Alkylation reaction device and reaction method

Abstract

An Alkylation reaction device and a method. The device comprises a reactor (1, 101); three intensification units (15, 5, 4) are vertically arranged inside the reactor (1, 101); a first intensification unit (15) is arranged at the bottom of the reactor (1, 101), a second intensification unit (5) is arranged directly above the first intensification unit (15), and a third intensification unit (4) is arranged in the middle of the reactor (1, 101); a sensor (2, 103) is further arranged in the reactor (1, 101), the sensor (2, 103) is tightly attached to the inner wall of the reactor (1, 101), and the sensor (2, 103) is located above the third intensification unit (4); and a main piping system is arranged at the top of the reactor (1, 101). The reaction device can improve the reaction efficiency and the product purity, reduce the reaction energy consumption, and prolong the service life of equipment.

Description

An alkylation reaction apparatus and reaction method Technical Field

[0001] This invention belongs to the field of chemical technology, specifically to an alkylation reaction apparatus and reaction method. Background Technology

[0002] Alkylation is an important type of organic reaction. Through alkylation, new carbon-carbon and carbon-heterovalent bonds can be formed, thereby lengthening the molecular skeleton of organic compounds, changing the chemical structure of the alkylated product, endowing it with new properties, and producing many organic chemicals with specific applications. Traditional processes often suffer from low solubility between reactants and catalysts, leading to decreased reaction efficiency. Furthermore, the catalyst and residual reactants are difficult to recover, resulting in waste.

[0003] In view of this, the present invention is hereby proposed.

[0004] Summary of the Invention

[0005] The primary objective of this invention is to provide an alkylation reaction apparatus that, through dual-circulation and internal circulation pipelines and supporting devices, improves reaction efficiency and product purity, reduces reaction energy consumption, and enables effective recovery of catalysts and remaining reactants; and is equipped with an intelligent control system to control the reaction apparatus.

[0006] A second objective of the present invention is to provide a reaction method for the above-mentioned alkylation reaction, which can be used in conjunction with a reaction apparatus to simplify the reaction process and improve the reaction efficiency.

[0007] To achieve the above-mentioned objectives of this invention, the following technical solution is adopted:

[0008] This invention provides an alkylation reaction apparatus, comprising:

[0009] The reactor, wherein three intensifier units are vertically arranged inside the reactor;

[0010] The first intensifier unit is located at the bottom of the reactor, the second intensifier unit is located directly above the first intensifier unit, and the third intensifier unit is located in the middle of the reactor.

[0011] The reactor is also equipped with a sensor, which is attached to the inner wall of the reactor and located above the third intensifier unit.

[0012] The reactor is equipped with a main pipeline at the top.

[0013] In this invention, a first intensifier unit is provided to break down and disperse the gaseous reactants introduced therein. A second intensifier unit, positioned directly above the first intensifier unit, is used to mix and disperse the catalyst and reaction liquid introduced therein. The broken gas rises and mixes thoroughly with the broken and dispersed catalyst and reaction liquid, reacting to generate products. Because incomplete reactions may occur during actual reaction processes, in this invention, some incompletely reacted reactants can continue to react through a third intensifier unit, allowing the reactants to undergo a complete reaction, thus solving the technical problem proposed by this invention.

[0014] In this invention, the positions of each intensifier unit are defined. The first intensifier unit is located at the bottom of the reactor. When the first intensifier unit is at the bottom, the broken-up gas can escape into the second intensifier unit, where it collides. If the positions of the two intensifier units change, the reaction is difficult to occur. Furthermore, the position of the third intensifier unit is defined; it is located in the middle of the reactor. This is because, after the reaction, the reactants rise continuously, resulting in a large amount of gas in the middle of the reactor. When the third intensifier unit is located here, not only can as much unreacted gas participate in the reaction as possible, but the sensor located above the third intensifier unit can also better detect the state of the reactor after passing through it, improving reaction efficiency and providing accurate detection. Finally, when the third intensifier unit is located in the middle of the reactor, it also ensures that the reactants passing through the first circulation pipeline are not drawn into the second intensifier unit, thus preventing the formation of byproducts.

[0015] At the same time, due to the enhanced unit setup, the reaction temperature inside the reactor can be effectively reduced, thereby accelerating the reaction process and reducing energy consumption.

[0016] The reactor of this invention is also equipped with a sensor, which should be located above the third intensifier unit. The sensor is used to detect the content of each substance in the reactor after complete reaction in order to confirm the reaction status, and to provide feedback on the reaction status in the reactor. The sensor is also used to control the control valve according to the reaction status to achieve control of the reaction process.

