Acid Catalyst Conjunct Polymer Hydrocarbon Conversion
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Solution Overview
Problem
Current hydrocarbon conversion processes using acid catalysts face inefficiencies due to low conjunct polymer content and molar ratios of Al to heteroatoms, leading to catalyst deactivation and reduced hydrocarbon conversion rates.
Innovation Solution
A process involving an acid catalyst with greater than 15 wt % conjunct polymer and a molar ratio of Al to heteroatoms (N, P, O, S, or combinations) greater than 2.0, formed by mixing aluminum chloride with a hydrocarbon solvent and an organic chloride, optionally with an ionic liquid, to create an effective ionic liquid catalyst for hydrocarbon conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional acid catalysts with low conjunct polymer content are used, then the catalyst preparation is simpler, but the hydrocarbon conversion rate decreases and catalyst deactivation occurs
Solution Approach 1:
The patent applies parameter changes by increasing the conjunct polymer content to greater than 15 wt% and adjusting the molar ratio of Al to heteroatoms to greater than 2.0. These specific parameter modifications transform the catalyst properties to achieve high conversion rates while preventing deactivation, directly resolving the contradiction between productivity and composition complexity.
2Reliability
If acid catalysts with high conjunct polymer content are used, then catalyst stability improves and continuous operation is enabled, but the catalyst preparation process becomes more complex
Solution Approach 1:
The patent employs composite materials by creating an ionic liquid catalyst that integrates multiple components: aluminum chloride, hydrocarbon solvent, organic chloride, and optionally ionic liquid, forming a complex composite structure with greater than 15 wt% conjunct polymer. This composite approach achieves high stability and continuous operation capability while managing the preparation complexity through systematic composition design.
3Duration of action of moving object
If conventional catalysts are used, then the preparation process is simpler, but solid precipitation occurs and continuous operation is limited
Solution Approach 1:
The patent applies parameter changes by precisely controlling the molar ratio of Al to heteroatoms to be greater than 2.0 and conjunct polymer content to be greater than 15 wt%. These parameter modifications prevent solid precipitation during extended operation at 25°C or below, enabling continuous operation for extended periods without regeneration while managing composition complexity through targeted adjustments.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The catalyst maintains high conversion rates and stability, with less than 0.1 wt % solid precipitation at 25°C, allowing continuous operation for extended periods without regeneration, and achieving commercially significant hydrocarbon conversion efficiencies such as 75% or higher in isoparaffin/olefin alkylation.
Implementation Method 1
conjunct polymers are formed asymmetrically from two or more reacting units by concurrent acid-catalyzed transformations including polymerization, alkylation, cyclization, additions, eliminations and hydride transfer reactions
Implementation Method 2
mixing aluminum chloride in the presence of a hydrocarbon solvent and an organic chloride... whereby the resulting acidic ionic liquid catalyst has greater than 15 wt % conjunct polymer and has a molar ratio of Al to a heteroatom selected from the group consisting of N, P, O, S, and combinations thereof greater than 2.0
Data Source
AI summary
A process for hydrocarbon conversion, comprising: contacting a hydrocarbon with an acid catalyst containing greater than 15 wt % conjunct polymer. The acid catalyst has a molar ratio of Al to a heteroatom selected from the group of N, P, O, S, and combinations thereof greater than 2.0. The hydrocarbon is converted during the contacting. Also a method to make a catalyst having greater than 15 wt % conjunct polymer and a high molar ratio of Al to the heteroatom, wherein an acidic ionic liquid catalyst is made that is effective for catalyzing a reaction. There are also provided catalyst compositions having greater than 15 wt % conjunct polymer.