Conversion of HF alkylation units for ion liquid catalyzed alkylation processes

Abstract

A method for converting an HF alkylation unit comprising an HF clarifier into an ionic liquid alkylation system, the method comprising: a) providing an ionic liquid-specific subsystem comprising an ionic liquid alkylation reactor and an ionic liquid separator; and b) connecting the ionic liquid alkylation reactor to the HF clarifier to feed an alkylation reactor effluent from the ionic liquid alkylation reactor to the HF clarifier, the HF clarifier being configured to separate the alkylation reactor effluent into a hydrocarbon phase and an ionic liquid phase; and c) connecting the HF clarifier to the ionic liquid separator to feed the hydrocarbon phase from the HF clarifier to the ionic liquid separator.

Description

TECHNICAL AREA

[0001] The present invention relates to the conversion of HF alkylation units for ion liquid catalyzed alkylation processes. GENERAL STATE OF THE ART

[0002] Hydrofluoric acid (HF) is used as a catalyst in common industrial processes for reactions such as aromatic and olefin alkylation, including refining processes for the production of high-octane gasoline, distillate, and lubricating base oil. The hazards of HF, such as those related to its volatility, are well documented. The use of additives to reduce HF volatility is costly and does not eliminate the need for large quantities of HF in the plant. Efforts to develop safer alternative catalysts have encountered significant challenges. Converting HF alkylating units to use sulfuric acid (H₂SO₄) as a catalyst requires considerably more capital and increased operating costs, while also introducing the hazards associated with highly corrosive concentrated H₂SO₄.Furthermore, it has been found that solid alkylation catalysts are difficult to commercialize due to rapid fouling and rapid deactivation.

[0003] Fig. 1 is a block diagram that schematically depicts an HF alkylation unit 10 represents the state of the art. The HF alkylation unit 10 can a hydrocarbon feed line 13 , an HF alkylation reactor 16 with hydrocarbon injectors and an HF clarifier 16 exhibiting, which is connected to the RF reactor 18 It is coupled to separate an HF / hydrocarbon mixture into a hydrocarbon phase and an HF phase. The HF phase can be separated via an HF heat exchanger. 20 into the RF reactor 16 The heat can be recirculated. In a more compact design, the heat exchanger can be located inside the HF reactor.

[0004] Part of the RF is sent to an RF regeneration unit. 22directed, whereupon the regenerated RF is combined with the RF feedback current. The unit 10 can also be a fractionation unit 24 for fractionating the hydrocarbon phase and a product treatment unit 26 for treating sections from the fractionation unit 24 to provide one or more products. In some cases, a prior art HF alkylation unit can be a feed treatment unit. 12 for treating the hydrocarbon feed(s) to the HF reactor 16 exhibit.

[0005] US Patent No. 5,284,990, granted to Peterson et al., discloses a process for converting an HF alkylating unit into an H2SO4 alkylating unit. The disclosure of Patent '990 is hereby incorporated in its entirety into the present subject matter by cross-reference for all purposes.

[0006] Various groups from science and industry have conducted research in the search for an alternative catalytic system to replace the usual HF and H2SO4 catalysts in alkylation processes. So far, no viable replacement catalyst for carrying out such processes has been commercialized.

[0007] For some time now, there has been considerable interest in metal halide ionic liquid catalysts as alternatives to HF and H₂SO₄ catalysts. For example, the ionic liquid-catalyzed alkylation of isoparaffins with olefins is disclosed in US Patent No. 7,432,408 to Timken et al. Furthermore, US Patent No. 7,572,943 to Elomari et al. discloses the ionic liquid-catalyzed oligomerization of olefins and the alkylation of the resulting oligomer(s) with isoparaffins to produce alkylated olefin oligomers.

[0008] PCT Publication No. WO 2011 / 015664 discloses a process for converting an HF or H2SO4 alkylation unit into an ionic liquid alkylation unit, wherein one or more cyclone units are provided to promote the separation of the ionic liquid from hydrocarbons.

[0009] Liu et al. (Oil & Gas Journal (2006) Vol. 104, Issue 40) describe retrofitting an H2SO4 alkylation unit for use in a mixed-ion liquid-catalyzed alkylation by modifying the settling tank interior to improve the separation of the mixed-ion liquid from alkylate gasoline, and by providing a pressure equalization tank, with the mixed-ion liquid being transferred from the pressure equalization tank to a STRATCO ® -(continuously stirred) reactor.

[0010] There is a need for the efficient and cost-effective conversion of existing HF alkylation units into ion liquid alkylation systems suitable for ion liquid catalyzed alkylation processes. SUMMARY

[0011] In one embodiment of the present invention, a method for converting an HF alkylation unit into an ionic liquid alkylation system is provided, wherein the method comprises: providing an ionic liquid-specific subsystem comprising an ionic liquid alkylation reactor; and connecting at least one component of the ionic liquid-specific subsystem with at least one component of the HF alkylation unit.

[0012] In a further embodiment, a method for converting an HF alkylation unit into an ionic liquid alkylation system is provided, wherein the HF alkylation unit comprises a fractionation unit and wherein the method comprises: providing an ionic liquid alkylation reactor and an ionic liquid separator; connecting the ionic liquid alkylation reactor to at least one hydrocarbon feed line to supply at least one hydrocarbon feed to the ionic liquid alkylation reactor; and connecting the ionic liquid separator to the fractionation unit.

[0013] According to a further embodiment, a method for converting an HF alkylation unit into an ionic liquid alkylation system is provided, wherein the HF alkylation unit comprises a fractionation unit and the method comprises: providing an ionic liquid alkylation reactor configured for ionic liquid-catalyzed alkylation reactions, wherein the ionic liquid alkylation reactor comprises an ionic liquid / hydrocarbon injection unit connected thereto; connecting at least one hydrocarbon feed line to the ionic liquid / hydrocarbon injection unit to feed at least one hydrocarbon charge into the ionic liquid alkylation reactor; providing an ionic liquid / hydrocarbon separation unit;Connecting the liquid-ionic / hydrocarbon separation unit to the liquid-ionic alkylation reactor, wherein the liquid-ionic / hydrocarbon separation unit is configured to separate an alkylation reactor effluent from the liquid-ionic alkylation reactor into a liquid-ionic phase comprising a liquid-ionic catalyst and a hydrocarbon phase comprising alkylate; and connecting the liquid-ionic / hydrocarbon separation unit to the fractionation unit to direct at least a portion of the hydrocarbon phase to the fractionation unit.

[0014] In a further embodiment, an ionic liquid alkylation system is provided, derived from an existing HF unit with a fractionation unit, wherein the ionic liquid alkylation system comprises: an ionic liquid alkylation reactor configured for ionic liquid-catalyzed alkylation reactions; an ionic liquid / hydrocarbon separation unit in fluid communication with the ionic liquid alkylation reactor, wherein the ionic liquid / hydrocarbon separation unit is configured to separate a reactor efflux of the ionic liquid alkylation reactor into a hydrocarbon phase and an ionic liquid phase; wherein the ionic liquid alkylation system further comprises the fractionation unit, wherein the fractionation unit is in fluid communication with the ionic liquid / hydrocarbon separation unit.

