U.S. patent application number 14/323262 was filed with the patent office on 2016-01-07 for novel reactor for ionic liquid catalyzed alkylation based on motionless mixer.
This patent application is currently assigned to Chevron U.S.A. Inc.. The applicant listed for this patent is Moinuddin Ahmed, Bong Kyu Chang, Arthur William Etchells, III, Michael John Girgis, Huping Luo, Donald Henry Mohr, Krishniah Parimi, Hye Kyung Cho Timken. Invention is credited to Moinuddin Ahmed, Bong Kyu Chang, Arthur William Etchells, III, Michael John Girgis, Huping Luo, Donald Henry Mohr, Krishniah Parimi, Hye Kyung Cho Timken.
Application Number | 20160001255 14/323262 |
Document ID | / |
Family ID | 52630504 |
Filed Date | 2016-01-07 |
United States Patent
Application |
20160001255 |
Kind Code |
A1 |
Luo; Huping ; et
al. |
January 7, 2016 |
NOVEL REACTOR FOR IONIC LIQUID CATALYZED ALKYLATION BASED ON
MOTIONLESS MIXER
Abstract
Systems and apparatus for ionic liquid catalyzed hydrocarbon
conversion may comprise a modular reactor comprising a plurality of
mixer modules. The mixer modules may be arranged in series. One or
more feed modules may be disposed between the mixer modules. Such
systems may be used for ionic liquid catalyzed alkylation
reactions. Processes for ionic liquid catalyzed hydrocarbon
conversion are also disclosed.
Inventors: |
Luo; Huping; (Richmond,
CA) ; Etchells, III; Arthur William; (Philadelphia,
PA) ; Mohr; Donald Henry; (Orinda, CA) ;
Timken; Hye Kyung Cho; (Albany, CA) ; Ahmed;
Moinuddin; (Hercules, CA) ; Parimi; Krishniah;
(Alamo, CA) ; Chang; Bong Kyu; (San Ramon, CA)
; Girgis; Michael John; (Richmond, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Luo; Huping
Etchells, III; Arthur William
Mohr; Donald Henry
Timken; Hye Kyung Cho
Ahmed; Moinuddin
Parimi; Krishniah
Chang; Bong Kyu
Girgis; Michael John |
Richmond
Philadelphia
Orinda
Albany
Hercules
Alamo
San Ramon
Richmond |
CA
PA
CA
CA
CA
CA
CA
CA |
US
US
US
US
US
US
US
US |
|
|
Assignee: |
Chevron U.S.A. Inc.
San Ramon
CA
|
Family ID: |
52630504 |
Appl. No.: |
14/323262 |
Filed: |
July 3, 2014 |
Current U.S.
Class: |
585/728 ;
422/224 |
Current CPC
Class: |
B01J 2219/0002 20130101;
B01J 14/00 20130101; B01J 4/004 20130101; B01D 17/0208 20130101;
B01J 2219/00777 20130101; C10G 29/205 20130101; B01F 13/1016
20130101; B01F 5/061 20130101; B01J 19/006 20130101; B01J 19/245
20130101; C07C 2/62 20130101; B01F 2015/0221 20130101; B01F 5/102
20130101; B01J 19/24 20130101 |
International
Class: |
B01J 19/24 20060101
B01J019/24; C07C 2/62 20060101 C07C002/62 |
Claims
1. A system for ionic liquid catalyzed hydrocarbon conversion, the
system comprising: a modular reactor comprising a plurality of
static mixer modules and one or more feed modules, wherein: said
static mixer modules are arranged in series, each said static mixer
module and each said feed module is vertically aligned, said static
mixer modules are arranged alternately with said feed modules such
that each feed module is disposed between two of said static mixer
modules, and each said static mixer module is arranged coaxially
with each said feed module.
2. The system according to claim 1, wherein the number of said
static mixer modules is n, and the number of said feed modules is
(n-1).
3. The system according to claim 2, wherein the number of said
static mixer modules, n, is in the range from two (2) to 10.
4. The system according to claim 1, wherein: each said static mixer
module is in contact with at least one of said feed modules, and
each said feed module is in contact with two of said static mixer
modules.
5. The system according to claim 1, wherein: each said static mixer
module and each said feed module has a circular cross-section, and
each said static mixer module and each said feed module has the
same internal diameter.