[0017] The main pipeline is connected in parallel with the first circulation pipeline and the second circulation pipeline;

[0018] The first circulation pipeline is connected to the second circulation pipeline to form an internal circulation, and a circulation pump is installed on the internal circulation pipeline;

[0019] Control valve a and control valve b are respectively installed at the connection between the first circulation pipeline and the second circulation pipeline;

[0020] The outlet of the first circulation pipeline is connected to the third intensifier unit.

[0021] In this invention, the arrangement of the first and second circulation pipelines enables unreacted reactants to undergo sufficient reaction, improving reaction efficiency and facilitating catalyst recovery. A sensor located above the third intensifier unit monitors the reactor environment. When the sensor detects a significant amount of unreacted reactants, the controller activates the circulation pump to power the reactants in the circulation pipeline and closes control valves a and b, allowing the reaction liquid to circulate once in the internal circulation pipeline. This allows the unreacted reactants to react and disperse using residual heat from the reaction process. After one circulation, the circulation pump is shut off and control valve a is opened, allowing the reactants to be crushed, mixed, and reacted again in the third intensifier unit to obtain the product. Subsequently, the controller closes control valve a and opens control valve b, allowing the product to enter the second circulation pipeline for further separation.

[0022] In the actual reaction process, due to the presence of the internal circulation pipeline, the internal circulation pipeline, the first circulation pipeline, and the second circulation pipeline are each opened only once. This single opening ensures that the reactants participate in the reaction and react completely. Opening the circulation pipeline two or more times will lead to over-reaction and increase the content of by-products. Therefore, in this invention, only one cycle is needed to ensure the complete reaction of the reactants, thereby achieving energy saving and reducing by-products.

[0023] Furthermore, the outlet of the first circulation pipeline is connected to the third intensifier unit, but not to any other intensifier units. This is because the reactants require power from other mechanical devices, and the third intensifier unit creates a low-pressure zone that attracts the substances in the pipeline, allowing them to quickly re-enter the reaction system and rapidly complete the reaction. The outlet of the first circulation pipeline cannot be connected to the second intensifier unit. This is because at the end of the first reaction, there are a large amount of products and a small amount of unreacted reactants in the pipeline. If the first circulation pipeline were connected to the second intensifier unit, the large amount of products and the small amount of reactants would continue upwards through the third intensifier unit after passing through the second intensifier unit. This double reaction would lead to over-reaction, causing a large amount of products to undergo side reactions, thus reducing the reaction efficiency and contradicting the original purpose of the circulation pipeline.

[0024] The second circulation pipeline is connected to the separation device;

[0025] The separation device is connected to the storage tank.

[0026] After the reaction is complete, the reactants are separated using a separation device. Different alkylation reactions require different separation devices, which can be single or multiple, depending on the specific needs. The catalyst and reactants after separation can be returned to their respective storage tanks for reuse, thus achieving the recovery of catalysts and unused reactants.

[0027] Preferably, as a further specific embodiment, a guide port is provided above the first strengthening unit, and a baffle is provided above the guide port.

[0028] Since the first intensifier unit is connected to the gas storage tank, the guide port and baffle located above the first intensifier unit can cause the gas entering the intensifier unit to collide and disperse, thereby making the reaction more complete and improving the reaction efficiency.

[0029] Preferably, as a further specific embodiment, the alkylation reaction apparatus further includes a catalyst storage tank, a gas storage tank, and a liquid storage tank;

[0030] The gas storage tank is directly connected to the first enhancement unit via a gas pipeline, and a gas pipeline control valve is installed on the gas pipeline.

[0031] The catalyst storage tank supplies catalyst through a catalyst pipeline control valve on the catalyst pipeline, and the liquid storage tank supplies reaction liquid through a liquid pipeline control valve on the liquid pipeline. The catalyst pipeline and the liquid pipeline are connected in parallel to form a mixing pipeline, which is directly connected to the second enhancement unit.

[0032] The catalyst and reaction liquid enter the mixing pipeline, where they are premixed. The premixed liquids then enter the second intensifier unit, which allows for more thorough and uniform mixing.

[0033] Preferably, the alkylation reaction apparatus is equipped with a control valve in its pipeline, and the reaction state is controlled by the opening and closing of the control valve and the flow rate.

[0034] Preferably, as a further specific embodiment, the alkylation reaction apparatus further includes a controller, which can display the data transmitted from the sensor in real time and control all control valves in the alkylation reaction apparatus.

[0035] The location and type of the control valve can be adjusted according to the different reactants involved in the reaction. Some devices in the reaction pipeline of this invention (such as heat exchangers) can also be configured according to the actual reaction requirements. The control valve selected in this invention can control the opening and closing of the pipeline and regulate the flow rate of substances in the pipeline.

