Evaluation of the maximum yields of synthetic petroleum and methane in coal conversion processes

A procedure for the calculation of minimum consumptions of coals of different ranks for the production of liquid motor fuels and methane from them by direct hydrogenation and gasification followed by the Fischer-Tropsch synthesis is proposed. This procedure takes into account the composition of the initial coal, the degree of conversion of its organic matter into a mixture of CO + H₂, and the H₂/CO ratio in this mixture. As an example of its application, the yields of liquid motor fuel and methane from brown and black coals (D, G, and SS) from a number of deposits, which are of interest for performing these processes, were calculated.     

煤层气经合成气制液体燃料的关键技术

介绍了煤层气、煤矿瓦斯抽放气的治理和利用现状及存在的问题,同时讨论了煤层气制取液体燃料的重要性及其关键技术,并对其发展前景进行了展望。煤层气经合成气制取液体燃料的可移动装置将成为分散的煤层气转化利用的主要途径,紧凑造气技术与微通道反应器合成技术是提高效率并实现移动转化装置的关键。     

Tri-reforming of CH4 using CO2 for production of synthesis gas to dimethyl ether

In general, there are three processes for production of synthesis gas; steam reforming, CO₂ reforming and partial oxidation of methane or natural gas. In the present work, we refer to tri-reforming of methane to synthesize syngas with desirable H₂/CO ratios by simultaneous oxy-CO₂-steam reforming of methane. In this study, we report the results obtained on tri-reforming of methane over the Ni/ZrO₂ based catalyst in order to restrain the carbon deposition and to evaluate the catalytic performance. Results of tri-reforming of CH₄ by three catalysts (Ni/Ce–ZrO₂, Ni/ZrO₂ and Haldor Topsoe R67-7H) are showed that the coke on the reactor wall and the surface of catalyst were reduced dramatically. It was found that the weak acidic site, basic site and redox ability of Ce–ZrO₂ play an important role in tri-reforming of methane conversion. Carbon deposition depends not only on the nature of support, but also on the oxidant as like steam or oxygen. Therefore, the process optimization by reactant ratios is important to manufacture the synthesis gas from natural gas and carbon dioxide.     

ALTERNATIVE GENERATION OF H2, CO AND H2, CO2 MIXTURES FROM STEAM-CARBON DIOXIDE REFORMING OF METHANE AND THE WATER GAS SHIFT WITH PERMEABLE (MEMBRANE) REACTORS

A new process is proposed which converts CO₂ and CH₄ containing gas streams to synthesis gas, a mixture of CO and H₂ via the catalytic reaction scheme of steam-carbon dioxide reforming of methane or the respective one of only carbon dioxide reforming of methane, in permeable (membrane) reactors. The membrane reformer (permreactor) can be made by reactive or inert materials such as metal alloys, microporous ceramics, glasses and composites which all are hydrogen permselective. The rejected CO reacts with steam and converted catalytically to CO₂ and H₂ via the water gas shift in a consecutive permreactor made by similar to the reformer materials and alternatively by high glass transition temperature polymers. Both permreactors can recover H₂ in permeate by using metal membranes, and H₂ rich mixtures by using ceramic, glass and composite type permselective membranes. H₂ and CO₂ can be recovered simultaneously in water gas shift step after steam condensation by using organic polymer membranes. Product yields are increased through permreactor equilibrium shift and reaction separation process integration.

CO and H₂ can be combined in first step to be used for chemical synthesis or as fuel in power generation cycles. Mixtures of CO₂ and H₂ in second step can be used for synthesis as well (e.g., alternative methanol synthesis) and as direct feed in molten carbonate fuel cells. Pure H₂ from the above processes can be used also for synthesis or as fuel in power systems and fuel cells. The overall process can be considered environmentally benign because it offers an in-situ abatement of the greenhouse CO₂ and CH₄ gases and related hydrocarbon-CO₂ feedstocks (e.g., coal, landfill, natural, flue gases), through chemical reactions, to the upgraded calorific value synthesis gas and H₂, H₂ mixture products.     

Plasma methane conversion using dielectric-barrier discharges with zeolite A

Experimental investigation on plasma methane conversion in the presence of carbon dioxide using dielectric-barrier discharges (DBDs) has been conducted. Zeolite A has been applied to inhibit the formation of carbon black and plasma-polymerized film during such plasma methane conversion. A co-generation of syngas, light hydrocarbons and liquid fuels has been achieved. The conversions and selectivities are determined by the CH₄/CO₂ feed ratio, residence time and input power. Compared to the use of zeolite X within the DBDs, plasma methane conversion with zeolite A leads to a higher selectivity of light hydrocarbons (C₂–C₄).     

