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TWI865915B - 生產用於裂解操作之脫碳藍氫氣的系統及方法 - Google Patents

生產用於裂解操作之脫碳藍氫氣的系統及方法 Download PDF

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TWI865915B
TWI865915B TW111133110A TW111133110A TWI865915B TW I865915 B TWI865915 B TW I865915B TW 111133110 A TW111133110 A TW 111133110A TW 111133110 A TW111133110 A TW 111133110A TW I865915 B TWI865915 B TW I865915B
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湯瑪士 Ｍ 瓊斯
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Abstract

本發明揭示利用諸如變壓吸附(PSA)之標準分離製程將氫與烴之尾氣混合物分離成氫氣及PSA流出物以生產用於裂解操作之脫碳藍氫氣之系統及方法，該PSA流出物在氫產生單元中使用以生產用於裂解操作之脫碳藍氫氣。

Description

生產用於裂解操作之脫碳藍氫氣的系統及方法
本發明一般而言係關於生產用於裂解操作之脫碳藍氫氣之系統及方法。更特定而言，所揭示系統及方法利用諸如變壓吸附(PSA)之標準分離製程將氫與烴之尾氣混合物分離成氫氣及PSA流出物，該PSA流出物在氫產生單元中用來生產用於裂解操作之脫碳藍氫氣。
裂解係一種其中蒸氣中存在之烴分子被轉換成具有碳碳雙鍵之分子之製程，諸如，例如，可用於生產諸如聚乙烯之石化產品之乙烯。蒸氣裂解操作通常使用係在該製程中產生之氫與烴(例如，甲烷及/或乙烷)之混合物之尾氣來提供蒸氣裂解及產生能量密集型碳碳雙鍵所必需之燃料。在裂解爐中加熱或點火烴之製程產生被排放至大氣之二氧化碳(CO2)及其他溫室氣體。
圖1在習用乙烯生產系統 100中圖解說明此製程。在使用尾氣流 106作為燃料加熱(點火)之蒸氣裂解爐 104中處理烴原料流 102，該尾氣流可係氫(H2)與烴(CH4)之混合物。乙烯裂解爐之正常燃料係富氫尾氣副產物，其具有在裂解爐中產生CO2之高質量含量之甲烷或其他烴。該尾氣可含有多達75體積%至80體積%之氫，其餘大部分係甲烷。對於某些原料，尾氣中之氫濃度低至5體積%至10體積%。
將經裂解烴原料流 108發送至分離鏈 110，該分離鏈將經裂解烴原料流 108分離成尾氣流 106、乙烯流 112及其他副產物 114，該等副產物可包含丙烯、液化石油氣(LPG)及天然氣液體(NGL)。使用諸如PSA之已知分離技術，但分離鏈 110可採用聚合物分離膜且甚至低溫蒸餾，不過PSA係乙烯生產系統中使用之較佳分離技術。來自蒸氣裂解爐 104之排放物 116含有CO2(由於烴燃燒)及水蒸氣(H20)。由於日益增加之環境問題及對碳排放之操作限制，諸多石化公司被迫減少來自其當前蒸氣裂解操作之碳排放。
相關申請案的交叉參考
本申請案主張於2021年09月1日提出申請之美國臨時申請案第63/239,844號之優先權，該申請案之全部內容以引用方式倂入本文中。
具體闡述本發明之標的物，然而，說明本身並不意欲限制本發明之範疇。因此，亦可以其他方式來體現標的物，以包含類似於及/或少於本文中結合其他當前或未來技術闡述之彼等之不同結構、步驟及/或組合。雖然術語「步驟」在本文中可用來闡述所採用方法之不同元件，但該術語不應解釋為暗指本文中揭示之各種步驟當中或之間的任何特定次序，除非本說明另外明確地限制為特定次序。在檢驗下列圖及詳細說明時，所揭示實施例之其他特徵及優點將係或將變得為熟習此項技術者所瞭解。所有此等額外特徵及優點意欲包含在所揭示實施例之範圍內。此外，本文中闡述之所圖解說明之圖及尺寸僅係實例性的且並不意欲確定或暗指關於其中可實施不同實施例之環境、架構、設計或製程之任何限制。就以下說明中引用之溫度及壓力之程度，彼等條件僅係說明性的且並不意味著限制本發明。
本文中揭示之系統及方法藉由將氫與烴之尾氣混合物分離成氫氣及PSA流出物來減少來自蒸氣裂解操作之碳排放，PSA流出物在氫產生單元中用來生產用於蒸氣裂解操作之脫碳藍氫氣。因此，氫產生單元可包含蒸氣甲烷重組、自發性熱重組及部分氧化。