[0036] The present invention also provides a reaction method for an alkylation reaction apparatus, comprising:

[0037] The catalyst is first mixed with the reaction solution, and then mixed with the gas to carry out an enhanced reaction, thus obtaining the product.

[0038] When the alkylation reaction is to prepare high-octane alkylated gasoline from isobutane and butene, the catalyst is a liquid-phase catalyst or can be dissolved in liquid-phase feedstock.

[0039] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0040] (1) By setting up a first circulation pipeline and sensors, the state of the reactants in the reactor can be detected, and unreacted reactants can be promptly reintroduced into the reaction system, improving reaction efficiency and avoiding over-reaction, thus ensuring the purity of the products. By setting up a second circulation pipeline, the ionic liquid can be recovered, realizing the recovery of the catalyst. At the same time, an internal circulation pipeline is set up, which can premix the unreacted reactants once, allowing the premixed reactants to re-enter the reaction system, improving reaction efficiency and reducing energy consumption.

[0041] (2) By setting up the intensified unit, the reactants and catalyst can be fully mixed and dispersed, thus improving the reaction efficiency; at the same time, by setting up guide ports and baffles, the gases participating in the reaction can be fully offset and collide, further improving the reaction efficiency.

[0042] (3) The reaction device realizes the recovery of reactants and catalysts that have not participated in the reaction. The sensor and controller settings enable the reaction to proceed automatically and provide real-time feedback on the situation inside the reactor, ensuring the safety of the reactor reaction while improving the reaction efficiency. Attached Figure Description

[0043] Figure 1: Schematic diagram of an apparatus for the alkylation reaction of isobutane and butene to produce high-octane alkylated gasoline. Wherein:

[0044] 1-Reactor; 2-Sensor; 3-Controller; 4-Third Enhancement Unit; 5-Second Enhancement Unit;

[0045] 6-Guide port; 7-Ionic liquid storage tank; 8-Liquid storage tank; 9-Baffle; 10-Gas storage tank;

[0046] 11-Ionic liquid line control valve; 12-Liquid line control valve; 13-Gas line control valve;

[0047] 14-Control valve e; 15-First enhanced unit; 16-Control valve b; 17-Control valve a;

[0048] 18-Circulating pump; 19-Separation device; 20-Phase separator; 21-Control valve c; 22-Control valve d.

[0049] Figure 2: Schematic diagram of the apparatus for the reaction of ethylene and benzene to produce ethylbenzene. Wherein:

[0050] 101-Reactor; 102-Controller; 103-Sensor; 104-Third Enhancement Unit;

[0051] 105 - Second Intensifier Unit; 106 - Baffle; 107 - Guide Port; 108 - First Intensifier Unit;

[0052] 109 - Gas pipeline control valve; 110 - Gas storage tank; 111 - Heat exchanger; 112 - Circulation pump;

[0053] 113-Control valve a; 114-Control valve b; 115-Distillation column; 116-Catalyst storage tank;

[0054] 117 - Liquid storage tank; 118 - Catalyst pipeline control valve; 119 - Liquid pipeline control valve;

[0055] 120 - Control valve e; 121 - Control valve f; 122 - Control valve g. Detailed Implementation

[0056] The technical solution of the present invention will be clearly and completely described below with reference to the accompanying drawings and specific embodiments. However, those skilled in the art will understand that the embodiments described below are some embodiments of the present invention, but not all embodiments, and are only used to illustrate the present invention, and should not be regarded as limiting the scope of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. Where specific conditions are not specified in the embodiments, conventional conditions or conditions recommended by the manufacturer shall be followed. Where the manufacturers of reagents or instruments are not specified, they are all conventional products that can be purchased commercially.

[0057] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0058] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0059] Example 1

[0060] High-octane alkylated gasoline is prepared by alkylation reaction of isobutane with butene.

[0061] In this reaction process, an ionic liquid is selected as a catalyst to carry out the catalytic reaction.