[0015] As used here, the terms “comprehensive” and “includes” mean the inclusion of the elements or steps listed after these terms, but without necessarily excluding other unnamed elements or steps. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] It shows:

[0017] Fig. 1 A block diagram schematically showing a prior art hydrofluoric acid (HF) alkylation unit.

[0018] Fig. 2 in graphical representation a converted ion liquid catalyzed alkylation system according to an embodiment of the present invention;

[0019] Fig. 3 a drawing of the subsystem for an ionic liquid alkylation system according to a further embodiment of the present invention; and

[0020] Fig. 4 a graphic representation of an ionic liquid catalyst / hydrocarbon separation unit for an ionic liquid alkylation system according to a further embodiment of the present invention. DETAILED DESCRIPTION

[0021] Ionic liquid catalysts are suitable for a wide variety of hydrocarbon conversion reactions, including alkylation reactions for the production of alkylate gasoline blends, distillate, lubricants, and the like. Conventional HF alkylation units, as such, are not suitable for carrying out ionic liquid-catalyzed alkylation processes. However, according to embodiments of the present invention, one or more components of a conventional HF alkylation unit can be used in or adapted for use in ionic liquid alkylation systems and processes.

[0022] In one embodiment, the present invention provides methods for converting existing HF alkylation units into liquid ion alkylation systems configured for the efficient execution of liquid ion catalyzed alkylation processes. Such system conversions can be extremely cost-effective during the commercialization of liquid ion catalyzed alkylation processes. In another embodiment, a liquid ion alkylation system is provided that is derived from a conventional, existing, or previous HF alkylation unit.

[0023] The disclosure of the jointly filed US patent application entitled “Conversion of sulfuric acid alkylation units for ionic liquid catalyzed alkylation processes”, filed on the same date, is incorporated in its entirety into the present subject matter by cross-reference. Feedstocks for ion liquid catalyzed processes

[0024] In one embodiment, feeds for ion-liquid-catalyzed hydrocarbon conversion processes can include various streams from an oil refinery, a gas-to-liquid conversion plant, a coal-to-liquid conversion plant, or naphtha crackers, middle distillate crackers, or wax crackers, including FCC exhaust gas, light FCC naphtha, coker exhaust gas, coker naphtha, hydrocracker naphtha, and the like. In one embodiment, such streams can contain isoparaffin(s) and / or olefin(s).

[0025] Examples of olefin-containing streams include FCC exhaust, coker exhaust, olefin metathesis unit exhaust, polyolefin gasoline unit exhaust, methanol-to-olefin unit exhaust, light FCC naphtha, light coker naphtha, Fischer-Tropsch unit condensate, and cracker naphtha. Some olefin-containing streams may contain two or more olefins selected from ethylene, propylene, butylenes, pentenes, and up to C 10 -Olefins are included. Such olefin-containing streams are further described, for example, in US Patent No. 7,572,943, the disclosure of which is incorporated in its entirety into the present subject matter by cross-reference.

[0026] Examples of isoparaffin-containing streams include, but are not limited to, FCC naphtha, hydrocracker naphtha, coker naphtha, Fisher-Tropsch unit condensate, and cracker naphtha. Such streams may comprise a mixture of two or more isoparaffins. In a dependent embodiment, an isoparaffin feed for an ion liquid-catalyzed process may include isobutane, which may be obtained, for example, from a hydrocracking unit or a butane isomerization unit or purchased.

[0027] In one embodiment, olefins and isoparaffins in the feed(s) can participate in ion-liquid-catalyzed isoparaffin-olefin alkylation reactions. In another embodiment, olefins in the feed(s) can undergo oligomerization when they are brought into contact with an ion-liquid catalyst in a hydrocarbon conversion reactor. Ionic liquid-catalyzed olefin oligomerization can be carried out under the same or similar conditions as ion-liquid-catalyzed olefin-isoparaffin alkylation. Ionic liquid-catalyzed olefin oligomerization and olefin-isoparaffin alkylation are disclosed, for example, in U.S. Patents Nos. 7,572,943 and 7,576,252, both jointly granted to Elomari et al., which are hereby incorporated in their entirety by cross-reference into the present subject matter. Method for converting an HF alkylation unit into an ionic liquid alkylation system

[0028] A typical HF alkylation unit is shown schematically in Fig. Figure 1 above illustrates such an existing or previous HF alkylation unit. This unit may include, among other things, an HF reactor, an HF settling tank downstream of the HF reactor, and a fractionation unit upstream of the HF settling tank. For various reasons, such as differences in the physical and chemical properties of the liquid ion catalyst, the optimal process conditions in the alkylation reactor and the process conditions for HF alkylation units with liquid ion catalyst-catalyzed alkylation as such are unsuitable for the commercialization of liquid ion catalyst-catalyzed alkylation processes. However, an existing HF alkylation unit can be converted into a liquid ion catalyst alkylation system configured for the effective performance of liquid ion catalyst-catalyzed alkylation processes.The ionic liquid catalyst alkylation system can also be referred to as the ionic liquid alkylation system.

[0029] The conversion of an existing or previous HF alkylation unit into an ionic liquid (IL) alkylation system can be referred to here as an "HF / IL conversion." Such conversions can be achieved, for example, by replacing and / or separating one or more components of an HF alkylation unit, by adapting one or more components of the HF alkylation unit for ionic liquid-catalyzed alkylation processes, and / or by connecting one or more components of an ionic liquid alkylation system to one or more components of the HF alkylation unit. In an HF / IL conversion, one or more components of an HF alkylation unit can be separated, for example, by closing one or more valves, and / or by removing, sealing, or exchanging one or more lines or connections between two or more components of the HF alkylation units.

[0030] In one embodiment, a method for converting an HF alkylating unit into an ionic liquid alkylation system may include providing an ionic liquid catalyst-specific subsystem. The ionic liquid catalyst-specific subsystem may also be referred to as the ionic liquid-specific subsystem. Such an ionic liquid-specific subsystem may comprise one or more components configured to connect with one or more components of the HF alkylating unit; and the HF / IL conversion method may further comprise connecting at least one component of the ionic liquid-specific subsystem with at least one component of the HF alkylating unit. In one embodiment, one or more components of the ionic liquid-specific subsystem may be provided de novo for the HF / IL conversion.

[0031] In one embodiment, the ion liquid-specific subsystem can comprise an ion liquid catalyst alkylation reactor. The ion liquid catalyst alkylation reactor can be configured for one or more ion liquid-catalyzed hydrocarbon conversion reactions, such as isoparaffin-olefin alkylation. The ion liquid catalyst alkylation reactor can also be referred to simply as an ion liquid alkylation reactor.

[0032] In one embodiment, the ion-liquid-specific subsystem can further comprise an ion-liquid catalyst / hydrocarbon injection unit, and the HF / IL conversion method can further comprise connecting the ion-liquid catalyst / hydrocarbon injection unit to at least one hydrocarbon feed line. The ion-liquid catalyst / hydrocarbon injection unit can also be referred to as the ion-liquid / hydrocarbon injection unit.

[0033] In one embodiment, the ionic liquid / hydrocarbon injection unit can be formed integrally with the ionic liquid alkylation reactor. In another embodiment, at least one section, e.g., a distal section, of the ionic liquid / hydrocarbon injection unit can extend into a cavity or space within the ionic liquid alkylation reactor. In another embodiment, the ionic liquid / hydrocarbon injection unit can be formed at least partially within the ionic liquid alkylation reactor. In yet another embodiment, the ionic liquid / hydrocarbon injection unit can be a part or component of the ionic liquid alkylation reactor.