6. The system according to claim 1, wherein each said static mixer
module occupies essentially the entire cross-sectional area of the
modular reactor.
7. The system according to claim 1, further comprising a feed
supply line, wherein: each said feed module includes a feed
conduit, each said feed conduit is in fluid communication with the
feed supply line, and the system is configured for delivering
hydrocarbon feed to the modular reactor via each said feed
module.
8. The system according to claim 1, wherein each said feed module
comprises a sparger.
9. (canceled)
10. The system according to claim 1, wherein: each said static
mixer module has a static mixer module proximal end and a static
mixer module distal end, and each said static mixer module
comprises a static mixer module proximal flange at the static mixer
module proximal end and a static mixer module distal flange at the
static mixer module distal end, each said feed module has a feed
module proximal end and a feed module distal end, each said feed
module comprises a feed module proximal flange at the feed module
proximal end and a feed module distal flange at the feed module
distal end, the static mixer module distal flange is configured for
coupling to the feed module proximal flange, and the feed module
distal flange is configured for coupling to the static mixer module
proximal flange.
11. The system according to claim 1, further comprising: a
circulation loop in fluid communication with the modular reactor,
the modular reactor having a base and a top, the circulation loop
having a first loop end coupled to the base of the modular reactor,
and the circulation loop further having a second loop end coupled
to the top of the modular reactor, the system configured for
withdrawing reactor effluent from the modular reactor via the first
loop end into the circulation loop, and the system further
configured for delivering a recirculation stream to the top of the
modular reactor via the second loop end, wherein the circulation
loop comprises: an ionic liquid catalyst inlet configured for
adding fresh ionic liquid catalyst to withdrawn reactor effluent to
provide the recirculation stream, and a heat exchanger configured
for cooling the recirculation stream.
12. The system according to claim 1, additionally comprising: a
feed supply line in fluid communication with each said feed
module.
13. The system according to claim 12, wherein: each said feed
module includes a feed conduit, each said feed conduit is in fluid
communication with the feed supply line, and the system is
configured for delivering hydrocarbon feed to the modular reactor
via each said feed module.
14. The system according to claim 12, wherein: each said static
mixer module is in fluid communication with, and in contact with,
at least one of said feed modules, and each said feed module is in
fluid communication with, and reversibly affixed to, two of said
static mixer modules.
15. The system according to claim 12, wherein: each said feed
module comprises a sparger.
16. The system according to claim 13, further comprising: a
circulation loop in fluid communication with the modular reactor,
the modular reactor having a base and a top, the circulation loop
having a first loop end coupled to the base of the modular reactor,
and the circulation loop further having a second loop end coupled
to the top of the modular reactor, the system configured for
withdrawing reactor effluent from the modular reactor via the first
loop end into the circulation loop, wherein the circulation loop
comprises: an ionic liquid catalyst inlet configured for adding
fresh ionic liquid catalyst to withdrawn reactor effluent to
provide a recirculation stream, and a heat exchanger configured for
cooling the recirculation stream.
17. The system according to claim 16, wherein: the plurality of
static mixer modules comprise a first static mixer module and at
least a second static mixer module disposed downstream from the
first static mixer module, the first static mixer module is in
fluid communication with the second loop end for receiving the
recirculation stream from the circulation loop, the first static
mixer module is configured for mixing the recirculation stream, and
the second static mixer module is configured for mixing the
hydrocarbon feed with the recirculation stream.
18. A system for ionic liquid catalyzed hydrocarbon conversion, the
system comprising: a modular reactor having a base and a top; and a
circulation loop in fluid communication with the modular reactor,
the circulation loop having a first loop end coupled to the base of
the modular reactor, the system configured for withdrawing reactor
effluent from the base of the modular reactor into the circulation
loop, the circulation loop further having a second loop end coupled
to the top of the modular reactor, and the system further
configured for delivering a recirculation stream to the top of the
modular reactor; wherein the modular reactor comprises: a first
static mixer, a first feed module comprising a sparger, disposed
downstream from, and in fluid communication with, the first static
mixer, and a second static mixer disposed downstream from, and in
fluid communication with, the first feed module, wherein the first
static mixer is coaxial with the first feed module and the second
static mixer.
