Patent Grant
7192565
The present invention relates to a method of collecting and removing mercaptans present in a gaseous feed, notably in a hydrocarbon feed.
Prior to being marketed, natural gas is subjected to three main operations: deacidizing, dehydration and gasoline extraction.
The purpose of the deacidizing operation is to remove the acid compounds such as carbon dioxide (CO2), hydrogen sulfide (H2S), carbonyl sulfide (COS) and mercaptans, mainly methylmercaptan, ethylmercaptan and propylmercaptans. The specifications generally allowed for deacidized gas are 2% CO2, 4 ppm H2S and 20 to 50 ppm total sulfur content.
The dehydration operation then allows to control the water content of the deacidized gas in relation to transport specifications.
Finally, the gasoline extraction operation allows to guarantee the hydrocarbon dew point of the natural gas, also according to transport specifications.
The deacidizing operation, which is essentially intended to reduce the CO2 and H2S content of the gas, is for example performed by means of an absorption method, using notably chemical solvents like, for example, alkanolamines such as diethanolamine (DEA) or methyldiethanolamine (MDEA). After this treatment, the gas meets the specifications relative to the CO2 content, typically below 2% by mole, and to the H2S content, typically 4 ppm by mole. Part of the light mercaptans, notably methylmercaptan, is removed during this operation. The heavier mercaptans such as ethyl, propyl and butylmercaptan, or containing more than four carbon atoms, are not soluble enough in an aqueous solution or acid enough to significantly react with the alkanolamines generally used for deacidizing, and a large part thereof therefore remains in the gas. Most of these acid compound absorption methods have a mercaptan extraction efficiency ranging between 40% and 60%. Some technical solutions using solvents with a high physical absorption capacity such as water-alkanolamine-sulfolane mixtures, which achieve a 90% sulfur compound elimination but with a significant energy consumption, notably because of the high solvent flow rates required by such performances, can however be mentioned.
The dehydration operation can be carried out by means of a glycol process (for example the process described in document FR-2,740,468), using notably TEG, which allows to lower the water content of the gas down to a value close to 60 ppm by mole. The mercaptans are not eliminated in this stage. An adsorption method of T.S.A. (Thermal Swing Adsorption) type on molecular sieve, for example of 3A or 4A or 13X type, or on silica gel or alumina, can also be used. In this case, the water content of the gas is typically below 1 ppm by mole.
A last fractionation operation by cooling finally allows the treated gas to be separated into its different constituents so as to upgrade each cut produced: C1 cut, C2 cut, or C1+C2 cut, C3 cut, C4 cut, and heavier C5+ cut, possibly further separated into various complementary fractions. The major part of the sulfur compounds is concentrated in the liquid phases, which therefore have to be processed later to meet the sulfur specifications generally required.
It is therefore necessary to carry out one or more additional processing stages, depending on the distribution of the mercaptans in the various cuts obtained after fractionation. Generally, the mercaptans are removed from the liquid hydrocarbon cuts by caustic washing. Countercurrent contacting, in a plate column, of the hydrocarbon feed with a concentrated soda solution, between 10% and 20% by weight, provides elimination of all the sulfur compounds such as COS and the mercaptans. The mercaptans react with the soda and give mercaptides, which are then oxidized in the presence of a catalyst present in the solvent to give disulfides, while regenerating the caustic solution. The latter are then separated by decantation of the aqueous phase. The efficiency of this technique is furthermore closely linked with the nature of the mercaptans to be removed: it decreases as the number of carbon atoms of the hydrocarbon chain of the mercaptan increases. This can be explained by the low solubility in an aqueous solution of mercaptans having more than three carbon atoms.
An alternative to the caustic washing technique is the elimination of the mercaptans upstream from the fractionation stage. This complementary processing intended to lower the residual mercaptan proportion can consist of an adsorption stage using for example a 13X zeolite for desulfurization, the pore size of these zeolites allowing selective adsorption of the mercaptans. The methods used are then T.S.A. (Thermal Swing Adsorption) type processes wherein adsorption takes place at ambient or moderate temperature, typically ranging between 20° C. and 60° C., and high-temperature desorption, typically between 200° C. and 350° C., under sweeping of a purge gas, which can notably be part of the purified gas, generally between 5% and 20% of the flow of feed gas. The desorption gas containing a large amount of mercaptans then has to be treated prior to being recycled, for example by washing with a basic solution (soda or potash), with well-known limitations due to the low solubility of the mercaptans in an aqueous solution. The pressure is either maintained substantially constant throughout the cycle, or lowered during the regeneration stage so as to favour regeneration. At the outlet of this adsorption purification stage, the gas meets the total sulfur specifications.
