Ionic Liquid Catalyst Regeneration for Conjunct Polymer Recovery
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Solution Overview
Problem
Conjunct polymers formed during acid-catalyzed alkylation reactions negatively affect the yield and catalyst performance in alkylation processes, particularly deactivating catalysts and being difficult to isolate due to their integration with acid phases, leading to wasteful incineration in sulfuric acid and HF-based processes.
Innovation Solution
Regenerating ionic liquid catalysts to recover conjunct polymers, which can be processed into lighter, usable hydrocarbon products, unlike HF and sulfuric acid catalysts, allowing for their extraction without residual acid contaminants and subsequent upgrading into valuable fuels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional acid catalysts (sulfuric acid or HF) are used for alkylation reactions, then high octane alkylate gasoline can be produced, but conjunct polymers are difficult to isolate and must be incinerated, causing loss of valuable hydrocarbon products
Solution Approach 1:
The patent changes the chemical parameters of the catalyst system by using ionic liquids instead of traditional sulfuric acid or HF catalysts. This parameter change enables selective extraction of conjunct polymers while maintaining alkylate gasoline production, converting a waste disposal problem into a valuable product recovery opportunity
Solution Approach 2:
The patent extracts conjunct polymers from the reaction mixture using a specific extraction process with ionic liquid catalysts. This extraction separates the valuable hydrocarbon products from the catalyst phase, allowing recovery and reuse of conjunct polymers that would otherwise be lost through incineration
2Loss of substance
If conjunct polymers are recovered from HF or sulfuric acid catalysts, then hydrocarbon products can be obtained, but residual acid contaminants make the recovery process complex and require incineration
Solution Approach 1:
The patent converts the previously harmful residual acid contaminants into a benefit by using ionic liquid catalysts that can be selectively removed. The ionic liquid catalyst system allows for clean separation of conjunct polymers without residual acid contamination, simplifying the recovery process and eliminating the need for complex incineration steps
Solution Approach 2:
The patent uses an intermediary extraction process with ionic liquid catalysts that mediates between the reaction mixture and the conjunct polymer products. This intermediary system enables selective extraction and separation, simplifying the overall recovery process by avoiding direct contact between residual acids and the hydrocarbon products
3Duration of action of stationary object
If conjunct polymers are incinerated to recover catalyst, then catalyst can be reused, but valuable hydrocarbon products are destroyed and environmental pollution occurs
Solution Approach 1:
The patent extracts and separates conjunct polymers from the catalyst phase using ionic liquid catalysts, allowing both the catalyst and hydrocarbon products to be recovered and reused. This extraction process eliminates the need for incineration, preserving valuable hydrocarbon products while enabling catalyst reuse
Solution Approach 2:
The patent recovers and reuses both the catalyst and the conjunct polymer hydrocarbon products through a selective extraction process. Instead of discarding conjunct polymers via incineration, the process recovers them as valuable products while maintaining catalyst activity for continued use
4Loss of substance
If ionic liquid catalysts are used for alkylation reactions, then conjunct polymers can be recovered without residual acid contaminants, but the catalyst regeneration process must be implemented
Solution Approach 1:
The patent employs a catalyst regeneration process that is integrated into the existing alkylation reaction system. The ionic liquid catalyst regenerates in-situ during the reaction process, eliminating the need for separate complex regeneration steps while maintaining high purity recovery of conjunct polymers
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 regeneration of ionic liquid catalysts enables the recovery of conjunct polymers, which are less viscous and cleaner, facilitating their conversion into high-quality hydrocarbon products with minimal pretreatment, unlike traditional alkylation processes, and can be used to produce diesel fuel, jet fuel, and high energy fuels with improved properties.
Implementation Method 1
Conjunct polymers are common by-products of acid-catalyzed alkylation reactions including the alkylations of isoparaffins, e.g. isobutane and isopentane, with light olefins, e.g. propylene and butenes
Implementation Method 2
conjunct polymers produced in ionic liquid alkylations are recoverable from the catalyst phase with no residual acid contaminants and can be readily sent to processing units in the refinery
Data Source
AI summary
A process comprising regenerating a used ionic liquid catalyst, recovering conjunct polymer from the regenerated catalyst and using at least a portion of the conjunct polymer is disclosed.