浆态床反应器中多相分离研究进展

doi:10.16085/j.issn.1000-6613.2024-0670

摘要/Abstract

摘要：

在低温费-托合成浆态床反应器中涉及液态产品与催化剂颗粒的分离、反应器顶部气体中夹带液体（固体）的分离与浆液中催化剂细粉的去除三类多相分离问题，三类问题的有效解决对浆态床反应器的连续、稳定运行至关重要。本文综述了不同分离技术用于解决三类多相分离问题的应用与研究进展。对于液态产品与催化剂颗粒分离，器内过滤是工业装置普遍采用的技术，但存在气体泄漏等问题。器外过滤可避免器内过滤存在的问题，但研究相对欠缺。重力沉降设备的创新及与其他技术的结合可有效缩短分离周期。磁分离与超临界流体萃取因分离精度较高具有潜在优势，但目前研究尚处于实验室阶段。对于气体中夹带液体（固体）分离，主要采用旋风分离器和折流板分离器，根据工业建议，两种设备的组合使用可提升分离效果。对于浆液中催化剂细粉去除，不同孔径的过滤单元因无法精确控制去除颗粒大小而无法实施，而基于水力旋流器的“透析式”细粉连续分级技术可在高效去除细粉的同时回收有效催化剂。最后，对后续的研究进行了展望，以工业应用为导向，开展更广、更深的研究是未来的重点方向。

关键词: 低温费-托合成, 浆态床反应器, 液固分离, 气液（固）分离, 颗粒分级

Abstract:

In low-temperature Fischer-Tropsch synthesis slurry bed reactors, three types of multiphase separation challenges are involved, including the separation of liquid products from catalyst particles, the separation of liquid (solid) entrained in the gas at the top of the reactor, and the removal of catalyst fines in slurry. Efficient solution of these three separation challenges is paramount for the continuous and stable operation of slurry bed reactors. The paper reviewed the application and research advancements of various separation techniques in addressing three types of multiphase separation challenges. For the separation of liquid products and catalyst particles, in-vessel filtration was a commonly employed technique in industrial plants, but there existed issues such as gas leakage. External filtration can avoid the issues existing in in-vessel filtration, yet the research thereon was relatively lacking. The innovation of gravity sedimentation equipment and its combination with other techniques can effectively shorten the separation cycle. Magnetic separation and supercritical fluid extraction had potential advantages due to their relatively high separation accuracy, but the current research was still in the laboratory stage. For the separation of liquid (solid) entrained in gases, cyclone and baffle-plate separator were primarily employed. According to industrial recommendations, the combined use of the two equipment can effectively enhance the separation performance. For the removal of catalyst fines in slurry, the filter units with different pore sizes were impractical due to the inability to accurately control the size of the removed particles, while the hydrocyclone "dialysis" continuous classification technology can efficiently remove catalyst fines and recover coarse catalyst simultaneously. Finally, the subsequent research was prospected. Guided by industrial application, broader and deeper research is the key direction in the future.

Key words: low temperature Fischer-Tropsch synthesis, slurry bed reactor, liquid solid separation, gas liquid (solid) separation, particle classification

中图分类号:

TQ028

柳永兵, 王亚军, 谷平, 张永民, 郭怀勇, 刘凯. 浆态床反应器中多相分离研究进展[J]. 化工进展, 2025, 44(6): 3345-3363.

LIU Yongbing, WANG Yajun, GU Ping, ZHANG Yongmin, GUO Huaiyong, LIU Kai. A review on multiphase separation researches in slurry bed reactors[J]. Chemical Industry and Engineering Progress, 2025, 44(6): 3345-3363.

图/表 25

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粒度分布	铁基新鲜催化剂粒度占比/%	铁基平衡催化剂粒度占比/%
≤5μm	0	6.58
≤22μm	0	13.03
≤44μm	1.53	23.41
≤100μm	20.55	66.77
≤150μm	49.25	91.55
≤250μm	87.85	99.84

粒度分布	铁基新鲜催化剂粒度占比/%	铁基平衡催化剂粒度占比/%
≤5μm	0	6.58
≤22μm	0	13.03
≤44μm	1.53	23.41
≤100μm	20.55	66.77
≤150μm	49.25	91.55
≤250μm	87.85	99.84

