The present invention relates to the field of the synthesis of hydrocarbons from a mixture comprising carbon monoxide (CO), hydrogen (H2) and possibly carbon dioxide (CO2), generally known as synthesis gas.
The method of the invention means that the operation of a unit for synthesizing hydrocarbons starting from synthesis gas (also known as Fischer-Tropsch synthesis) can be optimized, or it can re-establish stable operation with a view to maximizing the yield of C5+ hydrocarbons (hydrocarbons containing 5 or more carbon atoms).
The method of the invention is a method for controlling the Fischer-Tropsch synthesis in which the ratio of the partial pressures of water and hydrogen, PH2O:PH2, is used as a control parameter for said synthesis.
The reaction for converting synthesis gas (CO—(CO2—H2) mixture) into hydrocarbons has been known since the start of the twentieth century and is also termed the Fischer-Tropsch synthesis. The units were operated in Germany during the Second World War, then in South Africa to synthesize synthetic fuels. The majority of such units, essentially dedicated to the production of synthetic fuels, were or are still operated with iron-based catalysts.
More recently, interest in such syntheses has resurged, more particularly as regards the use of catalysts comprising cobalt which can orientate the reaction towards the formation of heavier hydrocarbons, principally paraffins, essentially C5+ hydrocarbons (hydrocarbons containing 5 or more carbon atoms per molecule), while minimizing the formation of methane and hydrocarbons containing 2 to 4 carbon atoms per molecule (C2-C4). The hydrocarbons formed thereby may be transformed in a downstream hydrocracking unit in order to produce mainly kerosene and gas oil. Such a process is, for example, described in patent EP-B-1 406 988. The use of a catalyst comprising cobalt is more suited to treating synthesis gas (feed) which is richer in hydrogen, derived in particular from the transformation of natural gas.
Many cobalt-based formulations have been described in the prior art (see, for example, patent applications EP-A-0 313 375 or EP-A-1 233 011). In contrast to iron-based catalysts which are active in the conversion of CO to CO2 (water gas shift reaction, WGSR): CO+H2O→CO2+H2, cobalt-based catalysts have only a low activity for this reaction (B H Davies, Catalysis Today, 84, 2003, p 83).
However, under certain conditions, catalysts comprising cobalt may develop a CO conversion activity (WGSR) which then competes with the Fischer-Tropsch synthesis reaction and severely affects this synthesis. The CO conversion reaction (WGSR) consumes part of the reagent CO by forming CO2 instead of the desired hydrocarbons and it simultaneously produces an excess of hydrogen which modifies the H2:CO ratio and causes degradation of the selectivity of the reaction towards the lightest products. Thus, the selectivites for methane and C2 to C4 hydrocarbons are increased.
Patent U.S. Pat. No. 6,534,552 B2 describes a process for producing hydrocarbons from natural gas in which the natural gas is converted into synthesis gas which is sent to a Fischer-Tropsch synthesis section to produce hydrocarbons and a tail gas. A separation section can separate hydrogen from a fraction of that gas, said hydrogen being permanently recycled either to the Fischer-Tropsch section or to the synthesis gas production section.
Patent U.S. Pat. No. 4,626,552 describes a procedure for starting up a Fischer-Tropsch reactor, in which the H2:CO ratio is maintained at a low value by imposing a hydrogen flow rate in the range 15% to 90% of the stabilized flow rate. Next, the flow rate of the gas feed, the pressure and the temperature are increased gradually and finally, the H2:CO ratio is adjusted to the optimum desired value by increasing the inlet hydrogen flow rate.
The method of the invention is a method for optimizing the operation of a unit for synthesizing hydrocarbons starting from a feed comprising synthesis gas, operated in the presence of a catalyst comprising cobalt.
The method of the invention concerns a process for synthesizing hydrocarbons from a feed comprising synthesis gas, operated with a catalyst comprising cobalt. Said method comprises the following steps: determining the theoretical molar ratio of the partial pressures of water and hydrogen, PH2O:PH2, in the Fischer-Tropsch reaction section, followed by possible adjustment of said ratio then determining the new value for this ratio. These steps are then optionally repeated until said ratio has a value of less than 1.1, preferably strictly less than 1 and highly preferably strictly less than 0.9, still more preferably strictly less than 0.8, or even strictly less than 0.65.
