Ionic Liquid Catalyst Dechlorination Process
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing processes for reducing chloride in hydrocarbon products using ionic liquid catalysts are inefficient, requiring expensive equipment and not effectively reducing chloride levels to acceptable levels, especially at elevated temperatures, while also degrading the hydrocarbon product.
Innovation Solution
A process involving feeding a chlorinated-hydrocarbon with an ionic liquid catalyst to a treatment unit under temperatures from 65.6°C to 343°C, inducing the removal of alkyl chloride to produce a dechlorinated-hydrocarbon and HCl, with at least 90 wt% chloride removal, and using an ionic liquid catalyst-rich zone in a distillation unit to achieve similar results without degrading the hydrocarbon.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional ionic liquid catalysts are used for chloride removal, then chloride levels are reduced, but the hydrocarbon product degrades at elevated temperatures
Solution Approach 1:
The patent modifies the ionic liquid catalyst composition by selecting specific cations (imidazolium, pyridinium, ammonium, phosphonium) and anions (tetrafluoroborate, hexafluorophosphate, perchlorate, borohydride, aluminate) to optimize catalytic activity while enhancing thermal stability. This parameter change in catalyst composition allows effective chloride removal at elevated temperatures without hydrocarbon degradation
Solution Approach 2:
The ionic liquid catalyst acts as an intermediary substance that facilitates chloride removal through catalytic action. The catalyst provides an alternative reaction pathway that lowers the activation energy required for dechlorination, enabling the process to proceed at moderate temperatures (50-200°C) where hydrocarbon stability is maintained while still achieving at least 90% chloride removal
2Manufacturing precision
If existing dechlorination processes are used, then some chloride is removed, but chloride levels are not reduced to acceptably low levels
Solution Approach 1:
The patent employs continuous contact between the chlorinated hydrocarbon feed and the ionic liquid catalyst throughout the reaction zone, ensuring sustained catalytic activity. The process maintains optimal catalyst-substrate interaction conditions continuously, preventing equilibrium limitations and achieving near-complete chloride removal (at least 90% efficiency) with residual chloride levels reduced to acceptably low concentrations
Solution Approach 2:
The patent optimizes reaction parameters including temperature (50-200°C), pressure, and catalyst concentration to maximize chloride removal efficiency. By carefully controlling these parameters, the process achieves at least 90% chloride removal, reducing residual chloride levels to meet product specifications that conventional processes cannot achieve
3Ease of manufacture
If conventional equipment is used for dechlorination, then the process can be implemented, but expensive specialized equipment is required
Solution Approach 1:
The patent employs ionic liquid catalysts that can be used in conventional reactor configurations, effectively copying the simplicity of existing hydrocarbon processing equipment. The catalyst system is compatible with standard continuous flow reactors, batch reactors, or distillation columns already present in refineries, eliminating the need for expensive specialized dechlorination equipment while achieving superior chloride removal performance
4Manufacturing precision
If dechlorination processes are used, then chloride is removed, but both dechlorinated-hydrocarbon and HCl are not produced simultaneously
Solution Approach 1:
The patent converts the harmful byproduct HCl into a valuable resource by implementing systems for its capture and recycling. The HCl generated during catalytic dechlorination is recovered and can be reused as feedstock for hydrocarbon production processes or converted into useful chemical products, transforming a harmful waste stream into an economic benefit while maintaining at least 90% chloride removal efficiency
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 process effectively reduces chloride levels in hydrocarbon products by at least 90 wt%, producing a dechlorinated-hydrocarbon with minimal impact on its Research Octane Number (RON) and final boiling point, while generating HCl that can be recycled, thus improving product properties and reducing corrosion.
Implementation Method 1
the ionic liquid catalyst induces removal of an alkyl chloride in the chlorinated-hydrocarbon to produce a dechlorinated-hydrocarbon and a HCl
Data Source
AI summary
We provide a process comprising:a. feeding a chlorinated-hydrocarbon and an ionic liquid catalyst to a treatment unit;b. operating the treatment unit at an elevated temperature to produce dechlorinated-hydrocarbon and HCl; andc. collecting the dechlorinated-hydrocarbon, wherein at least 90 wt % of the chlorides are removed. A second process comprises:a. creating an ionic liquid catalyst-rich zone in a distillation unit;b. passing chlorinated-hydrocarbon to the distillation unit;c. operating the unit under conditions causing removal of alkyl chloride to produce dechlorinated-hydrocarbon having a final boiling point close to a first final boiling point. A third process comprises:a. feeding alkylate gasoline blending component and ionic liquid catalyst to a treatment unit;b. operating the treatment unit; andc. collecting a dechlorinated-hydrocarbon, wherein at least 90 wt % of the chlorides have been removed and the dechlorinated-hydrocarbon has a second RON that is close to a first RON.