CN101910375B - 用于碳质原料的催化气化的蒸汽发生浆液气化器 - Google Patents

用于碳质原料的催化气化的蒸汽发生浆液气化器 Download PDF

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CN101910375B
CN101910375B CN200880122970.1A CN200880122970A CN101910375B CN 101910375 B CN101910375 B CN 101910375B CN 200880122970 A CN200880122970 A CN 200880122970A CN 101910375 B CN101910375 B CN 101910375B
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F·S·劳
E·T·罗宾逊
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Shunguan Investment Co., Ltd
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Abstract

用于提供用于碳质原料催化气化的高压高温蒸汽的蒸汽发生气化反应器能够基于适用于处理包括至少40％水的吹氧气化反应器。该浆液气化器的废气至少包括蒸汽、一氧化碳和氢气。能够改变该浆液组成和该氧气∶燃料比以控制该发生器废气中的碳质气体比。通过将该浆液气化反应器产生的基本所有废气引导通过该催化气化器并然后进行气体分离和螯合方法，能够得到更高的能量效率和降低的碳印迹。

Description

用于碳质原料的催化气化的蒸汽发生浆液气化器
发明领域
本发明涉及由含水碳质进料浆液制备蒸汽和合成气的蒸汽发生浆液气化器。此外，本发明涉及用于在由该浆液气化器产生的蒸汽和合成气的存在下碳质原料通过催化气化制备气态产物(特别为甲烷)的方法。
发明背景
由于多种因素(例如较高的能量代价和环境关注)，由较低燃料值的碳质原料(例如石油焦和煤)制备增值气态产物重新受到关注。例如在US3828474、US3998607、US4057512、US4092125、US4094650、US4204843、US4468231、US4500323、US4541841、US4551155、US4558027、US4606105、US4617027、US4609456、US5017282、US5055181、US6187465、US6790430、US6894183、US6955695、US2003/0167961A1、US2006/0265953A1、US2007/000177A1、US2007/083072A1、US2007/0277437A1和GB1599932中公开了此类材料制备甲烷和其他增值气体的催化气化。
碳质材料催化气化为合成天然气的方法需要蒸汽存在以与处于气相中的或该碳质材料表面上的碳反应以生成甲烷和二氧化碳。通常预期使用燃煤锅炉来产生所需的蒸汽。此类方法具有以下缺点：该锅炉需要另外的燃料来源，同时产生包括另外的酸性气体(例如二氧化碳、二氧化硫、氮氧化物)的废气，必须将其处理并排放到大气中或另外合(sequestered)。因而现有技术中存在开发更有效地利用燃料来源并降低整个方法的碳印迹的用于将碳质材料催化气化为合成天然气的装置和方法。
发明概述
在第一方面，提供了用于由经催化的碳质原料制备包括氢气、一氧化碳、二氧化碳、硫化氢、氨气和其他高级烃中的一种或多种以及甲烷的第一多种气体的气化器装置，该气化器装置包括：流化床气化器，其经构造以接收该经催化的碳质原料和包括蒸汽、氢气和一氧化碳的第二多种气体，和用来排出该第一多种气体；以及浆液气化器，其经构造以将该第二多种气体供给该流化床气化器，该浆液气化器包括气化器腔；用于将含水碳质浆液作为反应物供给该气化器腔的浆液导管；用于非必要地将合成气供给该气化器腔的非必要的与合成气源和该气化器腔连通的合成气导管；用于将富氧气体作为反应物供给该流化床气化器腔的氧气导管；和用于将该第二多种气体从该浆液气化器供给该流化床气化器的与该流化床气化器连通的经加热的气体导管。
在第二方面，提供用于由含水碳质浆液制备包括蒸汽、氢气和一氧化碳的多种气体的浆液气化器，该浆液气化器包括：气化器腔；用于非必要地将合成气供给该气化器腔的非必要的与合成气源和该气化器腔连通的合成气导管；用于将富氧气体作为反应物供给该气化器腔的氧气导管；用于将含水碳质浆液作为反应物供给该气化器腔的浆液导管；和用于排出该多种气体的加热气体导管。
在第三方面，提供了用于由含水碳质浆液产生包括蒸汽、氢气和一氧化碳的多种气体的方法，该方法包括以下步骤：(a)提供浆液气化器；(b)将含水碳质浆液、富氧气体和非必要的合成气供给该浆液气化器，该浆液包括重量比为约5∶95～约60∶40的碳质物质和水；和(c)将该含水碳质浆液在该浆液气化器中在氧气存在下以及在适合的温度和压力下反应以产生该多种气体。