[0034] In one embodiment, at least one hydrocarbon feed line can be provided de novo as a component of the liquid ion alkylation system. In another embodiment, at least one hydrocarbon feed line of the liquid ion alkylation system can comprise a component of an HF alkylation unit, and the HF / IL conversion process can include disconnecting the HF reactor from the at least one hydrocarbon feed line. Disconnecting the HF reactor from the at least one hydrocarbon feed line or other component(s) can serve to shut down the HF reactor. Subsequently, the HF reactor can either be temporarily or permanently relocated, removed, or disposed of, or remain in place.

[0035] In one embodiment of an HF / IL conversion process, the liquid ion alkylation reactor can be connected to at least one hydrocarbon feed line via the liquid ion / hydrocarbon injection unit. In some embodiments, the liquid ion alkylation reactor can be equipped with or include the liquid ion / hydrocarbon injection unit. At least one hydrocarbon feed can be supplied to the liquid ion alkylation reactor via the at least one hydrocarbon feed line and the liquid ion / hydrocarbon injection unit. The at least one hydrocarbon feed can be treated, e.g., by a feed treatment unit arranged upstream of the liquid ion / hydrocarbon injection unit (see, e.g., Fig. 2).

[0036] The HF / IL conversion process can further include connecting the liquid-ion / hydrocarbon injection unit to a liquid-ion catalyst feed line for introducing a liquid-ion catalyst into the liquid-ion alkylation reactor. The liquid-ion catalyst feed line can also be referred to simply as the liquid-ion feed line.

[0037] The ionic liquid / hydrocarbon injection unit can be configured to inject the ionic liquid catalyst and at least one hydrocarbon charge together into the ionic liquid alkylation reactor. In one embodiment, the ionic liquid / hydrocarbon injection unit can comprise at least one nozzle. The use of nozzles for ionic liquid-catalyzed alkylation is disclosed, for example, in the jointly filed US patent applications Nos. 20090166257, 20090171133 and 20090171134, and in US patent application No. 12 / 780452, filed on May 14, 2010, the disclosures of which are incorporated in their entirety into the present subject matter by cross-reference.

[0038] In one embodiment, the ionic liquid alkylation reactor and the ionic liquid / hydrocarbon injection unit can be configured together to form a mixture comprising an ionic liquid phase and a hydrocarbon phase. Such a mixture can be formed in the ionic liquid alkylation reactor. In one embodiment, the mixture can comprise a dispersed ionic liquid phase and a continuous hydrocarbon phase. For example, a reaction mixture in the ionic liquid alkylation reactor can comprise an emulsion containing droplets of the ionic liquid catalyst suspended in liquid hydrocarbons. In one embodiment, these droplets can be uniformly suspended in the hydrocarbon phase to provide a homogeneous emulsion.The liquid ion phase can also be referred to as the liquid ion catalyst phase, whereby it is understood that the liquid ion catalyst used may have been at least partially consumed or degraded in some other way, e.g. downstream of the liquid ion alkylation reactor.

[0039] In one embodiment, the ionic liquid alkylation reactor can include, or be used in conjunction with, one or more nozzles to generate the emulsion of ionic liquid catalyst and hydrocarbon. In other embodiments, various configurations of the ionic liquid alkylation reactor can be used to provide a uniform or homogeneous mixture of the ionic liquid catalyst and the hydrocarbon, such as a reactor system containing one or more in-line mixers (e.g., static mixers) or a continuously stirred reactor with one or more paddles.

[0040] In one embodiment, the ion liquid-specific subsystem can further comprise an ion liquid catalyst separator, and the HF / IL conversion method can further comprise connecting the ion liquid catalyst separator to a fractionation unit to feed the hydrocarbon phase to the fractionation unit. The ion liquid catalyst separator can also be referred to here as the ion liquid separator.

[0041] In one embodiment, the fractionation unit of the ionic liquid alkylation system can comprise at least a section of a conventional fractionation unit from an HF alkylation unit. In another embodiment, the conventional fractionation unit of the HF alkylation unit can be modified, for example, during an HF / IL conversion, to provide a modified fractionation unit for the ionic liquid alkylation system. In another embodiment, the modified fractionation unit can comprise a section of the fractionation unit from an HF alkylation unit in combination with one or more fractionation unit components that are provided de novo for the ionic liquid alkylation system. In another embodiment, the one or more fractionation unit components that are provided de novo for the ionic liquid alkylation system can comprise a nickel alloy.In one embodiment, one or more components of a conventional fractionation unit (which may include, for example, carbon steel) can be upgraded, for example, by replacing them with an alloy such as a Ni / Cu alloy or a Ni / Cr alloy.

[0042] It is understood that such an upgrade of the metallurgy is not necessarily limited to the fractionation section of a retrofitted or converted alkylation system. In general, the upgrade of carbon steel components of an existing HF alkylation unit to a higher metallurgy can be carried out for streams that mainly contain liquid ion catalyst, such as the liquid ion catalyst regeneration section and the liquid ion catalyst return line.

[0043] In one embodiment, the HF / IL conversion process may include modifying at least one distillation column of the fractionation unit from an HF alkylation unit to provide a retrofitted distillation column for the ionic liquid alkylation system. The retrofitted distillation column may be configured to produce an HCI-rich C 3- to separate the -fraction from the hydrocarbon phase. The ionic liquid alkylation system can be configured to separate the HCl-rich C 3- The recycling of an HCl- and propane-rich fraction to an ionic liquid alkylation reactor is disclosed in the jointly filed US Publication No. 20110155640, the disclosure of which is incorporated in its entirety into the present subject matter by cross-reference.

[0044] In one embodiment, the ion liquid alkylation system may include a primary separation vessel. In another embodiment, the primary separation vessel may be provided de novo for the ion liquid alkylation system, such that the HF clarifier may be redundant from the existing HF alkylation unit for ion liquid-catalyzed alkylation requirements. In this case, a method for HF / IL conversion may include separating the HF clarifier from the fractionation unit. Separating the HF clarifier from the fractionation unit may serve to decommission the HF clarifier. The HF clarifier may be decommissioned temporarily or permanently. As non-limiting examples, after separation from the fractionation unit, the HF clarifier may either be temporarily or permanently relocated, removed, or disposed of, or remain in place.

[0045] A method for the HF / IL conversion of an HF alkylation unit can further comprise connecting the liquid ion alkylation reactor to the primary separation vessel to feed an alkylation reactor effluent from the liquid ion alkylation reactor to the primary separation vessel. The primary separation vessel can be configured to separate the alkylation reactor effluent into a hydrocarbon phase and a liquid ion phase. In one embodiment, the HF / IL conversion method can further comprise connecting the primary separation vessel to the liquid ion separator to feed the hydrocarbon phase from the primary separation vessel to the liquid ion separator.

