Vertical Reactor System for Ionic Liquid Alkylation
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Solution Overview
Problem
Conventional reactor systems for ionic liquid catalyzed processes require significant plot space due to the large volume and time needed for reaction and separation, making it challenging to integrate them into existing facilities like those using hydrofluoric acid or sulfuric acid catalysts.
Innovation Solution
The implementation of vertically oriented reactor systems, heat exchangers, and separation vessels that include static mixers and staged injection processes to efficiently disperse ionic liquids and hydrocarbons, allowing for compact design and reduced space requirements while maintaining effective reaction and separation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If conventional horizontal reactor systems are used for ionic liquid catalyzed processes, then adequate reaction and separation volume is provided, but significant plot space is required
Solution Approach 1:
The patent applies vertical orientation to reactors, heat exchangers, and separation vessels, transitioning from horizontal to vertical configuration. This dimensional change allows the system to achieve adequate reaction and separation volume while minimizing plot space footprint, directly resolving the technical contradiction between volume requirements and area consumption.
2Productivity
If ionic liquid catalyst is dispersed into droplets for intimate contact with reactants, then reaction efficiency is improved, but separation into phases requires additional time and volume
Solution Approach 1:
The patent employs vertical separation vessels that utilize gravity-driven phase separation in a vertical configuration. This vertical arrangement optimizes the separation process by allowing efficient gravity-based phase separation of ionic liquid and hydrocarbon phases, reducing both separation time and volume while maintaining the droplet dispersion approach for reaction efficiency.
3Productivity
If ionic liquid catalyst is dispersed into droplets for intimate contact with reactants, then reaction efficiency is improved, but additional volume is required for separation
Solution Approach 1:
The vertical orientation of separation vessels in the patent enables more compact separation volume by utilizing vertical gravity separation. This approach maintains effective phase separation of dispersed ionic liquid droplets from hydrocarbon phases while minimizing the overall separation volume required, thus resolving the contradiction between reaction efficiency and separation volume.
4Reliability
If existing HF or sulfuric acid catalyst units are revamped to use ionic liquid catalyst, then catalyst safety is improved, but requisite space for additional vessels and equipment is unavailable
Solution Approach 1:
The patent's vertical configuration of reactors, heat exchangers, and separation vessels enables compact integration into existing facility footprints. This vertical arrangement provides the requisite equipment for safe ionic liquid catalyst operation while minimizing plot space requirements, making revamping of existing units feasible where horizontal expansion is not possible.
5Area of stationary object
If vertically oriented reactors and heat exchangers are used, then plot space is reduced, but device complexity increases
Solution Approach 1:
The patent integrates multiple functions into vertically oriented units where reactors, heat exchangers, and separation vessels are configured in vertical arrangements. This merging of spatial requirements into vertical configurations reduces plot space while the functional integration within each vertical unit helps manage overall system complexity.
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 configuration reduces the plot space needed for ionic liquid alkylation equipment, enabling the revamping of existing facilities and improving the efficiency of ionic liquid catalyzed reactions by minimizing the formation of undesirable products and optimizing heat transfer.
Implementation Method 1
the ionic liquid catalyst is typically dispersed into droplets to provide intimate contact between the reactants and the ionic liquid catalyst
Implementation Method 2
The first heat exchange zone comprises a heat exchanger having an inlet for cooling fluid, an outlet for cooling fluid, an inlet for process fluid, and, an outlet for a cooled process fluid
Implementation Method 3
The mixture of ionic liquid, reactants, and reaction products are typically separated by gravity into two phases, a heavier ionic liquid phase and a lighter hydrocarbon phase
Data Source
AI summary
Reactor systems for use with ionic liquid catalyst. The reactor systems include one or more stages, which include a reactor and a heat exchanger, and a separation zone. The reactor and the heat exchanger may have a vertical orientation. Additionally, a separation vessel may also include a vertical orientation. The heat exchanger may allow for linear flow of process fluid to control residence time.