在第四方面，提供了用于将碳质材料转化为包括氢气、一氧化碳、二氧化碳、硫化氢、氨气和其他高级烃中的一种或多种以及甲烷的第一多种气体的方法，该方法包括以下步骤：提供依照第一方面的具有流化床气化器和浆液气化器的气化器装置；将包括碳质材料和气化催化剂的颗粒组合物供给该流化床气化器，其中该气化催化剂在蒸汽存在下以及在适合的温度和压力下表现出通过其生成该第一多种气体的气化活性；将含水碳质浆液、富氧气体和非必要的合成气供给该浆液气化器；将该含水碳质浆液在该浆液气化器中在氧气存在下以及在适合的温度和压力下反应以产生包括蒸汽、氢气和一氧化碳的第二多种气体；将该第二多种气体引入该流化床气化器；将该颗粒组合物在该流化床气化器中在该第二多种气体存在下以及在适合的温度和压力下反应以生成该第一多种气体；和将该第一多种气体的至少一部分分离出来以产生包括主要量的该第一多种气体中的一种气体的流，其中该气化催化剂包括至少一种碱金属的来源，且该催化剂的含量足以在该颗粒组合物中提供在约0.01～约0.08范围的碱金属原子∶碳原子比；以及该含水碳质浆液包括重量比为约5∶95～约60∶40范围的碳质物质和水的混合物。
附图简述
图1是本发明的示例性浆液气化器的示意图。
图2是描述了用于使用依照本发明的包括浆液气化器和流化床气化器的气化器装置由碳质原料产生气体的系统的流程图。
详细描述
本发明涉及用于提供高压高温蒸汽的蒸汽发生浆液气化器。本发明的浆液气化器是以适用于加工包括至少40％水的浆液原料的气化反应器为基础的。能够将此类浆液气化器整合到用于催化气化碳质原料的方法中。
在以下中公开了催化气化技术的近期进展：共同拥有的US2007/0000177A1、US2007/0083072A1和US2007/0277437A1；和美国专利申请序列号12/178,380(2008年7月23日提交)、12/234,012(2008年9月19日提交)和12/234,018(2008年9月19日提交)。而且，能够结合以下美国专利申请(其各自都是与本申请同一日提交的)的主题实施本发明的方法：名称为“PETROLEUM COKECOMPOSITIONS FOR CATALYTIC GASIFICATION”的序列号______(代理机构档案号FN-0008 US NP1)；名称为“CATALYTICGASIFICATION PROCESS WITH RECOVERY OF ALKALI METALFROM CHAR”的序列号______(代理机构档案号FN-0007 USNP1)；名称为“PETROLEUM COKE COMPOSITIONS FORCATALYTIC GASIFICATION”的序列号______(代理机构档案号FN-0011 US NP1)；名称为“CARBONACEOUS FUELS ANDPROCESSES FOR MAKING AND USING THEM”的序列号______(代理机构档案号FN-0013 US NP1)；名称为“CATALYTICGASIFICATION PROCESS WITH RECOVERY OF ALKALI METALFROM CHAR”的序列号______(代理机构档案号FN-0014 USNP1)；名称为“COAL COMPOSITIONS FOR CATALYTICGASIFICATION”的序列号______(代理机构档案号FN-0009 USNP1)；名称为“PROCESSES FOR MAKING SYNTHESIS GAS ANDSYNGAS-DERIVED PRODUCTS”的序列号______(代理机构档案号FN-0010 US NP1)；名称为“CATALYTIC GASIFICATIONPROCESS WITH RECOVERY OF ALKALI METAL FROM CHAR”的序列号______(代理机构档案号FN-0015 US NP1)；名称为“CATALYTIC GASIFICATION PROCESS WITH RECOVERY OFALKALI METAL FROM CHAR”的序列号______(代理机构档案号FN-0016 US NP1)；名称为“CONTINUOUS PROCESSES FORCONVERTING CARBONACEOUS FEEDSTOCK INTO GASEOUSPRODUCTS”的序列号______(代理机构档案号FN-0018 US NP1)；和名称为“PROCESSES FOR MAKING SYNGAS-DERIVEDPRODUCTS”的序列号______(代理机构档案号FN-0012 US NP1)。所有上述都通过引用并入此处用于所有目的，如同完全陈述的一样。
如果没有相反指示，此处提及的所有公开文件、专利申请、专利和其他参考文件都通过引用整体明确引入此处用于所有用途，如同完全陈述的一样。
除非相反定义，此处所用的所有技术和科学术语都具有与本发明所属领域的普通技术人员通常理解的相同的含义。在抵触情况下，包括定义的本说明书将占主导。
除非明确指出，商标以大写字母显示。
