CN101395088A - 轻气体与卤素的分离方法 - Google Patents

轻气体与卤素的分离方法 Download PDF

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CN101395088A
CN101395088A CNA2007800081079A CN200780008107A CN101395088A CN 101395088 A CN101395088 A CN 101395088A CN A2007800081079 A CNA2007800081079 A CN A2007800081079A CN 200780008107 A CN200780008107 A CN 200780008107A CN 101395088 A CN101395088 A CN 101395088A
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S·B·加德沃
P·K·斯托米诺夫
P·格鲁索
E·W·麦克法兰
A·W·布里德
M·J·威斯
M·D·维尔斯塔
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Abstract

提供了将一种或多种轻气体与溴或氯分离的方法,该方法使用一种或多种物理分离,并与化学洗涤剂接触以回收额外的卤素。一方面,本发明包括(a)将含有一种或多种轻气体的卤素进料提供至蒸馏塔或闪蒸蒸发器;(b)操作所述蒸馏塔或闪蒸蒸发器以将所述进料分离成(i)第一液体,其含有主要量的卤素和不多于次要量的一种或多种轻气体和(ii)第一蒸气,其含有主要量的一种或多种轻气体和不多于次要量的卤素;和(c)将所述蒸气提供至化学洗涤塔以从所述蒸气中回收卤素。

Description

轻气体与卤素的分离方法
发明领域
本发明通常涉及将惰性气体和其它化合物与卤素分离的方法。
发明背景
选择空气或氧气作为氧化介质已经为许多工业方法进行了探索。对于可用空气进行氧化而不对反应化学有不利影响的方法来说,空气比纯氧气是优选的,因为投资和操作成本降低。氧气的较高成本来自于将氧气与氮气分离的花销,传统上这使用膜或蒸馏来完成。与空气相比优选使用纯氧气的一个实例是合成气生产,它是使用费托合成从天然气生产液体烃的第一个步骤。除了影响反应化学以外,在合成气生产中使用空气需要将氮气与未转化的天然气分离。将氮气与天然气分离是投资密集型的,传统上这使用膜或变压吸附来进行。
捕集惰性气流中的痕量溴的常规方法是使用碱性洗涤剂(scrubber),例如NaOH水溶液。从该常规洗涤方法回收所捕集的溴并不容易。其它常规方法包括使用亚硫酸钠、亚硫酸氢钠、或氢氧化钙水溶液等,其中每一种都受困于同一缺点:所捕集的溴难以回收。
由Santa Barbara的GRT,Inc.开发的工艺允许通过在反应器中混合烃和卤素以生成烷基卤化物和卤化氢HX来由甲烷或天然气合成较高级的烃。将所述烷基卤化物和HX引至与金属氧化物或类似物质接触以生成较高级的烃和金属卤化物。该金属卤化物被氧化成金属氧化物和卤素,这二者都可以再循环。当用空气进行氧化时,所生成的卤素含有惰性气体例如氮气和二氧化碳,它们如果不除去,将会穿过卤化区和产生较高级的烃的偶联区。在由GRT,Inc.开发的其它工艺中,通过在催化剂的存在下使烷基卤化物与氢气反应来生成烃,HX作为副产物而生成。为了再生卤素以用于整个工艺的下一次循环,在催化剂的存在下用空气或氧气来氧化HX。对于这两种类型的工艺,希望在将卤素用于下一次工艺循环之前将再生的卤素与N2、CO2和其它轻气体(例如未反应的轻质烃)和水分离。对于循环的或连续的工艺,如果不分离的话,这些气体,特别是氮气,将迅速积累。显然需要将惰性气体和其它化合物与卤素分离的有效率的、成本有效的方法。
发明概述