[0062] Figure 1 shows the alkylation reaction apparatus of the present invention, comprising: a reactor-1, where the alkylation reaction takes place; three intensifier units are vertically arranged from bottom to top inside the reactor-1, wherein the first intensifier unit-15 is located at the bottom of the reactor-1 and is directly connected to the gas storage tank-10 via a pipeline, and a gas pipeline control valve-13 is installed on the gas pipeline; a guide port-6 is provided directly above the first intensifier unit-15, and a baffle-9 is provided above the guide port-6. The second intensifier unit-5 is located above the baffle-9 and is connected to a mixing pipeline, which is connected in parallel to the ionic liquid storage tank-7 and the liquid storage tank-8 respectively. The third intensifier unit-4 is located in the middle of the reactor, directly above the second intensifier unit-5, and a sensor-2 is installed above the third intensifier unit-4, the sensor-2 being close to the inner wall of the reactor-1. The controller-3 can display the value detected by the sensor-2 and control all control valves in the reaction system. The reactor-1 has a main pipeline at its top for discharging materials. This main pipeline is connected in parallel to the first and second circulation pipelines. A control valve a-17 is installed on the first circulation pipeline to control its opening and closing, as well as the status of the inner circulation pipeline. The outlet of the first circulation pipeline is connected to the third enhancement unit-4. A control valve b-16 is installed on the second circulation pipeline to control its opening and closing, as well as the status of the inner circulation pipeline. The first and second circulation pipelines are connected by a pipe to form an inner circulation pipeline. A circulation pump-18 is installed on the inner circulation pipeline, and control valves a-17 and b-16 are respectively located at two connection points between the first and second circulation pipelines. The second circulation pipeline is connected to the phase separator-20 via a gas-liquid separator-19, which is also connected to a gas storage tank-10 via a pipe. Phase separator-20 is connected to ionic liquid storage tank-7 via a pipeline, and is also provided with a pipeline outlet to allow the product to flow out of the reaction system.

[0063] The practical application of the alkylation reactor in this embodiment includes the following process:

[0064] Gas storage tank-10 stores a mixture of butene and isobutane, with a molar ratio of isobutane to butene of 10:1. Liquid storage tank-8 stores gasoline, and ionic liquid storage tank-7 stores an ionic liquid with strong acid properties used for catalysis. At the start of the reaction, the controller activates ionic liquid pipeline control valve-11, liquid pipeline control valve-12, gas pipeline control valve-13, and sensor-2, and adjusts the flow rate by controlling the valves to ensure that the reactants enter reactor-1 at a reasonable flow rate. When the gas pipeline control valve-13, ionic liquid pipeline control valve-11, and liquid pipeline control valve-12 are opened, the mixture of butene and isobutane enters the first intensifier unit-15 through the gas pipeline, where the two gases are thoroughly mixed and broken up. Gasoline enters the mixing pipeline through the liquid pipeline, and the ionic liquid enters the mixing pipeline through the ionic liquid pipeline. The gasoline and ionic liquid undergo a premixing process in the mixing pipeline. The premixed mixture then enters the second intensifier unit-5 for further breaking up, ensuring the ionic liquid is fully dispersed in the gasoline. Subsequently, the broken mixture in the first intensifier unit-15 is further dispersed by collision through the guide port-6 and baffle-9, and then enters the second intensifier unit-5 to react with the gasoline and ionic liquid, producing high-octane alkylated gasoline.

[0065] High-octane alkylated gasoline and a mixture of some unreacted butene and isobutane enter the third enhanced unit-4 for crushing reaction. Sensor-2 monitors the state inside reactor-1 in real time and returns the state inside the reactor to controller-3. When sensor-2 detects the presence of unreacted reactants, the controller, upon receiving the data, closes control valves a-17 and b-16 and opens circulation pump-18. The unreacted reactants undergo an initial internal circulation in the internal circulation pipeline under the action of circulation pump-18. Subsequently, control valve b-16 remains closed while control valve a-17 opens, allowing the reactants to re-enter the third enhanced unit-4 for further reaction. Sensor-2 then re-detects the reactants after the second reaction and monitors the state within reactor-1 in real time. Simultaneously, controller-3 closes control valve a-17 and opens control valve b-16 and circulation pump-18, allowing the mixture of high-octane alkylated gasoline, ionic liquid, and butene to enter the gas-liquid separator-19 through the second circulation pipeline, separating the butene from the reaction system. Controller-3 then opens control valve d-22, allowing the separated butene to return to the gas storage tank-10 via pipeline for recycling within the reaction system. When the gas-liquid separation is complete, controller-3 opens control valve c-21, allowing the liquid containing ionic liquid and high-octane alkyl gasoline to enter phase separator-20 for separation. The separated ionic liquid re-enters ionic liquid storage tank-7, while the product, high-octane alkyl gasoline, flows out through the pipeline of control valve e-14.

[0066] The temperature inside reactor 1 is controlled between 20℃ and 30℃.

[0067] Example 2

[0068] High-octane alkylated gasoline is prepared by alkylation reaction of isobutane with butene.