尽管在本发明的实践或测试中能够使用与此处公开的那些相似或等效的方法和材料，但此处描述了适合的方法和材料。
除非相反声明，所有百分比、份数、比例等都是以重量计的。
当量、浓度或其他数值或参数作为范围或一系列上限和下限值给出时，其应当理解为特别公开了由任何对任意上限和下限范围界限形成的所有范围，无论该范围是否被单独公开。在此处列举了数值范围的情况下，除非相反声明，该范围意于包括其端点以及该范围内的所有整数和分数。本发明的范围并不意于限定于在限定范围时列举的特别值。
当在描述数值或范围端点中使用术语“约”时，本发明应当理解为包括所涉及的该特别数值或端点。
此处所用的术语“包括”、“包含”、“含有”、“具有”、“拥有”或其其他变型都意于包括开放式含义。例如，包括一系列要素的工艺、方法、制品或装置不必限定于仅这些要素，而是能够包括未明确列出的或此类工艺、方法、制品或装置固有的其他要素。此外，除非明确相反声明，“或”表示开放式的或而非封闭式的或。例如，条件A或B是由以下中的任一种满足的：A真(或存在)和B假(或不存在)；A假(或不存在)和B真(或存在)；和A和B都真(或存在)。
此处用于描述多个要素或组分的“a”或“an”的使用仅用于方便且给出所公开的一般含义。除非显然有相反含义，该说明书应当阅读为包括一个或至少一个而且单数形式还包括多个。
此处的材料、方法和实例都仅是示例性的，以及除非特别声明，都不意于限制。
蒸汽发生气化反应器
本发明的蒸汽发生气化反应器(浆液气化器；10)的一个实施方案示于图1中并在其操作中使用浆液原料。该浆液原料典型地包括水和碳质材料，如下所述。该反应床(80)能够基于流化床反应器、两级流化床反应器、逆流固定床反应器、并流固定床反应器、曳流反应器或移动床反应器。将该浆液原料依照本领域已知的方法通过浆液导管(70)引入该反应器。将富氧气体(或空气)作为反应物通过氧气导管(40)供给该反应床。能够依照本领域技术人员已知的方法将富集的氧供给该氧气导管；例如，能够由集气筒或由基于变压吸附(PSA)、变真空吸附(VSA)、变真空-压力吸附(VPSA)等的空气产生单元供给该氧气。与合成气源(30)连接的非必要的合成气导管(20)可以将合成气作为反应物和/或流化气体供给该反应器床。该合成气能够由来源(例如用于将循环合成气供给该浆液气化器的循环合成气源)供给合成气导管。最后，经加热的气体导管(50)可以将产物气体排放到其它制备工业(例如第二反应器)。
在用包括碳质材料的浆液原料使用时，该浆液气化器废气可以包括多种气体，其包括蒸汽、氢气、一氧化碳和其他非必要的气体(例如甲烷、二氧化碳、硫化氢和氨气)，此类气体是由该浆液原料产生的。能够基于该浆液原料的组成和/或操作条件控制该废气的组成。例如，具有较大的碳含量的浆液原料能够产生较高的CO和/或CO2废气浓度。此外，提高的操作温度能够有助于CO与甲烷相比更高的浓度。总的来讲，产生摩尔比为在从约70∶30或从约60∶40，直到约40∶60或直到约30∶70(蒸汽∶其他气体)范围的蒸汽和该第二多种气体中的其他气体。
此外，本发明的浆液气化器能够制备由于该浆液原料的气化而导致的焦炭(或炉渣)。典型地，该浆液气化器另外包括用于从该气化器的底部除去焦炭(60)的导管。适合的导管包括但不局限于闭锁式料斗，但本领域技术人员已知其他方法。
该浆液气化器温度通常将保持等于或高于约450°F，或等于或高于约1200°F，且等于或低于约2000°F，或等于或低于约1600°F；该压力将至少约200psig，或至少约400psig，或至少约600psig，或至少约1000psig，直到约1500psig，或直到约2000psig，特别地为约600psig～约2000psig，或约1000psig～约2000psig。
在一种实施方案中，本发明的浆液气化器能够用于将所需要的蒸汽通过该加热导管(50)供给用于由碳质原料制备气态产物的催化气化反应器。通常，在用于此时，该浆液气化器的操作温度和压力将高于该催化气化反应器的操作温度和压力。
在某些实施方案中，该浆液气化器包括流化床反应器(80)。在此类情况中，可以通过经由该非必要的合成气导管(20)引入合成气来维持反应床流化。在一些情况中，该合成气源(30)能够是来自气体分离操作的循环合成气流，如下面关于整合催化气化所讨论的那样。如果需要，能够将该循环合成气通过气体压缩机和/或预热器然后再引入该浆液气化器反应床中。
有利地，通过制备用于依照本发明的催化气化方法的蒸汽，将由蒸汽发生制备的基本所有CO2都引导通过该气体分离和螯合方法，如下所述，由此能使碳印迹大大降低。
用于浆液气化器的浆液原料
供给该浆液气化器的原料典型地包括碳质材料的含水浆液。该含水浆液能够包含在约5∶95～约60∶40的碳质材料∶水的重量比，例如该比值能够为约5∶95、约10∶90、约15∶85、约20∶80、约25∶75、约30∶70、约35∶65、或约40∶60、或约50∶50、或约60∶40、或其间的任意值。任意碳质材料能够单独或组合使用并与水(如果需要)形成浆液以产生具有预设的碳和水含量的含水浆液。用于该浆液原料的碳质材料能够包括以干重量计包含至少约20％，或至少约30％，或至少约40％，或至少约50％，或至少约60％，或至少约70％，或至少约80％碳的碳源。