根据本发明,提供了将一种或多种轻气体与溴或氯分离的方法,该方法使用一种或多种物理分离,并与化学洗涤剂接触以回收额外的卤素。根据本发明的一个方面,所述方法包括(a)将含有一种或多种轻气体的卤素进料提供至蒸馏塔或闪蒸蒸发器;(b)操作所述蒸馏塔或闪蒸蒸发器以将所述进料分离成(i)第一液体,其含有主要量的卤素和不多于次要量的一种或多种轻气体和(ii)第一蒸气,其含有主要量的一种或多种轻气体和不多于次要量的卤素;和(c)将所述蒸气提供至化学洗涤塔以从所述蒸气中回收卤素。
在本发明的第二个方面,使用两个或更多个物理分离,每个分离分别导致卤素在液相中和轻气体在蒸气相中的继续更大的富集。例如,来自蒸馏塔的蒸气(富含一种或多种轻气体)可进料至第二蒸馏塔,该第二蒸馏塔进一步将物料分离成新的蒸气和新的液体,该新蒸气更富含一种或多种轻气体,和该新液体更富含卤素。
本发明中所使用的化学洗涤塔含有一种或多种卤素清除剂(scavenger),这是能够化学吸收卤素的物质,在某些实施方案中通过与卤素的氧化还原反应来化学吸收。优选的物质是溴化亚铜(I)(CuBr,“溴化亚铜”),其可以通过转化为溴化铜(II)(CuBr2,“溴化铜”)来吸收溴。
附图简述
当参照以下详细描述并参考以下附图考虑时,本发明的特征和优点将变得更容易理解。
图1是根据本发明的一个方面将轻气体与溴分离的工艺示意图;
图2是图1所示工艺的示意图,增加了溴生成(“溴再生”)和水吸附的环节;
图3是根据本发明的另一方面使用三个串联闪蒸蒸发器将一种或多种轻气体与溴分离的工艺示意图;
图4是将天然气转化为较高级的烃的连续工艺的示意图,并包括根据本发明的一方面将该在工艺中生成的溴与轻气体分离的子工艺;
图5是确定卤素在本发明的一个实施方案中所使用的卤素清除剂中的卤素穿透的实验方法的图解说明;
图6是根据本发明的一个方面已经暴露于溴/氮气料流的CuBr管的照片。
发明详述
在本发明的新方法中,通过将含有一种或多种轻气体的卤素进料物理分离成液体和蒸气来将一种或多种轻气体与溴或氯分离,所述液体含有主要量的卤素和不多于次要量的一种或多种轻气体,和所述蒸气含有主要量的一种或多种轻气体和不多于次要量的卤素。通过使该蒸气穿过含有卤素清除剂的化学洗涤塔来从该蒸气中除去额外的卤素。本文使用的“轻气体”是指与卤素混合在一起的沸点比卤素低的气体。溴和氯的常压沸点分别为约59℃和-34℃。该定义包括诸如氮气(N2)、二氧化碳(CO2)和“轻质烃”即C1-C4烃之类的气体,需要说明的是,如果氯是想要的卤素的话,C4烃(丁烷和丁烯)不认为是“轻气体”,因为氯的沸点低于C4烃的沸点。术语“主要量的”和“次要量的”是相对的;含有主要量的第一组分和次要量的第二组分的液体(或蒸气)含有比第二组分更多的第一组分。通常,在本发明的大多数实施方案中,给定的液相(或蒸气相)将由绝大部分的一种组分(卤素或一种或多种轻气体)和非常少的其它组分组成。
本发明的一个实施方案举例说明于图1,其描述了用于将轻气体(在此例中为氮气和二氧化碳)与溴分离的系统10。将含有N2和CO2的溴进料12提供至具有塔顶16和塔底18的蒸馏塔14中。换热器20和22分别起到部分冷凝器和全回流的作用,使得富含溴的液体“塔底产物”(并含有不多于次要量的轻气体-一般不多于两种气体在溴中的溶解度极限)从该蒸馏塔中引出,并通过换热器24实现额外降温。
在该塔的顶部,通过换热器22来促进来自回流罐的液体的全回流,产生富含轻气体的蒸气(并含有不多于次要量的溴),将该蒸气引至化学洗涤塔26,在那里除去该次要量的溴,产生轻气体(氮气和二氧化碳输出)。如以下所述,可通过加热该洗涤塔来从洗涤塔中回收溴。
在本发明的另一个实施方案中(未示出),两个或更多个蒸馏塔串联连接,每个塔的塔顶产物(蒸气)引作下一个塔的进料,以从每个塔中连续地将轻气体富集在蒸气中并将溴富集在“塔底产物”料流中。
对于蒸馏装置,一般的压力未0.1-50巴,更优选5-20巴,温度取决于蒸馏系统的压力,牢记,溴的正常沸点为约59℃。级数可为2-200,更优选5-30。
图2举例说明了图2中所示的实施方案的变型,卤素进料(例如Br2)来自于卤素再生单元28。在该实施方案中,来自28的卤素进料含有水,水在水吸附单元(含有干燥剂)中除去。或者,首先蒸馏该进料以从水中移出溴,至多至所生成的溴-水共沸物的极限,残留的水在具有干燥剂的水吸收塔中除去。
