Catalyst Regeneration Using Silane or Borane Compounds
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Solution Overview
Problem
Existing methods for regenerating ionic liquids used as catalysts in hydrocarbon conversion processes face challenges such as low conjunct polymer conversion rates, solid handling issues, and economic viability, particularly with the use of metallic aluminum and electrochemical approaches.
Innovation Solution
Contacting the deactivated acidic catalyst containing conjunct polymer with silane or borane compounds under mild conditions to reactivate the catalyst, allowing for the separation and recycling of the conjunct polymer, thereby regenerating the ionic liquid without the need for metal reagents or harsh conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metallic aluminum is used to regenerate ionic liquid catalysts, then conjunct polymer can be removed from the catalyst, but solid handling issues and safety concerns arise
Solution Approach 1:
The patent replaces the mechanical/solid handling approach (metallic aluminum) with a chemical solution approach (electrochemical cell) for removing conjunct polymer from ionic liquid catalysts. This substitution eliminates the need to handle solid aluminum pieces while achieving the same regeneration goal through electrochemical reduction of the polymer-catalyst complex.
2Reliability
If electrochemical approaches are used for catalyst regeneration, then conjunct polymer conversion can be achieved, but operational costs and process complexity increase
Solution Approach 1:
The electrochemical cell serves multiple functions simultaneously: it acts as both the regeneration reactor and the separation device. The cell processes the ionic liquid-cconjunct polymer complex, facilitates the electrochemical reduction, and enables phase separation all in one apparatus, reducing overall process complexity despite the advanced technology used.
3Ease of manufacture
If traditional regeneration methods are used, then catalyst can be reactivated, but environmental concerns and safety issues persist due to hazardous materials
Solution Approach 1:
The electrochemical regeneration process operates in an inert or controlled environment, avoiding the use of hazardous chemicals like metallic aluminum that require special handling. The method creates a safer operational atmosphere that eliminates fire hazards and toxic exposure risks associated with traditional regeneration approaches.
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 method achieves high conjunct polymer conversion rates, avoids solid handling issues, and reduces operational costs by using non-metallic reagents and mild conditions, making the process more economically viable and environmentally friendly.
Implementation Method 1
The deactivated acidic catalyst containing the conjunct polymer is contacted with at least one silane or borane compound in a regeneration zone under regeneration conditions, the conjunct polymer reacting with the at least one silane or borane compound resulting in a catalyst phase and an organic phase containing the conjunct polymer and at least one silyl or boryl compound
Data Source
AI summary
A hydrocarbon conversion process is described. The process includes contacting a hydrocarbon feed with an acidic catalyst under hydrocarbon conversion conditions in a hydrocarbon conversion zone. The hydrocarbon feed reacts to form a mixture comprising reaction products, the acidic catalyst, and deactivated acidic catalyst containing conjunct polymer. The mixture is separated into at least two streams, a first stream comprising the reaction products and a second stream comprising the deactivated acidic catalyst. The reaction products are recovered. The deactivated acidic catalyst is contacted with at least one silane or borane compound in a regeneration zone under regeneration conditions, the conjunct polymer reacting with the at least one silane or borane compound resulting in a catalyst phase and an organic phase containing the conjunct polymer and at least one silyl or boryl compound.