用于制备该含水浆液的水是由清水进料(例如市政水源)和/或循环方法制备的。例如，能够将来自酸性污水分离操作(601，图2)和/或催化原料干燥操作(如下)的再生水引导用于制备该含水浆液。在一种实施方案中，该水不是清洁的而是包含有机物质，例如来自农业、采煤、市政污水处理装置或类似来源的未经处理的废水。该废水中的无机物质成为如下所述碳质材料的一部分。
此处所用的术语“碳质材料”表示任意碳质材料，包括但不局限于煤、石油焦、沥青质、液体石油残余物、废机油和其他废物处理的石油来源、未经处理或经处理的污水、垃圾、塑料、木材和其他生物质或其混合物。
此处所用的术语“石油焦”包括(i)在石油加工中得到的高沸点烃馏分的固体热分解产物(重残余物)；和(ii)加工焦油砂的固体热解产物(沥青砂或油砂)。此类碳化产物包括例如生焦、煅烧焦、针状焦和流化床石油焦。该石油焦通常是由延迟焦化或流体焦化制备的。该石油焦能够是在将干馏焦油砂(例如开采的)加热以提取任意油之后剩余的残余材料。
残油petcoke能够来自原油，例如通过用于升级高重力残余原油的焦化方法，基于该焦的总重量，该石油焦包含作为少量组分的典型地为约1.0wt％或更少，或更典型地为约0.5wt％或更少的灰分。典型地，此类较低灰分的焦中的灰分主要包括金属，例如镍和钒。
焦油砂petcoke能够来自油砂，例如通过用于升级油砂的焦化方法。基于该焦油砂petcoke的总重量，该焦油砂petcoke包含作为少量组分的典型地在约2wt％～约12wt％的范围内，或更典型地在约4wt％～约12wt％的范围的灰分。典型地，此类较高灰分的焦中的灰分主要包含例如硅和/或铝化合物的材料。
基于该石油焦的总重量，该石油焦能够包括至少约70wt％的碳，至少约80wt％的碳，或至少约90wt％的碳。典型地，基于该石油焦的重量，该石油焦包括小于约20wt％的无机化合物。
此处所用的术语“液体石油残余物”包括(i)石油加工中得到的高沸点烃馏分的液体热解产物(重残余物-“残油液体石油残余物”)和(ii)加工焦油砂的液体热解产物(沥青砂或油砂-“焦油砂液体石油残余物”)。该液体石油残余物基本上不是固体，例如其能够是粘稠流体或污泥的形式。
残油液体石油残余物能够来自原油，例如通过用于升级高重力原油蒸馏残余物的方法。基于该残余物的重量，此类液体石油残余物包含作为少量组分的典型地为约1.0wt％或更少，或更典型地为约0.5wt％或更少的灰分。典型地，此类较低灰分的残余物中的灰分主要包括金属，例如镍和钒。
焦油砂液体石油残余物能够来自油砂，例如通过用于升级油砂的方法。基于该残余物的总重量，该焦油砂液体石油残余物包含作为少量组分的典型地在约2wt％～约12wt％的范围内，或更典型地在约4wt％～约12wt％的范围内的灰分。典型地，此类较高灰分的残余物中的灰分主要包含例如硅和/或铝化合物的材料。
此处所用的术语“煤”表示泥煤、褐煤、亚烟煤、烟煤、无烟煤或其混合物。在某些实施方案中，基于煤的总重量以重量计，该煤具有小于约85％，或小于约80％，或小于约75％，或小于约70％，或小于约65％，或小于约60％，或小于约55％，或小于约50％的碳含量。在其他实施方案中，基于煤的总重量以重量级，该煤具有高达约85％，或高达约80％，或高达约75％的碳含量。可用的煤的实例包括但不局限于：Illinois #6、Pittsburgh #8，Beulah(ND)、Utah Blind Canyon和Powder River Basin(PRB)煤。以干重量计，无烟煤、烟煤、亚烟煤和褐煤可以分别包含该煤总重量的约10wt％，约5～约7wt％，约4～约8wt％，和约9～约11wt％的灰分。然而，任意特定煤源的灰分含量将取决于该煤的品级和来源，如本领域技术人员熟知的那样。例如参见“Coal Data：A Reference”，Energy Information Administration，Officeof Coal，Nuclear，Electric and Alternate Fuels，U.S.Department ofEnergy，DOE/EIA-0064(93)，1995年2月。
沥青质通常包括在室温下为芳香碳质固体，且能够源自例如原油和原油焦油砂的加工。
此外，用于该浆液原料的碳质材料能够包括如下所述在气化催化剂回收之后在催化气化反应器中产生的焦炭。
催化气化方法
本发明的浆液气化器(100，图2)特别适用于用于将碳质材料转化为可燃烧的气体(例如甲烷)的整合催化气化方法中。图2中描述了用于整合到用于由碳质材料产生可燃烧气体的方法中的典型的流程图，此处对其参考。
用于此类方法的该催化气化反应器(催化气化器；200)典型地是在中等高的压力和温度下进行的，需要将经催化的原料(405)引入该催化气化器的反应区域中，同时保持所需的温度、压力和原料流速。本领域的技术人员熟知用于将原料提供到高压和/或高温环境中的进料系统，包括星式进料机、螺旋进料机、旋转活塞和闭锁式料斗。应当认识到该进料系统能够包括两个或更多个将会可替代使用的压力平衡元件，例如闭锁式料斗。
