CN103874749B - 合成气冷却器***和运行方法 - Google Patents

合成气冷却器***和运行方法 Download PDF

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CN103874749B
CN103874749B CN201280024943.7A CN201280024943A CN103874749B CN 103874749 B CN103874749 B CN 103874749B CN 201280024943 A CN201280024943 A CN 201280024943A CN 103874749 B CN103874749 B CN 103874749B
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synthesis gas
recirculation
cooling
blending
syngas
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CN103874749A (zh
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彼得·S·贝尔
尼古拉斯·旺埃克
伯纳德·德斯卡勒斯
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Jupeng Bio HK Ltd
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Ineos Bio SA
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Abstract

一种用于冷却合成气的方法和***提供了有效的合成气冷却，并在合成气冷却设备中引起积垢水平降低。用于冷却合成气的方法包括将合成气与有效量的冷却再循环合成气掺混，以提供在合成气冷却器的入口处温度约为600℉至约1400℉的掺混的合成气。所述掺混的合成气在所述合成气冷却器的入口之前改变流动方向至少一次。

Description

合成气冷却器***和运行方法
本申请要求都于2011年4月6日提交的美国临时申请号61/516,667、61/516,704和61/516,646的利益，并且将它们所有以其全文通过引用并入本文。
技术领域
提供了一种用于冷却合成气的方法和***。更具体来说，将合成气与冷却的再循环合成气掺混以提供掺混的合成气。所述掺混的合成气随后被转移到合成气冷却器。
背景技术
微生物可以通过气态底物的发酵从一氧化碳（CO）生产乙醇和其他化合物。通常将CO作为采取合成气形式的气态底物的一部分提供给发酵。将含碳材料气化以生产包含一氧化碳和氢气的发生炉气体或合成气体或合成气，在本领域中是公知的。这样的气化过程通常包括含碳材料的部分氧化或贫空气氧化，其中向气化过程供应低于化学计算量的氧以促进一氧化碳的产生。
通过本领域中描述的气化过程生产的合成气可能是热的，并且在下游加工和随后的发酵之前需要冷却。包含在气化装置中产生的一氧化碳的热合成气，在气化装置下游的热交换器或废热锅炉中冷却，参见例如美国专利号6,435,139、美国专利号7,587,995和美国专利号7,552,701。合成气的有效和受控的冷却在最小化积垢中是重要的。
发明概述
一种用于冷却合成气的方法和***提供了有效的合成气冷却，并在合成气冷却设备中引起积垢水平降低。在一种情况下，用于冷却合成气的方法包括，将合成气与有效量的冷却再循环合成气掺混，所述有效量用于提供在合成气冷却器的入口处温度约为600℉至约1400℉的掺混的合成气。所述掺混的合成气在所述合成气冷却器的入口之前改变流动方向至少一次。
在另一种情况下，合成气混合***包括直径为DH的气化室和直径为DC的合成气再循环入口。所述合成气再循环入口在所述气化室的远端处进入所述气化室。所述***包括直径为DM的气化出口。所述气化出口与所述气化室的远端相延续，并且所述气化出口在进入合成气冷却器之前包括至少一次方向改变。
在另一种情况下，用于冷却合成气的方法包括将合成气与有效量的冷却再循环合成气掺混，所述有效量用于提供在合成气冷却器的入口处温度在约600℉至约1400℉范围内的掺混的合成气。所述冷却的再循环合成气通过直径为DC的合成气再循环入口供应到直径为DH的气化室的远端，并且DC/DH为约0.25至约0.75。
