Low Silica Zeolite Catalyst for Alkylation Poison Removal
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Alkylation catalysts in alkylation systems experience rapid deactivation due to poisons present in the input stream, leading to frequent regeneration and replacement needs.
Innovation Solution
Incorporating a preliminary alkylation system with a zeolite catalyst having a SiO2/Al2O3 ratio of 25 or less to reduce poison levels before the main alkylation system, and using a first alkylation system with a different zeolite catalyst to extend catalyst life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional alkylation catalyst is used directly in the main alkylation system, then the alkylation reaction can proceed, but the catalyst experiences rapid deactivation due to poisons in the input stream
Solution Approach 1:
The patent applies preliminary action by introducing a preliminary alkylation system before the main alkylation system. This preliminary system processes the input stream first, removing poisons and contaminants before they reach the main catalyst. The preliminary system performs the protective function in advance, preventing catalyst deactivation in the main system.
Solution Approach 2:
The patent uses an intermediary approach by placing a preliminary alkylation system between the input stream and the main alkylation system. This intermediary system acts as a buffer or mediator that processes the harmful input stream and protects the main catalyst from direct exposure to poisons.
2Stability of the object's composition
If the SiO2/Al2O3 ratio of the zeolite catalyst is increased to improve catalyst stability, then catalyst strength increases, but catalyst deactivation occurs more rapidly due to poison accumulation
Solution Approach 1:
The patent applies parameter changes by optimizing the SiO2/Al2O3 ratio of the zeolite catalyst to a specific range (20-40). This parameter optimization balances the catalyst's stability and resistance to deactivation. The patent also changes operational parameters like temperature and pressure to enhance catalyst performance and reduce deactivation.
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
Significantly reduces catalyst deactivation and extends the life of alkylation catalysts, minimizing the need for frequent regeneration and replacement.
Implementation Method 1
contacting the input stream with a preliminary catalyst including a zeolite catalyst having a SiO2/Al2O3 ratio of 25 or less
Implementation Method 2
contacting the input stream with an alkylation catalyst to form an output stream
Data Source
AI summary
Alkylation systems and methods of minimizing alkylation catalyst regeneration are described herein. The alkylation systems generally include a preliminary alkylation system adapted to receive an input stream including an alkyl aromatic hydrocarbon and contact the input stream with a preliminary alkylation catalyst disposed therein to form a first output stream. The preliminary alkylation catalyst generally includes a zeolite catalyst having a SiO2/Al2O3 ratio of less than about 25. The alkylation systems further include a first alkylation system adapted to receive the first output stream and contact the first output stream with a first alkylation catalyst disposed therein and an alkylating agent to form a second output stream.