The drawback of these adsorption sieves partly lies in the co-adsorption of water on the sieve. Furthermore, these methods are generally penalized by the production of a mercaptan-rich gaseous effluent which also has to be processed.
Besides, there are many methods for removing the mercaptans contained in a liquid hydrocarbon phase. Document U.S. Pat. No. 4,029,589 recommends to mix the hydrocarbon cut with halogenides (iodides, bromides . . . ) or complexing agents such as amines, carboxylic acids.
Documents U.S. Pat. No. 4,207,173 and U.S. Pat. No. 4,490,246 use a phthalocyanine-based catalyst in the presence of base and oxygen. The base used is tetra-alkylguanidine for converting the mercaptans to disulfides.
Similarly, document U.S. Pat. No. 4,383,916 uses an oxide catalyst in the presence of methanol for eliminating the mercaptans. Documents U.S. Pat. No. 4,459,205 and U.S. Pat. No. 4,466,906 use a metallic complex of polyaminoalkylpolycarboxylic acid deposited on an ion-exchange resin for converting the mercaptans to disulfides. Document U.S. Pat. No. 4,514,286 proposes using peroxides of hydroxide and cumene hydroperoxide type in the presence of amine.
Furthermore, document U.S. Pat. No. 4,794,097 discloses a method based on a catalyst obtained by combustion of wool on which cobalt phthalocyanine is deposited.
There are many techniques in this field, most of them based on oxidation of the mercaptans to disulfides according to the following reaction in the presence of a base:
R1SH+R2SH+½O2→R1S—SR2+H2O
where R1 and R2 are hydrocarbon chains.
The present invention provides a new technique for removing the mercaptans contained in a gaseous feed. In general terms, the mercaptan-laden gaseous effluent is contacted with a liquid feed containing olefins, in the presence of an acid catalyst. Under suitable conditions, the mercaptans are absorbed in the liquid feed and react with the olefins to form sulfides and not disulfides, soluble in the solvent. A solvent regeneration stage allows the collecting agent to be recycled.
In general terms, the present invention relates to a method of collecting the mercaptans contained in a gaseous feed, wherein the feed is contacted with a solvent comprising olefins and an acid catalyst so that the mercaptans are absorbed by the solvent and react with the olefins contained in the solvent to form sulfides, then the mercaptan-depleted gaseous feed is discharged.
According to the invention, the solvent is contacted with the feed at a relative pressure ranging between 1 bar and 200 bars, preferably between 5 bars and 150 bars, more preferably between 10 bars and 100 bars, and at a temperature ranging between 0° C. and 200° C., preferably between 20° C. and 150° C., more preferably between 40° C. and 120° C.
The catalyst can comprise at least one of the following compounds: phosphoric acid, sulfuric acid, boric acid, sulfonic acid, nitric acid, carboxylic acid, a faujasite, a mordenite, a zeolite, a fluorinated alumina, a chlorinated alumina, a natural clay, a synthetic clay.
The solvent can comprise between 0.001% and 100% olefins, preferably between 0.01% and 50%, the olefins comprising three to twenty carbon atoms, preferably between five and fifteen carbon atoms, more preferably between eight and fourteen carbon atoms, ideally between ten and twelve carbon atoms. The solvent can further comprise hydrocarbons with more than eight carbon atoms.
According to the invention, the sulfide-laden solvent can be discharged. The sulfide-laden solvent can be expanded so as to release elements co-absorbed upon contacting of the feed with the solvent. Furthermore, the sulfide-laden solvent can be distilled so as to release elements co-absorbed upon contacting of the feed with the solvent.
The sulfide-laden solvent can be incinerated.
The sulfide-laden solvent can be regenerated by hydrotreating, then at least part of the regenerated solvent is recycled by being contacted with the gaseous feed.