Oxidative Coupling of Methane to Higher Hydrocarbons

Natural gas is an abundant resource in various parts of the world. Methane is the major component of natural gas, often comprising over 90 mol% of the hydrocarbon fraction of the gas. Methane itself is primarily used as a fuel, while the nonmethane components can be separated and used as feedstocks for the production of chemicals or liquid fuels. In many cases, however, natural gas reserves are found in locations distant from their place of utilization. Since it is not generally economical to transport liquefied natural gas, efficient methods are needed to convert methane into transportable liquid products. A possible route is oxidative dimerization of methane followed by oligomer-ization of the C₂ products.     

Catalytic hydrogen transfer due to FeSO4 and Co&z.sbnd;Mo in coal liquefaction

The liquefaction behaviour of a Kentucky coal was studied in batch autoclave experiments at 410 °C under either a H₂ or a N₂ atmosphere (≈ 13.8 MPa) for reaction times of up to 2 h. To understand the catalytic roles of FeSO₄ and a Co&z.sbnd;Mo catalyst in coal liquefaction and to assess the feasibility of using FeSO₄ as a model for coal pyrites, effects of impregnation of the coal with FeSO₄ and direct charges of a Co&z.sbnd;Mo catalyst on coal liquefaction and tetralin dehydrogenation were examined. Both catalysts increase the conversion to benzene-soluble material by 7–10%, and improve the selectivity values for conversion to oil and gas. In addition they are also active in the dehydrogenation of tetralin. The dehydrogenation activities of these catalysts correlate with their catalytic activities during coal liquefaction. Analyses of the mean chemical structures and the product distributions of the coal-derived liquid from liquefaction in H₂ and in N₂ atmospheres indicate that:

1. (1) H-transfer from tetralin is the only major mechanism of coal liquefaction; and

2. (2) both pyrrhotite, generated in-situ from FeSO₄, and Co&z.sbnd; Mo catalyst can provide a major liquefaction mechanism by catalysing the H-transfer from the donor solvent to the coal or the coal-derived liquid.

     

The Catalytic Synthesis of Hydrocarbons from Carbon Monoxide and Hydrogen

The increasing demand for energy, coupled with the uncertainty and expense of crude oil imports, has renewed interest in the production of fuels and chemicals from hydrogen-deficient materials. These energy sources such as coal, residua, oil shale, and tar sands can be gasified with steam and oxygen to produce a gas containing large quantities of carbon monoxide and hydrogen. Once methane is removed from this CO/H₂ mixture it is purified to remove S poisons and then reacted over a catalyst to produce a variety of organic products. The synthesis of hydrocarbon products, with the exception of methane, is commonly referred to as the Fischer-Tropsch synthesis reaction.     

褐煤热解-气化-制油系统的CO2减排策略

褐煤热解-气化-制油系统是现代煤化工发展的一个重要研究内容。来自系统多个单元产生的CH₄和CO₂如果发生重整反应,将重整得到H₂/CO比值较高的合成气添加到制油流程中,可实现更多的C被固定到产品中而减少CO₂的直接排放量。对CH₄-CO₂和CH₄-H₂O两种重整反应方式、来自煤热解和费托合成两股甲烷气和典型的干粉气化和水煤浆气化两种流程进行了组合研究。分析结果显示,来自热解和费托合成的甲烷重整后不足以提供调节合成气H₂/CO比例所需的氢气,水煤气变换反应对于褐煤制油系统来说是必需的。从C转化成油的角度来看,采用干粉气化和CH₄-H₂O重整的方案是较好的选择。     

Partial oxidation of methane to synthesis gas over iridium–nickel bimetallic catalysts

Partial oxidation of methane to synthesis gas was carried out using supported iridium–nickel bimetallic catalysts, in order to reduce loading levels of iridium and nickel, and to avoid carbon deposition on nickel-based catalysts by adding iridium. The performance of supported iridium–nickel bimetallic catalysts in synthesis gas formation depended strongly upon the support materials. La₂O₃ gave the best performance among the support materials tested. Ir(0.25 wt%)–Ni(0.5 wt%)/La₂O₃ afforded 36% conversion of methane (CH₄/O₂=5) to give CO and H₂ with the selectivities of above 90% at 800°C, and those at 600°C were 25.3% conversion of methane and CO and H₂ selectivities of about 80%, respectively. Reduced monometallic Ir(0.25 wt%)/La₂O₃ and Ni(0.5 wt%)/La₂O₃ catalysts did not produce synthesis gas at 600°C. A higher conversion of methane was obtained by synergistic effects. The product concentrations of CO, H₂, and CO₂, and CH₄ conversion were maintained in high values, even increasing the space velocity of feed gas over Ir–Ni/La₂O₃ catalyst, indicating that rapid reaction takes place. As a by-product, a small amount of carbon deposition was observed, but carbon formation decreased with increasing the space velocity. On the other hand, with reduced monometallic Ni(10 wt%)/La₂O₃ catalyst, yield of synthesis gas and carbon decreased with increasing the space velocity.     

