结构化多相反应器多尺度传递和加氢脱硫反应性能研究
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摘要
结构化反应器具有压降小、操作范围大、传质性能好、扩散距离短、返混小和催化剂利用效率高等优点，是替代常规多相反应器、强化多相催化反应过程的新反应器形式。
本文以结构化多相反应器强化加氢脱硫过程为背景，采用实验和理论方法在单通道和床层两个尺度上研究结构化多相反应器的传递和加氢脱硫反应性能。
首先，采用计算流体力学的方法研究了毛细管中泰勒流的气液传质及轴向混合特性，结果表明：在整个气液界面上传质系数出现三个峰值，分别位于半球帽顶端、半球帽下方以及液膜处，膜接触时间增加时，液膜处的传质系数降低，而半球帽处传质系数变化较小。采用场协同原则对单元胞内速度场和浓度场进行分析，解释了局部传质特性及强化机理，并给出了分别预测短和长膜接触时间下泰勒流液侧体积传质系数的关联式，该式在较宽的管径尺度范围（0.25-3mm）内的预测效果良好。此外，在Bo数大于10~5时泰勒流的液相返混程度随液栓长度增大略有减小，随液膜长度和气泡速度增大而增大，最后给出了预测轴向扩散准数（VDN）的关联式。
第二，研究了泰勒流下结构化反应器床层压降、持液量和气液传质性能，重点考察了两种不同分布器对床层内流动和气液传质的影响。结果表明：分布器对结构化床层中的压降和持液量有很大影响，相比喷嘴分布器，玻璃珠填充床分布器具有较大的压降和持液量，这主要归因于后者具有较高的气液分散性能。通过对压降和持液量数据的分析，分别给出了相应的预测关联式。床层中的不稳定区对分布器也较敏感，玻璃珠填充床分布器下床层具有更小的不稳定区。在实验的操作条件下，床层内的液侧体积传质系数随液体表观速度增大而增大，随气体表观速度变化的影响较小。玻璃珠填充床分布器下的传质系数高于相同条件下喷嘴分布器下的值。三种不同载体的液侧体积传质系数均与各自的摩擦压降呈现线性关系。对Jepsen的关联式进行了修正，得到的关联式的预测值误差在±30%以内。
第三，采用微电导实验测量了两种不同分布器下结构化反应器床层内不同孔道的气液分布状态。结果表明：床层液体分布均匀性随液体表观速度增大而改善，而对于喷嘴，气速增大可能导致床层出现气体主导的孔道，比较两种分布器可知玻璃珠填充床分布器的液体分布效果更好。通过半经验的分析获得了床层中的液栓长度，比较两种分布器下的液栓长度发现，相同气液条件下，玻璃珠填充床分布器下的液栓长度偏小。建立了全床尺度传质模型预测了整体床层的液侧体积传质系数，结果与实验值偏差大部分在±30%以内。
最后，在温度为300-380°C，压力为3-5MPa的条件下，实验研究了负载Ni_2P/SBA-15的堇青石催化剂上噻吩和二苯并噻吩（DBT）加氢脱硫反应动力学，分别采用Langmuir-Hinshelwood型动力学和一级动力学模型拟合了噻吩和二苯并噻吩加氢脱硫反应的动力学实验数据，比较发现在本文操作条件下Ni-P催化剂的DBT加氢脱硫反应活性与工业上常用的双金属Co-Mo催化剂相当。建立了单通道结构化反应器和滴流床模型，比较了两者加氢脱硫反应性能，结果发现，在处理含相同浓度DBT的物料时结构化反应器的催化剂用量是滴流床的三分之一，但是前者所用的反应器体积更大。而本文提出的两段反应器组合（前段为结构化反应器，后段为滴流床）体积产率和催化剂质量产率均优于滴流床反应器。分布对结构化反应器加氢脱硫反应性能有显著影响，表观气速增大，结构化床层加氢脱硫性能略有降低，表观液速增大，结构化床层加氢脱硫性能改善。相比喷嘴分布器，填充床分布器下床层的加氢脱硫性能更接近均匀分布的情况，在较大液速下，尽管仍然存在液体的不均匀分布，填充床分布器下床层加氢脱硫性能接近单通道模型的计算结果。
Monolithic reactors (MRs) present advantages such as low pressuredrop, uniform flow distribution, enhanced mass transfer, low liquid axialmixing, and high catalyst effectiveness. Therefore, MRs are viewed asnew “process intensification” three-phase reactors to replace theconventionally used trickle beds and slurry bubble columns.