This method for controlling the Fischer-Tropsch synthesis means that high performances can be maintained, especially as regards the yield of heavy products (C5+ hydrocarbons). It can also maximize the selectivity for the heaviest hydrocarbons in the Fischer-Tropsch reaction and prevent degradation of the selectivity due to development of the CO conversion reaction (WGSR).
The method of the invention is a method for controlling and optimizing the Fischer-Tropsch synthesis in which the molar ratio of the partial pressures of water and hydrogen, PH2O:PH2, in the Fischer-Tropsch reaction section is used as a parameter for controlling and optimizing this system.
The method of the invention can improve the operation of the Fischer-Tropsch synthesis unit by optimizing its yield and preventing any drift of selectivity towards the CO conversion reaction (water gas shift reaction or WGS reaction). This novel control and optimization method is of particular advantage during transitional phases, in particular when starting up a unit or during temporary dysfunction of the unit (for example, when an incident such as breakage of part of the feed supply occurs, which will disturb the operation of the reaction section).
This is also the case when the operating parameters (temperature, pressure, gas flow rate, etc) are modified due to a temporary dysfunction of the unit or due to catalyst deactivation. By way of illustration, we can mention the case in which, during the unit start up phase, the activity of the catalyst increases during its final construction stage in situ in the synthesis gas (H Schutz et al, Catalysis Today, 71, 351, 2002).
The envisaged aim is the synthesis of a mixture of hydrocarbons comprising mainly paraffins and mainly long carbon chain compounds (hydrocarbons containing more than 5 carbon atoms per molecule, preferably containing more than 20 carbon atoms per molecule), in the presence of a catalyst comprising cobalt, also known as the Fischer-Tropsch synthesis. In order to attain this objective, it is important to minimize as far as possible the transitional phases mentioned above during which conversion and/or selectivity of the Fischer-Tropsch reaction are not generally optimized.
The method for controlling and optimizing the operation of a hydrocarbon synthesis unit of the invention means that high performance can be maintained, in particular as regards the yield of heavy products (C5+ hydrocarbons). More precisely, it can maximize the selectivity for the heaviest hydrocarbons using the Fischer-Tropsch reaction and prevent degradation of the selectivity due to development of the CO conversion reaction.
In the Fischer-Tropsch synthesis unit of the invention, said catalyst may be used in a fixed bed (reactor with one fixed bed catalyst with one or more beds of catalyst in the same reactor) or, as is preferable, in a three-phase reactor (used in slurry mode) comprising the catalyst in suspension in an essentially inert liquid phase and the reactive gas phase (synthesis gas).
The synthesis gas used in the Fischer-Tropsch synthesis step of the invention may be obtained via transformation of natural gas, coal or biomass using processes such as steam reforming or partial oxidation, or by methanol decomposition, or from any other process which is known to the skilled person. Any feed comprising at least hydrogen and carbon monoxide may thus be suitable. Preferably, the synthesis gas used in the Fischer-Tropsch synthesis has a H2:CO molar ratio in the range 1:2 to 5:1, more preferably in the range 1.2:2 to 3:1 and still more preferably in the range 1.5:1 to 2.6:1.
The Fischer-Tropsch synthesis is generally carried out at a pressure in the range 0.1 MPa to 15 MPa, preferably in the range 1 MPa to 10 MPa and more preferably in the range 1.5 MPa to 5 MPa. The hourly space velocity of the synthesis gas is generally in the range 100 to 20000 h−1 (volume of synthesis gas per volume of catalyst per hour), preferably in the range 400 to 10000 h−1.
Any catalyst comprising cobalt which is known to the skilled person is suitable for the method of the invention, in particular those mentioned in the “prior art” section in the present application. Preferably, the catalysts comprising cobalt which are used are deposited on a support selected from the following oxides: alumina, silica, zirconia, titanium oxide, magnesium oxide or mixtures thereof. Various promoters which are known to the skilled person may also be added, in particular those selected from the following elements: rhenium, ruthenium, molybdenum, tungsten, chromium. It is also possible to add at least one alkali or alkaline-earth to these catalytic formulations.