[0069] The process includes the following steps:

[0070] Gas storage tank-10 stores a mixture of butene and isobutane, with a molar ratio of isobutane to butene of 10:1. Liquid storage tank-8 stores gasoline, and ionic liquid storage tank-7 stores an ionic liquid with strong acid properties used for catalysis. At the start of the reaction, the controller activates ionic liquid pipeline control valve-11, liquid pipeline control valve-12, gas pipeline control valve-13, and sensor-2, and adjusts the flow rate by controlling the valves to ensure that the reactants enter reactor-1 at a reasonable flow rate. When the gas pipeline control valve-13, ionic liquid pipeline control valve-11, and liquid pipeline control valve-12 are opened, the mixture of butene and isobutane enters the first intensifier unit-15 through the gas pipeline, where the two gases are thoroughly mixed and broken up. Liquid gasoline enters the mixing pipeline through the liquid pipeline, and the ionic liquid enters the mixing pipeline through the ionic liquid pipeline. The gasoline and ionic liquid undergo a premixing process in the mixing pipeline. The premixed mixture then enters the second intensifier unit-5 for further breaking up, ensuring the ionic liquid is fully dispersed in the gasoline. Subsequently, the gas broken up in the first intensifier unit-15 is further dispersed by collision through the guide port-6 and baffle-9, and then enters the second intensifier unit-5 to react with the gasoline and ionic liquid, producing high-octane alkylated gasoline.

[0071] High-octane alkylated gasoline and a mixture of unreacted butene and isobutane enter the third enhanced unit-4 for a crushing reaction. Sensor-2 monitors the state within reactor-1 in real time and reports this status back to controller-3. When sensor-2 detects that the isobutane and gasoline reaction in reactor-1 is complete, controller-3 closes control valves a-17 and b-16. The high-octane alkylated gasoline then enters separation unit-19 through control valve b-16 for separation. After separation, controller-3 opens control valve d-22, allowing butene gas to re-enter gas storage tank-10 for further reaction. Controller-3 then opens control valves c-21 and e-14, allowing the remaining liquid mixture after gas-liquid separation to enter phase separator-20 for further separation. The separated high-octane alkylated gasoline flows out through control valve e-14, while the ionic liquid, acting as a catalyst, re-enters the reaction system through ionic liquid storage tank-7.

[0072] The temperature inside reactor 1 is controlled between 20℃ and 30℃.

[0073] Example 3

[0074] Benzene reacts with ethylene to produce ethylbenzene.

[0075] Figure 2 shows the alkylation reaction apparatus of the present invention, comprising: a reactor-101 where the alkylation reaction occurs; three intensifier units are vertically arranged from bottom to top inside the reactor-101, wherein the first intensifier unit-108 is located at the bottom of the reactor-101 and is directly connected to the gas storage tank-110 via a pipeline, and a gas pipeline control valve-109 is installed on the gas pipeline; a guide port-107 is provided directly above the first intensifier unit-108, and a baffle-106 is provided above the guide port-107. The second intensifier unit-105 is located above the baffle-106 and is connected to a mixing pipeline, which is connected in parallel to the catalyst storage tank-116 and the liquid storage tank-117 respectively. The third intensifier unit-104 is located in the middle of reactor-101, directly above the second intensifier unit-105. A sensor-103 is installed above the third intensifier unit-104, attached to the inner wall of reactor-101. The controller-102 displays the values ​​detected by sensor-103 and controls all control valves in the reaction system. A main pipeline for discharging the reactants is located at the top of reactor-101. A heat exchanger-111 is installed on the main pipeline for heat exchange. The main pipeline is connected in parallel to the first and second circulation pipelines. A control valve a-113 is installed on the first circulation pipeline to control the opening and closing of the first circulation pipeline and the status of the inner circulation pipeline. The outlet of the first circulation pipeline is connected to the third intensifier unit-104. A control valve b-114 is installed on the second circulation pipeline to control the opening and closing of the second circulation pipeline and the status of the inner circulation pipeline. The first and second circulation pipelines are connected by a pipeline to form an internal circulation pipeline. Circulation pump-112 is installed on the internal circulation pipeline, and control valves a-113 and b-114 are respectively located at the two connections between the first and second circulation pipelines. The second circulation pipeline is connected to catalyst storage tank-116 and liquid storage tank-117 via distillation column-115. Control valves-118 (catalyst pipeline),-119 (liquid pipeline), e-120, f-121, and g-122 control the reaction process.

[0076] The practical application of the alkylation reactor in this embodiment includes the following process:

[0077] Ethylene is stored in gas storage tank-110, benzene in liquid storage tank-117, and catalyst in catalyst storage tank-116, which catalyzes the reaction. At the start of the reaction, the controller activates catalyst pipeline control valve-116, liquid pipeline control valve-119, gas pipeline control valve-109, and sensor-103, and adjusts the flow rate to ensure the reactants enter reactor 101 at a suitable flow rate. When gas pipeline control valve-109, liquid pipeline control valve-119, and gas pipeline control valve-109 are open, ethylene gas enters the intensification unit-108 through the gas pipeline for crushing and dispersion, benzene enters the mixing pipeline through the liquid pipeline, and the catalyst enters the mixing pipeline through the catalyst pipeline. Benzene and catalyst undergo premixing in the mixing pipeline. The premixed mixture then enters the second intensification unit-105 for crushing, ensuring the catalyst is fully dispersed in the benzene. Subsequently, the gas, after being broken up in the first intensifier unit-108, is further dispersed by collision through the guide port-107 and the baffle-106, and then enters the second intensifier unit-105 to react with benzene and catalyst to obtain ethylbenzene.