煤直接转化制高品质液体燃料和化学品

介绍了国家重点研发计划项目“低变质煤直接转化制高品质液体燃料和化学品的基础研究”的背景、研究现状以及研究任务与目标。研究工作可望在深入认识低变质煤中矿物特性和弱键合结构以及分子水平反应规律、直接转化过程反应途径、产物调控机制及定向催化转化原理;构建高品质和高产率油气的煤热解新反应器、煤加氢液化富产芳烃新工艺、高性能喷气燃料及化学品制备的高效催化剂以及新技术等方面取得突破,从而完善低变质煤直接转化制取高品质液体燃料及化学品的工艺技术体系。     

Partial oxidation of CH4 and C2H6 over noble metalcoated monoliths

The direct partial oxidation of hydrocarbons offers promising alternatives to chemical synthesis. By replacing endothermic processes such as steam reforming and steam cracking, fast and exothermic oxidation reactions should require much smaller and simpler reactors. However, direct oxidation reactions are much more difficult to manage because of potential heat release in total oxidation and hazardous because of the possibility of homogeneous reactions which are nonselective and can produce flames and explosions. We describe experiments in which monolith catalysts are used for partial oxidation of CH₄ and C₂H₆ to produce synthesis gas or alkenes by direct oxidation at or above atmospheric pressure in pure O₂ in nearly adiabatic reactors operating at 1000°C with very high flowrates (space velocities of 10⁶h⁻¹ and residence times of 10⁻³ s). With methane oxidation we obtain over 90% selectivities to synthesis gas (a 2:1 H₂:CO mixture) with> 90% conversion of the methane and complete conversion of O₂ on Rh coated ceramic monoliths with contact times of 10⁻³ s. With Pt catalysts under the same conditions, the H₂ selectivity drops to 70%; while with Pd, the catalyst rapidly forms carbon. This process appears to be primarily a surface reaction in which CH4 pyrolyzes on the hot Rh surface and the H atoms dimerize and the carbon is oxidized to CO. A model has been constructed which accurately predicts the conversions and selectivities and the variations between Rh and Pt. With higher alkanes, synthesis gas is produced on Rh with comparable selectivities and conversions on metal-coated monoliths. However, with Pt we observe up to 70% selectivity to alkenes with 80% conversion of alkanes at adiabatic temperatures near 1000°C with approximately 5 ms contact times. These results can be explained as occurring by predominantly surface reactions in which the alkane adsorbs to form the alkyl by H abstraction with adsorbed O atoms. Then the adsorbed alkyls undergo primarily β-elimination reactions on Pt to produce alkenes. These products are therefore far from thermodynamic equilibrium at these very short contact times, even though the temperatures are very high. The use of very short contact times and high temperatures promises to provide new routes to production of partial oxidation products with very small adiabatic reactors and thus opens up new types of reactions and reactors for chemical synthesis.     

铁基移动床化学链技术进展

在日益增长的能源需求与日益严峻的全球气候变化带来的双重压力下,清洁、高效且经济的能源利用方法显得尤为重要。将化学链概念用于传统化石能源的转化是一种前景广阔的新技术。化学链燃烧利用载氧体间接转化含碳燃料,同时实现二氧化碳的捕集。俄亥俄州立大学研发了采用铁基载氧体和移动床反应器的化学链技术,可实现天然气、煤、生物质等多种燃料向电力、氢、液体燃料等产品的零排放转化。目前,合成气化学链（syngas chemical looping,SCL）和煤直接化学链（coal direct chemical looping,CDCL）技术两套25 kW_th级小试装置已成功运行总计超过850 h,一套250 kW_th级的高压SCL装置即将投入示范运行。     