19. The system according to claim 18, wherein the modular reactor
further comprises: a second feed module disposed downstream from,
and in fluid communication with, the second static mixer, and a
third static mixer disposed downstream from, and in fluid
communication with, the second feed module, wherein: the first feed
module is reversibly affixed to, and in contact with, each of the
first static mixer and the second static mixer, the first static
mixer is coaxial with the second feed module and the third static
mixer, and the second feed module is reversibly affixed to, and in
contact with, each of the second static mixer and the third static
mixer.
20. The system according to claim 19, wherein: the first feed
module is configured for distributing hydrocarbon feed between the
first static mixer and the second static mixer, and the second feed
module is configured for distributing hydrocarbon feed between the
second static mixer and the third static mixer.
21. A process for ionic liquid catalyzed hydrocarbon conversion,
comprising: a) withdrawing reactor effluent from a modular reactor,
the reactor effluent comprising unreacted hydrocarbons from a
hydrocarbon feed; b) adding ionic liquid catalyst to the reactor
effluent to provide a recirculation stream; c) introducing the
recirculation stream into a first static mixer module of the
modular reactor; d) via the first static mixer module, mixing the
recirculation stream to provide an ionic liquid/hydrocarbon
emulsion comprising the ionic liquid catalyst and the unreacted
hydrocarbons; e) via a first feed module, distributing the
hydrocarbon feed at an elevation between the first static mixer
module and at least a second static mixer module disposed
downstream from the first static mixer module; and f) via at least
the second static mixer module, mixing the hydrocarbon feed with
the ionic liquid/hydrocarbon emulsion.
22. The process according to claim 21, wherein step d) comprises
contacting the unreacted hydrocarbons with the ionic liquid
catalyst in the first static mixer module under alkylation
conditions to provide an alkylate product.
23. The process according to claim 22, wherein step f) comprises
contacting the hydrocarbon feed with the ionic liquid catalyst in
at least the second static mixer module under alkylation conditions
to provide an additional amount of the alkylate product.
24. The process according to claim 21, wherein each of the first
static mixer module and the second static mixer module comprises a
static mixer that is a helical type- or a plate type-static mixer
that produces high turbulence and good radial mixing.
25. The process according to claim 21, wherein: the first feed
module is disposed downstream from the first static mixer module,
the second static mixer module is disposed downstream from the
first feed module, and the first feed module is coaxial with both
the first static mixer module and the second static mixer
module.
26. The process according to claim 21, wherein the first feed
module comprises a sparger.
27. The process according to claim 23, wherein: the ionic liquid
catalyzed hydrocarbon conversion comprises paraffin alkylation, the
hydrocarbon feed comprises at least one C.sub.2-C.sub.10 olefin and
at least one C.sub.4-C.sub.10 isoparaffin, the ionic liquid
catalyst comprises a chloroaluminate ionic liquid, and the
alkylation conditions comprise a temperature in the range from
-40.degree. C. to 150.degree. C., and a pressure in the range from
atmospheric pressure to 8000 kPa.
28. The process according to claim 21, wherein the ionic
liquid/hydrocarbon emulsion comprises droplets of the ionic liquid
catalyst having a diameter in the range from 1-1000 microns by
choosing a combination of a static mixer element and a liquid
linear velocity.
29. The process according to claim 21, wherein the ionic liquid
catalyzed hydrocarbon conversion is selected from the group
consisting of: paraffin alkylation, paraffin isomerization, olefin
oligomerization, cracking of olefins or paraffins, and aromatic
alkylation.
30. The process according to claim 21, further comprising: g)
adding at least one of a co-catalyst and a catalyst promoter to the
modular reactor, wherein the co-catalyst comprises an alkyl
chloride and the catalyst promoter comprises HCl.
31. The process according to claim 21, wherein step b) comprises
maintaining the overall ionic liquid catalyst volume in the modular
reactor in the range from 0.5 to 50 vol %.
32. The system according to claim 1, wherein said static mixer
modules comprise helical type- or plate type-static mixers that
produce high turbulence and good radial mixing.
33. The system according to claim 12, wherein said static mixer
modules comprise helical type- or plate type-static mixers that
produce high turbulence and good radial mixing.
34. The system according to claim 18, wherein the first static
mixer or the second static mixer is a helical type- or a plate
type-static mixer that produces high turbulence and good radial
mixing.