参考文献	反应器种类	过滤介质类型	固相介质及粒径	研究参数
徐国文等^[52]	搅拌釜反应器	2mm厚度涤纶滤布，绕于孔径5mm的铝管外部	α-氧化铝,粒径范围76~97μm；硅镁铝氧化物，平均粒径80μm	搅拌速度，固含率，过滤压差，过滤速率，气液流量比
梁鹏等^[23]	浆态鼓泡床反应器	平均孔径25μm烧结金属丝网板	铁粉，粒径范围分别为40~70μm和60~90μm	过滤压差，温度，固相浓度和粒径，过滤速率
李建文等^[56]	搅拌釜反应器	孔径分别为5μm、10μm和15μm金属粉末烧结板	钴基催化剂，粒径范围分别为30~38μm和38~63μm	过滤压差，温度，搅拌速度，固含率，过滤介质孔径，过滤速率
Khodagholi等^[25]	浆态鼓泡床反应器	孔径分别为4μm和16μm金属烧结管	氧化铝，粒径范围为15~100μm	过滤压差，液相种类，滤液质量，过滤速率，过滤介质孔径
王方方等^[57]	射流式内环流反应器	孔径2μm的过滤式不锈钢烧结粉末导流筒	活性炭，粒径范围为5~10μm	过滤压力，循环流量，表观气速，固相浓度，过滤通量
郑博等^[53]	气升式浆态床外环流反应器	孔径3.2μm金属粉末烧结膜管	钴基催化剂，d₅₀=62.1μm	表观气速，固含率，跨膜压差，滤膜通量

参考文献	反应器种类	过滤介质类型	固相介质及粒径	研究参数
徐国文等^[52]	搅拌釜反应器	2mm厚度涤纶滤布，绕于孔径5mm的铝管外部	α-氧化铝,粒径范围76~97μm；硅镁铝氧化物，平均粒径80μm	搅拌速度，固含率，过滤压差，过滤速率，气液流量比
梁鹏等^[23]	浆态鼓泡床反应器	平均孔径25μm烧结金属丝网板	铁粉，粒径范围分别为40~70μm和60~90μm	过滤压差，温度，固相浓度和粒径，过滤速率
李建文等^[56]	搅拌釜反应器	孔径分别为5μm、10μm和15μm金属粉末烧结板	钴基催化剂，粒径范围分别为30~38μm和38~63μm	过滤压差，温度，搅拌速度，固含率，过滤介质孔径，过滤速率
Khodagholi等^[25]	浆态鼓泡床反应器	孔径分别为4μm和16μm金属烧结管	氧化铝，粒径范围为15~100μm	过滤压差，液相种类，滤液质量，过滤速率，过滤介质孔径
王方方等^[57]	射流式内环流反应器	孔径2μm的过滤式不锈钢烧结粉末导流筒	活性炭，粒径范围为5~10μm	过滤压力，循环流量，表观气速，固相浓度，过滤通量
郑博等^[53]	气升式浆态床外环流反应器	孔径3.2μm金属粉末烧结膜管	钴基催化剂，d₅₀=62.1μm	表观气速，固含率，跨膜压差，滤膜通量

参考文献	过滤与反冲洗介质	研究参数	关键结论
梁鹏等^[23]	平均孔径25μm烧结金属丝网板；氮气	反冲洗压差，颗粒粒径	①反冲洗压差较大时，过滤性能恢复效果越好；②颗粒粒径越小，达到再生前过滤效果所需的反冲洗压差越大
郑博等^[53,59]	孔径3.2μm、10μm金属粉末烧结膜管；柴油，水	反冲洗压差，反冲洗时间，反冲洗操作模式	①在过滤初期，反冲洗时间越长，获得的渗膜通量越大；②反冲洗压差存在临界值，超过临界值后不再显著提升渗膜通量；③脉冲式反冲洗可更有效恢复渗膜通量
Garmroodi等^[63]	孔径分别为4μm、8μm和12μm金属烧结管；液态石蜡，空气	滤管孔径，温度	①由于催化剂磨损产生的细颗粒导致较大孔径滤管堵塞，反冲洗后小孔径滤管的过滤性能恢复效果相对更好；②对于所有孔径的滤管，提升浆液温度并不能提升过滤性能恢复效果
Gu等^[64]	孔径分别为30μm、50μm和80μm的约翰逊网滤管；空气和水	气、液反冲洗特性，反冲洗压力，反冲洗频率	①液体反冲洗优于气体反冲洗；②气、液反冲洗压力均存在临界值；③增加气体的反冲洗频率可显著提升过滤通量；④气体反冲洗会引起床层压力剧烈波动