Zeolitic Molecular Sieve, Process for Its Preparation and Its Use
The invention relates to a zeolitic molecular sieve, a process for its preparation and its use for separating components from gases .
It is known that zeolitic molecular sieves are used in so-called dry processes for purifying gases, such as e.g. for desulphurizing natural gas. These molecular sieves separate the gaseous components according to the molecule size, adsorptive interaction energy or diffusion rate of the molecules in the micropore system. Because the capacity is markedly lower compared with absorption processes, molecular sieves are used in particular for the treatment of gases with low impurity levels, so-called lean gases.
When lean gases which also contain substantial quantities of carbon dioxide in addition to hydrogen sulphide are desulphurized, hydrogen sulphide is converted in the presence of carbon dioxide into carbon oxide sulphide (COS) and water in accordance with the reaction H2S + C02 "■* COS + H20. The driving force of the reaction, which as a pure gas-phase reaction with an equilibrium constant of K = 6.7 x 10" at 298° K lies on the side of the educts, is the high affinity of the reaction water to the molecular sieve. While the water is selectively adsorbed, the formed carbon oxide sulphide leaves the treatment plant with the clean gas. Unlike hydrogen sulphide, carbon oxide sulphide does not cause any stress-cracking corrosion in the absence of water, but has a toxic effect in the same manner as hydrogen
sulphide and is therefore to be separated from clean gases generally.
The formation of COS is greatly accelerated by alkali ions, e.g. sodium ions. It follows that sodium-poor zeolites, e.g. highly exchanged calcium (CaNa) zeolites A, were recommended for the desulphurization of C02-containing natural gases . A completely exchanged Ca zeolite A should accordingly be COS-inert (D.M. Ruthen: Principles of Adsorption and Adsorption Processes. John Wiley & Sons, New York, 1984, p. 360). It has however been shown that when the adsorption plants are operated economically, i.e. when long sorption phases are realized, COS is also formed to a great extent with Ca zeolites A. Even though the catalytic effect can be ignored in the CaNa molecular sieve A, the equilibrium position of the reaction is always shifted to the side of the products via the selective adsorption of the reaction water. The effect increases as the C02/H2S gradient becomes steeper.
The use of zeolites loaded with heavy metal ions in accordance with DD-A-241196 and 241202 actually initially reduces the formation of COS. However, on account of the irreversible formation of heavy metal sulphides, the molecular sieves quickly suffer a loss of selectivity and even chemical stability. Moreover, ecologically damaging products occur with the spent zeolites .
In order to shift the equilibrium position of the reaction to the side of the educts, it was proposed to preload the molecular sieve with water (M.R. Cines, D.M. Haskell and C.G. Houser: Chemical Engineering Progress 72 (1972), 8, 89). This variant of COS minimization greatly shortens the break-through times of the hydrogen sulphide since the selectivity of the molecular sieve vis-a-vis H2S is considerably reduced because of the competing adsorption of the H20. Moreover, it is doubtful
whether the water is homogeneously distributed over the entire molecular sieve bed.
It is the object of the invention to prepare new zeolitic molecular sieves which are suitable for purification processes and which prevent the formation of undesired components, in particular the formation of COS during gas desulphurizations , such as natural gas desulphurization.
In order to achieve this object, a zeolitic molecular sieve is proposed which is characterized in that its cavities are partially blocked.
The subject of the invention is furthermore a process for the preparation of a zeolitic molecular sieve with partially blocked cavities, which is characterized in that sodium silicate is reacted with sodium aluminate in aqueous medium in a Si:Al ratio in the range from 0.5 to 2.0 in the presence of from 5 to 10 wt.% of alkali metal and/or alkaline-earth metal salts which have mono- or bivalent anions, and is converted at 60 to 90°C in a manner known per se into a polycrystalline , partially blocked zeolite .
The subject of the invention is moreover the use of the zeolitic molecular sieve according to the invention for separating components from gases, in particular for purifying gases (in particular lean gases).
Surprisingly, the formation of COS can be suppressed by the incorporation of blocking substances into the cavities of the zeolite, without this impairing the sorption process. The partial blocking according to the invention of the cavities of the zeolite essentially concerns the small cavities of the zeolite, the so-called sodalite or β cages. For steric reasons, of the reactants involved in the formation of COS, only the water molecules can diffuse into the β cages of the zeolite. Depending
on the type of cations present in the zeolite, there is room for two to four water molecules in one β cage. For the water molecule, the stay in the β cage is greatly favoured in terms of energy, which is why it is no longer available for the reverse reaction. Since, however, the β cages are blocked according to the invention, both COS and H20 are to be found in the cages, where, on account of the equilibrium constant of K = 6.7 x 10" (298° K) , they are converted again into the educts H2S and C02 immediately after their formation.
The zeolites suitable for the partial blocking according to the invention are synthetic zeolites . In addition to zeolites of type X and Y, those of type A are preferred, in particular zeolite 4A and zeolite 5A. These zeolites are preferably ion- exchanged. A zeolite 5A prepared by ion exchange of zeolite 4A with Ca ions has proved to be particularly suitable.
All materials, except for water, which are capable of becoming deposited in the β cages of the zeolite and which do not, or only slightly, impair the sorption process are suitable for the partial blocking of the zeolitic molecular sieve. Particularly suitable are alkali metal and/or alkaline-earth metal salts with mono- or bivalent anions. Alkali metal salts, in particular sodium salts, are preferred. The anions for the alkali metal and/or alkaline-earth metal salts are preferably selected from the group consisting of nitrate, nitrite, chloride, bromide, iodide, chlorate, bromate, iodate, rhodanide, cyanide, carbonate, sulphate and aluminate. However, mixtures of these anions can of course also be present. Nitrite, rhodanite and aluminate are particularly preferred.