[0078] Ethylbenzene and partially and partially unreacted ethylene react with gaseous benzene in the third enhanced unit-104 to react. Sensor-103 monitors the state inside reactor-101 in real time and returns the state inside the reactor to controller-102. The reaction product is cooled by heat exchanger-111 on the main pipeline. At the same time, when sensor-103 detects that there are still some unreacted reactants, the controller, upon receiving the data, closes control valves a-113, b-114, and circulation pump-112. The unreacted reactants then undergo an internal circulation in the internal circulation pipeline under the action of circulation pump-112. Subsequently, control valve b-112 of the second circulation pipeline remains closed, while control valve a-114 is opened, allowing the reactants to re-enter the third intensifier unit-104 for further reaction. Then, sensor-103 re-detects the reactants after the second reaction and monitors the state inside reactor-101 in real time. Simultaneously, controller-102 closes control valve a-113 and opens control valve b-114 and circulation pump-112, allowing the mixture of ethylbenzene, catalyst, and benzene to enter the distillation column-115 through the second circulation pipeline. Since benzene is in excess during the reaction of benzene and ethylene, the mixture does not contain unreacted ethylene. Therefore, it is only necessary to separate the catalyst and benzene from the reaction system. At this time, the controller-102 opens the control valves f-121 and e-120, so that the benzene obtained by distillation returns to the liquid storage tank-117 through the pipeline and re-enters the reaction system for recycling. The catalyst returns to the catalyst storage tank-116.

[0079] At this time, the reaction temperature in reactor-101 is controlled at 150℃-160℃.

[0080] The reaction pressure is controlled at around 5 atmospheres.

[0081] Example 4

[0082] Benzene reacts with ethylene to produce ethylbenzene.

[0083] Ethylene is stored in gas storage tank-110, benzene in liquid storage tank-117, and catalyst in catalyst storage tank-116, which catalyzes the reaction. At the start of the reaction, the controller activates catalyst pipeline control valve-116, liquid pipeline control valve-119, gas pipeline control valve-109, and sensor-103, and adjusts the flow rate to ensure the reactants enter reactor 101 at a suitable flow rate. When gas pipeline control valve-109, liquid pipeline control valve-119, and gas pipeline control valve-109 are open, ethylene gas enters the intensification unit-108 through the gas pipeline for crushing and dispersion, benzene enters the mixing pipeline through the liquid pipeline, and the catalyst enters the mixing pipeline through the catalyst pipeline. Benzene and catalyst undergo premixing in the mixing pipeline. The premixed mixture then enters the second intensification unit-105 for crushing, ensuring the catalyst is fully dispersed in the benzene. Subsequently, the gas, after being broken up in the first intensifier unit-108, is further dispersed by collision through the guide port-107 and the baffle-106, and then enters the second intensifier unit-105 to react with benzene and catalyst to obtain ethylbenzene.

[0084] Ethylbenzene and partially and partially unreacted ethylene react with gaseous benzene in the third enhanced unit-104. Sensor-103 monitors the state within reactor-101 in real time and returns the status to controller-102. The reaction products are cooled by heat exchanger-111 on the main pipeline. At this point, sensor-103 detects the absence of unreacted benzene and ethylene in the reactor. Controller-102 closes control valve a-113 and circulation pump-112 and opens control valve b-114. Due to complete reaction, all ethylene in the reactor is consumed, leaving only benzene as a reactant. The product ethylbenzene and catalyst enter the distillation column-115 through the second circulation pipeline for distillation, yielding benzene, catalyst, and the product ethylbenzene. Then, controller-102 sequentially opens control valves e-120, f-121, and g-122, returning the catalyst to catalyst storage tank-116, returning benzene to liquid storage tank-117, and allowing the product ethylbenzene to flow out.

[0085] At this time, the reaction temperature in reactor-101 is controlled at 150℃-160℃.

[0086] The reaction pressure is controlled at around 5 atmospheres.

[0087] Example 5

[0088] The specific implementation method is the same as that in Example 1, except that the first circulation pipeline is not set.

[0089] Example 6

[0090] The specific implementation method is the same as the embodiment, but without setting a second circulation pipeline.

