Ionic Liquid Catalyst Regeneration via Ammonium Halide Interaction
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Solution Overview
Problem
The commercial use of chloroaluminate ionic liquid catalysts is hindered by their inability to be regenerated and recycled, leading to costly replacements and operational disruptions due to the accumulation of excess aluminum trichloride, which causes gumming and plugging problems in regeneration units.
Innovation Solution
A process involving the interaction of a regenerated ammonium-based metal-halide ionic liquid catalyst with a parent ammonium halide or a corresponding mixed salt, with a molar ratio of 0 to less than 2.0, to remove excess aluminum trichloride and rejuvenate the catalyst by converting inactive AlCl3 species back into active forms, using metals like aluminum in the presence or absence of hydrogen, and incorporating inert hydrocarbons for separation and regeneration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ionic liquid catalysts are used for alkylation reactions, then catalyst activity and product quality are improved, but excess metal halides accumulate causing gumming and plugging problems
Solution Approach 1:
The patent implements a regeneration process where spent ionic liquid catalyst is treated to remove accumulated metal halides (AlCl3, Al2Cl7-). The regeneration involves contacting the spent catalyst with a source of halide ions to convert metal halides into soluble complexes that can be separated, thereby recovering the catalyst for reuse and preventing gumming and plugging in the system
Solution Approach 2:
The patent extracts harmful metal halide components from the ionic liquid catalyst system through a separation process. By adding halide sources and forming soluble complexes, the metal halides are extracted from the catalyst phase into a separate phase that can be removed, eliminating the harmful effects while preserving the active catalyst
2Reliability
If ionic liquid catalysts are replaced frequently due to deactivation, then catalyst activity is maintained, but operational costs increase and process disruptions occur
Solution Approach 1:
Instead of discarding deactivated ionic liquid catalyst, the patent implements a recovery and regeneration system. The spent catalyst undergoes treatment to remove deactivating metal halide accumulations, restoring its activity. This allows the same catalyst to be reused multiple times, eliminating frequent replacements and associated operational disruptions
Solution Approach 2:
The patent establishes a continuous catalyst circulation and regeneration system where deactivated catalyst is continuously regenerated and returned to service. This maintains continuous catalytic activity without interruption from catalyst replacement, ensuring uninterrupted production while controlling costs
3Reliability
If aluminum trichloride is added to ionic liquid during regeneration, then catalyst activity is restored, but excess aluminum trichloride precipitates causing plugging problems
Solution Approach 1:
The patent controls the composition parameters of the ionic liquid system during regeneration. By carefully controlling the ratio of aluminum trichloride to ionic liquid components and adjusting halide ion concentrations, the system maintains aluminum trichloride in solution at active levels without reaching saturation points that would cause precipitation and plugging
Solution Approach 2:
The patent uses halide ion sources as intermediaries to manage aluminum trichloride solubility. The halide ions form soluble complexes with aluminum trichloride, acting as mediators that keep the aluminum species in solution at catalytically active concentrations without causing precipitation, thus preventing plugging while maintaining activity
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 method effectively regenerates and recycles chloroaluminate ionic liquid catalysts, preventing plugging issues and maintaining catalyst activity, thereby reducing operational costs and extending the lifespan of industrial processes.
Implementation Method 1
interacting a regenerated ammonium-based metal-halide ionic liquid catalyst or an ammonium-based metal-halide ionic liquid catalyst undergoing regeneration with either the parent ammonium halide salt from which the ionic liquid catalyst was made or a corresponding mixed salt
Data Source
AI summary
A process for removing metal halides from regenerated ionic liquid catalyst comprising interacting a regenerated ammonium-based metal-halide ionic liquid catalyst or an ammonium-based metal-halide ionic liquid catalyst undergoing regeneration with either the parent ammonium halide salt from which the ionic liquid catalyst was made or a corresponding mixed salt having an ammonium halide to metal halide molar ratio of 0 to less than 2.0 is disclosed.