[0046] In an alternative embodiment, the HF clarifier can be retained from an existing or previous HF alkylation unit and / or adapted as a component of the ionic liquid alkylation system. For example, the HF clarifier can be configured to separate alkylation reactor effluent into the hydrocarbon and ionic liquid phases, and the HF clarifier can serve as or include the primary separation vessel. In this situation, a method for HF / IL conversion can include connecting the ionic liquid alkylation reactor to the HF clarifier to feed the alkylation reactor effluent to the HF clarifier and connecting the HF clarifier to the ionic liquid separator to feed the hydrocarbon phase from the HF clarifier to the ionic liquid separator.

[0047] According to a further embodiment of the present invention, a method for converting an HF alkylation unit into an ionic liquid alkylation system may comprise: providing an ionic liquid alkylation reactor and an ionic liquid separator, and connecting the ionic liquid alkylation reactor to at least one hydrocarbon feed line and an ionic liquid feed line via an ionic liquid / hydrocarbon injection unit. The ionic liquid / hydrocarbon injection unit may be configured to inject the ionic liquid catalyst and at least one carbon charge into the ionic liquid alkylation reactor to form a homogeneous reaction mixture in the ionic liquid alkylation reactor comprising a dispersed ionic liquid phase and a continuous hydrocarbon phase.

[0048] The ion liquid separator can be in fluid communication with the ion liquid alkylation reactor, for example, via a primary separation vessel coupled to an outlet port of the ion liquid alkylation reactor. In one embodiment, the primary separation vessel can include an HF clarifier, and a method for HF / IL conversion can further include separating the HF clarifier from the HF reactor, whereby the HF reactor can be shut down. In another embodiment, the primary separation vessel can include a component that is provided de novo for the HF / IL conversion, for example, a component specific to the ion liquid alkylation system, and a method for HF / IL conversion can further include separating the HF clarifier from the fractionation unit, whereby both the HF reactor and the HF clarifier can be shut down.

[0049] The ion liquid separator and the primary separation vessel can together form an ion liquid / hydrocarbon separation unit. A method for HF / IL conversion can involve connecting the primary separation vessel to the ion liquid alkylation reactor such that the primary separation vessel can be in fluid communication with the ion liquid alkylation reactor to supply an alkylation reactor effluent from the ion liquid alkylation reactor to the primary separation vessel. The primary separation vessel can be configured to separate the alkylation reactor effluent into a hydrocarbon phase and an ion liquid phase.

[0050] The ion liquid separator can capture at least a portion of the hydrocarbon phase from the primary separation vessel. In one embodiment, the hydrocarbon phase from the primary separation vessel can be incompletely separated from the ion liquid; for example, the hydrocarbon phase from the primary separation vessel can include entrained ion liquid. The ion liquid separator can be configured to separate the entrained ion liquid from the carbon phase, and the ion liquid alkylation system can be configured to return the entrained ion liquid from the ion liquid separator to the ion liquid alkylation reactor.

[0051] In one embodiment, the HF / IL conversion method may further include connecting the liquid ion separator to the fractionation unit. The fractionation unit may be retained from the existing HF alkylation unit undergoing conversion, or it may be derived from or adapted from one or more components of the fractionation unit of the HF alkylation unit.

[0052] An HF alkylation unit intended for conversion to an ionic liquid alkylation system may comprise at least one component comprising a material, e.g., carbon steel, that is incompatible with one or more zones of ionic liquid-catalyzed alkylation processes. In one embodiment, a method for HF / IL conversion may involve replacing one or more components of the HF alkylation unit with one or more components comprising a suitable material, e.g., a nickel alloy. In a sub-embodiment, the Ni alloy may also comprise a Ni / Cr alloy comprising primarily Ni (> 50 wt.% Ni) in combination with up to approximately 26 wt.% Cr. In a further sub-embodiment, the Ni alloy may also comprise a Ni / Cu alloy comprising primarily Ni (> 50 wt.% Ni) in combination with up to approximately 32 wt.% Cu.Non-restrictive examples of a Ni / Cr alloy and a Ni / Cu alloy are alloy C-276 and alloy 400, respectively.

[0053] According to another embodiment, an HF alkylation unit for conversion into an ionic liquid alkylation system can comprise an HF reactor, an HF settling tank arranged downstream of the HF reactor, and a fractionation unit arranged downstream of the HF settling tank. A method for converting the HF alkylation unit into an ionic liquid alkylation system can include providing an ionic liquid alkylation reactor configured for ionic liquid-catalyzed alkylation reactions. The ionic liquid alkylation reactor can include an ionic liquid / hydrocarbon injection unit connected to it. In one embodiment, the ionic liquid / hydrocarbon injection unit can be integrally formed with, arranged within, and / or be a component of the ionic liquid alkylation reactor.

[0054] In a further embodiment, the HF / IL conversion method can configure the liquid-ion / hydrocarbon injection unit for the simultaneous injection of the liquid-ion catalyst and at least one hydrocarbon feed into the liquid-ion alkylation reactor. In another embodiment, the liquid-ion alkylation reactor and the liquid-ion / hydrocarbon injection unit can be configured together to form a homogeneous mixture in the liquid-ion alkylation reactor comprising a dispersed liquid-ion phase and a continuous hydrocarbon phase.

[0055] The ionic liquid / hydrocarbon injection unit can be connected to at least one hydrocarbon feed line for supplying at least one hydrocarbon charge to the ionic liquid alkylation reactor. In one embodiment, the at least one hydrocarbon charge can be treated via a charge treatment unit located upstream of the ionic liquid / hydrocarbon injection unit.

[0056] In one embodiment, the at least one hydrocarbon feed can comprise an isoparaffin-containing feed and an olefin-containing feed. The feed treatment unit can comprise at least one feed drying unit for drying the hydrocarbon feed(s). The feed treatment unit can further comprise a hydroisomerization unit for treating an olefin-containing feed, e.g., for removing butadiene and isomerizing 1-butene to 2-butene.

[0057] In one embodiment, the feed treatment unit may comprise a component of an existing or previous HF alkylation unit. In another embodiment, an existing HF alkylation unit for conversion to an ionic liquid alkylation system may lack a suitable feed treatment unit, and the feed treatment unit for the ionic liquid alkylation system may comprise one or more components that are provided de novo for the HF / IL conversion.

[0058] In an HF / IL conversion, the liquid-to-hydrocarbon separation unit can be connected to the liquid-to-hydrocarbon alkylation reactor. The liquid-to-hydrocarbon separation unit can be configured to separate the alkylation reactor effluent from the liquid-to-hydrocarbon alkylation reactor into the liquid-to-hydrocarbon phase and the hydrocarbon phase. The liquid-to-hydrocarbon phase may contain a liquid-to-hydrocarbon catalyst, while the hydrocarbon phase may contain an alkylate. The hydrocarbon phase may also contain unconverted light hydrocarbons.

[0059] The liquid-ion / hydrocarbon separation unit can comprise a primary separation vessel and a liquid-ion separator that is in fluid communication with the primary separation vessel. In one embodiment, the liquid-ion / hydrocarbon separation unit can be connected to the liquid-ion alkylation reactor via the primary separation vessel. In another embodiment, the primary separation vessel can comprise the HF clarifier.

[0060] A method for HF / IL conversion can further include connecting the ion liquid / hydrocarbon separation unit to the fractionation unit in order to supply at least a portion of the hydrocarbon phase to the fractionation unit. In one embodiment, the ion liquid / hydrocarbon separation unit can be connected to the fractionation unit via the ion liquid separator.

