Integrated Perchloroethylene Decomposition Reactor for Isomerization
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Solution Overview
Problem
Current isomerization processes for C4 and C5-6 hydrocarbons require separate chloride decomposition and gas treatment units, leading to increased costs and inefficiencies, as they operate at suboptimal temperatures due to the need for continuous chloride replenishment and separate equipment for each unit.
Innovation Solution
Implementing a common organic chloride decomposition reactor and chloride treater for both C4 and C5-6 isomerization units, which allows for improved chloride recovery and reduces equipment costs by sharing gas streams and eliminating the need for fresh chloride injection to the C4 isomerization reaction zone.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate chloride decomposition and gas treatment units are provided for C4 and C5-6 isomerization units, then each unit can operate independently, but equipment costs and process complexity increase
Solution Approach 1:
The patent combines the chloride decomposition function and gas treatment function into a single integrated unit that serves both C4 and C5-6 isomerization zones. The decomposition reactor receives chloride feed and produces HCl gas, which is then directly utilized in the isomerization reaction zones, eliminating the need for separate treatment units for each isomerization process.
Solution Approach 2:
The integrated chloride decomposition reactor and gas treatment unit performs multiple functions: it decomposes organic chloride to HCl, treats gas streams from both C4 and C5-6 isomerization zones, and supplies HCl to both reaction zones. This multi-functional design reduces overall equipment requirements while maintaining operational flexibility.
2Reliability
If minimum decomposition temperature of perchloroethylene (105°C) is used, then chloride decomposition is ensured, but isomerization reaction temperature must be elevated above optimal range
Solution Approach 1:
The patent introduces a dedicated chloride decomposition reactor that pre-decomposes organic chloride to HCl before the HCl enters the isomerization reaction zone. This preliminary decomposition action allows the isomerization reaction to proceed at lower, more optimal temperatures since the chloride activation function is performed separately in the decomposition reactor.
Solution Approach 2:
The process is segmented into two distinct functional zones: a chloride decomposition reactor that operates at temperatures suitable for perchloroethylene decomposition, and an isomerization reaction zone that operates at optimized temperatures for hydrocarbon isomerization. This segmentation allows each process to occur at its optimal temperature without compromise.
3Reliability
If continuous fresh chloride feed is introduced to replace removed chloride, then catalyst activity is maintained, but process efficiency decreases due to continuous addition requirement
Solution Approach 1:
The patent implements a feedback mechanism where HCl is recovered from the effluent stream of the isomerization reaction zone and recycled back to the reaction zone to replace chloride that is continuously removed. This closed-loop feedback system maintains catalyst activity while reducing the net consumption of fresh chloride feed, thereby improving process efficiency.
Solution Approach 2:
Instead of continuously discarding and replacing chloride through fresh feed addition, the system recovers HCl from the reaction zone effluent and reuses it to maintain catalyst activity. This recovery and reuse approach reduces waste and improves overall process efficiency while maintaining the necessary chloride levels for catalyst function.
4Ease of operation
If separate gas treatment units are provided for C4 and C5-6 isomerization units, then gas streams can be treated independently, but equipment costs increase by 50%
Solution Approach 1:
The patent merges the gas treatment functions for C4 and C5-6 isomerization units into a single integrated gas treatment unit. This combined unit processes gas streams from both isomerization zones simultaneously, reducing equipment costs by eliminating duplicate treatment equipment while maintaining the ability to treat different gas streams independently through separate flow paths.
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 integrated process enhances overall chloride recovery from 85% to over 92%, decreases equipment costs by 50%, and avoids the use of a net gas compressor, resulting in significant capital and operating savings while maintaining efficient HCl recovery and product yield.
Implementation Method 1
the chloride promoter decomposes to form hydrogen chloride that activates, e.g., promotes or regenerates, the catalyst by replenishing the chloride removed from the catalyst's surface
Implementation Method 2
HCl from the isomerization reactor effluent stream is recovered in an HCl absorber and recycled back to the reactor zone
Implementation Method 3
The reactors contain chlorided platinum-alumina catalyst, which is contacted with a light straight-run (LSR) naphtha feed
Data Source
AI summary
Processes incorporating a common organic chloride decomposition reactor and chloride treater to be used by both the C4 and C5-6 isomerization reaction zones are described. A portion of the C4 isomerization reaction zone off gas is routed to the C4 HCl absorber, which provides about 85% of the HCl requirement for the C4 isomerization reaction zone. A small amount of the C5-6 isomerization reaction zone off gas is mixed with the C4 isomerization reaction zone off gas portion going to the C4 HCl absorber.