在本发明的备选实施方案中,使用一个或多个蒸气-液体闪蒸分离单元(“闪蒸蒸发器”)来将卤素进料与轻气体分离,然后在化学洗涤塔中进行额外的分离。图3举例说明了一种这样的系统50,其中将含有氮气和二氧化碳的溴进料提供至第一闪蒸蒸发器52中。该蒸发器的内容物被闪蒸,得到富含溴(例如97%的Br2回收率)的第一液体和仅含有次要量的溴的富含轻气体的第一蒸气(N2、CO2)。该第一蒸气进料至第二闪蒸蒸发器并闪蒸其内容物,得到富含溴的第二液体(此处,例如额外回收1.5%的溴)和富含轻气体的第二蒸气,该蒸气穿过第二换热器58并进料至第三闪蒸蒸发器60。然后闪蒸第三闪蒸蒸发器的内容物,得到例如额外0.5%的Br2(液体)和非常高度富含轻气体的蒸气。在溴洗涤塔62中除去该第三蒸气料流中的痕量的溴。
如果希望,可使用额外的闪蒸蒸发器。然而,作为实践主题,存在一个收益递减点(就所回收的额外的溴量而言),超过该点则增加的资金需求和操作开销有可能不合算。
可使用既采用一个或多个蒸馏塔又采用一个或多个蒸发器的混合系统。
通常,为了将轻气体与溴分离,每个闪蒸蒸发器的操作温度为-60℃至40℃,更优选-20℃至10℃,和压力为0.1-50巴,更优选5-20巴,牢记卤素和所含的轻气体之间的沸点差异。优选1-3个闪蒸器。各个闪蒸器中的压力可以变化;然而,为了降低成本,希望在系统压力下操作这些闪蒸器以避免昂贵的压缩。这些闪蒸器的操作温度取决于压力。例如,高压操作甚至在中等高的温度下可允许良好的溴分离。然而,对于较低的压力,需要致冷剂以冷却闪蒸单元。蒸气-液体闪蒸系列可由一个或多个闪蒸组成。
本发明的一个重要方面是从主要由轻气体组成的非常稀的气流中化学洗涤溴或氯的方法。该方法使用能够吸收卤素的卤素清除剂。优选地,所述清除剂从稀释的气流中吸收溴蒸气,然后可以可逆地定量释放出游离溴。可在室温或升高的温度下进行溴吸附。
通常,能够与溴反应并经加热后释放溴的任何物质可用作溴清除剂。被认为是适合用作卤素清除剂的非限制性实例包括CuBr、CuCl、FeBr2、FeCl2、AuCl、AuBr、InBr、InCl、FeO、Cu2O、Hg2Br2、Cu、Ag、Au、Hg、Pt、Pd、Ru、Rh、Fe、Os和Ir,可单独使用或组合使用。当前,CuBr是优选的。如果使用具有高表面积(在载体上)的溴化亚铜,即便溴化亚铜的总量显著更低,仍观察到高得多的活性。还发现由沉淀方法制备的CuBr优于普通的(stock)CuBr。
溴化亚铜(I)与溴按照以下反应反应生成溴化铜(II):2CuBr+Br2→2CuBr2。该反应迅速且完全,并有利地在低温下发生。该反应似乎是表面结合的(surface-bound)。当使用块状CuBr时,在穿透发生前使用了约1%的固体。(CuBr和CuBr2的密度密度非常相似,和表面不会良好更新;4.6对4.0g/cm3)。因为CuBr与Br2蒸气的反应是气体与固体的反应,反应速率受到固-气界面的限制,并因此,表面积越高,反应性越高。事实上,纯CuBr的大晶体是效果最差的吸附剂。当发生穿透时(Br2不再被固体所保留),所消耗的CuBr的量约为固体总体积的0.2%,这意味着仅固体的表面参与了反应。低反应温度消除了离子迁移的可能性,也消除了剩下的现存块状CuBr的使用。
CuBr在低温下吸收Br2的能力是部分有利的,因为从溴分离中出来的惰性气流(含有痕量的溴)处于低温或环境温度下;因此,在环境温度或接近环境温度下操作该洗涤塔不需要额外输入能量。
通过将固体加热至高于250℃,一般为250-275℃,来再生该固体(在本例中为溴化铜(II)),由此来回收所洗下的溴。该再生反应为:2CuBr2(加热)→2CuBr+Br2。当洗涤剂为溴化亚铜时,该再生是热活化的并且不需要氧气。