在一項實施例中，本發明包含生產用於裂解操作之脫碳藍氫氣流之系統，其包括：i)裂解爐，其包括烴原料及來自用於生產經裂解烴原料流之脫碳藍氫氣流之脫碳藍氫氣；及排放物，其包括水蒸氣及殘餘二氧化碳；ii)分離鏈，其用於將經裂解烴原料流分離成尾氣流及產物流；iii)分離系統，其用於將尾氣流分離成氫氣流及流出物流；及iv)氫產生單元，其用以處理流出物流且生產脫碳藍氫氣流及二氧化碳排放物。
在另一實施例中，本發明包含生產用於裂解操作之脫碳藍氫氣流之方法，其包括：i)使用脫碳藍氫氣流來裂解烴原料以生產經裂解烴原料流以及包括水蒸氣及殘餘二氧化碳之排放物；ii)將經裂解烴原料流分離成尾氣流及產物流；iii)將尾氣流分離成氫氣流及流出物流；及iv)處理流出物流以生產脫碳藍氫氣流及二氧化碳排放物。
現在參考 圖 2，示意圖圖解說明經改造乙烯生產系統 200之一項實施例。尾氣流 106被饋送穿過氫/烴分離系統(例如，PSA) 202，該氫/烴分離系統將尾氣流 106分離成具有大於98體積%之高純度之氫氣流(H2) 204及包括烴(CH4)及殘餘氫氣之PSA流出物流 206。PSA流出物流 206被饋送至氫產生單元 208，該氫產生單元可整合有補充燃料氣流 210以操作藍氫單元 208 ，該補充燃料氣流包括來自管線或其他源之補充天然氣。
氫產生單元 208生產脫碳藍氫氣流 212，副產物 214(包括甲烷、一氧化碳、水、未回收氫、未回收CO2及惰性氣體)及CO2排放物 216，CO2排放物可經捕獲及壓縮以供封存及儲存。藍氫氣流 212可與氫氣流 204組合以形成用於加熱(點火)蒸氣裂解爐 104之氫燃料氣流 218。補充燃料氣流 210可經調整以平衡蒸氣裂解爐 104之總要求。對於無法點火100%氫燃料之蒸氣裂解爐，亦可為氫燃料氣流 218補充尾氣流 106。
來自蒸氣裂解爐 104之排放物 220含有水蒸氣(H20)及痕量位準之殘餘CO2排放物。以此方式，烴被轉換成氫以消耗副產物燃料且捕獲CO2(預燃燒)使得其不排放至大氣。
現在參考 圖 3，示意圖圖解說明經改造乙烯生產系統 300之另一實施例。氫燃料氣流 218亦可發送至燃氣輪機發電機 302，其中排氣流 306整合至蒸氣裂解爐 104中作為空氣預熱，該燃氣輪機發電機生產電力輸出 304且減少生產單位質量之乙烯所需之總能量(比能量含量)。
本文中揭示之系統及方法界定使用組合有氫產生單元之現有尾氣源自清潔燃燒之氫經濟地生產所需之全部氫裂解器燃料之獨特方式。此方法之獨特性在於藉由化學變換成清潔燃燒之氫保留經分離甲烷之能量值，然後與初始分離之氫組合。可將自尾氣生產之任何過量氫饋送至組合式循環燃氣輪機或廠外鍋爐而以經減少排放物來產生電力/蒸氣且可使用整合至裂解爐中之燃氣輪機發電機來增強生產單位質量之乙烯所需之能量。因此，該等系統及方法藉由將天然氣饋料轉換成在燃燒時僅排放水蒸氣之藍氫氣而可用於安裝在數個石化複合體中之組合式循環電廠。
由於與後燃燒CO2相比，自製程流移除預燃燒CO2更具經濟性，因此本文中揭示之系統及方法為世界各地之多個石化場所之現有操作呈現脫碳機會。全球生產的乙烯超過1億5千萬噸，因此可藉由經由轉換氫產生單元中之基於烴之燃料預燃燒捕獲之CO2而消除可能超過1億噸之乙烯裂解爐CO2排放物。
儘管已結合當前較佳實施例闡述本發明，但熟習此項技術者應理解其並不意欲限制彼等實施例之揭示內容。例如，系統及方法可應用於其中生產不同於或除乙烯之外的產品之各種裂解操作。因此，審慎考慮可對所揭示實施例進行各種替代實施例及修改，而不背離隨附申請專利範圍及其等效物之精神及範疇。
100:習用乙烯生產系統 102:烴原料流 104:蒸氣裂解爐 106:尾氣流 108:經裂解烴原料流 110:分離鏈 112:乙烯流 114:副產物 116:排放物 200:經改造乙烯生產系統 202:氫/烴分離系統 204:氫氣流 206:PSA流出物流 208:氫產生單元 210:補充燃料氣流 212:脫碳藍氫氣流 214:副產物 216:CO2排放物 218:氫燃料氣流 220:排放物 300:經改造乙烯生產系統 302:燃氣輪機發電機 304:電力輸出 306:排氣流
以下參考其中以相同參考符號指代相同元件之附圖闡述詳細說明，附圖中：
圖1係圖解說明習用乙烯生產系統之示意圖。
圖2係圖解說明經改造乙烯生產系統之一項實施例之示意圖。
圖3係圖解說明經改造乙烯生產系統之另一實施例之示意圖。
102:烴原料流
104:蒸氣裂解爐
106:尾氣流
108:經裂解烴原料流
110:分離鏈
112:乙烯流
114:副產物
200:經改造乙烯生產系統
202:氫/烴分離系統
204:氫氣流
206:PSA流出物流
208:氫產生單元
210:補充燃料氣流
212:脫碳藍氫氣流
214:副產物
216:CO2排放物
218:氫燃料氣流
220:排放物