[0061] The HF / IL conversion process may further include providing an ionic liquid catalyst regeneration unit for regenerating the ionic liquid catalyst and connecting the ionic liquid catalyst regeneration unit to the ionic liquid / hydrocarbon separation unit to feed a portion of the ionic liquid phase from the ionic liquid / hydrocarbon separation unit to the ionic liquid catalyst regeneration unit. The ionic liquid phase from the ionic liquid / hydrocarbon separation unit may include at least partially consumed ionic liquid catalyst, and the ionic liquid / hydrocarbon separation unit may be configured to regenerate the ionic liquid catalyst to provide regenerated ionic liquid catalyst.

[0062] The HF / IL conversion process may further comprise connecting the liquid ion catalyst regeneration unit to the liquid ion alkylation reactor in order to supply at least a portion of the regenerated liquid ion catalyst to the liquid ion alkylation reactor. The regeneration of liquid ion catalysts is disclosed, for example, in the jointly granted US patents Nos. 7,674,739 and 7,691,771, the disclosures of which are incorporated in their entirety into the present subject matter by cross-reference.

[0063] After completion of the HF / IL conversion, the resulting liquid ion alkylation system can commence operation following a suitable commissioning process. A method for initiating and operating liquid ion catalyzed hydrocarbon conversion processes and systems is disclosed in the jointly filed, concurrently pending US patent application No. 12 / 825121, filed on June 28, 2010, the disclosure of which is incorporated in its entirety into the present subject matter by cross-reference. Ion liquid-catalyzed alkylation processes

[0064] With reference to Fig. 2– Fig. 4 can occur during an ion-liquid-catalyzed alkylation process associated with the system 100 The process involves introducing one or more treated hydrocarbon feeds into the ionic liquid alkylation reactor. 220 be introduced. The ionic liquid alkylation reactor220 It can also be referred to as an ionic liquid alkylation zone. The hydrocarbon feed(s) can be supplied using the feed treatment unit. 12' The hydrocarbon feed(s) can / can contain at least one hydrocarbon reactant. In a sub-elaboration, the hydrocarbon reactant can be a first reactant, the C4-C 10 -isoparaffin, and a second reactant comprising a C2-C 10-olefin is included. The treatment of the hydrocarbon feed(s) may include drying the feed(s), removal of dienes, and hydroisomerization of olefins in olefin feeds. The selective hydrogenation and hydroisomerization of feedstocks for ion liquid-catalyzed alkylation is disclosed in the jointly filed US patent application No. 20110092753, the disclosure of which is incorporated herein by reference in its entirety into the present subject matter.

[0065] The ionic liquid catalyst and at least one hydrocarbon feed can be supplied via an ionic liquid / hydrocarbon injection unit. 210 into the ionic liquid alkylation reactor 220The ionic liquid catalyst can be introduced in one embodiment, comprising a chloroaluminate ionic liquid as described below. A cocatalyst, such as anhydrous HCl, and / or a catalyst promoter can also be added to the ionic liquid alkylation reactor. 220 to be supplied. The ionic liquid / hydrocarbon injection unit 210 It can also be used here as an ionic liquid catalyst / hydrocarbon injection unit. 210 be designated.

[0066] An expert recognizes that Fig. 2– Fig. Four schematic diagrams are shown, indicating the fluid connection between units or components. Fig. 2– Fig. Figure 4 is not intended to show the relative size, shape, or spatial relationships between components or units. For example, the ionic liquid / hydrocarbon injection unit 210in one embodiment integrally with the ionic liquid alkylation reactor 220 be designed. In one embodiment, at least one section, e.g. a distal section, of the ionic liquid / hydrocarbon injection unit can be configured. 210 into a cavity or space in the ionic liquid alkylation reactor 220 extend. In one embodiment, the ionic liquid / hydrocarbon injection unit can 210 at least partially within the ionic liquid alkylation reactor 220 be designed. In one embodiment, the ionic liquid / hydrocarbon injection unit can be 210 a part or component of the ionic liquid alkylation reactor 220 be.

[0067] During alkylation processes according to the embodiments of the invention, the ionic liquid alkylation reactor can 220a two-phase mixture comprising an ionic liquid phase and a hydrocarbon phase. The hydrocarbon phase may include at least one hydrocarbon product of the ionic liquid-catalyzed reaction. The ionic liquid phase may be separated via the ionic liquid / hydrocarbon separation unit. 230 to be separated from the hydrocarbon phase. The ionic liquid / hydrocarbon separation unit 230 It can also be used here as an ionic liquid catalyst / hydrocarbon separation unit 230 The ionic liquid / hydrocarbon separation unit 230 can be a primary separation container 232 and an ion liquid separator 234 include the ion liquid separator. 234 It can also be used here as an ion liquid catalyst separator. 234 be designated.

[0068] In one embodiment, at least a part of the ionic liquid phase can be separated from the ionic liquid / hydrocarbon separation unit. 230 to the liquid ion alkylation reactor 220 be traced back. During continued operation of the system. 100 The liquid ion catalyst can be at least partially deactivated. To maintain the catalytic activity of the liquid ion catalyst, a portion of the liquid ion catalyst phase can be regenerated by the liquid ion catalyst regeneration unit. 230 to regenerate the liquid ion catalyst. Subsequently, at least a portion of the regenerated liquid ion catalyst can be fed to the liquid ion alkylation reactor. 220 can be returned, e.g. via an ionic liquid feed line. 252 and the ionic liquid / hydrocarbon injection unit 210 .

[0069] In one embodiment, at least a part of the hydrocarbon phase can be removed by the ion liquid separator. 234 the fractionation unit 24' are fed in to fractionate the hydrocarbon phase and provide one or more hydrocarbon products. The hydrocarbon product(s) can then be fed into the product treatment unit. 26' to be supplied in order to treat the hydrocarbon product(s). In one embodiment, the fractionation unit can 24' , which may include a variety of distillation or fractionation columns, a modified fractionation unit, which is achieved by modifying the fractionation unit 24 the usual alkylation unit 10 ( Fig. 1) was obtained. The fractionation unit 24' may include at least one converted, modified or retrofitted distillation column used to separate an HCl-rich C 3--fraction is configured. At least a portion of the HCl-rich C 3- The -fraction can be fed into the ionic liquid alkylation reactor 220 can be recycled. At least one fraction, comprising isobutane, can also be fed back to the liquid ion alkylation reactor. 220 to be recycled. For the sake of clarity, only a single line is used to recycle HCl- and isobutane-containing fractions to the liquid ion alkylation reactor. 220 depicted. liquid ion catalysts

[0070] Ionic liquids are generally organic salts with melting points below 100°C (212°F) and often below room temperature. They can be used in various chemical reactions, solution processes, and electrochemistry. The use of chloroaluminate ionic liquids as alkylation catalysts in petroleum refining, for example, was disclosed in Jointly granted US patents Nos. 7,531,707, 7,569,740, and 7,732,654, the disclosures of which are incorporated in their entirety into the present subject matter by reference.

