Ionic Catalyst Oligomerization Waterless Silica Gel Separation
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Solution Overview
Problem
The existing processes for producing low viscosity poly alpha olefin (PAO) base oils using BF3 catalysts generate hazardous aqueous waste and are costly, with challenges in efficiently removing ionic catalysts from reaction mixtures, leading to contamination and waste generation.
Innovation Solution
A hydrophobic process utilizing silica gel to remove ionic catalysts from reaction mixtures, eliminating the need for aqueous washing and reducing waste, with the process involving oligomerization of normal alpha olefins using ionic liquid or ionic complex catalysts, followed by hydroisomerization to produce premium base oils.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If BF3 catalyst is used for oligomerization, then low viscosity PAO base oil is produced with excellent low temperature flow properties, but hazardous aqueous waste is generated requiring deep well injection disposal
Solution Approach 1:
The patent extracts and removes the harmful aqueous waste generation step from the process by using ionic liquid catalysts that can be separated and recycled, eliminating the need for water quenching and washing steps that generate hazardous waste
Solution Approach 2:
The patent changes the catalyst system from BF3 (which requires aqueous workup) to ionic liquids (which are immiscible with hydrocarbons and can be separated by phase separation), fundamentally changing the separation parameter from aqueous washing to liquid-liquid phase separation
2Object-generated harmful factors
If ionic liquid catalyst is used for oligomerization, then hazardous waste generation is reduced, but the ionic liquid becomes entrained in the hydrocarbon phase requiring additional separation steps
Solution Approach 1:
The patent uses silica gel, a porous material, to adsorb and remove entrained ionic liquid catalyst from the hydrocarbon phase. The porous structure of silica gel provides large surface area for adsorption of the ionic liquid catalyst droplets that remain after phase separation
Solution Approach 2:
The patent introduces silica gel as an intermediary substance that facilitates the removal of ionic liquid from the hydrocarbon phase. The silica gel acts as a mediator between the ionic liquid catalyst and the hydrocarbon product, enabling easy separation through adsorption
3Productivity
If conventional phase separation is used to separate ionic liquid from hydrocarbon, then bulk separation is achieved, but small droplets of ionic liquid remain entrained in the hydrocarbon phase
Solution Approach 1:
The patent employs silica gel, a porous material with high surface area, to adsorb the small entrained droplets of ionic liquid that conventional gravity separation cannot remove. The porous structure captures the fine droplets effectively
4Reliability
If C10 and C12 normal alpha olefins are used as feedstock, then low viscosity PAO with excellent properties is produced, but the feedstock cost is high and supply is limited
Solution Approach 1:
The patent changes the feedstock parameter from limited C10-C12 NAO to more abundant C14-C24 NAO. The ionic liquid catalyst system enables effective oligomerization of these higher carbon number olefins to produce PAO with comparable properties to those from C10-C12 feedstock
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 reduces hydrocarbon loss, minimizes waste generation, and achieves lower residual catalyst levels in the hydrocarbon phase, improving process economy and product quality with enhanced low-temperature properties.
Implementation Method 1
a reaction mixture comprising an oligomerization reaction to produce PAO utilizing an ionic catalyst wherein the ionic catalyst is removed post reaction with a silica gel composition
Data Source
AI summary
Described herein is a base oil synthesis via ionic catalyst oligomerization further utilizing a hydrophobic process for removing an ionic catalyst from a reaction mixture with a silica gel composition, specifically a reaction mixture comprising an oligomerization reaction to produce PAO utilizing an ionic catalyst wherein the ionic catalyst is removed post reaction.