Ionic Liquid Alkylation Riser Reactor Mixing
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Solution Overview
Problem
Current ionic liquid catalyzed alkylation processes are hindered by high capital expenses due to the need for multiple mixer-reactors, making them less likely for commercial adoption.
Innovation Solution
A process that pre-mixes a paraffin stream with an ionic liquid catalyst stream and introduces the mixture into a riser reactor, using a low-efficiency pump to control droplet size and distribution, allowing for efficient separation and regeneration of the ionic liquid catalyst, thereby reducing equipment costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple mixer-reactors are used for ionic liquid catalyzed alkylation, then the alkylation reaction can be performed effectively, but capital expenses increase significantly
Solution Approach 1:
The patent combines the mixing and reaction functions into a single riser reactor system. The ionic liquid catalyst is introduced at the bottom of the riser reactor, and the paraffin stream is injected through a sparger to create fine droplets that mix with the catalyst in the reaction zone, eliminating the need for separate mixer-reactors while maintaining effective alkylation reaction
Solution Approach 2:
The patent performs preliminary mixing of the paraffin stream with the ionic liquid catalyst in a pre-mixer before the mixture enters the riser reactor. This pre-mixing step ensures proper distribution of the catalyst and reactants before the main reaction zone, reducing the need for multiple reactor units
2Reliability
If multiple mixer-reactors are used for ionic liquid catalyzed alkylation, then the catalyst can be effectively utilized, but equipment costs increase
Solution Approach 1:
The patent merges multiple reactor units into a single riser reactor system with integrated mixing and reaction zones. The ionic liquid catalyst is introduced at the bottom and distributed through the paraffin stream using a sparger, creating an efficient single-unit system that reduces equipment costs while maintaining catalyst utilization effectiveness
Solution Approach 2:
The patent uses a simplified single riser reactor design that replicates the functional capabilities of multiple mixer-reactors. The reaction zone is created by introducing the paraffin stream through a sparger at the bottom of the riser reactor, which generates fine droplets that mix with the ionic liquid catalyst, achieving effective catalyst utilization in a less expensive single-unit system
3Device complexity
If a low-efficiency pump is used to mix paraffin and ionic liquid catalyst, then capital expenses are reduced, but mixing efficiency may be compromised
Solution Approach 1:
The patent replaces the traditional high-efficiency mechanical mixing system with a low-efficiency pump combined with a sparger system. The low-efficiency pump delivers the paraffin stream through a sparger at the bottom of the riser reactor, which creates fine droplets through gas-liquid interaction, achieving effective mixing without requiring high-power mechanical mixing equipment
Solution Approach 2:
The patent uses hydraulic principles by introducing the paraffin stream through a sparger at the bottom of the riser reactor. The fluid dynamics of the sparger create fine droplets and enhance mixing between the paraffin and ionic liquid catalyst through liquid-liquid interaction, eliminating the need for high-efficiency mechanical pumps
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 simplifies the alkylation process, enabling the conversion of existing units to use ionic liquid catalysts while lowering capital expenses and improving operational efficiency.
Implementation Method 1
mixing the premixed paraffin and ionic liquid catalyst stream in a variable speed, low-efficiency pump to form a paraffin and ionic liquid catalyst mixture
Implementation Method 2
The paraffin and ionic liquid catalyst mixture is introduced into the riser reactor to form a reaction mixture comprising alkylate and the ionic liquid catalyst
Implementation Method 3
The reaction mixture is separated in a settler into an ionic liquid catalyst stream and a hydrocarbon stream
Data Source
AI summary
An alkylation process and apparatus are described. The alkylation process includes pre-mixing a paraffin stream with an ionic liquid catalyst stream from a settler. The premixed paraffin and ionic liquid catalyst stream is mixed in a low-efficiency pump to form a paraffin and ionic liquid catalyst mixture. An olefin feed stream is introduced into a riser reactor. The paraffin and ionic liquid catalyst mixture is introduced into the riser reactor to form a reaction mixture comprising alkylate and the ionic liquid catalyst. The reaction mixture is separated in a settler into an ionic liquid catalyst stream and a hydrocarbon stream.