气煤联供实现资源高效利用和碳减排技术进展

为解决煤化工过程资源利用率低和碳排放高的问题,有研究者提出以天然气、焦炉气、页岩气等富氢资源和煤炭资源联供方案,旨在实现源头碳减排。文章指出依据联供过程技术的差异,较有代表性的方案可分为集成甲烷部分氧化和集成甲烷干/水蒸气重整的气煤联供过程。文章以生产甲醇为例,从资源利用和经济效益等方面对集成甲烷部分氧化和集成甲烷干/水蒸气重整的气煤联供过程进行分析和比较。集成甲烷部分氧化的工艺碳元素利用率达到57.9%,每吨甲醇排放CO₂为1.50t,较传统煤制甲醇工艺排放减少37.5%。甲醇产品成本稍低于传统工艺。集成甲烷干/水蒸气重整工艺的碳元素利用率最高,达到83.7%。减排效果最明显,每吨甲醇排放CO₂为0.90t,较传统工艺排放减少62.5%,但是由于CO₂转化增加能耗,甲醇产品成本有所提升。由于气煤联供过程有利于CO₂减排,当碳税高于65CNY/tCO₂时,两个气煤联供工艺的生产成本低于传统的煤制甲醇工艺。     

CO2合成醇酯类化学品和高分子材料研究进展

我国作为煤炭大国,燃烧化石燃料产生大量CO₂。通过化学作用将CO₂转化为能源燃料、基础化学品或高分子材料,有利于实现碳氧资源综合利用。从CO₂直接利用和间接利用的角度出发,分别综述了CO₂资源化利用研究进展。直接利用方面,重点阐述了CO₂直接加氢合成甲醇和乙醇;同时CO₂可作为羰化剂合成有机碳酸酯和高分子材料,包括碳酸二乙酯、聚碳酸酯和CO₂基可降解聚合物。在间接利用方面,重点综述了CO₂经碳酸乙烯酯的酯交换反应合成碳酸二甲酯,以及碳酸乙烯酯加氢制备甲醇联产乙二醇的研究进展。CO₂加氢直接合成甲醇催化剂主要包括铜基催化剂、贵金属催化剂,由于贵金属的成本高,廉价的Cu基催化剂研究较为广泛。CO₂加氢直接合成乙醇研究较广泛的催化剂为贵金属(Rh、Pd、Ru)基催化剂体系,还需进一步研究廉价、高活性和高稳定性的催化剂。CO₂与乙醇直接合成碳酸二乙酯(DEC)研究较多的催化剂为铈基多相催化剂,但由于生成物中水分的影响,限制了DEC的收率。环氧化物和CO₂耦合反应生成DEC过程中不产生水,可以有效克服热力学的限制,因此高能化合物与CO₂的耦合路线是高效制备DEC的有效途径。CO₂与环氧化物共聚制备聚碳酸酯材料多采用稀土三元催化剂体系,环氧化物的转化率和聚碳酸酯选择性较高,目前已经实现工业应用。CO₂通过碳酸乙烯酯与甲醇酯交换合成DMC,多使用碱性较强的催化剂和含碱性基团的离子交换树脂。CO₂经碳酸乙烯酯加氢制备甲醇和乙二醇的反应中,铜基催化剂展现出优异的催化性能。CO₂化学转化利用是CO₂碳氧资源综合利用的重要途径,将有效支撑我国未来碳中和目标实现。     

Production of synthesis gas

The state-of-the-art for the production of synthesis gas from the steam reforming of methane is reviewed and discussed. Particular attention is given to the design of the tubular reformer and carbon formation on the nickel catalyst. Improvements in syngas technology are discussed, including: CO₂ reforming, autothermal reforming and heat exchange reforming, and the energy efficiencies of direct and indirect methane conversion are compared and contrasted.     

Simulation of partial oxidation of natural gas to synthesis gas using ASPEN PLUS

Conversion of natural gas to liquid fuels is a challenging issue. In SMDS process natural gas is first partially oxidized with pure oxygen to synthesis gas (a mixture of H₂ and CO) which is then converted to high quality liquid transportation fuels by utilizing a modernized version of the Fischer-Tropsch reaction. This paper presents a computer simulation of the first stage of the process, i.e. the synthesis gas production from natural gas. ASPEN PLUS equipped with a combustion databank was used for calculations. Concentrations of over 30 combustion species and radicals expected in the synthesis gas have been calculated at equilibrium and several non-equilibrium conditions. Using a sensitivity analysis tool, the relative feed flow rates and reactor parameters have been varied searching to maximize the CO/O₂ yield as well as to minimize the undesired nitrogen compounds in the product stream. The optimum reactor temperature for maximizing the CO mole fraction in the synthesis gas was also calculated.     

