Ionic Liquid Reactor Cooling Fluid Control with Bypass Heat Exchange

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Solution Overview

Problem

Existing systems for controlling temperature in ionic liquid alkylation processes face challenges due to the high viscosity and potential fouling of ionic liquids, which complicates heat transfer and requires efficient heat removal methods that do not rely on vaporization, especially in exothermic reactions with variable temperatures and heat duties.

Innovation Solution

A cooling fluid circulation system that includes a chiller, reservoir, and bypass line, allowing for controlled temperature management by passing a cooling fluid through a heat exchange zone while adjusting flow rates based on the temperature of the cooled process fluid, using heat exchangers designed to minimize fouling and maintain reactants and products in a liquid state.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If heat exchange is used to control temperature in ionic liquid alkylation, then temperature control is improved, but heat transfer efficiency deteriorates due to high viscosity and fouling of ionic liquids

Engineering Contradiction:

Improvetemperature controlVSAvoidheat transfer efficiency

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The reactor is divided into multiple reaction zones with interspersed heat exchange zones. This segmentation allows heat to be removed at multiple points along the reaction path, preventing thermal buildup while minimizing the total heat transfer surface area required and reducing overall fouling exposure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A cooling fluid acts as an intermediary medium to transfer heat from the ionic liquid reaction mixture. The cooling fluid circulates through heat exchange zones, absorbing heat without direct contact with the ionic liquid, thereby preventing fouling of heat transfer surfaces while maintaining effective temperature control.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Temperature

If vaporization is used to control temperature in exothermic reactions, then temperature control is achieved, but process control and ionic liquid dispersion deteriorate

Engineering Contradiction:

Improvetemperature controlVSAvoidprocess control

Core Design Contradiction:

TemperatureVSEase of operation

Solution Approach 1:

The patent replaces the thermal-mechanical process of vaporization with a controlled heat exchange system using cooling fluid circulation. This substitution allows temperature control through regulated heat removal rather than phase change, maintaining liquid phase integrity and improving process controllability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system controls temperature by adjusting parameters of the cooling fluid system (flow rate, temperature) rather than relying on vaporization. This allows continuous, fine-tuned temperature control while keeping all reactants and products in the liquid phase, improving dispersion and process control.

Inventive Principle:

Principle #35Parameter changes

3Power

If heat exchanger surface area is increased to improve heat removal, then heat transfer capacity is improved, but fouling risk and system complexity increase

Engineering Contradiction:

Improveheat removal capacityVSAvoidheat exchanger configuration

Core Design Contradiction:

PowerVSDevice complexity

Solution Approach 1:

Instead of using one large heat exchanger, the system employs multiple smaller heat exchange zones distributed throughout the reactor. This segmentation achieves the required total heat transfer area while simplifying individual exchanger design, reducing fouling accumulation in any single location, and improving maintenance accessibility.

Inventive Principle:

Principle #1Segmentation

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 system effectively controls temperature in ionic liquid alkylation processes, maintaining product quality and flexibility across varying reaction conditions by ensuring efficient heat removal without vaporization, reducing fouling risks, and maintaining desired temperature ranges for the process fluid.

Implementation Method 1

absorbing heat from the process fluid with the cooling fluid in the heat exchange zone to provide a cooled process fluid

Methodology Applied

Scientific EffectHeat transfer: Heat Exchanger

Implementation Method 2

passing a cooling fluid from a chilling zone to a reservoir

Methodology Applied

Scientific EffectCooling: Cooling

Data Source

PatentUS10809022B2Processes and systems for controlling cooling fluid in an ionic liquid reactor system with a heat exchanger

Publication Date: 2020.10.20 UOP LLC

AI summary

Processes for controlling the rate and temperature of cooling fluid through a heat exchange zone in, for example, an alkylation reactor using an ionic liquid catalyst. A cooling fluid system may be used to provide the cooling fluid which includes a chiller and a reservoir. The cooling fluid may pass from the reservoir through the heat exchange zone. A bypass line may be used to pass a portion of the cooling fluid around the heat exchange zone. The amount of cooling fluid may be adjusted, with a valve, based upon the temperature of the cooled process fluid flowing out of the heat exchange zone. Some of the cooling fluid from the chiller may be circulated back to the chiller in a chiller loop.