The sulfide-laden solvent can be regenerated by cracking, the solvent being contacted, at a temperature above 100° C., with an acid catalyst, then at least part of the regenerated solvent is recycled by contacting with the gaseous feed.
The method according to the invention allows a natural gas comprising mercaptans to be processed.
Other features and advantages of the invention will be clear from reading the description hereafter, with reference to the accompanying figures wherein:
In
The gaseous feed flowing in through line 1 is contacted in contacting zone ZA with a liquid solvent flowing in through line 2. The solvent comprises between 0.001% and 100% by weight of a liquid olefin having between three and twenty carbon atoms, preferably between five and fifteen carbon atoms. Contacting in zone ZA is carried out in the presence of an acid catalyst.
In zone ZA, the gaseous mercaptans are absorbed by the liquid solvent and react with the olefins in the presence of the acid catalyst so as to form a sulfide.
The chemical reaction carried out in zone ZA can be:
This addition reaction is not modified by the length of the alkyl chain of the mercaptan or the number of carbon atoms of the hydrocarbon chain of the olefin.
The sulfides formed solubilize in the liquid solvent, under suitable operating conditions. For example, according to the reaction described above, at atmospheric pressure, the methylmercaptan whose boiling point is 6.2° C. adds to methyl-2-butene-2 (boiling point 38.6° C.) so as to form a sulfide whose boiling point ranges between 130° C. and 140° C.
The purified gaseous feed, i.e. comprising no or little mercaptans, is discharged from zone ZA through line 3. The solvent laden with reaction product, i.e. sulfide, is discharged through line 4.
Gas-liquid contact between the mercaptan-laden gaseous feed and the olefin-containing liquid solvent, in the presence of a catalyst, simultaneously guarantees absorption of the mercaptan by the solvent and its reaction with the olefin present in this solvent. During contact, the mercaptans present in the gaseous feed solubilize in the solvent. The solubility of the mercaptan increases with its molecular mass, which allows to ensure elimination of the mercaptans comprising more than two carbon atoms, that are generally difficult to remove by means of the conventional caustic washing techniques used for processing liquid cuts from natural gas fractionation. The chemical reaction between the mercaptans and the olefin present in the solvent displaces the solubility equilibrium so as to absorb and to cause all the mercaptans present in the gaseous effluent to be desulfurized to react.
The acid catalyst allows to promote the addition reaction performed in zone ZA. The acid catalyst can consist of phosphoric, sulfuric, boric, sulfonic, nitric acids. These acids can come in liquid form in the aqueous phase or in form of ionic liquids or of molten salts. These acids can be supported on solid supports made of silica, alumina, or silica-alumina, or any other solid support. Acid catalysts such as natural or synthetic zeolites can also be used for implementing the present invention. By way of example, faujasites, mordenites, zeolites, X and Y for example, can be mentioned. Other acid solids can be used, such as fluorinated or chlorinated aluminas, natural or synthetic clays. Any catalyst form can be used for implementing the invention.
The acid catalyst can be in solution in the liquid solvent. The catalyst in solid form can be fixed to gas-liquid distribution elements of zone ZA (distribution plates, column packing) or it can be used as packing itself.
The olefins making up the liquid solvent comprise at least three carbon atoms. In order to limit losses by entrainment in the gaseous effluent, the olefins preferably have more than five carbon atoms, ideally more than eight. The olefins can be linear or branched. These olefins preferably have a single double bond. However, diolefins can be used if necessary rather than olefins. These olefins can be used pure, in admixture or diluted in a mixture of hydrocarbons having at least eight carbon atoms. Preferably, these hydrocarbons and the olefin used have a carbon chain of equal length, and the standard boiling-point temperatures of the former do not differ by more than 30° C. from that of the olefin.
The solvent flowing in through line 2 can come from processing and regeneration unit RE through line 7 and/or from an olefin reserve through line 8.
In zone ZA, gas-liquid contact is achieved under the thermodynamic conditions of availability of the gaseous effluent. In the case of a natural gas from a deacidizing unit, gas-liquid contacting can be carried out at a pressure ranging between 10 and 100 bars, and at a temperature ranging between 0° C. and 100° C., preferably between 20° C. and 60° C. Processing of other gaseous effluents such as synthesis gases can be performed under pressure conditions ranging between 1 and 100 bars, and temperatures ranging between 20° C. and 100° C.
