Self-Heat-Extracting Flash Evaporation for Sulfuric Acid Alkylation
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Solution Overview
Problem
In the sulfuric acid alkylation process, existing methods face issues with insufficient heat extraction, clogging of fillers, low hydrocarbon vaporization rates, and excessive sulfuric acid entrainment, leading to inefficient temperature control and reduced acid utilization.
Innovation Solution
A method and apparatus combining a coalescence-vaporization unit and a reinforced separation unit, where the sulfuric acid alkylation reaction product is preliminarily distributed and vaporized, followed by further separation to enhance heat transfer and acid-hydrocarbon separation, utilizing a coalescence-vaporization assembly with a multi-stage porosity structure and an acid-hydrocarbon separation-coalescence baffle to improve contact time and area, reducing clogging and entrainment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional vaporization methods are used to extract heat from alkylation reaction product, then heat extraction can be achieved, but the sulfuric acid and hydrocarbons stratify due to large density difference, resulting in insufficient mixing and poor heat transfer effect
Solution Approach 1:
The flash tank is divided into multiple functional sections: a mixing section with fillers for initial contact and heat exchange, a vaporization section with vaporization fillers for enhanced vaporization, and a separation section with separation fillers for acid-hydrocarbon separation. This segmentation allows each section to perform its specific function optimally, preventing stratification and improving overall heat transfer efficiency.
Solution Approach 2:
The patent introduces an intermediary mixing and vaporization process using fillers as a medium. The fillers provide a large surface area for contact between sulfuric acid and hydrocarbons, acting as an intermediary that facilitates heat transfer and prevents direct stratification of the two phases.
2Temperature
If self-vaporization of hydrocarbons is used to cool the reaction product, then cooling can be achieved, but froth entrainment is serious causing excessive sulfuric acid to be entrained in the alkylation product
Solution Approach 1:
The flash tank separates the cooling and separation functions into distinct sections. The mixing and vaporization sections handle temperature reduction, while the dedicated separation section with separation fillers handles acid-hydrocarbon separation. This segmentation prevents froth entrainment from contaminating the final product.
Solution Approach 2:
The patent converts the harmful froth entrainment phenomenon into a beneficial separation mechanism. The separation fillers in the separation section utilize the froth structure to enhance contact between phases, converting the problematic entrainment into an effective separation process that recovers sulfuric acid.
3Loss of energy
If fillers are used in the flash tank for heat extraction, then heat transfer area is increased, but inclusions in the effluent clog the filler leading to low utilization
Solution Approach 1:
The fillers are divided into different types placed in different sections: mixing fillers for initial contact, vaporization fillers for vaporization processes, and separation fillers for final separation. This segmentation allows each filler type to be optimized for its specific function and makes it easier to clean or replace individual sections without shutting down the entire system.
Solution Approach 2:
The mixing section with its fillers performs preliminary mixing and heat exchange before the effluent reaches the vaporization and separation sections. This preliminary action prevents large inclusions from directly clogging the vaporization and separation fillers, extending their service life and maintaining high utilization.
4Speed
If the reaction product is rapidly vaporized to extract heat, then cooling speed is increased, but the contact time between sulfuric acid and hydrocarbons is reduced leading to poor heat transfer
Solution Approach 1:
The cooling process is segmented into multiple stages occurring in different sections of the flash tank. The mixing section provides initial heat exchange, the vaporization section enhances cooling through vaporization, and the separation section completes the process. This segmentation allows sufficient contact time at each stage while maintaining overall rapid cooling.
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 increases the vaporization rate of hydrocarbons, lowers the sulfuric acid temperature effectively, enhances acid recovery, and reduces production costs by improving energy utilization and separation efficiency.
Implementation Method 1
METHOD AND APPARATUS FOR SELF-HEAT-EXTRACTING FLASH EVAPORATION OF SULFURIC ACID ALKYLATION REACTION PRODUCT
Implementation Method 2
utilizing endothermic self-vaporization of the alkylation reaction product
Implementation Method 3
coalescence-vaporization unit and a reinforced separation unit, where the sulfuric acid alkylation reaction product is preliminarily distributed and vaporized
Implementation Method 4
a liquid distributor, a bubble cap plate, an irregular microporous medium, a cyclone separator and an inclined plate separator
Implementation Method 5
due to the large difference in density between sulfuric acid and the mixed hydrocarbons, stratification can occur easily
Data Source
AI summary
The present disclosure relates to a method and an apparatus for self-heat-extracting flash evaporation of a sulfuric acid alkylation reaction product. There is provided a method for self-heat-extracting flash evaporation of a sulfuric acid alkylation reaction product. One step is to coalesce and vaporize a preliminarily distributed sulfuric acid alkylation reaction product to cause preliminary vaporization of a hydrocarbon therein, thereby taking heat away and preliminarily separating the hydrocarbon from sulfuric acid. Another step is to subject the preliminarily separated alkylation reaction to reinforced separation, where the hydrocarbon is further vaporized to take heat away and further separate the hydrocarbon from the sulfuric acid. There is also provided an apparatus for self-heat-extracting flash evaporation of a sulfuric acid alkylation reaction product.