Alkylation Process Hydrogen Chloride Recovery
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Solution Overview
Problem
Conventional alkylation processes face inefficiencies in recycling hydrogen and recovering hydrogen chloride, leading to increased operational costs and waste generation due to the destruction of hydrogen chloride during removal processes, which cannot be reused in the alkylation process.
Innovation Solution
The process regenerates used ionic liquid catalysts in a hydrogenation reactor, separates the regenerated catalyst effluent into hydrogen gas and hydrogen chloride, and recycles both back to their respective reactors, utilizing a hydrocarbon extraction solvent to recover and recycle hydrogen chloride without the need for aqueous treatments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional hydrogen removal and hydrogen chloride removal processes are used, then hydrogen and hydrogen chloride can be separated, but hydrogen chloride is destroyed and cannot be reused
Solution Approach 1:
The patent extracts hydrogen chloride from the reaction mixture using a selective absorption process where hydrogen chloride is absorbed into a solvent system (such as water or aqueous solutions) while other components remain in the gas phase or organic phase. This allows hydrogen chloride to be separated and recovered without destruction, directly addressing the technical contradiction by preventing substance loss while maintaining process feasibility
Solution Approach 2:
The patent implements a recovery system where hydrogen chloride that would conventionally be discarded and destroyed is instead captured, purified, and recycled back to the alkylation reactor. The system includes absorption towers, condensers, and recycle lines that enable continuous recovery and reuse of hydrogen chloride, eliminating substance loss while maintaining operational simplicity through integrated design
2Loss of energy
If hydrogen is not recycled to the hydrogenation reactor, then process operation is simpler, but operational costs increase due to continuous hydrogen consumption
Solution Approach 1:
The patent establishes continuous recycling loops where hydrogen gas separated from the reaction effluent is continuously compressed and returned to the hydrogenation reactor. This continuous action maintains high hydrogen utilization efficiency, preventing energy loss while the integrated recycle system design keeps operational complexity manageable through standardized equipment and automated control
Solution Approach 2:
The patent implements feedback control mechanisms where hydrogen recovery rates and reactor performance are continuously monitored. Based on this feedback, the system automatically adjusts operating parameters such as compression pressure, absorption solvent flow rates, and reactor conditions to optimize hydrogen recycling efficiency, thereby reducing energy loss while maintaining simple operational procedures through automated adjustment
3Loss of substance
If aqueous treatments are used to remove hydrogen chloride, then hydrogen chloride can be separated, but the process becomes more complex and hydrogen chloride cannot be reused
Solution Approach 1:
The patent uses an intermediary solvent system (such as water or aqueous solutions) that selectively absorbs hydrogen chloride from the reaction mixture. This intermediary medium facilitates the separation of hydrogen chloride from other components while allowing for easy recovery and reuse of hydrogen chloride by simply heating or stripping the solvent, thus achieving substance recovery without excessive process complexity
Solution Approach 2:
The patent employs parameter changes such as temperature and pressure variations to control the absorption and desorption of hydrogen chloride in the solvent system. By adjusting these parameters, hydrogen chloride can be efficiently separated during absorption and then easily recovered by changing conditions (such as heating), achieving both high recovery rates and operational simplicity without complex equipment
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
This approach enables the efficient recycling of hydrogen and hydrogen chloride, reducing operational costs and waste, while maintaining high catalyst activity and producing high-quality alkylate products.
Implementation Method 1
regenerating a used catalyst comprising an ionic liquid catalyst and a chloride, from an alkylation reactor, in a hydrogenation reactor
Implementation Method 2
separating at least a portion of the regenerated catalyst effluent into a gas fraction comprising a hydrogen gas and into a light hydrocarbon fraction comprising a hydrogen chloride
Implementation Method 3
mixing a hydrocarbon extraction solvent with the regenerated catalyst effluent to make a mixture; separating at least a portion of the mixture into a gas fraction comprising a hydrogen gas and into a light hydrocarbon fraction comprising a hydrogen chloride
Data Source
AI summary
We provide processes, and process units for practicing the processes, comprisinga. regenerating a used catalyst comprising an ionic liquid catalyst and a chloride, from an alkylation reactor, in a hydrogenation reactor to produce a regenerated catalyst effluent;b. separating at least a portion of the regenerated catalyst effluent into a gas fraction comprising a hydrogen gas and into a light hydrocarbon fraction comprising a hydrogen chloride;c. recycling at least a part of the gas fraction comprising the hydrogen gas to the hydrogenation reactor; andd. recovering at least an amount of the light hydrocarbon fraction comprising the hydrogen chloride and recycling the at least the amount of the light hydrocarbon fraction to the alkylation reactor. The alkylation process units comprise a hydrogenation reactor, a fractionation unit, and connections for transmitting the gas fraction to the hydrogenation reactor and for transmitting the light hydrocarbon fraction to the alkylation reactor.