Ionic Liquid Catalyst Regeneration via Brønsted Acid
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Solution Overview
Problem
Existing methods for regenerating ionic liquid catalysts used in hydrocarbon conversion processes, such as alkylation, isomerization, and oligomerization, face challenges in achieving high conversion rates of conjunct polymers and often result in the extraction of active catalytic metals into the ionic liquid phase, leading to safety issues and process inefficiencies.
Innovation Solution
A method involving the use of a Brønsted acid derived from a mineral acid, such as HCl, to contact and separate conjunct polymers from deactivated acidic ionic liquid catalysts, allowing for regeneration without the need for added metals and under mild conditions, thereby avoiding the extraction of active catalytic metals and reducing safety concerns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If reducing metals (e.g., Al) and hydrogen are used to regenerate ionic liquid catalysts, then conjunct polymer can be transferred to hydrocarbon phase, but active catalytic metals are extracted into ionic liquid phase causing safety issues
Solution Approach 1:
The patent extracts only the conjunct polymer from the ionic liquid catalyst using hydrocarbon solvents, while deliberately excluding metal-based regeneration agents. This selective extraction removes the harmful metal extraction problem while maintaining high conjunct polymer conversion rates through multiple wash cycles.
Solution Approach 2:
The patent introduces hydrocarbon solvents as intermediary substances to facilitate conjunct polymer removal. These solvents act as mediators that selectively dissolve and transfer conjunct polymer to a separate phase without introducing metals into the ionic liquid system, thus avoiding catalyst contamination and safety hazards.
2Productivity
If homogeneous metal hydrogenation catalysts are added for regeneration, then conjunct polymer is reduced and transferred to hydrocarbon layer, but process complexity and cost increase
Solution Approach 1:
The patent enables the ionic liquid catalyst to regenerate itself through simple hydrocarbon washing without requiring external metal hydrogenation catalysts. The conjunct polymer is removed by its affinity for hydrocarbon solvents, allowing the ionic liquid to self-regenerate through a simplified process that eliminates additional catalyst handling and complexity.
Solution Approach 2:
The patent replaces expensive, complex metal hydrogenation catalysts with inexpensive, easily removable hydrocarbon solvents. The hydrocarbons serve as disposable washing agents that can be easily separated from the ionic liquid after use, significantly reducing process complexity and operational costs compared to metal catalyst systems.
3Productivity
If traditional acid catalysts (sulfuric acid, hydrofluoric acid) are used, then alkylation reaction proceeds efficiently, but environmental hazards and corrosion issues arise
Solution Approach 1:
The patent fundamentally changes the physical state and chemical properties of the acid catalyst from traditional liquid mineral acids to ionic liquids. This parameter change transforms the catalyst into a non-volatile, environmentally friendly alternative that maintains high alkylation efficiency while eliminating the corrosiveness and environmental hazards associated with sulfuric and hydrofluoric acids.
Solution Approach 2:
The patent employs ionic liquids as composite acid catalysts that combine the desirable catalytic properties of traditional strong acids with the environmental benefits of non-volatile, recyclable materials. These ionic liquid catalysts integrate acid functionality with environmentally benign components, achieving both high reaction efficiency and reduced environmental impact.
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 effectively regenerates the ionic liquid catalysts with high efficiency, achieving above 90% conversion of conjunct polymers and reducing operating and capital costs by using less expensive materials and milder conditions, while minimizing safety hazards.
Implementation Method 1
contacting the deactivated acidic ionic liquid catalyst containing the conjunct polymer with at least one Brønsted acid in a regeneration zone under regeneration conditions
Implementation Method 2
the at least one Brønsted acid being derived from a mineral acid and containing at least one organic group resulting in a mixture comprising regenerated acidic ionic liquid catalyst, the at least one Brønsted acid, and the released conjunct polymer
Data Source
AI summary
A method for regenerating deactivated acidic ionic liquid catalyst containing conjunct polymer is described. The method includes contacting the deactivated acidic ionic liquid catalyst containing the conjunct polymer with at least one Brønsted acid in a regeneration zone under regeneration conditions, resulting in a mixture comprising regenerated acidic ionic liquid catalyst, the Brønsted acid, the released conjunct polymer. The Brønsted acid is derived from a mineral acid and contains at least one organic group. The released conjunct polymer can be separated from the regenerated acidic ionic liquid catalyst and the at least one Brønsted acid.