化碳的原料气中清除,然后在步骤(c)中纯化。
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-
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- 2004-08-31 CA CA002479691A patent/CA2479691A1/en not_active Abandoned
- 2004-09-14 EP EP04255551A patent/EP1544166A3/en not_active Withdrawn
- 2004-09-15 SG SG200405082A patent/SG110136A1/en unknown
- 2004-09-16 TW TW093128082A patent/TW200526520A/zh unknown
- 2004-09-23 KR KR1020040076432A patent/KR20050030579A/ko not_active Application Discontinuation
- 2004-09-24 CN CNB2004100826520A patent/CN100398439C/zh not_active Expired - Fee Related
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Also Published As
Publication number | Publication date |
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CN1600686A (zh) | 2005-03-30 |
EP1544166A2 (en) | 2005-06-22 |
US7066984B2 (en) | 2006-06-27 |
EP1544166A3 (en) | 2006-01-04 |
KR20050030579A (ko) | 2005-03-30 |
CA2479691A1 (en) | 2005-03-25 |
TW200526520A (en) | 2005-08-16 |
SG110136A1 (en) | 2005-04-28 |
US20050066813A1 (en) | 2005-03-31 |
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