Ionic Liquid Catalyst Regeneration with Reduced Hydrogen
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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, posing environmental and economic challenges with hazardous acids like sulfuric and hydrofluoric acids.
Innovation Solution
A process that reduces the amount of hydrogen used in regenerating spent ionic liquid catalysts by contacting it with hydrogen in a reactor under specific conditions, achieving effective removal of conjunct polymers with less than 550 SCF/BBL of hydrogen, eliminating the need for complex recycle compressors and HCl separation processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional hydroprocessing processes use large excess of hydrogen (1,500-15,000 SCF/BBL) to regenerate spent ionic liquid catalyst, then conjunct polymer is effectively removed from the catalyst, but hydrogen consumption is excessive and equipment complexity increases
Solution Approach 1:
The invention changes the parameter of hydrogen quantity from conventional large excess (1,500-15,000 SCF/BBL) to a optimized range (500-2,000 SCF/BBL), achieving effective conjunct polymer removal while significantly reducing hydrogen consumption and simplifying equipment requirements
Solution Approach 2:
The invention extracts and removes the harmful conjunct polymer byproduct from the spent ionic liquid catalyst through controlled hydrogenation, restoring catalyst effectiveness without requiring excessive hydrogen or complex separation equipment
2Reliability
If sulfuric acid or hydrofluoric acid is used as catalyst in alkylation, then catalytic activity is maintained, but environmental hazards and corrosiveness increase requiring extensive environmental controls
Solution Approach 1:
The invention converts the harmful effect of conjunct polymer accumulation (which deactivates the catalyst) into a beneficial regeneration process using hydrogen, allowing the ionic liquid catalyst to be restored and reused, thereby eliminating the need for hazardous acids while maintaining catalytic activity
Solution Approach 2:
The invention changes the catalyst material parameter from hazardous chemicals (sulfuric acid, hydrofluoric acid) to environmentally friendly ionic liquid, which can be regenerated through hydrogenation, thus eliminating environmental hazards and corrosiveness while preserving catalytic function
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 significantly reduces hydrogen consumption, simplifies equipment requirements, and maintains catalyst effectiveness, offering a cost-effective and environmentally friendly method for regenerating ionic liquid catalysts while minimizing hazardous material usage.
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 by contacting the ionic liquid catalyst with hydrogen gas in a regeneration reactor. The amount of hydrogen is less than 550 SCF/BBL (97.96 m3/m3) of spent ionic liquid catalyst, or less than 500 SCF/BBL (89.05 m3/m3) of spent ionic liquid catalyst, or between 550 and 45 SCF/BBL (97.96 and 8.015 m3/m3) of spent ionic liquid catalyst, or between 500 and 50 SCF/BBL (89.05 and 8.905 m3/m3) of spent ionic liquid catalyst. Alkylation processes are also disclosed.