将经催化的原料从原料制备操作(400)提供到该催化气化器(200)中，且通常包括压碎的碳质材料和气化催化剂的颗粒组合物，如下所述。在一些情况中，该经催化的原料(405)能够在高于催化气化器的操作压力的压力条件下制备。因此，能够将该经催化的原料(405)直接通入该催化气化器中而不用进一步加压。
在此处所述的方法中能够使用数种催化气化器(200)中的任何种。适合的气化反应器包括逆流固定床、并流固定床、流化床、曳出流和移动床反应器。该气化反应器(200)中的压力典型地能够为约10～约100atm(约150～约1500psig)。该气化反应器的温度能够维持在约至少约450℃，或至少约600℃，到至少约900℃，或至少约750℃，或约600℃～约700℃，压力为至少约50psig，或至少约200psig，或至少约400psig，到约1000psig，或到约700psig，或到约600psig。
用于该颗粒组合物的加压和反应的催化气化器中所用的气体包括蒸汽和非必要地氧气或空气。能够依照本领域技术人员已知的方法将后者供给到该反应器(图2中未示出)。
将蒸汽从该本发明的浆液气化器(100)的废气(101)供给该催化气化器并通过经加热的气体导管从该浆液气化器输送到该催化气化器(200)。如前所述将来自浆液原料制备操作(402)和富氧气流(103)的浆液原料(404)供给该浆液气化器(100)。其中，在一种实例中，能够使用在将碳质材料压碎以制备用于该催化气化器的该经催化的原料(401)中产生的微粒(403)来制备(402)本发明的浆液原料(404)。显然，微粒的第二来源能够来自烟煤清洁和存在的废煤收集器或池的废微粒，由此有助于改进并防止由采矿和处理操作造成的环境污染。
来自其他工艺操作的循环蒸汽也能够用于为该催化气化器补充蒸汽。例如在该经催化的原料的制备中，在用如前所述的流化床浆液干燥器干燥该浆态颗粒组合物时，则能够将产生的蒸汽供给该催化气化反应器(200)。
能够通过用本领域技术人员已知的任意方法使供给该气化反应器的蒸汽和循环气体的气体混合物过热来提供该催化气化器少量的所需供热。在一种方法中，能够将CO和H2的压缩循环气体与蒸汽混合，然后通过与气化反应器流出物进行热交换并然后在循环气体炉中过热，进一步使所得到的蒸汽/循环气体混合物过热。
在该方法中能够非必要地包括甲烷重整器(1000)以补充来自浆液气化器的循环的CO和H2流以及废气(101)以确保该催化气化器在基本热中性(绝热)条件下运行。在此类情况中，能够将来自该甲烷产物(901)的甲烷(901a)供给该重整器，如下所述。
该催化气化器(200)中的经催化的原料(405)与浆液气化器(100)中的浆液原料(404)在所需条件下的反应提供了来自该催化气化反应器的粗产物气体和焦炭(202)和对于该浆液气化器的废气(101)和焦炭(102)。
将催化气化器工艺中产生的焦炭(202)典型地以连续或间歇方式从该气化反应器中除去用于取样、净化和/或催化剂回收。用于回收焦炭的方法是本领域技术人员公知的。例如能够使用由EP-A-0102828教导的一种此类方法。能够定期从该气化反应器中通过闭锁式料斗系统取出该焦炭，但本领域技术人员已知其他方法。
通常，将来自该催化气化器的焦炭(202)引向催化剂回收和循环工艺(300)。已经开发了用于从固体清除物回收碱金属以降低原材料成本并使催化气化工艺对环境的影响最小化的方法。例如，能够用循环气体和水对该焦炭(202)淬火并将其引向用于提取和重新利用该碱金属催化剂的催化剂循环操作。特别有用的回收和循环方法描述于以下中：US4459138，以及之前引用的US4057512、US2007/0277437A1、名称为“CATALYTIC GASIFICATION PROCESSWITH RECOVERY OF ALKALI METAL FROM CHAR”的美国专利申请序列号_______(代理机构档案号FN-0007 US NP1)；名称为“CATALYTIC GASIFICATION PROCESS WITH RECOVERY OFALKALI METAL FROM CHAR”的美国专利申请序列号_______(代理机构档案号FN-0014 US NP1)；名称为“CATALYTICGASIFICATION PROCESS WITH RECOVERY OF ALKALI METALFROM CHAR”的美国专利申请序列号_______(代理机构档案号FN-0015 US NP1)；和名称为“CATALYTIC GASIFICATION PROCESSWITH RECOVERY OF ALKALI METAL FROM CHAR”的美国专利申请序列号_______(代理机构档案号FN-0016 US NP1)。对于进一步的工艺细节，能够参考这些文件。
一旦完成催化剂回收，能够将此处所述的基本不含气化催化剂的焦炭(302)和回收的催化剂(301)(作为溶液或固体)引向该原料制备操作(400)，其包括经催化的原料的制备工艺(401)和浆液原料制备工艺(402)，如此处所述。