This work aims to intensification of the hydrodesulfurization (HDS)process by using MRs. The transport and HDS performance of MRs werestudied experimentally and theoretically at a single scale and monolithbed scale.
Firstly, the characteristics of liquid side mass transfer and liquidaxial mixing under Taylor flow in capillaries were studied withComputational Fluid Dynamics (CFD) method. Three peak values oflocal mass transfer coefficient were found on bubble surface. Masstransfer coefficient in liquid film decreases with an increase in filmcontact time, whereas that in the caps changes little. Moreover, theprinciple of field synergy was used to explain the characteristics andenhancement of local mass transfer. The results also show that short filmcontact time for the same contact area could enhance the gas-liquid masstransfer under Taylor flow. Empirical correlations were proposed topredict the liquid side volumetric mass transfer coefficients for short andlong film contact time respectively, and the predicted values in capillarieswith diameters of0.25-3mm have a relative error within±20%. To study the liquid axial mixing, the vessel dispersion number (VDN) wasevaluated by using particle tracking method at high Bodenstein numbers.The VDN increases with increasing liquid film length and bubble velocity.An empirical correlation was proposed to predict the vessel dispersionnumber for Bo>10~5.
Secondly, total pressure drop, liquid holdup and gas-liquid masstransfer coefficients in three different monolith packings wereinvestigated experimentally in the Taylor flow regime. The effect ofdistributor design on the flow distribution was investigated using twodifferent types of distributor (nozzle distributor and packed beddistributor with1mm glass beads). A close relation of the distributordesign to the hydrodynamics in monolith beds was observed to exist,evidenced by the larger pressure drop and liquid hold-up values for themonolith packings with the use of the packed bed distributor, whencompared with the nozzle distributor. An analysis of the unstable flowphenomenon characterized by negative pressure drops within bed showsthat the unstable region is not only dependent on the operating conditionsand properties of monolith but also on the distributor design. Empiricalcorrelations of friction factor and liquid hold-up for the three monolithswere proposed. The mass transfer coefficient increases with increasingsuperficial gas or liquid velocities. Moreover, the mass transfercoefficients for these three types of monolith packing show a linearrelation to bed pressure drop. An empirical correlation of mass transfercoefficients based on Jepsen’s correlation was proposed, which has arelative error within±30%.
Thirdly, flow distribution experiments were carried out in a columnwith monolith packings of cell density of50cpsi with two differentdistributors. Liquid saturation in individual channels was measured byusing a self-made micro-conductivity probe. A mal-distribution factor was used to evaluate uniform degree of phase distribution in monoliths.For liquid flow distribution, it is found that the superficial liquid velocityis a crucial factor and the packed bed distributor is better than the nozzledistributor. A semi-theoretical analysis using single channel modelsshows that the packed bed distributor always yields shorter and uniformlydistributed liquid slugs compared to the nozzle distributor, which in turnensures a better mass transfer performance. A bed scale mass transfermodel is proposed by employing the single channel models in individualchannels and incorporating effects of non-uniform liquid distributionalong the bed cross-section. The model predicts the overall gas-liquidmass transfer coefficient with a relative error within±30%.
Finally，reaction kinetics of thiophene and dibenzothiophene (DBT)hydrodesulfurization over Ni_2P/SBA-15/cordierite catalyst wasinvestigated at temperatures of300-380°C and total pressures of3.0-5.0MPa. Comparison studies of the performance of the two types of reactors(the trickle bed and monolithic reactor) were performed by using theLangmuir-Hinshelwood model and the first-order model for fitting thethiophene and DBT experimental data in a batch recycle operation,respectively. It was found that, both the activation energy and the rateconstant over Ni-P monolithic catalyst in the stated operating conditionsare close to those over conventionally used HDS catalysts. The resultsindicat that, the productivity of the monolithic reactor is3times higherthan that of the trickle bed reactor on the catalyst weight basis due to aneffective utilization of the catalyst in the monolithic reactor, but thevolumetric productivity of the monolithic reactor is lower for HDS ofDBT. Here, we proposed two-stage reactors, i.e., a monolithic reactorfollowed by a tickled bed reactor and it was found that, the two-stagereactor outperforms the trickle bed reactor in both reactor volume andcatalyst weight basis. The effect of the flow distribution on HDS performance of the monoliths was discussed. The results show the HDSperformance of the monoliths is improved with the increasing liquidvelocity and decreasing gas velocity and the packed bed distributor isbetter than the nozzle distributor. At high liquid velocity, thoughmal-distribution was observed, the HDS simulation results of themonoliths with packed bed distributor are close to those of the singlechannel with10%decrease.