附图简述
从下面的图，所述方法的几种实施方式中的上述和其他方面、特点和优点将更加明显。
图1示出了合成气混合***。
图2示出了合成气混合***的底视图。
在整个几张图的视图中，相应的参考符号指示相应的部件。专业技术人员将会认识到，图中的元件被简单明了地图示，并且不一定是按比例绘制的。例如，图中的某些元件的尺寸可能相对于其他元件被夸大，以帮助改进对本发明的方法和装置的各个方面的理解。此外，在商业上可行的情况下有用或必需的普通但公知的元件通常没有被示出，以便于提供这些各种情况的较少受到遮挡的视图。
详细描述
下面的描述不应被当作限制性意义的，而是仅仅出于描述示例性实施方式的一般性原理的目的而做出的。本发明的范围应该参考权利要求书来确定。
合成气冷却方法和***在能够有效地提供有效的合成气冷却和设备积垢降低的温度下运行。***的设计提供了有效的合成气混合。
定义
除非另有定义，否则在本公开的整个本说明书中使用的下列术语如下所定义，并且可以包括下面所限定的定义的单数或复数形式：
修饰任何量的术语“约”是指在真实世界环境中例如在实验室、中试厂或生产设施中遇到的，所述量的变化。例如，在混合物中使用的成分或测量值的量或数量，当用“约”修饰时，包括在生产工厂或实验室中的实验条件下测量时的变化性或通常使用的照管程度。例如，当用“约”修饰时，产物的组分的量包括在工厂或实验室中的多次实验中不同批次之间的变化性，以及分析方法固有的变化性。不论是否用“约”修饰，所述量都包括那些量的等同值。本文中陈述并用“约”修饰的任何数量，也可以在本公开中作为不用“约”修饰的量使用。
当在本文中使用时，“含碳材料”是指富含碳的材料例如煤和石化产品。然而，在本说明书中，含碳材料包括无论采取固态、液态、气态还是等离子态的任何碳材料。在可以被当作含碳材料的大量物品中，本公开设想了：含碳材料，含碳液体产物，含碳工业液体回收利用物，含碳市政固体废物（MSW或msw），含碳城市废物，含碳农业材料，含碳林业材料，含碳木材废物，含碳建筑材料，含碳植物材料，含碳工业废物，含碳发酵废物，含碳石化副产物，醇类生产含碳副产物，半无烟煤，轮胎，塑料，废塑料，焦炉焦油，软纤维（fibersoft），木质素，黑液，聚合物，废聚合物，聚对苯二甲酸乙二酯（PETA），聚苯乙烯（PS），污水污泥，动物废物，作物残留物，能源作物，林业加工残留物，木材加工残留物，家畜粪便，家禽粪便，食品加工残留物，发酵过程废物，乙醇副产物，酒糟，废微生物或其组合。
术语“软纤维”是指作为各种物质的软化和浓缩的结果而产生的一种类型的含碳材料；在一个实例中，含碳材料通过各种物质的蒸汽压热器处理来生产。在另一个实例中，软纤维可以包括市政、工业、商业和医疗废物的蒸汽压热器处理产生的纤维状糊状材料。
术语“市政固体废物”是指可以包含家庭、商业、工业和/或残余废物的废物。
术语“合成气”或“合成气体”是指用于称呼含有不同量一氧化碳和氢气的气体混合物的合成气体。生产方法的实例包括天然气或烃类的蒸汽重整以产生氢气，煤的气化以及在某些类型的废物产能气化设施中。该名称来自于它们作为产生合成天然气（SNG）的中间体的用途和用于生产氨或甲醇的用途。合成气是可燃烧的，并且通常被用作燃料源或作为中间体用于其他化学品的生产。
在一种情况下，含碳材料的气化提供合成气。气化包括生物质在受限的氧供应下的部分燃烧。得到的气体包括CO和H2。在这种情况下，合成气将含有至少约20mole%的CO，在一种情况下，约20mole%至约100mole%的CO，在另一种情况下，约30mole%至约90mole%的CO，在另一种情况下，约40mole%至约80mole%的CO，并且在另一种情况下，约50mole%至约70mole%的CO。合成气将具有至少约0.75的CO/CO2比率。系列号61/516,667、61/516,704和61/516,646描述了适合的气化方法和装置的一些实例（美国系列号61/516,667、61/516,704和61/516,646，其全都在2011年4月6日提交，并且将它们所有通过引用并入本文）。离开气化器的合成气将具有高于约1400℉的温度，并且在另一种情况下，至少约1400℉至约3500℉。气化过程有效地破坏焦油。
合成气冷却***