Contact between the catalyst, the gaseous feed to be processed and the liquid solvent can be achieved in many ways.
For example, zone ZA can be a reactor, shown in
Zone ZA can also be a gas-liquid contactor of washing column CL type as shown in
Contacting in zone ZA can be carried out by means of any other equipment or technique known to the man skilled in the art.
Various known plate or packing geometries can be used. The contacting methods and the catalytic packings generally used in reactive distillation operations are suited to the invention. By way of example, we can mention the MULTIPAK or KATAPAK type catalytic packings described by Kolodziej et al. (Catalysis Today 2001, 69, p. 75). Alternatively, it is also possible to use monolith packings insofar as the flow rates of the phases to be contacted can be adjusted in order to reach in the channels the Taylor flow regime for which transfer of the mercaptans from the gas phase to be processed to the solvent is optimized.
The chemical reaction between the mercaptans and the olefins being a balanced reaction, control of the mercaptan content of the treated gaseous effluent allows to control the efficiency of the mercaptan collection by the olefins. A detector for measuring the mercaptan content in the purified gaseous feed discharged through line 3 can be installed, for example in zone ZA or on line 3. The operating conditions in zone ZA can be modified according to the measured mercaptan content, for example the solvent or gaseous feed flow rate can be adjusted, or the amount of catalyst, the pressure and temperature conditions can be changed in order to best achieve the addition reaction of the mercaptans with the olefins.
The method allows to convert mercaptans (gaseous and toxic compounds) to sulfides (non-toxic liquid compounds). The used solvent thus obtained through line 4 can be processed in different ways according to the production site availabilities. If the size of the site (offshore platform) does not allow processing on the spot, the solvent can be readily transported in barrels by ship to a reprocessing site.
In
For example, expansion is carried out in one or two flash drums, at pressures ranging between 10 bars and 70 bars.
The distillation stage allows to concentrate at the column bottom the sulfides whose boiling-point temperature is higher than that of the other constituents of the used solvent. Distillation can be performed according to the process diagrammatically shown in
The elements released in gaseous form in unit C are discharged through line 5.
During the regeneration stage as described above, contacting the olefin-rich solvent with a catalyst of acid nature at high temperature can lead to an olefin loss due to an oligomerization reaction of these compounds. The fraction of olefins lost by oligomerization depends on the temperature conditions of the cracking section, on the nature of the catalyst, on the residence time of the olefins in this section, and therefore on the technology chosen for this section.
These oligomers are characterized by a higher boiling-point temperature than that of the other solvent compounds, i.e. mainly the olefins selected for collecting the mercaptans or the sulfides formed during the reaction in zone ZA, or possibly the hydrocarbons co-absorbed in ZA if section C is not used.
Separation of these oligomers can be achieved by distillation of the effluent from regeneration section RE. The operation can be carried out on all of the solvent recycled through line 7. It is preferably performed on a fraction of the stream taken from line 7.
During distillation, the compounds resulting from the oligomerization reaction and the sulfides that have not been cracked in RE concentrate at the bottom of the distillation column. The olefin-containing solvent is recovered at the top of the column and recycled to section ZA. The temperature and pressure conditions in this column are conditioned by the nature of the solvent and of the olefin used in the method.
Various by-products resulting from side reactions such as the oligomerization reactions can lead to the formation of heavy compounds. These reactions can occur in section ZA but they generally remain trivial because they are favoured by temperature. A solvent regeneration approach by thermal equilibrium displacement could favour these reactions. According to the installation configuration, these heavy products can accumulate in the solvent. In the case of the distillation of the solvent from section ZA described above, these heavy products are concentrated at the bottom of distillation column D and discharged with the sulfides.
The solvent processed in unit C is discharged through line 6 to be fed into regeneration or processing zone RE. In zone RE, various techniques can be used for processing or regenerating the used solvent.
For example, in zone RE, the used solvent flowing in through line 6 can be incinerated in refinery heaters. Thus, the sulfides are converted to sulfur oxides which are eliminated from the fumes through various conventional means.