Claims (20)

  1. 一種生產用於裂解操作之脫碳藍氫氣流之系統，其包括： 裂解爐，其包括烴原料及來自該脫碳藍氫氣流之脫碳藍氫氣，用於生產經裂解烴原料流以及包括水蒸氣及殘餘二氧化碳之排放物； 分離鏈，其用於將該經裂解烴原料流分離成尾氣流及產物流； 分離系統，其用於將該尾氣流分離成氫氣流及流出物流；及 氫產生單元，其用於處理該流出物流及生產該脫碳藍氫氣流及二氧化碳排放物。
  2. 如請求項1之系統，其中該分離鏈經組態以使用變壓吸附、聚合物分離膜或低溫蒸餾來分離該經裂解氫原料流。
  3. 如請求項1之系統，其中該分離系統經組態以使用變壓吸附來分離該尾氣流。
  4. 如請求項1之系統，其中該氫產生單元經組態以使用蒸氣甲烷重組、自發性熱重組或部分氧化來處理該流出物流。
  5. 如請求項1之系統，其中該流出物流包括烴及殘餘氫氣。
  6. 如請求項1之系統，其中該等裂解爐排放物包含較來自該氫產生單元之該等二氧化碳排放物少之二氧化碳。
  7. 如請求項1之系統，其進一步包括連接至該氫產生單元之包含天然氣的補充燃料氣流。
  8. 如請求項1之系統，其中該脫碳藍氫氣流與該氫氣流經連接以形成連接至該裂解爐之氫燃料氣流。
  9. 如請求項8之系統，其進一步包括連接至該氫燃料氣流及該裂解爐以便生產電力輸出之燃氣輪機發電機。
  10. 如請求項1之系統，其中該產物流包括乙烯。
  11. 一種生產用於裂解操作之脫碳藍氫氣流之方法，其包括： 使用該脫碳藍氫氣流來裂解烴原料以生產經裂解烴原料流以及包括水蒸氣及殘餘二氧化碳之排放物； 將該經裂解烴原料流分離成尾氣流及產物流； 將該尾氣流分離成氫氣流及流出物流；及 處理該流出物流以生產該脫碳藍氫氣流及二氧化碳排放物。
  12. 如請求項11之方法，其中使用變壓吸附、聚合物分離或低溫蒸餾來分離該經裂解烴原料流。
  13. 如請求項11之方法，其中使用變壓吸附來分離該尾氣流。
  14. 如請求項11之方法，其中使用蒸氣甲烷重組、自發性熱重組或部分氧化來處理該流出物流。
  15. 如請求項11之方法，其中該流出物流包括烴及殘餘氫氣。
  16. 如請求項11之方法，其中來自裂解該烴原料之該等排放物包含較來自處理該流出物流之該等二氧化碳排放物少之二氧化碳。
  17. 如請求項11之方法，其進一步包括調整用於處理該流出物流且平衡該經裂解烴原料流之預定要求之補充燃料氣流。
  18. 如請求項11之方法，其進一步包括組合該脫碳藍氫氣流與該氫氣流以形成用於裂解該烴原料之氫燃料氣流。
  19. 如請求項18之方法，其進一步包括使用該氫燃料氣流來操作燃氣輪機發電且生產電輸出。
  20. 如請求項11之方法，其中該產物流包括乙烯。
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