In the method of the invention, the following control steps are carried out:
The ratio PH2O:PH2 of step a) may be determined using any means which is known to the skilled person. The reaction section may be constituted by one or more reactors. Step a) is preferably carried out using means selected from the means detailed below.
One preferred means consists of measuring the quantity of carbon monoxide in the gaseous effluent and evaluating the theoretical ratio, PH2O:PH2, from the degree of conversion of carbon monoxide in the whole of the reaction section comprising one or more reactors, the ratio H2:CO in the feed and the ratio H2:CO for the gas consumed by the reaction (also termed the use ratio).
The degree of conversion of carbon monoxide (Cv) is defined from measurements of the carbon monoxide which enters the reaction section for hydrocarbon synthesis (inlet CO) and the carbon monoxide which leaves said reaction section (outlet CO). These measurements are generally carried out by gas phase chromatography using a catharometric detector. In the same manner, the hydrogen is measured with a column and a specific detector in the gas streams entering and leaving the reaction section for hydrocarbon synthesis in order to calculate the various H2/CO ratios.
Thus, the degree of conversion of carbon monoxide (Cv), the ratio (or H2/CO quotient) of the feed (R1) and the use ratio (or H2/CO quotient) (Rft) are defined as follows:
Cv=(CO inlet−CO outlet)/CO inlet
R1=H2/CO feed=H2 inlet/CO inlet (mol/mol)
Rft=H2/CO reaction=(H2 inlet−H2 outlet)/(CO inlet−CO outlet).
Thus, the theoretical ratio PH2O:PH2 in the reaction section can be evaluated using the following equation:
Theoretical PH2O:PH2=Cv/(R1−(Rft×Cv)).
The use ratio Rft qualifies to some extent the intrinsic selectivity of the Fischer-Tropsch synthesis catalyst. It is generally determined under normal Fischer-Tropsch synthesis conditions, i.e. when the shift reaction (WGSR) is minor and practically negligible. By default, it can be taken to be equal to 2.0, in accordance with the general reaction stoichiometry of the Fischer-Tropsch synthesis reaction [1] which is repeated below, knowing that the estimation of the theoretical ratio PH2O:PH2 will be conservative (i.e. slightly under-estimated).
Fischer-Tropsch reaction: CO+2H2→—(CH2)—+H2O [1]
Step b) for optional adjustment of the ratio PH2O:PH2 determined in step a) to a value strictly less than 1 may be carried out using means selected from the following means:
In more detail, this adjustment may be carried out using one of the following means:
Which of these means is selected depends essentially on the means which are available in the industrial unit and the operating conditions at the time.
The highly preferred means used in optional step b) for optional adjustment of the ratio PH2O:PH2 are generally as follows:
In certain cases, in particular after an incident on one unit such as an unforeseen reduction in the operating temperatures, for example, other means are preferably used in step b) for optional adjustment of the ratio PH2O:PH2, namely the following means:
In such cases, these means are generally easier to implement.
When the ratio PH2O:PH2 has been adjusted in step b), its new theoretical value is determined again (step c)) in order to check that it its strictly less than 1.1, preferably strictly less than 1.0 and more preferably strictly less than 0.9, still more preferably strictly less than 0.8 or even strictly less than 0.65.
If this is not the case, steps a) to c) are repeated (step d)) until the criterion that the theoretical ratio PH2O:PH2 is strictly less than 1.1, preferably strictly less than 1.0 and more preferably strictly less than 0.9, still more preferably strictly less than 0.8, or even strictly less than 0.65 is satisfied.
In summary, the invention concerns a method for optimizing the operation of a reaction section for hydrocarbon synthesis starting from a feed comprising synthesis gas, operated in the presence of a catalyst comprising cobalt, said method comprising the following steps:
Said reaction section may comprise one or more hydrocarbon synthesis reactors.
The following examples illustrate the invention.
The Fischer-Tropsch synthesis reaction was operated in a device comprising an autoclave type continuously stirred three-phase reactor (CSTR [continuously stirred tank reactor]). This reactor could be maintained under pressure and at temperature and operated continuously. The reactor was supplied with a synthesis gas with a H2/CO ratio which may be adjusted between 1.5 to 2.5.