When selecting these salts, account should be taken of their alkali resistance and temperature resistance owing to the conditions of the synthesis and calcination. The salts must be alkali-resistant to the extent that the salts do not decompose on synthesis of the zeolites. The temperature resistance should
more advantageously be at least 250 C, preferably 400 C and in particular 500°C, i.e. no substantial decomposition of the salts must take place- at these temperatures.
In order to achieve an adequate partial blocking of the cavities of the zeolitic molecular sieve, the alkali metal and/or alkaline-earth metal salt content which has become deposited for the partial blocking should be at least 1 wt . % , at most 10 wt . % and preferably 1 to 8 wt . % , relative to the total weight of the loaded molecular sieve in the dry state. Quantities of deposited salts of 1.5 to 4.0 wt . % are particularly preferred. These quantities are generally sufficient to achieve the 50 to 100% blocking of the β cages which is sought according to the invention.
The preparation of the zeolitic molecular sieve according to the invention can take place in various ways. An effective partial blocking of the cavities of the molecular sieve takes place with the incorporation of salts during or after the synthesis of the zeolite. A preferred process according to the invention for preparing zeolitic molecular sieves with partially blocked cavities consists of reacting sodium silicate with sodium aluminate in aqueous medium in a Si:Al ratio in the range from 0.5 to 2.0 in the presence of from 5 to 10 wt . % of alkali metal and/or alkaline-earth metal salts which have mono- or bivalent anions, and converting it at 60 to 90 C in a manner known per se into a polycrystalline, partially blocked zeolite. The quantity of the alkali metal and/or alkaline-earth metal salts to be used relates to the weight of the synthesis mixture.
A zeolitic molecular sieve which is partially blocked with aluminate can be obtained directly when the aluminium component is used in excess .
A possible subsequent partial blocking can take place by loading with the corresponding salts from the salt melt.
In practice, the zeolitic molecular sieves according to the invention are in most cases used together with a binder. To that end, they are mixed in a known manner with suitable quantities of binder and processed to form suitable moulded bodies (for example granular material). Suitable inert binders are part of the state of the art and are for example montmorillonite, attapulgite and kaolinite.
The zeolitic molecular sieves according to the invention with partially blocked cavities are suitable for purifying gases, in particular for desulphurizing natural gas, since their use minimizes COS formation. A further preferred use is the separation of methanol from gases, e.g. from the C02 occurring in the Rectisol process (to prevent the formation of dimethyl ether) .
Comparative Example 1
A zeolite NaA (4A) customary in the trade was loaded with a mixture of 80% carbon dioxide and 20% hydrogen sulphide after being activated for ten hours at 400°C in a vacuum of less than 0.133 Pa (10" torr) . The loading was 5 mol of mixture per 1 kg of zeolite. After five hours' contact time of the mixture on the zeolite, 78% of the hydrogen sulphide were converted into carbon oxide sulphide (COS) . Since the same quantity was found after 100 hours, the 78% correspond to the equilibrium value of the COS formation under these specific test conditions.
After complete exchange of the sodium ions for calcium ions, the COS formation on the now catalytically less active CaA zeolite (5A) after five hours' contact time was still only 16 vol.%. However, after 100 hours, 72% of the hydrogen sulphide had already converted into COS.
A commercial NaX zeolite exhibits a COS formation of 65% after 5 hours and 76% after 100 hours.
Example 1
A cylindrical vessel made of polytetrafluoroethylene was half filled with a mixture consisting of 7 parts by weight of a 0.5 molar sodium silicate solution. The same quantity of a solution which was made up of 7 parts by weight of a 1.4 molar sodium aluminate solution and 0.07 mol of sodium nitrite was added to this .
The mixture was converted into polycrystalline zeolite NaA (4A) in the closed vessel at 80°C. The material loaded with nitrite was washed with water and calcined at 400°C. It contained 3 wt . % of sodium nitrite.
After five hours' contact time with the mixture of carbon dioxide/hydrogen sulphide described in Comparative Example 1, a COS formation of 2.5 vol . % was analysed. After 100 hours, the COS formation was 7 vol . % .
Example 2
7 parts by weight of a 0.5 molar sodium silicate solution and 1 part by weight of triethanolamine were mixed with a mixture of 7 parts by weight of a 1.4 molar sodium aluminate solution, 1 part by weight of triethanolamine and 0.07 mol of sodium rhodanide and stirred for a short time. The gel obtained was converted into polycrystalline zeolite NaA (4A) at 80°C . The subsequent procedure was as in Example 1. The quantity of deposited sodium rhodanide was 1 wt . % .
After five hours' contact time with the mixture of carbon dioxide/hydrogen sulphide described in Comparative Example 1, the COS formation was 1.5 vol.%, and after 100 hours 5.5 vol.%.
Example 3
7 parts by weight of a 0.5 molar sodium silicate solution were intimately mixed_ with 7 parts by weight of a 0.7 molar sodium aluminate solution with addition of 0.07 mol of sodium nitrite and converted into polycrystalline zeolite NaX at 80 °C. The subsequent procedure was as in Example 1. The loading with sodium nitrite was 6 wt . % .
The COS formation was 2% after five hours' contact time with the mixture of carbon dioxide/hydrogen sulphide described in Comparative Example 1, and 4.5% after 100 hours.
Comparison of the above examples with Comparative Example 1 shows that a markedly reduced, minimized COS formation is to be observed after partial blocking of the cavities of the zeolite with salts.