Alternatively, zone RE can use a hydrotreating process diagrammatically shown in
The hydrotreating process diagrammatically shown in
The reaction products obtained in line 11 at the outlet of reactor R2 are:
The liquid and gaseous fractions are separated in drum B1. The gaseous fraction is discharged through line 9. The liquid fraction is discharged through line 7, and it can be recycled by being sent through line 2 to zone ZA. Preferably, only part of the liquid fraction is discharged through line 7 to be recycled to zone ZA through line 2, the other part being ejected. An olefin supply through line 8 to zone ZA allows part of the olefin to be regularly replaced.
Alternatively, zone RE can use a sulfide cracking operation, this operation being diagrammatically shown in
The used solvent flowing in through line 6 is contacted with an acid catalyst in reactor R3 at high temperature, for example at a temperature above 100° C. Reactor R3 can be heated and/or the used solvent can be heated prior to being fed into reactor R3.
The catalyst can consist of phosphoric, sulfuric, boric, sulfonic, nitric acids. These acids can come in form of ionic liquids or of molten salts. These acids can be supported on solid supports such as silicas, aluminas, or silica-aluminas, or any other solid support. Acid catalysts such as natural or synthetic zeolites can be used. By way of example, faujasites, mordenites, X and Y zeolites can be mentioned. Other acid solids can be used, such as fluorinated or chlorinated aluminas, natural or synthetic clays. The solid catalyst can have any geometrical shape.
The temperature in cracking reactor R3 can range between 100° C. and 500° C., preferably between 120° C. and 400° C., and more preferably between 150° C. and 350° C. The ratio of the volume flow rate of feed flowing in through line 6 to the volume of catalyst in reactor R3 ranges between 0.01 m3/m3/h and 20 m3/m3/h, preferably between 0.1 m3/m3/h and 10 m3/m3/h. The pressure in reactor R3 is so adjusted that the feed is at the minimum 60% in the liquid phase at the catalytic zone inlet, and preferably 90% in the liquid phase.
The cracking operation generates two fractions that are separated in drum B2:
The cracking operation in zone RE can be carried out by means of a distillation operation diagrammatically shown in
The mercaptan collection method according to the invention can be used in a natural gas processing chain. In
Alternatively, mercaptan removal unit RM can be arranged downstream from dehydration unit DH. In this case, the natural gas is subjected, in order, to the following treatments: deacidizing, dehydration, mercaptan removal and gasoline extraction.
The examples given hereafter are intended to illustrate the invention but they are in no way limitative. These examples show that the present invention allows to remove the mercaptans from a gaseous cut, that this method works whatever the length of the alkyl chain, and that it is definitely possible to regenerate the solvent under suitable conditions.
The experiment was carried out using a reactor as shown in
A second experiment was carried out with the same experimental device as in example 1, i.e. the reactor of
The reaction being balanced, example 3 was carried out to show the regenerability of the solvent. The used solvent, i.e. laden with sulfides from the methylmercaptan and dodecene reaction, is fed with the catalyst into a drum. The used solvent is obtained upon stabilization of the system described in example 1. Heating to 100° C. of the used solvent in the drum leads to invert the reaction and to reform the methylmercaptan which desorbs solvent. The temperature rise up to 120° C. allows to facilitate regeneration of the solvent. 90% of the sulfur compounds present in the solvent are eliminated in gaseous form during this test.
The experimental device used in this example is substantially identical to washing column CL of
Under such conditions, the butylmercaptan elimination is about 99%.
The experimental device used in this example is substantially identical to the washing column of
Under such conditions, the butylmercaptan elimination is about 93%.
The experimentation was continued in order to examine the stability of this system. The results of the butylmercaptan elimination as a function of time are given in the table hereafter:
Consequently, example 5 shows that the catalyst is not deactivated in the course of time. This allows the mercaptans to be eliminated in a stable and efficient manner in the course of time.
| Number | Date | Country | Kind |
|---|---|---|---|
| 04 08548 | Aug 2004 | FR | national |
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| Number | Date | Country | |
|---|---|---|---|
| 20060034742 A1 | Feb 2006 | US |