[0071] Most ionic liquids are made from organic cations and inorganic or organic anions. Cations include, but are not limited to, ammonium, phosphonium, and sulfonium. Anions include, but are not limited to, BF4. – , PF6 – , halogen aluminates such as Al2Cl7 – and Al2Br7 – , [(CF3SO2)2N] –, Alkyl sulfates (RSO3) – ) and carboxylates (RCO2 – Ionic liquids for acid catalysis can include those derived from ammonium halides and Lewis acids, such as AlCl3, TiCl4, SnCl4, and FeCl3. Chloroaluminate ionic liquids may represent the most widely used ionic liquid catalyst systems for acid-catalyzed reactions.

[0072] Exemplary ionic liquids for use as catalysts in ionic liquid-catalyzed alkylation reactions may include at least one compound of the general formulas A and B: wherein R is selected from the group consisting of H, Methyl, Ethyl, Propyl, Butyl, Pentyl or Hexyl, wherein R1 and R2 are each selected from the group consisting of H, Methyl, Ethyl, Propyl, Butyl, Pentyl or Hexyl, wherein R1 and R2 may be the same or different, and X is a chloroaluminate.

[0073] Non-restrictive examples of chloroaluminate ionic liquid catalysts that can be used in alkylation processes according to embodiments of the present invention include those comprising 1-butyl-4-methylpyridinium chloroaluminate, 1-butyl-3-methylimidazolium chloroaluminate, 1-H-pyridinium chloroaluminate, N-butylpyridinium chloroaluminate and mixtures thereof. Reaction conditions for ion liquid-catalyzed hydrocarbon conversion reactions

[0074] Due to the low solubility of hydrocarbons in ionic liquids, hydrocarbon conversion reactions (including isoparaffin-olefin alkylation reactions) in ionic liquids are generally two-phase and take place at the interface in the liquid state. The volume of the ionic liquid catalyst in the reactor can generally range from about 1 to 70 vol%, and typically between about 4 and 50 vol%. In one embodiment, an ionic liquid / hydrocarbon injection unit can be used to inject the reactant and ionic liquid catalyst together into the ionic liquid alkylation reactor to ensure good contact between the ionic liquid catalyst and the reactants.

[0075] The reaction temperature can generally range from about -40 to +250°C (-40 to +482°F), typically from about -20 to +100°C (-4 to 212°F), and frequently from about +4 to +60°C (+40 to +140°F). The reactor pressure can range from atmospheric pressure to about 8000 kPa. Typically, the reactor pressure is sufficient to keep the reactants in the liquid phase.

[0076] The residence time of the reactants in the reactor can generally range from a few seconds to several hours, and typically from about 0.5 to 60 minutes. In the case of ion liquid-catalyzed isoparaffin-olefin alkylation, the reactants can be introduced in a molar ratio of isoparaffin to olefin that is generally about 1–100, more typically about 2–50, and frequently 2–20. Heat generated by the reaction can be removed by various means known to those skilled in the art. Reactor conditions can be adjusted to optimize the process performance for a particular ion liquid-catalyzed alkylation process. Ionic liquid alkylation systems derived from HF alkylation units

[0077] In one embodiment, the present invention provides an ionic liquid alkylation system for carrying out ionic liquid alkylation processes, wherein the system can be derived from an existing or previous HF alkylation unit. As an example, one or more components of an ionic liquid alkylation system according to embodiments of the present invention can be provided, derived, or adapted from an existing or previous HF alkylation unit.

[0078] Fig. Figure 2 schematically shows a converted ion-liquid-catalyzed alkylation system according to an embodiment of the present invention. The converted ion-liquid-catalyzed alkylation system 110 can an ionic liquid alkylation system 100 include. In one embodiment, the converted ion-liquid-catalyzed alkylation system can 110furthermore, one or more deactivated RF unit components 10' include. “Disabled HF unit components” refers to one or more components of the HF alkylation unit. 10 , which were temporarily or permanently taken out of service. The ionic liquid alkylation system 100 It can also be used here as an ionic liquid catalyst alkylation system 100 be designated.

[0079] The one or more deactivated RF unit components 10' can be caused by one or more retained components of the HF alkylation unit 10 to be separated. “Retained components” of the HF alkylation unit 10' denote one or more components of the HF alkylation unit 10 , which are to be retained, either unchanged or in modified form, to carry out ion liquid catalyzed alkylation processes.

[0080] In one embodiment, the deactivated RF unit components can 10' remain in place, e.g. adjacent to one or more ion liquid-specific components of the ion liquid alkylation system 100 In another embodiment, one or more deactivated RF unit components can be 10' removed and / or disposed of. Examples include decommissioned RF unit components. 10' the RF reactor 16 ( Fig. 1) include. Another example is decommissioned RF unit components. 10' the RF reactor 16 and the RF clarifier 18 This includes, for example, decommissioned RF unit components. 10' the RF reactor 16 , the HF clarifier 18 and the RF regeneration unit 22 include.

[0081] Referring to Fig. 2 and Fig. 3. The ionic liquid alkylation system 100 a loading and treatment unit 12' , at least one hydrocarbon feeder line 13' , an ion fluid-specific subsystem 200 , a fractionation unit 24' and a product treatment unit 26' include the ionic liquid alkylation system. 100 It can be used to efficiently carry out an ion-liquid-catalyzed alkylation process. The feed treatment unit 12' It can be configured to process at least one hydrocarbon feed for ion-liquid-catalyzed alkylation reactions. The fractionation unit 24' can be configured to remove the hydrocarbon phase from the ionic liquid alkylation reactor 220to fractionate in order to provide one or more hydrocarbon products, and to return HCl and isobutane to the ion liquid-specific subsystem 200 to separate. One or more of the hydrocarbon products can be transferred to the product treatment unit. 26' are added to remove impurities from the hydrocarbon product(s). In one embodiment, HCl can be separated and supplied as an HCl-rich C3- fraction to the ion liquid-specific subsystem. 200 be returned.

[0082] In one embodiment, at least one component of an existing HF alkylation unit can be at least temporarily used in the ionic liquid alkylation system. 100 be retained. Such retained components could include, for example, one or more of the feeding and handling units. 12' , the hydrocarbon feeder 13' , the fractionation unit24' and the product treatment unit 26' belong. In another embodiment, one or more components selected from the feeding and handling unit can be included. 12' , the hydrocarbon feeder 13' , the fractionation unit 24' and the product treatment unit 26' , provided de novo, e.g. specifically for the assembly of the ionic liquid alkylation system 100 .

[0083] In another embodiment, one or more components of the ionic liquid alkylation system can be 100 , selected from the loading / treatment unit 12' , the hydrocarbon feeder 13' , the fractionation unit 24' and the product treatment unit 26', include an adapted, retrofitted, or modified unit or component of a previous HF alkylation unit. A common fractionation unit can serve as a non-restrictive example. 24 be modified to create a modified fractionation unit 24' to provide, which are used to separate an HCl-rich C 3- The fraction is configured from the hydrocarbon phase. The ionic liquid alkylation system 100 During an HF / IL conversion, it can be configured or adapted to use HCl-rich C 3- -fraction to the liquid ion alkylation reactor 220 to be attributed to.

[0084] Fig. Figure 3 schematically shows an ion-liquid-specific subsystem for an ion-liquid alkylation system according to an embodiment of the present invention. The ion-liquid-specific subsystem 200 can an ionic liquid / hydrocarbon injection unit210 , an ionic liquid alkylation reactor 220 , an ionic liquid / hydrocarbon separation unit 230 , an ionic liquid catalyst regeneration unit 240 and an ionic liquid catalyst feed line 252 include.