本文以结构化多相反应器强化加氢脱硫过程为背景，采用实验和理论方法在单通道和床层两个尺度上研究结构化多相反应器的传递和加氢脱硫反应性能。
首先，采用计算流体力学的方法研究了毛细管中泰勒流的气液传质及轴向混合特性，结果表明：在整个气液界面上传质系数出现三个峰值，分别位于半球帽顶端、半球帽下方以及液膜处，膜接触时间增加时，液膜处的传质系数降低，而半球帽处传质系数变化较小。采用场协同原则对单元胞内速度场和浓度场进行分析，解释了局部传质特性及强化机理，并给出了分别预测短和长膜接触时间下泰勒流液侧体积传质系数的关联式，该式在较宽的管径尺度范围（0.25-3mm）内的预测效果良好。此外，在Bo数大于10~5时泰勒流的液相返混程度随液栓长度增大略有减小，随液膜长度和气泡速度增大而增大，最后给出了预测轴向扩散准数（VDN）的关联式。
第二，研究了泰勒流下结构化反应器床层压降、持液量和气液传质性能，重点考察了两种不同分布器对床层内流动和气液传质的影响。结果表明：分布器对结构化床层中的压降和持液量有很大影响，相比喷嘴分布器，玻璃珠填充床分布器具有较大的压降和持液量，这主要归因于后者具有较高的气液分散性能。通过对压降和持液量数据的分析，分别给出了相应的预测关联式。床层中的不稳定区对分布器也较敏感，玻璃珠填充床分布器下床层具有更小的不稳定区。在实验的操作条件下，床层内的液侧体积传质系数随液体表观速度增大而增大，随气体表观速度变化的影响较小。玻璃珠填充床分布器下的传质系数高于相同条件下喷嘴分布器下的值。三种不同载体的液侧体积传质系数均与各自的摩擦压降呈现线性关系。对Jepsen的关联式进行了修正，得到的关联式的预测值误差在±30%以内。
第三，采用微电导实验测量了两种不同分布器下结构化反应器床层内不同孔道的气液分布状态。结果表明：床层液体分布均匀性随液体表观速度增大而改善，而对于喷嘴，气速增大可能导致床层出现气体主导的孔道，比较两种分布器可知玻璃珠填充床分布器的液体分布效果更好。通过半经验的分析获得了床层中的液栓长度，比较两种分布器下的液栓长度发现，相同气液条件下，玻璃珠填充床分布器下的液栓长度偏小。建立了全床尺度传质模型预测了整体床层的液侧体积传质系数，结果与实验值偏差大部分在±30%以内。
最后，在温度为300-380°C，压力为3-5MPa的条件下，实验研究了负载Ni_2P/SBA-15的堇青石催化剂上噻吩和二苯并噻吩（DBT）加氢脱硫反应动力学，分别采用Langmuir-Hinshelwood型动力学和一级动力学模型拟合了噻吩和二苯并噻吩加氢脱硫反应的动力学实验数据，比较发现在本文操作条件下Ni-P催化剂的DBT加氢脱硫反应活性与工业上常用的双金属Co-Mo催化剂相当。建立了单通道结构化反应器和滴流床模型，比较了两者加氢脱硫反应性能，结果发现，在处理含相同浓度DBT的物料时结构化反应器的催化剂用量是滴流床的三分之一，但是前者所用的反应器体积更大。而本文提出的两段反应器组合（前段为结构化反应器，后段为滴流床）体积产率和催化剂质量产率均优于滴流床反应器。分布对结构化反应器加氢脱硫反应性能有显著影响，表观气速增大，结构化床层加氢脱硫性能略有降低，表观液速增大，结构化床层加氢脱硫性能改善。相比喷嘴分布器，填充床分布器下床层的加氢脱硫性能更接近均匀分布的情况，在较大液速下，尽管仍然存在液体的不均匀分布，填充床分布器下床层加氢脱硫性能接近单通道模型的计算结果。
Monolithic reactors (MRs) present advantages such as low pressuredrop, uniform flow distribution, enhanced mass transfer, low liquid axialmixing, and high catalyst effectiveness. Therefore, MRs are viewed asnew “process intensification” three-phase reactors to replace theconventionally used trickle beds and slurry bubble columns.
This work aims to intensification of the hydrodesulfurization (HDS)process by using MRs. The transport and HDS performance of MRs werestudied experimentally and theoretically at a single scale and monolithbed scale.
