Halide-Based Ionic Liquid Alkylation Catalyst Hydrotreating
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Solution Overview
Problem
Current alkylation processes using sulfuric and hydrofluoric acids as catalysts are environmentally unfriendly and produce trace amounts of organic chlorides, which are undesirable due to their potential to form dioxin during combustion, and no viable alternative catalyst systems have been implemented in commercial refineries.
Innovation Solution
An alkylation process using a halide-based acidic ionic liquid catalyst to convert light isoparaffins with olefins, followed by hydrotreating with hydrogen to reduce organic halide content in the product, employing catalysts like 1-butyl-pyridinium heptachloroaluminate and hydrotreating catalysts with precious metals such as palladium and platinum.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sulfuric and hydrofluoric acids are used as catalysts in alkylation processes, then high quality alkylate gasoline can be produced economically, but environmentally harmful effects occur and organic chlorides are generated
Solution Approach 1:
The patent changes the chemical parameters of the catalyst system by replacing traditional sulfuric and hydrofluoric acids with halide-based acidic ionic liquids. This parameter change maintains the catalytic activity needed for high-quality alkylate production while eliminating the harmful environmental effects and organic chloride formation associated with conventional catalysts.
Solution Approach 2:
The patent employs composite catalyst systems using halide-based acidic ionic liquids that combine multiple functional properties. These ionic liquid catalysts integrate the benefits of strong acidity for catalysis with improved environmental compatibility, creating a composite catalytic system that addresses both productivity and environmental concerns.
2Reliability
If halide-based acidic ionic liquid catalysts are used in alkylation, then organic halide content in product increases, but meeting product specifications requires reduction
Solution Approach 1:
The patent segments the process into two distinct stages: the alkylation reaction using halide-based acidic ionic liquid catalysts to produce high-quality alkylate, followed by a separate hydrotreating step to remove organic halides. This segmentation allows each stage to be optimized independently, maintaining catalyst performance while controlling final product purity.
Solution Approach 2:
The patent introduces hydrotreating catalysts as an intermediary substance to address the organic halide issue. The hydrotreating catalyst acts as a mediator that selectively removes organic halides from the alkylate product without affecting the desired alkylate gasoline quality, thus resolving the conflict between catalyst performance and product specifications.
3Productivity
If conventional alkylation catalysts are used, then high octane number gasoline cuts are produced, but safer and environmentally friendlier catalyst systems are needed
Solution Approach 1:
The patent fundamentally changes the chemical parameters of the catalyst system by transitioning from conventional sulfuric and hydrofluoric acids to halide-based acidic ionic liquids. This parameter change maintains the ability to produce high octane gasoline cuts while significantly improving environmental friendliness and safety profiles.
Solution Approach 2:
The patent converts the potential harm of halide-based catalysts (which can generate organic halides) into a benefit by using controlled, limited amounts of halide ionic liquids that can be effectively managed and removed through subsequent hydrotreating, while avoiding the more harmful sulfuric and hydrofluoric acid catalysts.
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 reduces the organic halide content in the alkylate product from 400 ppm to less than 5 ppm, meeting product specifications and avoiding dioxin formation during combustion, while maintaining gasoline quality.
Implementation Method 1
contacting a first hydrocarbon feed comprising at least one olefin having from 2 to 6 carbon atoms and a second hydrocarbon feed comprising at least one isoparaffin having from 3 to 6 carbon atoms with a halide-based acidic ionic liquid catalyst under alkylation conditions to produce an alkylate containing an organic halide
Implementation Method 2
contacting at least a portion of the alkylate with a hydrotreating catalyst in the presence of hydrogen under hydrotreating conditions to reduce the concentration of the organic halide
Data Source
AI summary
An alkylation process comprising contacting a first hydrocarbon feed comprising at least one olefin having from 2 to 6 carbon atoms and a second hydrocarbon feed comprising at least one isoparaffin having from 3 to 6 carbon atoms with a halide-based acidic ionic liquid catalyst under alkylation conditions to produce an alkylate containing an organic halide and contacting at least a portion of the alkylate with a hydrotreating catalyst in the presence of hydrogen under hydrotreating conditions to reduce the concentration of the organic halide is disclosed.