[0091] The specific reaction process is as follows: the high-octane alkylated gasoline and other mixtures from the third enhanced unit 4 are directly introduced into the gas-liquid separator-19 and the phase separator-20 for separation.

[0092] Example 7

[0093] The specific implementation method is the same as that in Example 1, except that the baffle and guide port are not provided.

[0094] Example 8

[0095] The specific implementation method is the same as that in Example 1, except that a circulation pipeline is not set.

[0096] Comparative Example 1

[0097] The reaction of isobutane with butene to produce high-octane alkylated gasoline.

[0098] The specific implementation method is the same as in Example 1, except that the third strengthening unit is not used.

[0099] Comparative Example 2

[0100] The reaction of isobutane with butene to produce high-octane alkylated gasoline.

[0101] The specific implementation method is the same as in Example 1, except that no sensors and controllers are set up.

[0102] Comparative Example 3

[0103] The reaction of isobutane with butene to produce high-octane alkylated gasoline.

[0104] Using hydrofluoric acid alkylation technology, catalytic distillation technology completes the catalytic reaction and distillation process in the same tower. High-octane alkylated gasoline enters an acid settling tank for separation. The acid at the bottom of the settling tank is recycled, while the hydrocarbon components at the top of the settling tank enter a fractionation tower to separate gases such as propane and n-butane. The product at the bottom of the tower is refined to obtain high-octane alkylated oil. The reaction temperature is 27℃-43℃, and circulating water cooling is used.

[0105] Comparative Example 4

[0106] The reaction of isobutane with butene to produce high-octane alkylated gasoline.

[0107] The reaction is carried out using sulfuric acid alkylation technology.

[0108] HQC ALKY technology employs a horizontal alkylation reactor and a reaction effluent cooling process. Liquid propane and butane in the reaction effluent undergo vacuum flash evaporation within the reactor tube bundle to absorb the heat released during the alkylation reaction. The vapor phase is then recompressed, condensed, and recycled back to the reactor. The effluent cooling process maintains a high concentration of isobutane within the reactor. The recycled isobutane is mixed with butane before entering the reactor; the acid hydrocarbons are mechanically stirred by an impeller to form an emulsion, ensuring uniform hydrocarbon distribution within the acid, reducing the temperature gradient, and suppressing side reactions.

[0109] Comparative Example 5

[0110] The specific implementation method is the same as that in Example 1, except that the third strengthening machine is placed directly above the second strengthening machine unit, and the distance between the third strengthening machine unit and the second strengthening machine unit is equal to the distance between the first strengthening machine unit and the second strengthening machine unit.

[0111] Comparative Example 6

[0112] The specific implementation method is the same as that in Example 1, except that the third intensifying unit is placed directly above the second intensifying unit and the third intensifying unit is close to the main pipeline.

[0113] Comparative Example 7

[0114] Ethylbenzene is produced by liquid-phase alkylation of benzene and ethylene.

[0115] The reaction is carried out using an AlCl3 liquid-phase method. The catalyst is dissolved in a benzene mixture, and the reactor contains dry benzene. The reaction occurs in a homogeneous liquid-phase alkylation and alkyl transfer system. This process achieves homogeneous alkylation by adjusting the ethylene feed rate to control the amount of catalyst added within the solubility range of the aromatics in the liquid phase.

[0116] Experimental Example 1

[0117] The examples and comparative examples were tested using different methods to determine the conversion rate of the reactants, the recovery rate of the catalyst, and the purity of the products. The experimental results are shown in Tables 1 and 2.

[0118] Table 1: Results of the reaction between isobutane and butene

[0119] Table 2: Results of the liquid-phase alkylation reaction of benzene and ethylene

[0120] Based on the above data, the following conclusions can be drawn:

[0121] Comparative examples and embodiments show that using the apparatus of the present invention can significantly improve the raw material conversion rate, catalyst recovery rate, and product purity. Furthermore, because the present invention uses an ionic liquid as a catalyst, it can reduce the corrosion of the reactor by strong acids and extend the service life of the equipment.

[0122] This invention employs a three-stage enhanced reaction unit, with baffles and guide ports positioned between the first and second enhanced reaction units. This ensures thorough dispersion and breakup of all reactants, significantly increasing the mass transfer area and overall mass transfer rate. Consequently, it dramatically improves reaction speed, effectively controls side reactions, increases product yield, significantly reduces energy and material consumption, and enhances safety in the reaction process. Furthermore, the three enhanced units and two circulation pipelines eliminate the need for distillation separation of the products, reducing reaction energy consumption. The ionic liquid can be recovered, and the heat generated during the reaction can be reused, lowering the reaction temperature and achieving energy savings.

