Integrated Alkylation-Isomerization Process Common Distillation

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Solution Overview

Problem

The integration of alkylation and isomerization processes in the petroleum refining industry faces challenges in efficiently combining and processing effluents from both reactions, leading to potential contamination, corrosion, and equipment issues due to the presence of light components like hydrogen chloride and hydrocarbons, which can deactivate catalysts and increase operational costs.

Innovation Solution

A process that uses a common distillation column to remove propane and lower-boiling components from both alkylation and isomerization reaction zone effluents, allowing for their combination without significant adverse consequences, and includes embodiments where hydrogen chloride is reacted with olefins to form chloroparaffins, which can be recycled to increase chloride utilization and reduce waste.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate stabilizer distillation columns are used for alkylation and isomerization effluents, then light components can be removed effectively, but capital costs and device complexity increase

Engineering Contradiction:

Improvelight component removal efficiencyVSAvoidnumber of distillation columns

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the stabilizer distillation functions for both alkylation and isomerization effluents into a single common distillation column. This merging approach maintains effective light component removal while reducing the number of separate units, thereby lowering capital costs and device complexity without sacrificing separation performance

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The common stabilizer distillation column is designed to handle multiple functions: removing light components from both alkylation and isomerization effluents, and managing hydrogen chloride and hydrocarbon separations. This multi-functional design eliminates the need for dedicated separate columns for each process stream

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If alkylation and isomerization effluents are combined, then processing efficiency improves, but contamination and catalyst deactivation risks increase

Engineering Contradiction:

Improveprocessing efficiencyVSAvoidcontamination and catalyst deactivation

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent applies preliminary separation actions by using the common stabilizer distillation column to remove light components, hydrogen chloride, and other harmful substances from both effluents before they are combined. This preliminary treatment prevents contamination and catalyst deactivation while maintaining processing efficiency

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The common stabilizer distillation column acts as an intermediary unit that processes both alkylation and isomerization effluents separately before combination. This intermediary function removes harmful components and prepares the streams for safe merging, preventing direct contamination between the two process streams

Inventive Principle:

Principle #24Intermediary (Mediator)

3Object-affected harmful factors

If hydrogen chloride is removed from the process, then corrosion is reduced, but chloride utilization decreases

Engineering Contradiction:

ImprovecorrosionVSAvoidchloride loss

Core Design Contradiction:

Object-affected harmful factorsVSLoss of substance

Solution Approach 1:

The patent converts the harmful effect of hydrogen chloride by reacting it with olefins in the alkylation reactor to form useful chlorinated hydrocarbon products. This transforms the corrosive hydrogen chloride from a waste product into a valuable component, reducing corrosion while maintaining chloride utilization in the product stream

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 reduces capital and operating costs by eliminating the need for separate stabilizer distillation columns, prevents undesirable contamination, and enhances chloride utilization, thereby improving the overall efficiency and safety of the alkylation-isomerization process.

Implementation Method 1

uses a common distillation column zone to remove propane and lower-boiling components that are present in both the alkylation and isomerization reaction zone effluents

Methodology Applied

Scientific EffectDistillation: Distillation

Implementation Method 2

hydrogen chloride is reacted with olefins to form chloroparaffins

Methodology Applied

Scientific EffectChemical reaction: Chemical Bonding

Data Source

PatentUS7439410B1Integrated alkylation-isomerization process

Publication Date: 2008.10.21 UOP LLC

AI summary

An integrated isomerization-alkylation process is disclosed that uses a common distillation zone. The process can comprise halogen removal. The process is suitable for the production of motor fuels from isoparaffins and olefins using solid alkylation and isomerization catalysts.