在该浆液气化器(100)反应器中制备的焦炭(102)典型地通过与该催化气化反应器所述类似的方法除去。然而，来自该浆液气化器(100)的焦炭(102)通常不通过催化剂回收处理而是能够处理用于丢弃。
能够将离开该催化气化器(200)的粗产物气体流出物(201)通过用作分离区域的反应器的一部分，在此处将重量太大以致于不能被离开所述反应器的气体夹带的颗粒(即微粒)返回到流化床。该分离区域能够包括一个或多个内部旋风分离器或类似的用于从气体中除去微粒和颗粒的装置。通过该分离区域并离开该气化反应器的气体流出物(201)包含CH4、CO2、H2和CO、H2S、NH3、未反应的蒸汽、夹带的微粒和其他污染物(例如COS)。
然后能够将从其中除去了微粒的气流(201)通过热交换器(500)以冷却该气体，且回收的热量能够用于预加热循环气体和产生高压蒸汽(501)。还能够通过任意已知的方法(例如外部旋风分离器然后文丘里洗涤器)除去残余的夹带微粒。能够对该回收的微粒进行处理以回收碱金属催化剂然后通过该浆液原料制备方法(402)或返回该催化气化反应器(100)。
离开该文丘里洗涤器的气流(502)能够供给包括COS水解反应器(601)的气体提纯操作(600)用于除去COS(酸性方法)并进一步在热交换器中冷却以回收残余的热量，然后进入水洗涤器(602)用于氨回收，产生包括至少H2S、CO2、CO、H2和CH4的经洗涤的气体。用于COS水解的方法是本领域技术人员已知的，例如参见US4100256。能够使用来自该经洗涤气体的残热来产生低压蒸汽。
能够加工洗涤器水(605)和酸性方法浓缩物(604)以汽提和回收H2S、CO2和NH3；此类方法是本领域技术人员公知的。NH3能够典型地作为含水溶液(例如20wt％)回收。可替代地，能够将洗涤器水(605)和酸性方法浓缩物(604)返回该浆液气化器，由此降低整体工艺水用量并消除对这些工艺流的分别清洗。
随后能够使用酸性气体去除工艺(603)通过包括气体的溶剂处理的物理吸附方法从该经洗涤的气流中除去H2S和CO2，以得到清洁气流。此类方法包括将该经洗涤的气体与溶剂(例如一乙醇胺、二乙醇胺、甲基二乙醇胺、二异丙基胺、二乙二醇胺、氨基酸的钠盐溶液、甲醇、热碳酸钾等)接触。一种方法能够包括使用具有两个序列的(UOP LLC，Des Plaines，IL USA)或(Lurgi AG，Frankfurt am Main，Germany)溶剂；每个序列都由H2S吸收器和CO2吸收器构成。能够通过本领域技术人员已知的任意方法再生包含H2S、CO2和其他污染物的废溶剂(607)，包括将该废溶剂与蒸汽或其他解吸气(stripping gas)接触以除去该污染物或通过将该废溶剂通过汽提塔。能够将回收的酸性气体送往硫回收处理；例如能够将从该酸性气体除去或酸性水汽提中任何回收的H2S通过本领域技术人员已知的任意方法转化为元素硫，包括Claus方法。硫能够作为熔融液体回收。能够将汽提的水引导用于在该经催化的原料和/或浆液原料的制备中循环使用。
有利地，在该方法中产生的CO2，无论是在蒸汽发生中还是在催化气化或两者中产生的，都能够回收用于随后使用或螯合，结果能造成碳印迹的大大降低(与原料直接燃烧相比)。
离开该气体提纯操作(600)的所得清洁气流(606)主要包含CH4、H2和CO以及典型地少量的CO2和H2O。能够对该清洁气流(606)进一步处理以通过本领域技术人员已知的任意适合的气体分离工艺(900)分离和回收CH4，包括但不局限于低温蒸馏和使用分子筛或陶瓷膜。一种用于从该清洁气流中回收CH4的方法包括将用于除去残余的H2O和CO2的分子筛吸收剂和用于分馏和回收CH4的低温蒸馏结合使用。典型地，通过该气体分离工艺(900)，能够产生两种气流：甲烷产物流(901)和合成气流(902，H2和CO)。
能够将该合成气流(902)压缩并循环。一种选择能够是将该合成气流直接循环到催化气化器(200)。在一种情况中，将该循环的合成气与该浆液气化器的废气(101)相结合，将该混合物引入该催化气化反应器(200)中。在另一种情况中，如图2中所示例，能够将该循环的合成气(902)直接引入该浆液气化器(100)中。在使用流化床反应器用于浆液气化器(100)时，该合成气能够提供该反应床的流化或辅助其流化。
如果必要，能够将一部分甲烷产物(901a)引向如前所述的重整器(1000)。能够通过例如该浆液气化器(100)的废气中的CO∶H2比来控制引导一部分该甲烷产物的需求。特别地，能够将甲烷引向重整器以补充(1001)供给该催化气化反应器的废气(101)，以及在一些情况中在该催化气化反应器的进料中提供约3∶1的H2∶CO比。还能够将一部分该甲烷产物用作燃气涡轮的装置燃料。
催化气化的原料
用于该催化气化器的经催化的原料(405)典型地包括如前所述的至少一种碳质材料和气化催化剂。