The flow rate of the feed (synthesis gas) was monitored and could also be adjusted to increase or reduce the reaction time. Fischer-Tropsch synthesis was carried out at 230° C., 2 MPa, in the presence of 35 g of a catalyst containing 13% by weight of cobalt deposited on an alumina support having a specific surface area of approximately 150 m2/g and a cubic gamma structure. The catalytic performances were evaluated by material balance by analyzing and measuring the various streams leaving the reactor. The compositions of the various departing streams (gas effluents, liquid hydrocarbon product and aqueous product) were determined by gas chromatography.
Several experiments were carried out under various different synthesis gas supply conditions:
Case 1: 80 Nl/h of synthesis gas with a H2/CO ratio of 2.0;
Case 2: 70 Nl/h of synthesis gas with a H2/CO ratio of 2.0;
Case 3: 60 Nl/h of synthesis gas with a H2/CO ratio of 2.0;
Case 4: 40 Nl/h of synthesis gas with a H2/CO ratio of 2.0;
Case 5: 100 Nl/h of synthesis gas with a H2/CO ratio of 2.5;
Case 6: 88 Nl/h of synthesis gas with a H2/CO ratio of 2.5;
Case 7: 75 Nl/h of synthesis gas with a H2/CO ratio of 2.5;
Case 8: 70 Nl/h of synthesis gas with a H2/CO ratio of 2.5;
Case 9: 64 Nl/h of synthesis gas with a H2/CO ratio of 2.5;
Case 10: 78 Nl/h of synthesis gas with a H2/CO ratio of 1.5;
Case 11: 66 Nl/h of synthesis gas with a H2/CO ratio of 1.5;
Case 12: 56 Nl/h of synthesis gas with a H2/CO ratio of 1.5.
The results obtained after 50 hours of test are shown in Table 1 below:
Selectivities, as % Carbon (CO2, CH4, C5+)
100× (number of moles of carbon in the form of CO2 or CH4 or C5+)/total number of moles of carbon transformed into products.
C5+ Productivity (kg/kg·h)
Kilograms of C5+ hydrocarbons formed per hour per kilogram of catalyst employed.
The results of Table 1 show that for H2:CO ratios of 1.5 to 2.5, the CO2 and methane selectivity rose substantially when the theoretical ratio PH2O:PH2 had a value of more than 1, which had a highly deleterious impact on the selectivity for C5+ hydrocarbons, the desired products in this synthesis. Below a PH2O:PH2 of 1, the influence of an increase in this ratio was much smaller.
Case No 2 of Example 1 was assumed to be the starting point (feed flow rate of 70 Nl/h). The performances obtained after 50 hours of test were those indicated in Table 1.
The temperature of the Fischer-Tropsch reaction section was increased by 5° C. (T=235° C. and 2 MPa) without changing the feed flow rate (synthesis gas at rate of 70 Nl/h). This caused a modification in the ratio PH2O:PH2 which rose above 1 and an increase in the methane and carbon dioxide (CO2) selectivities. These conditions are summarized in case 13 of Table 2.
The operating conditions were kept constant (T=235° C. and 2 MPa), but the ratio PH2O:PH2 was adjusted by dint of increasing the feed flow rate which rose to 100 Nl/h (case 14). This produced a theoretical ratio PH2O:PH2<1 with lower CO2 and methane selectivities, and a selectivity for C5+ hydrocarbons (hydrocarbons containing 5 or more carbon atoms) which was higher.
In case No 13, even though the C5+ hydrocarbon productivity increased slightly, a carbon loss was observed because the increase of conversion occurred with an increase in the methane and CO2 selectivities. A much greater fraction of carbon present in the feed was thus transformed into methane and carbon dioxide, which are unwanted products. In contrast, returning to a theoretical ratio, PH2O:PH2, of less than 1 again resulted in a high productivity with a low selectivity for CH4 and CO2, and thus minimized the carbon losses.
Number | Date | Country | Kind |
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0609879 | Nov 2006 | FR | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/FR07/01816 | 11/2/2007 | WO | 00 | 8/17/2010 |