Ionic Liquid Reactor with Hydrocyclones for Alkylation
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Solution Overview
Problem
Current ionic liquid reactor systems face challenges with droplet size control, material settling, and catalyst disposition due to high RPM mixers and inter-reactor exchangers, leading to inefficiencies and environmental concerns with hazardous catalysts like sulfuric and hydrofluoric acids.
Innovation Solution
Incorporating hydrocyclones and a low-efficiency pump with a mixing chamber recycle line to control droplet size and distribution, along with multiple olefin feed nozzles for flexible residence time, and cooling systems to manage reaction temperatures and catalyst separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high RPM mixers are used to control droplet size and distribution, then mixing efficiency is improved, but shaft movement and seal/packing complications increase
Solution Approach 1:
The patent replaces high RPM mechanical mixers with a static mixing chamber design that uses fluid dynamics and hydrocyclone technology to achieve effective mixing and separation without moving parts, eliminating shaft seal complications while maintaining mixing efficiency
Solution Approach 2:
The invention extracts and removes the problematic mechanical mixing components (shafts, seals, packing) from the system by using a static mixing chamber combined with hydrocyclones for droplet separation, achieving the same functional goals without the harmful mechanical elements
2Temperature
If inter-reactor exchangers are used for heat exchange, then thermal management is improved, but material settling and catalyst disposition problems increase
Solution Approach 1:
The patent merges the heat exchange function with the separation function by integrating cooling coils directly into the mixing chamber and using hydrocyclones for simultaneous thermal management and catalyst-hydrocarbon separation, eliminating the need for separate inter-reactor exchangers and preventing material settling
Solution Approach 2:
The hydrocyclones act as intermediaries that separate the ionic liquid catalyst from the hydrocarbon stream, preventing catalyst settling in exchangers while maintaining proper catalyst disposition through controlled droplet separation based on density differences
3Adaptability or versatility
If multiple reactors with inter-reactor exchangers are used, then reaction control is improved, but system complexity and environmental hazards increase
Solution Approach 1:
The patent creates a multi-functional single reactor system where the mixing chamber performs mixing, reaction, and thermal management functions, while hydrocyclones provide separation, simplifying the system architecture while maintaining reaction control flexibility through adjustable operating parameters
4Productivity
If conventional catalysts like sulfuric acid or hydrofluoric acid are used, then catalytic activity is improved, but corrosiveness and environmental hazards increase
Solution Approach 1:
The patent changes the fundamental parameter of catalyst phase from conventional liquid acids to ionic liquid phase, utilizing the unique properties of ionic liquids (low volatility, tunable properties) to maintain high catalytic activity while dramatically reducing corrosiveness and environmental hazards
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
Effectively maintains ionic liquid catalyst droplets below 100 microns, achieves high separation efficiency, and reduces the risk of catalyst settling, enhancing the control of residence time and reaction selectivity while minimizing environmental hazards.
Implementation Method 1
The use of one or more hydrocyclone(s) in combination with a low-efficiency pump and mixing chamber recycle line to control droplet size and size distribution within the mixing chamber of the reactor vessel
Implementation Method 2
passing the feed stream through a low efficiency mixer to create a mixed stream, whereby the low efficiency mixer creates droplets within the feed stream that are primarily within a predetermined size range
Implementation Method 3
cooling systems to manage reaction temperatures and catalyst separation
Data Source
AI summary
A method of alkylating a hydrocarbon stream including: providing a feed stream that includes hydrocarbons and ionic liquid catalyst; passing the feed stream through a low efficiency mixer to create a mixed stream, whereby the low efficiency mixer creates droplets within the feed stream that are primarily within a predetermined size range; passing the mixed stream and an olefin stream into a reactor; performing an alkylation reaction within the reactor, thereby forming a reacted stream; and separating the reacted stream into a settled ionic liquid catalyst stream and a hydrocarbon stream through the use of at least one hydrocyclone.