Ionic Liquid Catalyst Regeneration via Hydrogenation
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Solution Overview
Problem
The regeneration of ionic liquid catalysts used in hydrocarbon conversion processes, such as alkylation, is inefficient due to the formation of conjunct polymers, which reduce catalyst effectiveness and require either replacement or extensive hydrogen usage, especially with hazardous acids like sulfuric and hydrofluoric acid.
Innovation Solution
A process that reduces the amount of hydrogen used in regenerating spent ionic liquid catalysts by contacting them with hydrogen in a reactor under specific conditions, eliminating the need for complex hydrogen recycle systems and reducing hydrogen chloride separation processes, while maintaining effective conjunct polymer removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional hydroprocessing processes are used to regenerate spent ionic liquid catalyst, then conjunct polymer is removed effectively, but large amounts of hydrogen (1,500-15,000 SCF/BBL) are required and complex hydrogen recycle systems are needed
Solution Approach 1:
The patent changes the operating parameters of the regeneration process by using a fixed bed reactor configuration with controlled temperature (25-100°C) and pressure conditions. This allows the hydrogenation reaction to proceed effectively without requiring large excess hydrogen or complex recycle systems, reducing hydrogen consumption while maintaining regeneration effectiveness
Solution Approach 2:
The patent segments the regeneration process into distinct functional zones within the fixed bed reactor: a catalyst bed for hydrogenation, followed by a separation zone. This segmentation allows the process to achieve both conjunct polymer removal and hydrogen chloride separation in a single pass through the reactor, eliminating the need for complex external recycle and separation systems
2Quantity of substance
If spent ionic liquid catalyst is contacted with large amounts of hydrogen in conventional processes, then conjunct polymer is reduced, but costly hydrogen chloride separation equipment is required
Solution Approach 1:
The patent merges the hydrogenation function and hydrogen chloride separation function into a single integrated fixed bed reactor system. The catalyst bed performs hydrogenation to remove conjunct polymer, while the same reactor structure provides hydrogen chloride separation through controlled pressure and temperature conditions, eliminating the need for separate expensive separation equipment
Solution Approach 2:
The fixed bed reactor system is designed to self-regulate the separation of hydrogen chloride through the inherent properties of the catalyst bed and operating conditions. The system automatically maintains the appropriate pressure and temperature gradients that cause hydrogen chloride to be retained or separated without requiring additional active separation equipment, reducing both complexity and hydrogen chloride loss
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 allows for efficient regeneration of ionic liquid catalysts with significantly less hydrogen, eliminating costly recycle compressors and hydrogen chloride recovery equipment, and maintaining catalyst effectiveness with reduced hydrogen chloride loss, thereby enhancing environmental safety and economic efficiency.
Implementation Method 1
contacting spent ionic liquid catalyst with hydrogen in a reactor, the reactor operating at conditions sufficient to reduce an amount of conjunct polymer in the spent ionic liquid catalyst
Data Source
AI summary
Processes for regenerating ionic liquid catalyst in which reaction vessel is operated under conditions sufficient to perform, in the presence of an ionic liquid catalyst, a hydrocarbon conversion reaction and provide a reaction effluent. The reaction effluent is separated into a hydrocarbon phase and a spent ionic liquid catalyst, wherein the spent ionic liquid catalyst includes conjunct polymer. The spent ionic liquid catalyst is contacted with hydrogen in a regeneration zone at conditions sufficient to reduce an amount of conjunct polymer in the spent ionic liquid catalyst to provide a regenerated effluent. The regenerated effluent is separated into a liquid phase comprising regenerated ionic liquid catalyst and a vapor phase comprising hydrogen and hydrogen chloride. The hydrocarbon phase is separated into a plurality of liquid hydrocarbon streams. The vapor phase is isolated from the liquid hydrocarbon streams. Alkylation processes are also disclosed.