Phosphorus Removal in Alkylation Units
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Solution Overview
Problem
Existing methods for reducing phosphorus content in liquid hydrocarbons from ethylene dimerization processes are expensive, time-consuming, and inefficient, often resulting in phosphorus levels exceeding pipeline specifications, which limits their blending with gasoline and impacts process economics.
Innovation Solution
Co-feeding phosphorus-containing liquid hydrocarbons with an olefinic feed to an alkylation unit, where the phosphorus is removed and the hydrocarbon is upgraded to a higher octane number gasoline additive, utilizing the hydrocarbon's olefinic nature for minor alkylation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If distillation and oxidizing agent treatment are used to reduce phosphorus content, then phosphorus removal efficiency is improved, but process cost and time consumption increase significantly
Solution Approach 1:
The patent extracts phosphorus compounds from the liquid hydrocarbon stream by introducing an adsorbent material that selectively binds phosphorus, separating it from the hydrocarbon phase. This extraction approach avoids complex distillation columns and oxidizing agent treatment systems, achieving phosphorus removal through a simpler adsorption process.
Solution Approach 2:
The patent introduces an adsorbent material as an intermediary substance that mediates between the phosphorus-containing hydrocarbon and the desired purified product. The adsorbent selectively binds phosphorus compounds, acting as a mediator that facilitates phosphorus removal without requiring complex process equipment or additional chemical reagents.
2Adaptability or versatility
If phosphorus content is reduced to meet pipeline specifications, then gasoline blending capability is improved, but process economics deteriorate due to multiple treatment steps
Solution Approach 1:
The patent segments the phosphorus removal process into a simple, single-step adsorption operation rather than requiring multiple sequential treatment steps. The adsorbent material is introduced directly into the hydrocarbon stream, allowing phosphorus removal to occur in one pass, thereby maintaining process efficiency while achieving the required phosphorus levels for gasoline blending.
Solution Approach 2:
The adsorbent material performs the phosphorus removal function autonomously through its inherent adsorption properties, without requiring additional energy input, temperature control, or complex process intervention. The system essentially serves itself by utilizing the natural affinity of the adsorbent for phosphorus compounds, eliminating the need for expensive and time-consuming external treatment processes.
3Manufacturing precision
If high temperature oxidation is used to convert phosphorus to oxides, then phosphorus removal is improved, but energy consumption and process time increase
Solution Approach 1:
The patent replaces the thermal/chemical oxidation process with a physical adsorption mechanism. Instead of using high temperature and oxidizing agents to convert phosphorus to oxides, the system uses an adsorbent material that physically binds phosphorus compounds at ambient or moderate conditions. This substitution eliminates the need for high energy input while achieving equivalent or superior phosphorus removal efficiency.
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 reduces phosphorus content below 0.8 mg/gal, maintaining alkylate quality within specifications and enhancing the hydrocarbon's octane number, thereby improving blending capabilities and process economics.
Implementation Method 1
Co-feeding phosphorus-containing liquid hydrocarbons with an olefinic feed to an alkylation unit, where the phosphorus is removed and the hydrocarbon is upgraded
Implementation Method 2
upgrade the liquid hydrocarbon to a higher octane number gasoline additive
Data Source
AI summary
Methods of reducing a phosphorus content of a liquid hydrocarbon. The liquid hydrocarbon may be co-fed with an olefin to an alkylation unit to produce a low-phosphorus content liquid hydrocarbon product.