Extracted Conjunct Polymer Naphtha Alkylation Process
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Solution Overview
Problem
Current processes for producing high-quality alkylate gasolines are inefficient and do not meet the desired quality standards for spark-ignited automotive engines, particularly in terms of boiling point, Bromine Number, and naphthenes content.
Innovation Solution
The development of an extracted conjunct polymer naphtha and blended alkylate gasoline process involving the regeneration of used ionic liquid catalysts through hydrogenation, followed by blending with alkylate products, to produce a gasoline with a final boiling point less than 246°C, a Bromine Number of 5 or less, and at least 30 wt% naphthenes, using a conjunct polymer extraction solvent and an integrated alkylation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional alkylation processes are used to produce alkylate gasoline, then production can proceed with existing methods, but the final product does not meet desired quality standards for boiling point, Bromine Number, and naphthenes content
Solution Approach 1:
The patent applies preliminary action by hydrogenating the conjunct polymer in the ionic liquid catalyst before extraction. This pre-treatment converts the polymer to a hydrogenated form that can be more effectively extracted and blended, ensuring the final gasoline meets quality specifications for boiling point (<246°C) and Bromine Number (≤5) without requiring additional post-processing steps
Solution Approach 2:
The patent utilizes parameter changes by controlling hydrogenation conditions (temperature, pressure, catalyst) to optimize the conversion of conjunct polymer to hydrogenated conjunct polymer. By adjusting these parameters, the process achieves the desired naphthenes content (≥30 wt%) and boiling point characteristics in the extracted naphtha, which directly improves the final gasoline quality
2Manufacturing precision
If extraction steps are included to obtain high-quality naphtha from ionic liquid catalyst, then gasoline quality improves, but additional extraction steps increase process complexity and costs
Solution Approach 1:
The patent merges the extraction of conjunct polymer naphtha with the alkylation process by blending the extracted naphtha directly into the alkylation reactor feed or final gasoline product. This integration eliminates the need for separate extraction units and multiple processing steps, reducing device complexity while maintaining the quality benefits of extracted naphtha with ≥30 wt% naphthenes and controlled boiling point
Solution Approach 2:
The ionic liquid catalyst system provides self-service by continuously generating conjunct polymer during alkylation operations, which is then hydrogenated and extracted in-situ. This self-generating approach eliminates the need for external feedstock and separate extraction infrastructure, simplifying the overall process while ensuring consistent naphtha quality for gasoline blending
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 process results in a high-quality alkylate gasoline with improved road octane performance, meeting automotive fuel standards, and allowing for direct blending of extracted conjunct polymer naphtha with alkylate products to enhance fuel properties without the need for additional extraction steps, thereby simplifying the production process and reducing costs.
Implementation Method 1
regenerating a used ionic liquid catalyst comprising a conjunct polymer in a hydrogenation reactor (100) to make a regenerated catalyst effluent (10), wherein the hydrogenation reactor contacts the used ionic liquid catalyst with hydrogen and a hydrogenation catalyst and hydrogenation is carried out
Data Source
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AI summary
We provide an extracted conjunct polymer naphtha (45), comprising a hydrogenated conjunct polymer naphtha, from a used ionic liquid catalyst, having a final boiling point less than 246°C(475°F), a Bromine Number of 5 or less, and at least 30 wt% naphthenes. We also provide a blended alkylate gasoline (97) comprising the extracted conjunct polymer naphtha (45), and integrated alkylation processes to make the extracted conjunct polymer naphtha (45) and the blended alkylate gasoline (97). We also provide a method to analyze alkylate products, by determining an amount of methylcyclohexane in the alkylate products (80).