Firstly, the characteristics of liquid side mass transfer and liquidaxial mixing under Taylor flow in capillaries were studied withComputational Fluid Dynamics (CFD) method. Three peak values oflocal mass transfer coefficient were found on bubble surface. Masstransfer coefficient in liquid film decreases with an increase in filmcontact time, whereas that in the caps changes little. Moreover, theprinciple of field synergy was used to explain the characteristics andenhancement of local mass transfer. The results also show that short filmcontact time for the same contact area could enhance the gas-liquid masstransfer under Taylor flow. Empirical correlations were proposed topredict the liquid side volumetric mass transfer coefficients for short andlong film contact time respectively, and the predicted values in capillarieswith diameters of0.25-3mm have a relative error within±20%. To study the liquid axial mixing, the vessel dispersion number (VDN) wasevaluated by using particle tracking method at high Bodenstein numbers.The VDN increases with increasing liquid film length and bubble velocity.An empirical correlation was proposed to predict the vessel dispersionnumber for Bo>10~5.
Secondly, total pressure drop, liquid holdup and gas-liquid masstransfer coefficients in three different monolith packings wereinvestigated experimentally in the Taylor flow regime. The effect ofdistributor design on the flow distribution was investigated using twodifferent types of distributor (nozzle distributor and packed beddistributor with1mm glass beads). A close relation of the distributordesign to the hydrodynamics in monolith beds was observed to exist,evidenced by the larger pressure drop and liquid hold-up values for themonolith packings with the use of the packed bed distributor, whencompared with the nozzle distributor. An analysis of the unstable flowphenomenon characterized by negative pressure drops within bed showsthat the unstable region is not only dependent on the operating conditionsand properties of monolith but also on the distributor design. Empiricalcorrelations of friction factor and liquid hold-up for the three monolithswere proposed. The mass transfer coefficient increases with increasingsuperficial gas or liquid velocities. Moreover, the mass transfercoefficients for these three types of monolith packing show a linearrelation to bed pressure drop. An empirical correlation of mass transfercoefficients based on Jepsen’s correlation was proposed, which has arelative error within±30%.
Thirdly, flow distribution experiments were carried out in a columnwith monolith packings of cell density of50cpsi with two differentdistributors. Liquid saturation in individual channels was measured byusing a self-made micro-conductivity probe. A mal-distribution factor was used to evaluate uniform degree of phase distribution in monoliths.For liquid flow distribution, it is found that the superficial liquid velocityis a crucial factor and the packed bed distributor is better than the nozzledistributor. A semi-theoretical analysis using single channel modelsshows that the packed bed distributor always yields shorter and uniformlydistributed liquid slugs compared to the nozzle distributor, which in turnensures a better mass transfer performance. A bed scale mass transfermodel is proposed by employing the single channel models in individualchannels and incorporating effects of non-uniform liquid distributionalong the bed cross-section. The model predicts the overall gas-liquidmass transfer coefficient with a relative error within±30%.
Finally，reaction kinetics of thiophene and dibenzothiophene (DBT)hydrodesulfurization over Ni_2P/SBA-15/cordierite catalyst wasinvestigated at temperatures of300-380°C and total pressures of3.0-5.0MPa. Comparison studies of the performance of the two types of reactors(the trickle bed and monolithic reactor) were performed by using theLangmuir-Hinshelwood model and the first-order model for fitting thethiophene and DBT experimental data in a batch recycle operation,respectively. It was found that, both the activation energy and the rateconstant over Ni-P monolithic catalyst in the stated operating conditionsare close to those over conventionally used HDS catalysts. The resultsindicat that, the productivity of the monolithic reactor is3times higherthan that of the trickle bed reactor on the catalyst weight basis due to aneffective utilization of the catalyst in the monolithic reactor, but thevolumetric productivity of the monolithic reactor is lower for HDS ofDBT. Here, we proposed two-stage reactors, i.e., a monolithic reactorfollowed by a tickled bed reactor and it was found that, the two-stagereactor outperforms the trickle bed reactor in both reactor volume andcatalyst weight basis. The effect of the flow distribution on HDS performance of the monoliths was discussed. The results show the HDSperformance of the monoliths is improved with the increasing liquidvelocity and decreasing gas velocity and the packed bed distributor isbetter than the nozzle distributor. At high liquid velocity, thoughmal-distribution was observed, the HDS simulation results of themonoliths with packed bed distributor are close to those of the singlechannel with10%decrease.
引文
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