Perchloroethylene Decomposition Reactor for Isomerization Yield
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Solution Overview
Problem
Current isomerization processes for producing high-octane isomers require inlet temperatures of at least 105°C due to the decomposition of organic chloride promoters like perchloroethylene, leading to excessive cracking and limitations in using heavier hydrocarbon feeds.
Innovation Solution
Separating the organic chloride decomposition into a dedicated reactor allows for lower isomerization reaction zone temperatures, typically below 100°C, by decomposing perchloroethylene to HCl outside the isomerization reactor, using catalysts like nickel, platinum, or palladium on an inert support, and optimizing conditions such as temperature, pressure, and hydrogen to organic chloride molar ratios.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If perchloroethylene decomposition is performed in the isomerization reactor, then the catalyst is activated and maintained, but the inlet temperature must be at least 105°C causing excessive cracking
Solution Approach 1:
The patent divides the isomerization process into two separate reactors: a first reactor dedicated to perchloroethylene decomposition and HCl generation, and a second reactor for isomerization. This segmentation allows each reactor to operate at optimal temperatures for its specific function, eliminating the need for the isomerization reactor to operate at high temperatures just to decompose perchloroethylene.
Solution Approach 2:
The patent extracts the perchloroethylene decomposition function from the isomerization reactor and places it in a separate dedicated reactor. This extraction allows the isomerization reactor to operate at lower temperatures (below 105°C) without compromising catalyst activation, as the decomposition function has been removed to a separate unit.
2Quantity of substance
If inlet temperature is increased to 105°C for perchloroethylene decomposition, then organic chloride converts to HCl, but cracking increases and C5+ yield decreases
Solution Approach 1:
The patent segments the process into two distinct reaction zones: the first reactor where perchloroethylene decomposes to HCl at temperatures optimized for decomposition, and the second reactor where isomerization occurs at lower temperatures optimized for C5+ yield. This ensures HCl production and isomerization can each occur at their optimal temperatures.
Solution Approach 2:
The patent changes the temperature parameter for the isomerization reactor to operate below 105°C, which was previously impossible when perchloroethylene decomposition was performed in the same reactor. This parameter change is enabled by the separate reactor configuration and results in reduced cracking and increased C5+ yield.
3Productivity
If isomerization reactor temperature is reduced below 105°C, then cracking is reduced and C5+ yield increases, but perchloroethylene decomposition is insufficient
Solution Approach 1:
The patent segments the thermal processing into two distinct stages in separate reactors: high-temperature perchloroethylene decomposition in the first reactor, followed by low-temperature isomerization in the second reactor. This segmentation resolves the contradiction by allowing each process to operate at its optimal temperature without compromise.
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 reduces cracking, enables the use of heavier hydrocarbon feeds, and increases yield by up to 0.7 wt% C5+ isomers, minimizing unit costs and allowing flexible operation over a range of conditions.
Implementation Method 1
a decomposition catalyst to decompose the organic chloride
Implementation Method 2
in the presence of an isomerization catalyst to form an isomerization effluent
Data Source
AI summary
An improved isomerization process in which the inlet temperature to the isomerization reaction zone is less than 105° C. is described. A separate reactor is provided for the decomposition of the organic chloride. The product of the decomposition of the organic chloride is sent to an isomerization reactor along with a hydrocarbon feed containing paraffins. The use of the organic chloride decomposition reactor allows the operating temperatures for the isomerization reaction zone to be reduced.