如图1中所示，气体混合***包括气化室100。合成气再循环入口300进入气化室的远端或出口区段200。在这种情况下，合成气再循环入口300在外周处进入气化室100的远端200。气化入口300切向地进入气化室的远端200，并且可以采取一定角度（示为θ），所述角度为约15°至约165°，在另一种情况下为约30°至约150°，在另一种情况下为约45°至约135°，在另一种情况下为约60°至约120°，在另一种情况下为约75°至约105°，并且在另一种情况下为约85°至约95°。
离开气化器100的热合成气接触通过合成气再循环入口300的再循环的冷却合成气。再循环的冷却合成气在热合成气离开气化器之后以及掺混的合成气通过气化出口400进入合成气冷却器（未示出）之前的某处，接触所述热合成气。气化出口400可以是导管或管道。在这种情况下，“再循环的冷却合成气”是指已经在合成气冷却器中冷却到约350℉至约450℉的温度的合成气。
方法包括将再循环的冷却合成气与热合成气以约0.1至约20的比率掺混。在其他情况下，再循环的冷却合成气与热合成气的比率可以包括约1至约15、约1至约10、约1至约5、约1至约4、约1至约3、约1至约2和约1至约1。
掺混的合成气具有约1400℉或更低的温度，在另一种情况下约600℉至约1400℉，在另一种情况下约750℉至约1400℉，在另一种情况下约600℉至约1400℉，在另一种情况下约750℉至约1200℉，在另一种情况下约750℉至约900℉，在另一种情况下约750℉至约825℉，并且在另一种情况下约600℉至约900℉。在这种情况下，用热电偶测量合成气冷却器500入口处的温度。热电偶可以放置在横跨合成气冷却器500入口的直径的任何位置处。
当在本文中使用时，“平均温度”是指用已知方法测定横跨直径的多个温度，然后将那些多个温度测量值表示成平均值。在一种情况下，可以使用计算机建模来提供平均温度。在其他情况下，可以使用所装备的用于这样的测量的热电偶、红外感应等来测量多个温度。
合成气冷却器的温度、流速和构造能够有效防止再循环的冷却合成气和掺混的合成气流入气化室200。在这种情况下，通过合成气冷却器的流速大于约24米每秒。
正如在图1中进一步示出的，气化室200的远端与气化出口400相延续。气化出口400可以在进入合成气冷却器之前改变方向至少一次。如图1中所示，气化出口400以90°角改变方向一次。在这种情况下，气化出口400可以改变方向至少一次，其中方向的任何改变各自独立地采取约15°至约165°的角度。
如图1中所示，气化室200具有直径DH，合成气再循环入口300具有直径DC，气化出口400具有直径DM。合成气再循环入口300位于离气化出口400一定距离（L）处。测量值的比率可以如下：
DC/DH：约0.25至约0.75，在另一种情况下为约0.35至约0.65，并且在另一种情况下为约0.45至约0.55；
L/DH：约1至约10，在另一种情况下为约3至约8，并且在另一种情况下为约4至约6；以及
DH/DM：约0.5至约2.0，在另一种情况下为约0.75至约1.75，并且在另一种情况下为约1.0至约1.5。
在另一种情况下，合成气再循环入口300可以具有约32至约42英寸的直径，在另一种情况下为约34至约40英寸，并且在另一种情况下为约35至约38英寸。气化出口400可以具有约40至约52英寸的直径，在另一种情况下为约43至约49英寸，并且在另一种情况下为约45至约47英寸。
图2示出了合成气冷却***的底视图。在这种情况下，合成气再循环入口300在气化室的外周600处进入气化室100。
在另一种情况下，合成气再循环入口300在气化室100上方的某处进入气化室100，并且初始气体混合发生在气化室100上方的某处。在这种构造中，形成的任何沉积物可以向下落回到气化室100中。
实施例
实施例1：合成气冷却器入口温度对传热和积垢的影响
以下面描述的温度和流速运行具有本文中描述的设计的气化器。
如所示确定了积垢因子。
600℉的合成气冷却器入口温度下的积垢因子：
600℉的入口处的平均积垢因子为0.019Btu/(ft2小时℉)。
使用下面描述的较低合成气冷却器入口温度和流速来运行具有本文中描述的设计的气化器。如所示确定了积垢因子。
1300℉的合成气冷却器入口温度下的积垢因子：
1300℉的入口处的平均积垢因子为0.078Btu/(ft2小时℉)。
尽管已利用特定实施方式、实例及其应用对本文公开的发明进行了描述，但本领域技术人员可以对其做出大量修改和改变，而不背离权利要求书中提出的本发明的范围。