CO/CO2加氢高选择性合成化学品和液体燃料

一氧化碳/二氧化碳（CO/CO₂）转化利用是碳一化学与CO₂捕集利用中的重要环节,也是当今碳资源的非石油路线利用最具挑战性的方向之一。CO₂的高效活化与定向转化是CO₂利用过程中的关键问题,而CO加氢转化最大的瓶颈问题为如何有效控制C-O键的活化、C—C键的形成、碳链增长及终止。本文主要综述 CO/CO₂加氢高选择性合成重要化工原料低碳烯烃（C₂ ⁼～C₄ ⁼）以及一步高效合成汽油馏分（C₅～C₁₁）等方面取得的突破性进展。目前,CO/CO₂加氢主要经过费托合成与氧化物/分子筛双功能两条路线合成低碳烯烃与汽油燃料。针对费托合成C₂ ⁼～C₄ ⁼,分析表明棱柱状碳化钴得到的烃类产物分布可以显著突破Anderson-Schulz-Flory（ASF）分布的限制,而分子筛已被广泛用于构建双功能费托催化剂,由于酸性分子筛具有加氢裂化、低聚与异构化等功能,使得CO/CO₂还可以直接高选择性地转化为C₅～C₁₁烃类。另一方面,将可以活化CO或CO₂到甲醇的可还原型氧化物与具有C—C偶联功能的SAPO-34或HZSM-5分子筛进行耦合,也可以实现CO/CO₂加氢一步合成低碳烯烃或汽油且具有非常优异的选择性和高转化率。今后,借鉴纳米合成领域新方法,使产物分布打破经典ASF限制,最大限度地提高目标烃类化合物的选择性并显著减少甲烷的生成是研究关键。     

Catalytic conversion of methane to more useful chemicals and fuels: a challenge for the 21st century

The very large reserves of methane, which often are found in remote regions, could serve as a feedstock for the production of chemicals and as a source of energy well into the 21st century. Although methane currently is being used in such important applications as the heating of homes and the generation of hydrogen for ammonia synthesis, its potential for the production of ethylene or liquid hydrocarbon fuels has not been fully realized. A number of strategies are being explored at levels that range from fundamental science to engineering technology. These include: (a) stream and carbon dioxide reforming or partial oxidation of methane to form carbon monoxide and hydrogen, followed by Fischer–Tropsch chemistry, (b) the direct oxidation of methane to methanol and formaldehyde, (c) oxidative coupling of methane to ethylene, and (d) direct conversion to aromatics and hydrogen in the absence of oxygen. Each alternative has its own set of limitations; however, economical separation is common to all with the most important issues being the separation of oxygen from air and the separation of hydrogen or hydrocarbons from dilute product streams. Extensive utilization of methane for the production of fuels and chemicals appears to be near, but current economic uncertainties limit the amount of research activity and the implementation of emerging technologies.     

不同CO2捕集技术的CO2耦合绿氢制甲醇工艺研究

大量的化石燃料燃烧导致温室气体排放增加,全球气候变暖。世界各国以全球协约的方式减排CO₂,我国也由此提出“碳达峰·碳中和”目标。CO₂捕集以及转化制液体燃料和化学品是双碳目标下行之有效的碳减排措施之一,不仅可以实现CO₂的资源化利用,同时也缓解了国家能源安全问题。本文以燃煤电厂烟气CO₂捕集和CO₂合成甲醇为研究对象,分析了基于四种不同CO₂捕集技术的CO₂耦合绿氢制甲醇工艺。对四种不同CO₂捕集技术的CO₂制甲醇工艺进行了严格的稳态建模和模拟,分析和比较了不同CO₂捕集技术情景下的CO₂制甲醇工艺的技术和经济性能。结果表明,MEA、PCS、DMC和GMS情景的单位甲醇能耗分别是7.81、5.48、5.91和4.66 GJ/ t CH₃OH,GMS情景的单位能耗最低,其次是PCS情景,但随着更高效相变吸收剂的开发,PCS情景的单位甲醇产品的能耗将降低至2.29~2.58 GJ/t CH₃OH。四种情景的总生产成本分别是4314、4204、4279和4367 CNY/ t CH₃OH,PCS情景的成本最低,更具有经济优势。综合分析表明PCS情景的性能表现最好,为可用于燃煤电厂最佳的碳捕集技术,为CO₂高效合成燃料化学品提供方向,缓解化石燃料短缺和环境污染问题。