所述卤素清除剂可作为块状粉末使用,或沉积在载体上。非限制性实例包括氧化硅、氧化锆、氧化钛、WO3、CaO、MgO、Cr2O3、和各种碳化物、氮化物和类似物质。首要要求是该载体的表面积为5-1500M2/g。在我们的实验中,我们已经使用固体Cu(I)Br或沉积在具有高表面积(约300m2/g)的Davicat SiZr4700或Davicat Si1151A(Davidson Corporation)、氧化硅上的Cu(I)Br。Si4700B含有约3wt%的ZrO2。其它载体在溴化亚铜上进行该洗涤反应方面应该是同等有效的。
所述卤素清除剂,或清除剂加上载体,可在填料塔反应器结构或其它结构例如壳管反应器中使用。可使用标准的传热介质来传送所需要的热量以将洗涤塔的活性成份升至再生温度。该工艺方案可包括两个反应器,其中一个进行洗涤,而另一个进行再生。
所述固体洗涤剂能够完全保留来自惰性气流的所有的溴成份(来自洗涤塔的溴损失据估计小于1ppb)。在多次耗尽和再生循环后,负载的溴化亚铜(I)显示出可再生的结果。
当使用载体(例如氧化硅)时,非均匀的表面产生成核点,这导致生成更小的微晶,其具有大得多的表面积。即便在该负载的物质仅含有15wt%的CuBr时,它的较高的CuBr表面积使得它是用于溴蒸气保留的更好的物质。
为了探索溴化亚铜(I)作为卤素清除剂的效果,使用可商购得到的CuBr、负载的CuBr和由沉淀法生成的CuBr进行了一系列实验。原始的洗涤剂(CuBr)通过加热CuBr2来再生。结果示于表1。
表1Br2洗涤结果
Figure A200780008107D00101
注释:
%是由所述清除剂所保留的总Br量。
再生在275℃下在10-15分钟内完成。
测试了数个循环,CuBr/4700B的活性没有降低。
*-生成了痕量的AgBr,但重量经测量<10-4g。
**-再生后,其效果降低至所述商购物质的效果。
图6是在室温下暴露于溴/氮气流中30分钟的沉淀的CuBr的管的照片。暗色物质是CuBr2。经加热,颜色变回CuBr的浅绿色,释放溴。
实验程序(protocol):将与1.5sccm N2混合的30sccm/min的N2穿过冷却至0℃的Br2鼓泡器。所述固体吸附剂床含于直径为1cm的圆柱形玻璃管内。在室温下暴露于这样产生的在氮气中的稀释的溴的持续时间为40分钟。将该洗涤塔处理过的气体穿过含有1M NaOH的阱鼓泡。
负载的CuBr物质的制备:将载体分散在约20wt%的CuBr2水溶液中并用SO2鼓泡直到溶液颜色变得几乎无色。过滤该悬浮物并在115℃下干燥过夜。
再生:在耗尽后,在275℃下加热具有固体洗涤剂的反应器20分钟,由此再生保留的溴。通过将所释放的溴捕集在1M NaOH溶液阱中来收集所释放的溴并进行定量。有可能近乎完全回收所捕集的溴。
定量:未被洗涤剂保留的溴的量或从耗尽的洗涤剂中再生的溴的量通过在NaOH阱中的吸收来定量,其在最后用HNO3酸化直至pH值降至5或5以下,然后使用过量的0.5M AgNO3来沉淀出AgBr(加入直到不再有沉淀产生)。由用于过滤的玻璃烧结的过滤器的质量增量并干燥AgBr沉淀直至其重量不变来计算所存在的溴的量。
通过使用Br和BrO-与Ag+的沉淀来测定溴穿透,其中,NaOH阱用HNO3酸化直至酸性;加入AgNO3直至不再生成沉淀;允许将该悬浮物老化40分钟,然后在干燥的、预称重的玻璃烧结的漏斗上过滤,干燥直至恒重,质量差是AgBr。
AgNO3+Br-→AgBr↓+NO3 -
AgNO3+BrO-→AgBrO↓+NO3 -
AgBrO→AgBr+O2
AgBr的溶解度常数Ksp为5×10-13mol21-2。加入到总共约20-25ml酸化的NaOH阱中的AgNO3溶液为0.5M-3ml(或更多)。最终的Ag+浓度为约0.06M。Br-的最低的可检测浓度为约8×10-12M,对应于约0.6ppb。即便假定为非理想情况(高离子强度,离子活度不等于1),灵敏度仍处于ppb范围。
实施例