[0085] At least one hydrocarbon feed can be added to the ionic liquid alkylation reactor. 220 via the hydrocarbon feed line 13' and the ionic liquid / hydrocarbon injection unit 210 can be supplied. Simultaneously, ionic liquid catalyst can be supplied via the ionic liquid feed line. 252 and the ionic liquid / hydrocarbon injection unit 210 the ionic liquid alkylation reactor 220 to be supplied. The ionic liquid / hydrocarbon injection unit 210 can be used with the ionic liquid alkylation reactor 220be connected and in fluid contact to supply a mixture of ionic liquid and hydrocarbon to the ionic liquid alkylation reactor 220 to inject. In one embodiment, the ionic liquid / hydrocarbon injection unit can 210 integrally with the ionic liquid alkylation reactor 220 be trained, arranged within it, or be a component thereof.

[0086] The ionic liquid / hydrocarbon injection unit 210 may have at least one nozzle (not shown). Nozzles for introducing ionic liquid catalyst and hydrocarbon feeds are disclosed in the jointly filed US patent applications Nos. 20090166257, 20090171133 and 20090171134, as well as in US patent application No. 12 / 780452, filed on May 14, 2010, the disclosures of which are incorporated in their entirety into the present subject matter by cross-reference.

[0087] The ionic liquid alkylation reactor 220 It can be configured for ion liquid-catalyzed alkylation reactions. The mixture in the ion liquid alkylation reactor 220 It can comprise an ionic liquid phase and a hydrocarbon phase. The mixture in the ionic liquid alkylation reactor 22 It can comprise a reaction emulsion. The emulsion comprises a homogeneously dispersed ionic liquid phase in a continuous hydrocarbon phase.

[0088] Fig. Figure 4 schematically shows an ionic liquid / hydrocarbon separation unit for an ionic liquid alkylation system according to an embodiment of the present invention. The ionic liquid / hydrocarbon separation unit 230 can be a primary separation container 232 and an ion liquid separator 234 exhibit.

[0089] Further referring to Fig. 3 and Fig.4. The ionic liquid / hydrocarbon separation unit 230 via the primary separation container 232 with the liquid ion alkylation reactor 220 be connected. The primary separation container 232 can be configured to alkylation reactor effluent from the ionic liquid alkylation reactor 220 to absorb and separate the alkylation reactor effluent into a hydrocarbon phase and an ionic liquid phase. In one embodiment, the primary separation vessel can 232 the HF clarifier includes an HF alkylation unit that is undergoing or has undergone HF / IL conversion.

[0090] At least a first part of the ionic liquid phase from the primary separation vessel 232 can be connected to the ionic liquid alkylation reactor 220 be recycled. A second part of the ionic liquid phase from the ionic liquid / hydrocarbon separation unit. 230Can the ion liquid catalyst regeneration unit 240 to regenerate the liquid ion catalyst, and the regenerated liquid ion catalyst can be fed to the liquid ion alkylation reactor. 220 be traced back.

[0091] The ion liquid separator 234 can be used with the primary separation container 232 be connected and in fluid communication to remove at least part of the hydrocarbon phase from the primary separation vessel 232 to absorb. The ion liquid separator 234 It can be configured to separate the entrained ionic liquid from the hydrocarbon phase. The entrained ionic liquid can be separated by the ionic liquid separator. 234 to the liquid ion alkylation reactor 220 be traced back.

[0092] In one embodiment, the ion liquid separator can 234The separator comprises several stages or modules of separation material, and the stages may be arranged in series and / or parallel. The separation material may be selected to have a higher affinity for the ionic liquid phase than for the hydrocarbon phase, and the separation material may be fully wettable by the ionic liquid phase. The separation of an ionic liquid and hydrocarbon emulsion by a separator is disclosed in U.S. patent application No. 20100130800, filed jointly, the disclosure of which is incorporated in its entirety into the present subject matter by cross-reference.

[0093] There are numerous variations of the present invention that are possible in light of the teachings presented here. It is therefore understood that, within the scope of the following claims, the invention can be implemented differently than specifically described or illustrated herein.

