Ionic Liquid Catalyst Regeneration via Aluminum Reactant Extraction
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Solution Overview
Problem
Ionic liquid catalysts become deactivated by conjunct polymers, leading to reduced effectiveness and economic inefficiencies in alkylation processes, as existing regeneration methods are inefficient and prone to re-deactivation.
Innovation Solution
A system and apparatus involving a reactive extraction column where a slurry of aluminum metal and ionic liquid catalyst is reacted with a solvent and optionally hydrogen gas, freeing conjunct polymers from the catalyst, which are then extracted to regenerate the ionic liquid catalyst, ensuring immediate removal to prevent re-deactivation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If ionic liquid catalysts are used in alkylation processes, then catalytic activity and process efficiency are improved, but catalyst deactivation by conjunct polymers occurs leading to reduced effectiveness and increased replacement frequency
Solution Approach 1:
The patent extracts conjunct polymers from the ionic liquid catalyst using a selective solvent (such as n-pentane or n-heptane) that preferentially dissolves the polymers while leaving the catalyst intact. This extraction process removes the deactivating impurities and restores catalyst activity, allowing continuous reuse without replacement.
Solution Approach 2:
The patent changes physical parameters such as temperature and solvent composition to control the extraction process. By adjusting these parameters, the solvent selectively dissolves conjunct polymers at specific temperatures while maintaining catalyst stability, enabling effective regeneration through parameter optimization.
2Reliability
If existing regeneration methods are used to remove conjunct polymers, then some catalyst activity is restored, but the methods are inefficient and prone to re-deactivation
Solution Approach 1:
The patent introduces a selective solvent as an intermediary substance that mediates between the conjunct polymers and the ionic liquid catalyst. The solvent acts as a carrier that selectively binds to and removes polymers without interacting with the catalyst, enabling efficient separation and preventing re-deactivation through proper solvent-catalyst compatibility selection.
3Reliability
If frequent catalyst replacement is performed to maintain process effectiveness, then catalyst activity is ensured, but economic costs increase significantly
Solution Approach 1:
Instead of discarding deactivated catalysts, the patent recovers them through a simple extraction process using readily available solvents. The regenerated catalyst is recovered and reused, eliminating the need for frequent replacements and significantly reducing economic losses associated with catalyst procurement and disposal.
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 ionic liquid catalysts by simultaneously reacting and extracting conjunct polymers, maintaining catalyst activity and reducing economic costs associated with frequent replacements.
Implementation Method 1
reacting the aluminum metal with the ionic liquid catalyst in the presence or the absence of the hydrogen gas in the moveable bed to free the conjunct polymers from the ionic liquid catalyst
Implementation Method 2
extracting the conjunct polymers from the ionic liquid catalyst with the solvent to provide a regenerated ionic liquid catalyst
Data Source
AI summary
Disclosed are a system and an apparatus for regenerating an ionic liquid catalyst, which has been deactivated by conjunct polymers during any type of reaction producing conjunct polymers as a by-product, for example, isoparaffin-olefin alkylation. The system and apparatus are designed such that solvent extraction of conjunct polymers, freed from the ionic liquid catalyst through its reaction with aluminum metal, occurs as soon as the conjunct polymers de-bond from the ionic liquid catalyst.