Alkylation Unit Catalyst Separation via Horizontal Settler

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The existing alkylation processes face challenges with catalyst carryover, leading to corrosion and equipment deterioration in downstream distillation towers due to excessive throughput and undersized separation vessels, particularly when acidic catalysts are involved.

Innovation Solution

An alkylation unit and process that incorporate a settler and a boot mechanism to separate the alkylation catalyst from hydrocarbons upstream of the fractionation zone, utilizing a substantially horizontal line to allow gravitational separation and removal of the catalyst, thereby preventing corrosion and equipment deterioration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If excessive throughput is used in the alkylation unit, then productivity increases, but catalyst carryover to downstream equipment increases causing corrosion and equipment deterioration

Engineering Contradiction:

Improvealkylation throughputVSAvoidcatalyst carryover causing corrosion

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a horizontal separator and boot mechanism upstream of the distillation towers to preliminarily separate and remove catalyst before the effluent reaches downstream equipment. This preliminary action prevents catalyst carryover while allowing high throughput operation in the alkylation reactors.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The horizontal separator and boot act as intermediary devices between the alkylation reaction zone and downstream distillation towers. These intermediaries capture and remove catalyst particles from the effluent stream, protecting downstream equipment from corrosion while maintaining high productivity upstream.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Device complexity

If undersized separation vessels are used, then device complexity is reduced, but catalyst separation efficiency decreases leading to catalyst carryover

Engineering Contradiction:

Improveseparation vessel configurationVSAvoidcatalyst separation efficiency

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent segments the separation function into two distinct components: a horizontal separator for initial catalyst-hydrocarbon separation, and a boot mechanism for final catalyst removal. This segmentation achieves high separation efficiency without requiring a single large complex vessel, as each component performs a specific separation task efficiently.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent utilizes the horizontal dimension by introducing a horizontal separator and boot mechanism, rather than relying solely on vertical separation vessels. This dimensional change enables effective catalyst separation through gravitational settling in a horizontal flow configuration, achieving high separation efficiency with simpler equipment.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Duration of action of stationary object

If downstream equipment is exposed to alkylation catalyst, then maintenance costs increase and equipment service life decreases

Engineering Contradiction:

Improveequipment service lifeVSAvoidcorrosion from catalyst exposure

Core Design Contradiction:

Duration of action of stationary objectVSObject-generated harmful factors

Solution Approach 1:

The patent converts the potentially harmful catalyst effluent into a benefit by using the horizontal separator and boot to capture and remove catalyst particles. The removed catalyst can be recycled back to the alkylation reaction zone, while the cleaned effluent proceeds to downstream equipment without causing corrosion, thus extending equipment service life.

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

Effectively minimizes catalyst carryover, reducing maintenance costs and extending equipment service life by efficiently separating the alkylation catalyst from hydrocarbons before they reach downstream vessels.

Implementation Method 1

a boot coupled to a substantially horizontal portion of the line. Generally, the boot receives an effluent portion rich in the alkylation catalyst

Methodology Applied

Scientific EffectGravitational separation: Gravitation

Implementation Method 2

a settler communicating with the at least one alkylation reaction zone and the at least one cooler

Methodology Applied

Scientific EffectSedimentation: Sedimentation

Data Source

PatentUS9302952B2Alkylation unit and process relating thereto

Publication Date: 2016.04.05 UOP LLC

AI summary

One exemplary embodiment can be an alkylation unit. The alkylation unit can include at least one alkylation reaction zone having an alkylation catalyst, at least one cooler communicating with the at least one alkylation reaction zone, a settler communicating with the at least one alkylation reaction zone and the at least one cooler, a fractionation zone receiving an effluent from the settler passing through a line, and a boot coupled to a substantially horizontal portion of the line. Generally, the boot receives an effluent portion rich in the alkylation catalyst.