[0123] When no intensifier is installed, the reactants and ionic liquid cannot be well integrated when using the traditional reaction method. The mass transfer area is small, which prevents the ionic liquid from playing a good catalytic role and reduces the efficiency of the reaction.

[0124] Without the first circulation pipeline and the third intensifier unit, incompletely reacted reactants cannot undergo secondary reactions, thus reducing the reactant conversion rate. Without the second circulation pipeline and phase separator, the ionic liquid used as a catalyst cannot be effectively recovered and recycled, resulting in waste. The controller, through sensor feedback, controls the flow rate or opening and closing of control valves in the reaction apparatus, achieving intelligent regulation and real-time monitoring of the reaction process. This ensures reaction safety, reduces unnecessary reactions that may generate byproducts, lowers the byproduct content in the product, and improves product purity.

[0125] This invention also incorporates an internal circulation pipeline, which allows for the initial mixing and recirculation of incompletely reacted reactants, enabling pre-dispersion before they enter the third intensifier unit for secondary reaction. This design ensures that even if reactants are not fully reacted, a single circulation is sufficient to guarantee complete reaction, thus improving reaction efficiency and saving energy. In the reaction process of benzene and ethylene, the reaction apparatus used in this invention effectively reduces the reaction temperature and the temperature within the reactor, thereby reducing energy consumption and ensuring safety.

[0126] Finally, the location of the third intensifier unit is also specified in this invention. During the reaction, a large amount of gas accumulates in the middle of the reactor. Placing the third intensifier unit at this location ensures that the unreacted gas undergoes sufficient reaction, and the sensors can also work in conjunction with the third intensifier unit to better monitor the conditions inside the reactor. If the third intensifier unit is located too high, the sensors will detect gas that has not passed through the third intensifier unit due to irregular gas diffusion and provide feedback, causing the controller to issue incorrect instructions, ultimately leading to an increase in byproducts. Conversely, if the third intensifier unit is located too low in the reactor, some gas may be drawn in by the second intensifier unit, resulting in over-reaction.

[0127] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. An alkylation reaction apparatus, characterized in that, Includes a reactor, inside which three intensifier units are vertically arranged; The first intensifier unit is located at the bottom of the reactor, the second intensifier unit is located directly above the first intensifier unit, and the third intensifier unit is located in the middle of the reactor. The reactor is also equipped with a sensor, which is attached to the inner wall of the reactor and located above the third intensifier unit. The reactor is equipped with a main pipeline at the top.

2. The alkylation reaction apparatus according to claim 1, characterized in that, The main pipeline is connected in parallel with the first circulation pipeline and the second circulation pipeline; The first circulation pipeline is connected to the second circulation pipeline to form an internal circulation, and a circulation pump is installed on the internal circulation pipeline; Control valve a and control valve b are respectively installed at the connection between the first circulation pipeline and the second circulation pipeline; The outlet of the first circulation pipeline is connected to the third intensifier unit.

3. The alkylation reaction apparatus according to claim 2, characterized in that, The second circulation pipeline is connected to the separation device; The separation device is connected to the storage tank.

4. The alkylation reaction apparatus according to claim 1, characterized in that, A guide port is provided above the first strengthening unit, and a baffle is provided above the guide port.

5. The alkylation reaction apparatus according to claim 3, characterized in that, The storage tanks include catalyst storage tanks, gas storage tanks, and liquid storage tanks; The gas storage tank is directly connected to the first enhancement unit via a gas pipeline, and a gas pipeline control valve is installed on the gas pipeline. The catalyst storage tank is supplied with catalyst via a catalyst pipeline control valve on the catalyst pipeline, and the liquid storage tank is supplied with reaction liquid via a liquid pipeline control valve on the liquid pipeline. A mixing pipeline is formed in parallel with the liquid pipeline, and the mixing pipeline is directly connected to the second intensifier unit.

6. The alkylation reaction apparatus according to claim 1, characterized in that, The alkylation reaction apparatus is equipped with control valves in its pipelines, and the reaction state is controlled by the opening and closing of the control valves and the flow rate.

7. The alkylation reaction apparatus according to claim 1, characterized in that, The alkylation reaction apparatus also includes a controller, which can display the data transmitted from the sensor in real time and control all the control valves in the alkylation reaction apparatus.

8. A reaction method using an alkylation reactor as described in any one of claims 1-7, characterized in that, Includes the following steps: The catalyst is first mixed with the reaction solution, and then mixed with the gas to carry out an enhanced reaction, thus obtaining the product.

9. The reaction method according to claim 8, characterized in that, The catalyst is a liquid-phase catalyst or can be dissolved in liquid-phase raw materials.

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