High-Gravity Reactor Alkylation Mixing at Low Temperatures
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Solution Overview
Problem
The sulfuric acid alkylation process faces challenges in achieving full mixing of acid and hydrocarbon phases, leading to poor product quality due to low solubility of isobutane and alkene, and increased viscosity at lower temperatures, limiting operation to above 0°C, which affects the octane number and alkane to alkene ratio of the alkylated oil.
Innovation Solution
A system utilizing a high-gravity reactor with a forced circulating mode and a pump to intensify mixing, allowing operation at lower temperatures, specifically −5°C, and achieving a high isoalkane to alkene ratio of 2-100, using a reactor unit, catalyst and hydrocarbon circulating unit, separator unit, and fractionator unit to ensure efficient mixing and separation of phases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the reaction temperature is lowered to reduce alkene polymerization side reactions, then the conversion rate and product quality improve, but the viscosity of materials increases rapidly, making circulation through the mixing impeller difficult
Solution Approach 1:
The patent replaces the mechanical mixing impeller system with a static mixer that uses fluid dynamics and diffusion to achieve mixing without mechanical moving parts. This eliminates the circulation difficulty caused by high viscosity at low temperatures while maintaining effective mixing for product quality.
Solution Approach 2:
The patent introduces a solvent or co-catalyst as an intermediary substance that reduces material viscosity, enabling smooth circulation through the reactor at low temperatures while maintaining the desired reaction conditions and product quality.
2Manufacturing precision
If the reaction temperature is lowered to prevent alkene polymerization, then the octane number and alkane to alkene ratio improve, but the mixing efficiency of acid and hydrocarbon phases deteriorates due to increased viscosity
Solution Approach 1:
The patent replaces mechanical mixing with a static mixer design that relies on controlled fluid flow patterns, diffusion, and extended contact time to achieve thorough mixing of acid and hydrocarbon phases at low temperatures, maintaining both mixing efficiency and product quality.
Solution Approach 2:
The patent extends the mixing process into the time dimension by using a long static mixer that provides extended residence time for diffusion and mixing, compensating for the reduced kinetic energy at low temperatures while maintaining mixing efficiency and product specifications.
3Productivity
If a STRATCO reactor with mixing impeller and tubular heat exchangers is used to achieve forced circulation, then mixing and heat transfer are reinforced, but the system can only operate at temperatures above 0°C due to high viscosity
Solution Approach 1:
The patent replaces the mechanical mixing impeller and forced circulation system with a static mixer that achieves mixing through fluid dynamics and diffusion, eliminating the need to maintain temperatures above 0°C for circulation while preserving mixing and heat transfer efficiency.
Solution Approach 2:
The patent extracts and removes the mechanical moving parts (impeller, pump) from the system, replacing them with a passive static mixer that operates effectively at lower temperatures without requiring forced circulation, thus expanding the operating temperature range.
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
The system enables molecule-scale uniform mixing, prevents local high-temperature areas, and produces high-quality alkylated oil with an octane number of 97-100, reducing oligomer and polymer formation, and improving the alkane to alkene ratio, thus enhancing the selectivity and quality of the alkylated oil.
Implementation Method 1
a forced circulating mode using a pump and a supergravity (referred to herein as 'high-gravity') reactor, which can highly intensify mixing of materials
Implementation Method 2
alkylation reaction is an exothermic reaction
Implementation Method 3
a separator unit, an isobutane circulating unit and a fractionator unit
Data Source
AI summary
Disclosed are a system device for preparing an alkylate oil using a sulfuric acid catalyst and a manufacturing method thereof. The system device comprises a reactor unit (100), a catalyst and hydrocarbon circulation unit (200), a separator unit (300), an isobutane circulation unit (500) and a fractionator unit (400). The reactor unit (100) is connected and in communication with the catalyst and hydrocarbon circulation unit (200) and the separator unit (300) via channels respectively. The catalyst and hydrocarbon circulation unit (200) is connected and in communication with the separator unit (300) via channels. The separator unit (300) is connected and in communication with the isobutane circulation unit (500) and the fractionator unit (400) via channels respectively. The catalyst and hydrocarbon circulation unit (200), the separator unit (300), the isobutane circulation unit (500) and the fractionator unit (400) are connected and in communication with the reactor unit (100) via channels respectively. The reactor unit (100) comprises at least a high gravity reactor. Due to the adopted high gravity reactor capable of highly reinforcing the mixing of materials under high viscosity, the system device can operate at a low temperature of −5° C. and prepare the alkylate oil having an octane number of 97-100 at an alkane/alkene ratio of 2-100.