该经催化的原料典型地是作为具有从约250微米，或从约25微米，直到约500，或直到约2500微米的平均粒度的微粒颗粒供给的。本领域技术人员能够容易地确定个体颗粒和该经催化的原料的适合粒度。例如，当使用流化床气化反应器时，该经催化的原料能够具有能使该经催化的原料在该流化床气化反应器中所用的气体流速下开始流化的平均粒度。
催化剂组分
该经催化的原料进一步包括一定量的碱金属组分，作为碱金属和/或包含碱金属的化合物，以及非必要的助催化剂，如之前引入的参考文件中所公开的。典型地，该碱金属组分在该组合物中的量足以提供在从约0.01，或从约0.02，或从约0.03，或从约0.04，到约0.06，或到约0.07，或到约0.08的范围的碱金属原子∶碳原子比。此外，将该碱金属典型地负载在碳源之上以得到以质量计为该碳质材料(例如煤和/或石油焦)的总灰分含量的约3～约10倍高的碱金属含量。
适合的碱金属是锂、钠、钾、铷、铯及其混合物。特别有用的是钾源。适合的碱金属化合物包括碱金属的碳酸盐、碳酸氢盐、甲酸盐、草酸盐、氨化物、氢氧化物、乙酸盐或类似的化合物。例如，该催化剂能够包括以下中的一种或多种：Na2CO3、K2CO3、Rb2CO3、Li2CO3、Cs2CO3、NaOH、KOH、RbOH或CsOH，特别地为碳酸钾和/或氢氧化钾。
用于制备经催化的原料的方法
用于该颗粒组合物的制备中的碳质材料能够需要初始加工以制备用于催化气化的经催化的原料(405)。例如，在使用包括两种或更多种碳质材料(例如石油焦和煤)的混合物的经催化的原料时，能够将该石油焦和煤分别加工以在一个或两个部分中添加催化剂，然后混合。可替代地，能够在添加催化剂之前将该碳质材料组合。
能够依照本领域中已知的任意方法将该碳质原料压碎和/或磨碎，例如冲击粉碎和湿法或干法磨碎以产生各颗粒。根据用于压碎和/或磨碎该石油焦所用的方法，所得到的颗粒能够需要区分大小(size)(即依照尺寸分离)以提供适合的原料。
能够使用本领域技术人员已知的任意方法区分该颗粒大小。例如，能够通过将该颗粒过筛或通过一个或多个筛子而进行区分大小。过筛装置能够包括格筛、条杆筛和金属网筛。筛子能够是静态或混合机制，用于摇动或振动该筛子。可替代地，能够使用分级来分离该石油焦和煤颗粒。分级设备能够包括矿石分选机、气体旋风分离器、水力旋流器、耙式分级机、旋转转筒筛、或流化分级器。还能够在磨碎和/或压碎之前将该碳质材料区分大小或分级。能够将从该制备方法中分离出来的任意微粒(403)用于制备(402)用于该浆液气化反应器(100)的浆液原料，如前所述。
根据该碳质材料的质量，可能需要另外的原料加工步骤。例如，包含高水分含量的碳质材料(例如原污水和/或经处理的污水和高水分煤)能够需要在压碎之前干燥。一些块状煤能够需要部分氧化以简化气化反应器的操作。在离子交换位置的多种煤不足能够预处理以产生另外的离子交换位置以便于催化剂加载和/或结合。此类预处理能够由本领域已知的任意方法实现，其产生能够离子交换的位置和/或提高煤进料的孔隙率(例如参见之前引入的US4468231和GB1599932)。通常，预处理是使用本领域已知的氧化剂以氧化方式实现的。
在一种实施例中，通常将煤湿法磨碎并区分大小(例如粒度分布为约25～2500微米)，然后排出游离水(即脱水)到湿滤饼稠度。适用于湿法磨碎、区分大小和脱水的实例是本领域技术人员已知的，例如参见之前引入的美国专利申请序列号12/178,380(2008年7月23日提交)。
能够使用本领域技术人员已知的任意方法将一种或多种气化催化剂与该碳质材料结合。此类方法包括但不局限于：与固体催化剂源混合、将该催化剂浸渍在碳质材料颗粒上、初始润湿浸渍、蒸发浸渍、真空浸渍、浸泡浸渍和这些方法的结合。能够通过用该催化剂的溶液(例如含水的)制浆来将气化催化剂浸渍在该碳质材料(即颗粒)内。
能够处理该碳质材料颗粒以将其与至少第一催化剂(例如气化催化剂)结合，提供经催化的原料。在一些情况中，能够提供第二催化剂(例如助催化剂)；在此类情况中，能够在分开的加工步骤中处理该颗粒以提供该第一催化剂和第二催化剂。例如，能够提供主气化催化剂(例如钾和/或钠源)，然后单独处理以提供助催化剂源。可替代地，该第一和第二催化剂能够在单一处理中作为混合物提供。
在之前引入的美国专利序列号12/178,380(2008年7月23日提交)中描述了一种将煤与该气化催化剂和非必要的助催化剂相结合以提供颗粒组合物的特别方法，其中该多种组分通过离子交换与煤颗粒结合。该离子交换加载机理得到最大化(基于特别开发用于煤的吸附等温线)，控制保持湿润的另外的催化剂(包括在孔中的那些)以使得以受控方式得到该总催化剂目标值。此类加载提供了作为湿滤饼的颗粒组合物。该加载有催化剂且脱水的湿煤滤饼典型地包含例如约50％水分。通过控制催化剂组分在该溶液中的浓度以及接触时间、温度和方法来控制催化剂的总加载量，如相关领域普通技术人员在该原料煤的特征的基础上能够容易地确定的那样。
能够在引入该催化气化反应器中之前，通过本领域技术人员已知的任意方法将源自碳质颗粒的其他颗粒与该经催化的原料相结合。例如，能够将包括煤颗粒和气化催化剂的经催化的原料与生物质相结合。此类方法包括但不局限于：捏合和垂直或水平混合机，例如单螺杆或双螺杆的、带式的或鼓式的混合机。能够将该经催化的原料(405)储存用于未来的使用或输送到用于引入气化反应器中的进料操作。能够依照本领域技术人员已知的任意方法将该经催化的原料(405)输送到储存或进料操作，例如螺旋输送器或气动输送。