根据在当前实施方案中所述的方法,对含有约25体积%的溴的流量为40sccm(标准立方厘米每分钟)的氮气惰性气体流进行测试。将该料流冷却至25℃,这在工业上可通过使用空气冷却的换热器来实现。然后将该料流,其压力为25巴,在单一的在5℃下操作的蒸气液体闪蒸单元中闪蒸。来自该闪蒸的液体出口含有大于98%的初始进料中的溴,以及溶解在该溴料流中的一些惰性气体。然后使含有惰性气体和痕量溴的蒸气料流在室温下流过负载的溴化亚铜(I)的床层。从该惰性气体料流中捕集溴是完全的,和所述洗涤床层实现完全的溴捕集40分钟时间。将含有溴化铜(II)和溴化亚铜(I)的耗尽的洗涤床层加热到275℃,并在15分钟的期间内观察到几乎完全的溴回收。
本发明应该在许多使用卤素作为原料或中间体用于化学品生产的工业过程中具有实用性,其中卤素回收或提纯通过除去惰性气体或轻气体而得以改进,导致显著降低的资金和操作成本。这其中有在美国专利6,486,368、6,472,572、6,472,572、6,465,696、6,462,243、6,403,840中所述的用于制造醇、酯、烯烃和烷氧基化物的方法,和在刚好与本申请同一天提交的标题为“Continuous Process forConverting Hydrocarbon Foodstocks into Higher Hydrocarbons andOlefins"(代理人备案号56987/G506)”的美国专利申请中所述的用于制备较高级的烃的方法,将它们的全部内容通过该引用并入本文。例如,在由天然气制备汽油范围的烃的方法中,当用空气来再生时,氮气和二氧化碳进入溴化区和复分解(metathesis)区。为了再循环未转化的甲烷,需要将氮气与甲烷分离,这是高成本的。而且,在再生过程中产生的二氧化碳必须与未转化的甲烷分离,要么使用变压吸附要么使用胺基体系来分离,二者都是高成本的。将轻气体与溴分离不仅降低了反应器尺寸而且简化了轻气体与产物和未转化的反应物的分离。本文所述的分离方法提供了成本有效的将轻气体(包括氮气和二氧化碳)与卤素例如溴分离的方法。
本发明已经用多个实施方案和实施例来描述,但不限于此。所附权利要求的其它修改以及等价物落在本发明的范围内。

Claims (12)

1.将一种或多种轻气体与溴或氯分离的方法,包括:
(a)将含有一种或多种轻气体的卤素进料提供至蒸馏塔或闪蒸蒸发器;
(b)操作所述蒸馏塔或闪蒸蒸发器以将所述进料分离成(i)第一液体,其含有主要量的卤素和不多于次要量的一种或多种轻气体和(ii)第一蒸气,其含有主要量的一种或多种轻气体和不多于次要量的卤素;和
(c)将所述蒸气提供至化学洗涤塔以从所述蒸气中回收卤素。
2.权利要求1的方法,还包括将所述第一液体提供至蒸馏塔或闪蒸蒸发器以将所述第一液体分离成(i)第二液体,其含有主要量的卤素和不多于次要量的一种或多种轻气体和(ii)第二蒸气,其含有主要量的一种或多种轻气体和不多于次要量的卤素;和
(c)将所述第二蒸气提供至化学洗涤塔以从所述蒸气中回收卤素。
3.权利要求1的方法,其中所述卤素是溴。
4.权利要求1的方法,其中所述卤素是氯。
5.权利要求1的方法,其中所述一种或多种轻气体包括氮气。
6.权利要求1的方法,其中所述一种或多种轻气体包括氮气和一种或多种选自由二氧化碳和C1-C4烃组成的组的其它气体。
7.权利要求1的方法,其中所述化学洗涤塔包含负载的或非负载的化学清除剂的床层。
8.权利要求1的方法,其中所述卤素清除剂包括选自由CuBr、CuCl、FeBr2、FeCl2、AuCl、AuBr、InBr、InCl、FeO、Cu2O、Hg2Br2、Cu、Ag、Au、Hg、Pt、Pd、Ru、Rh、Fe、Os、Ir及其混合物组成的组的材料。
9.权利要求1的方法,其中所述卤素清除剂包括CuBr。
10.权利要求1的方法,其中将所述卤素清除剂负载在选自由金属氧化物、金属碳化物、金属氮化物、碳、粘土及其混合物组成的组的材料上。
11.权利要求1的方法,其中将所述卤素清除剂负载在选自由Al2O3、SiO2、ZrO2、TiO2、WO3、CaO、MgO、Cr2O、SiC、Mo4C、TiN、W2N、碳、沸石、蛭石及其混合物组成的组的材料上。
12.权利要求1的方法,还包括加热所述化学洗涤塔以从中释放卤素。
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