Claims (19)

1.一种用于冷却合成气的方法，所述方法包括：
将合成气与有效量的冷却再循环合成气掺混，所述有效量用于提供在合成气冷却器的入口处温度为600℉至1400℉的掺混的合成气，
其中所述掺混的合成气在所述合成气冷却器的入口之前改变流动方向至少一次，
其中将冷却的再循环合成气通过直径为DC的合成气再循环入口供应到直径为DH的气化室的远端；以及其中将掺混的合成气供应到直径为DM的气化出口，所述气化出口与所述气化室的远端相延续，并且
其中通过合成气冷却器的流速大于24米每秒。
2.权利要求1的方法，其中冷却的再循环合成气的温度为350℉至450℉。
3.权利要求1的方法，其中将冷却的再循环合成气与合成气以0.1至20的比率掺混。
4.权利要求1的方法，其中所述掺混的合成气的温度为600℉至900℉。
5.权利要求4的方法，其中所述掺混的合成气的温度为750℉至825℉。
6.权利要求1的方法，其中所述合成气再循环入口在所述气化室的外周处切向地进入所述气化室的远端。
7.权利要求1的方法，其中所述合成气再循环入口以15°至165°的角度进入所述气化室的远端。
8.权利要求1的方法，其中L/DH为1至10，并且其中L是合成气再循环入口离气化器出口的距离。
9.权利要求1的方法，其中DC/DH为0.25至0.75。
10.权利要求1的方法，其中DH/DM为0.5至2.0。
11.一种用于冷却合成气的方法，所述方法包括：
将合成气与有效量的冷却再循环合成气掺混，所述有效量用于提供在合成气冷却器的入口处温度为600℉至1400℉的掺混的合成气，
其中冷却的再循环合成气通过直径为DC的合成气再循环入口供应到直径为DH的气化室的远端，并且DC/DH为0.25至0.75；其中所述掺混的合成气在所述合成气冷却器的入口之前改变流动方向至少一次；以及其中将所述掺混的合成气供应到直径为DM的气化出口，所述气化出口与所述气化室的远端相延续，并且
其中通过合成气冷却器的流速大于24米每秒。
12.权利要求11的方法，其中冷却的再循环合成气的温度为350℉至450℉。
13.权利要求11的方法，其中将冷却的再循环合成气与合成气以0.1至20的比率掺混。
14.权利要求11的方法，其中所述掺混的合成气具有600℉至900℉的温度。
15.权利要求14的方法，其中所述掺混的合成气的温度为750℉至825℉。
16.权利要求11的方法，其中所述合成气再循环入口在所述气化室的外周处切向地进入所述气化室的远端。
17.权利要求11的方法，其中所述合成气再循环入口以15°至165°的角度进入所述气化室的远端。
18.权利要求11的方法，其中L/DH为1至10，并且其中L是合成气再循环入口离气化器出口的距离。
19.权利要求11的方法，其中DH/DM为0.5至2.0。
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