Claims

[1] Method for converting an HF alkylation unit into an ionic liquid alkylation system, the method comprising: a) Providing an ion liquid-specific subsystem comprising an ion liquid alkylation reactor; and b) Combining at least one component of the ion liquid-specific subsystem with at least one component of the HF alkylation unit. [2] The method of claim 1, wherein the ion liquid-specific subsystem further comprises an ion liquid / hydrocarbon injection unit which is in fluid communication with the ion liquid alkylation reactor, and wherein the method further comprises: c) Connecting the ionic liquid / hydrocarbon injection unit to at least one hydrocarbon feed line, wherein the ionic liquid alkylation reactor and the ionic liquid / hydrocarbon injection unit are jointly configured to form a mixture comprising an ionic liquid phase and a hydrocarbon phase. [3] The method of claim 1, wherein the HF alkylation unit comprises an HF settling tank and a fractionation unit arranged downstream of the HF settling tank, wherein the ion liquid-specific subsystem further comprises a primary separation vessel and wherein the method further comprises: d) Separating the HF settling tank from the fractionation unit; e) Connecting the liquid ion alkylation reactor to the primary separation vessel to feed an alkylation reactor effluent from the liquid ion alkylation reactor to the primary separation vessel, the primary separation vessel being configured to separate the alkylation reactor effluent into a hydrocarbon phase and an liquid ion phase. [4] The method of claim 3, wherein the ion liquid-specific subsystem further comprises an ion liquid separator, and wherein the method further comprises: f) Connecting the primary separation vessel to the ion liquid separator to transfer the hydrocarbon phase from the primary separation vessel to the ion liquid separator; and g) Connecting the ion liquid separator to the fractionation unit to feed the hydrocarbon phase from the ion liquid separator to the fractionation unit. [5] The method of claim 1, wherein the HF alkylation unit comprises an HF clarifier and the ion liquid-specific subsystem further comprises an ion liquid separator, wherein the method further comprises: (h) Connecting the ionic liquid alkylation reactor to the HF clarifier to feed an alkylation reactor effluent from the ionic liquid alkylation reactor to the HF clarifier, the HF clarifier being configured to separate the alkylation reactor effluent into a hydrocarbon phase and an ionic liquid phase; and i) Connecting the HF clarifier to the ion liquid separator to feed the hydrocarbon phase from the HF clarifier to the ion liquid separator. [6] The method of claim 1, wherein the HF alkylation unit comprises a fractionation unit, and wherein the method further comprises: j) Modifying the fractionation unit to provide a modified fractionation unit such that the modified fractionation unit is configured to separate an HCl-rich C3- fraction from the hydrocarbon phase. [7] Method according to claim 1, further comprising: k) Replacing at least one component of the HF alkylation unit with a component comprising a Ni / Cr alloy or a Ni / Cu alloy. [8] Method for converting an HF alkylation unit into an ionic liquid alkylation system, wherein the HF alkylation unit comprises a fractionation unit, and wherein the method comprises: a) Provision of an ionic liquid alkylation reactor and an ionic liquid separator; b) Connecting the liquid ion alkylation reactor to at least one hydrocarbon feed line to supply at least one hydrocarbon feed to the liquid ion alkylation reactor; and c) Connecting the ion liquid separator to the fractionation unit. [9] The method of claim 8, further comprising d) Providing an ionic liquid / hydrocarbon injection unit, wherein step b) comprises connecting the ionic liquid alkylation reactor to the at least one hydrocarbon feed line via the ionic liquid / hydrocarbon injection unit. [10] Method according to claim 9, further comprising e) connecting the ionic liquid / hydrocarbon injection unit to an ionic liquid feed line, wherein the ionic liquid / hydrocarbon injection unit is configured to inject an ionic liquid catalyst and at least one hydrocarbon feed into the ionic liquid alkylation reactor. [11] Method according to claim 9, wherein the ionic liquid alkylation reactor and the ionic liquid / hydrocarbon injection unit are configured together to form a mixture comprising a dispersed ionic liquid phase and a continuous hydrocarbon phase. [12] The method of claim 8, further comprising: f) Provision of a primary separation container; and g) Connecting the primary separation vessel to the ion liquid separator. [13] Method according to claim 12, further comprising h) connecting the primary separation vessel to the liquid ion alkylation reactor, wherein the primary separation vessel is in fluid communication with the liquid ion alkylation reactor to supply an alkylation reactor effluent from the liquid ion alkylation reactor to the primary separation vessel, and the primary separation vessel is configured to separate the alkylation reactor effluent into the hydrocarbon phase and the liquid ion phase. [14] The method of claim 13, wherein the HF alkylation unit comprises an HF reactor and an HF settling tank, the HF reactor being arranged downstream and upstream of the fractionation unit, and wherein the method further comprises: i) Disconnecting the HF reactor from the at least one hydrocarbon feed line; and j) Separating the HF settling tank from the fractionation unit. [15] The method of claim 8, wherein the HF alkylation unit comprises an HF reactor and an HF settling tank arranged downstream of the HF reactor and upstream of the fractionation unit, and wherein the method further comprises: k) Separating the RF clarifier from the RF reactor; l) Connecting the HF clarifier to the liquid ion alkylation reactor, wherein the HF clarifier is in fluid communication with the liquid ion alkylation reactor to supply an alkylation reactor effluent from the liquid ion alkylation reactor to the HF clarifier, and the HF clarifier is configured to separate the alkylation reactor effluent into the hydrocarbon phase and the liquid ion phase; and m) Connecting the HF clarifier to the ion liquid separator. [16] The method of claim 8, wherein an alkylation reactor effluent from the liquid ion alkylation reactor comprises a hydrocarbon phase, and wherein the method further comprises: n) Modifying the fractionation unit to provide a modified fractionation unit such that the modified fractionation unit is configured to separate an HCl-rich C3- fraction from the hydrocarbon phase, wherein the ionic liquid alkylation system is configured to return the HCl-rich C3- fraction to the ionic liquid alkylation reactor. [17] Method for converting an HF alkylation unit into an ionic liquid alkylation system, wherein the HF alkylation unit comprises a fractionation unit, and wherein the method comprises: a) Providing an ionic liquid alkylation reactor configured for ionic liquid alkylation reactor reactions, wherein the ionic liquid alkylation reactor has an ionic liquid / hydrocarbon injection unit connected to it in fluid communication; b) Connect at least one hydrocarbon feed line to the ionic liquid / hydrocarbon injection unit to supply at least one hydrocarbon feed to the ionic liquid alkylation reactor; c) Provision of an ionic liquid / hydrocarbon separation unit; d) Connecting the liquid-ion / hydrocarbon separation unit to the liquid-ion alkylation reactor, wherein the liquid-ion / hydrocarbon separation unit is configured to separate an alkylation reactor effluent from the liquid-ion alkylation reactor into a liquid-ion phase comprising a liquid-ion catalyst and a hydrocarbon phase comprising an alkylate; and e) Connecting the ionic liquid / hydrocarbon separation unit to the fractionation unit in order to supply at least a portion of the hydrocarbon phase to the fractionation unit. [18] Method according to claim 17, further comprising: f) providing an ion liquid catalyst regeneration unit, wherein the ion liquid alkylation system is configured to return regenerated ion liquid catalyst from the ion liquid catalyst regeneration unit to the ion liquid alkylation reactor. [19] The method of claim 17, further comprising: g) modifying the fractionation unit to provide a modified fractionation unit such that the modified fractionation unit is configured to separate an HCl-rich C3- fraction from the hydrocarbon phase, wherein the liquid ion alkylation system is configured to return the HCl-rich C3- fraction to the liquid ion alkylation reactor. [20] Method according to claim 17, wherein the ionic liquid / hydrocarbon separation unit comprises a primary separation vessel and an ionic liquid separator in fluid communication with the primary separation vessel, and wherein step d) comprises connecting the primary separation vessel to the ionic liquid alkylation reactor, and step e) comprises connecting the ionic liquid separator to the fractionation unit. [21] Method according to claim 20, wherein the HF alkylation unit further comprises an HF settling tank and the primary separation vessel comprises the HF settling tank. [22] An ionic liquid alkylation system derived from an existing HF unit with a fractionation unit, wherein the ionic liquid alkylation system comprises: an ion liquid alkylation reactor configured for ion liquid catalyzed alkylation reactions; an ionic liquid / hydrocarbon separation unit in fluid connection with the ionic liquid alkylation reactor, wherein the ionic liquid / hydrocarbon separation unit is configured to separate an alkylation reactor effluent of the ionic liquid alkylation reactor into an ionic liquid phase and a hydrocarbon phase; and the fractionation unit, wherein the fractionation unit is in fluid connection with the ionic liquid / hydrocarbon separation unit. [23] Ionic liquid alkylation system according to claim 22, further comprising an ionic liquid / hydrocarbon injection unit which is in fluid communication with the ionic liquid alkylation reactor to inject a mixture of ionic liquid and hydrocarbon into the ionic liquid alkylation reactor. [24] Ionic liquid alkylation system according to claim 23, wherein the ionic liquid / hydrocarbon injection unit is arranged at least partially within the ionic liquid alkylation reactor, and the ionic liquid alkylation reactor and the ionic liquid / hydrocarbon injection unit are configured together to form a homogeneous mixture in the ionic liquid alkylation reactor comprising a dispersed ionic liquid phase and a continuous hydrocarbon phase. [25] Ionic liquid alkylation system according to claim 22, wherein the ionic liquid / hydrocarbon separation unit comprises a primary separation vessel and an ionic liquid separator which is in fluid communication with the primary separation vessel to receive at least a part of the hydrocarbon phase from the primary separation vessel; and the ionic liquid separator is configured to separate entrained ionic liquid from the hydrocarbon phase. [26] Ionic liquid alkylation system according to claim 25, wherein the fractionation unit is in fluid communication with the ionic liquid separator to receive the hydrocarbon phase from the ionic liquid separator, and the fractionation unit is configured to separate at least one hydrocarbon product from the hydrocarbon phase. [27] Ionic liquid alkylation system according to claim 22, wherein the fractionation unit is modified to provide a modified fractionation unit such that the modified fractionation unit is configured to separate an HCl-rich C3- fraction from the hydrocarbon phase, and the ionic liquid alkylation system is configured to return the HCl-rich C3- fraction to the ionic liquid alkylation reactor.