实施例
实施例1
经催化和浆液原料的制备
能够将原始收到的煤(Powder River Basin)分级压碎以使具有在约0.85～约1.4mm范围的粒度的材料量最大化。能够通过振动筛分从该磨碎的材料中分离出微粒(＜0.85mm)并将其用于浆液原料的制备。
能够用碳酸钾的水溶液将该压碎的煤制浆，脱水并通过流化床浆液干燥剂干燥，以产生包含185lb煤(88wt％)、14.9lb催化剂(7wt％)和10.5lb水分(5wt％)的经催化的原料。能够将在该压碎阶段分离出的煤微粒用水制浆到75wt％水(263lb)和25wt％煤微粒(88lb)的组成，然后能够将其用作用于浆液气化器的浆液原料。
实施例2
催化气化
能够将实施例1的浆液原料提供给由富氧源(96lb/hr)和合成气源(17.7w％H2、82.3％CO；75.48lb/hr)供料的流化床气化反应器(浆液气化器)。该浆液气化器的典型气化条件将为：总压550psi和温度1700～1900°F；焦炭将会以12.1lb/hr的速率产生。
从该浆液气化器得到的废气(561.6lb/hr)将会包含蒸汽(277.5lb/hr)、氢气(12.89lb/hr)、CO(62.27lb/hr)、CO2(187.84lb/hr)和甲烷(11.06lb/hr)，并能够将其提供给供应有实施例1的经催化的原料(210lb/hr)的第二流化床气化反应器(催化气化器)。该经催化的原料将会在氮气的正压下引入(45.8lb/hr)。该催化气化器的典型条件将为：总压500psi和温度1200°F。该催化气化器的流出物(34.46lb/hr)将会包含甲烷(17.7mol％)、CO2(23.0mol％)、H2(17mol％)、CO(8.2mol％)、水(28.9mol％)、H2S(0.1mol％)、氨气(0.3mol％)和氮气(4.7mol％)。

Claims (8)

1.用于将碳质材料转化为包括氢气、一氧化碳、二氧化碳、硫化氢、氨气和其他高级烃中的一种或多种以及甲烷的第一多种气体的方法，其特征在于该方法包括以下步骤：
(a)提供气化器装置，其包括：
(1)经构造以接收经催化的碳质原料和包括蒸汽、氢气和一氧化碳的第二多种气体和用来排出该第一多种气体的流化床气化器；和
(2)经构造以将该第二多种气体供给该流化床气化器的浆液气化器，其中该浆液气化器包含：
气化器腔；
非必要的合成气导管，其与合成气源和该气化器腔连通，用于非必要地将合成气供给该气化器腔；
用于将富氧气体作为反应物供给该气化器腔的氧气导管；
用于将含水碳质浆液作为反应物供给该气化器腔的浆液导管；和
用于排出该第二多种气体的经加热的气体导管；
其中该浆液气化器的该经加热的气体导管与该流化床气化器连通用于将该第二多种气体从该浆液气化器供给该流化床气化器；
(b)将包括所述碳质材料和气化催化剂的颗粒组合物供给该流化床气化器，其中该气化催化剂在蒸汽存在下以及在适合的温度和压力下表现出通过其生成该第一多种气体的气化活性；
(c)将含水碳质浆液经由所述浆液导管、将富氧气体经由所述氧气导管和非必要地将合成气经由所述合成气导管供给该浆液气化器；
(d)将该含水碳质浆液在该浆液气化器中在氧气存在下以及在适合的温度和压力下反应以产生所述第二多种气体；
(e)将该第二多种气体经由所述经加热的气体导管引入该流化床气化器中；
(f)将该颗粒组合物在该流化床气化器中在该第二多种气体存在下以及在适合的温度和压力下反应以生成该第一多种气体；和
(g)将该第一多种气体的至少一部分分离出来以产生包括主要量的该第一多种气体中的一种气体的流，其中：
(i)该气化催化剂包括至少一种碱金属的来源，且该气化催化剂的存在量足以在该颗粒组合物中提供在0.01～0.08范围的碱金属原子：碳原子比；和
(ii)该含水碳质浆液包括重量比在5∶95～40∶60范围的碳质材料和水的混合物。
2.权利要求1的方法，其特征在于产生摩尔比在70∶30～30∶70的蒸汽：其他气体范围的蒸汽和该第二多种气体中的其他气体。
3.权利要求1或2的方法，其特征在于该第一多种气体包括二氧化碳，将其回收。
4.权利要求3的方法，其特征在于该二氧化碳是在步骤(d)和步骤(f)中产生的。
5.权利要求1～4中任一项的方法，其特征在于该浆液气化器的操作温度和压力大于该流化床气化器。
6.权利要求1～5中任一项的方法，其特征在于在步骤(f)中生成焦炭，以及将该焦炭从该流化床气化器中除去并送往催化剂回收和循环工艺。
7.权利要求1～6中任一项的方法，其特征在于该流包括主要量的来自该第一多种气体的甲烷。
8.权利要求1～7中任一项的方法，其特征在于在步骤(f)中，所述颗粒组合物在所述第二多种气体存在下在至少450℃至750℃的温度和至少50psig至1000psig的压力下反应。
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