35. The system according to claim 21, wherein the first static
mixer module or the second static mixer module comprise helical
type- or plate type-static mixers that produce high turbulence and
good radial mixing.
Description
TECHNICAL FIELD
[0001] This disclosure relates to reactors, systems, and processes
for ionic liquid catalyzed alkylation.
BACKGROUND
[0002] There is a need for apparatus, reactors, and systems for the
efficient mixing of two or more immiscible liquids, such as ionic
liquid catalysts and hydrocarbon feeds for ionic liquid catalyzed
hydrocarbon conversion processes including ionic liquid catalyzed
alkylation.
SUMMARY
[0003] In an embodiment there is provided a system for ionic liquid
catalyzed hydrocarbon conversion, the system comprising a modular
reactor comprising a plurality of mixer modules and one or more
feed modules. The mixer modules are arranged in series, each mixer
module and each feed module is vertically aligned, and each mixer
module is arranged coaxially with each feed module.
[0004] In another embodiment, there is provided a system for ionic
liquid catalyzed hydrocarbon conversion, the system comprising a
modular reactor comprising a plurality of mixer modules and one or
more feed modules, and a feed supply line in fluid communication
with each feed module. The mixer modules are arranged in series,
each feed module is disposed between two of the mixer modules, each
mixer module and each feed module is vertically aligned, and each
mixer module is coaxial with each feed module.
[0005] In yet another embodiment there is provided a system for
ionic liquid catalyzed hydrocarbon conversion, the system
comprising a modular reactor having a base and a top; and a
circulation loop in fluid communication with the modular reactor.
The circulation loop has a first loop end coupled to the base of
the modular reactor. The system is configured for withdrawing
reactor effluent from the base of the modular reactor into the
circulation loop. The circulation loop further has a second loop
end coupled to the top of the modular reactor. The system is
further configured for delivering a recirculation stream to the top
of the modular reactor. The modular reactor comprises a first
static mixer; a first feed module disposed downstream from, and in
fluid communication with, the first static mixer; and a second
static mixer disposed downstream from, and in fluid communication
with, the first feed module. The first static mixer is coaxial with
the first feed module and the second static mixer.
[0006] In still a further embodiment there is provided a process
for ionic liquid catalyzed hydrocarbon conversion, the process
comprising withdrawing reactor effluent from a modular reactor, the
reactor effluent comprising unreacted hydrocarbons from a
hydrocarbon feed; adding ionic liquid catalyst to the reactor
effluent to provide a recirculation stream; introducing the
recirculation stream into a first mixer module of the modular
reactor; via the first mixer module, mixing the recirculation
stream to provide an ionic liquid/hydrocarbon emulsion comprising
the ionic liquid catalyst and the unreacted hydrocarbons; via a
first feed module, distributing the hydrocarbon feed at an
elevation between the first mixer module and at least a second
mixer module disposed downstream from the first mixer module; and
via at least the second mixer module, mixing the hydrocarbon feed
with the ionic liquid/hydrocarbon emulsion.
[0007] Further embodiments of systems and processes for ionic
liquid catalyzed hydrocarbon conversion are described hereinbelow
and shown in the Drawings. As used herein, the terms "comprising"
and "comprises" mean the inclusion of named elements or steps that
are identified following those terms, but not necessarily excluding
other unnamed elements or steps.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIGS. 1A and 1B each schematically represent a system for
ionic liquid catalyzed hydrocarbon conversion processes, according
to embodiments of the present invention;
[0009] FIG. 2 schematically represents a system for ionic liquid
catalyzed hydrocarbon conversion processes, according to an
embodiment of the present invention;
[0010] FIG. 3 schematically represents a modular reactor as seen
from the side, according to an embodiment of the present
invention;
[0011] FIG. 4A schematically represents components of a modular
reactor in exploded view as seen from the side, according to an
embodiment of the present invention;
[0012] FIG. 4B schematically represents a modular reactor as seen
from the side, according to an embodiment of the present
invention;
[0013] FIG. 4C schematically represents a modular reactor as seen
along the line 4C-4C of FIG. 4B, according to an embodiment of the
present invention;
[0014] FIG. 4D schematically represents a modular reactor as seen
along the line 4D-4D of FIG. 4B, according to an embodiment of the
present invention;
[0015] FIG. 5 schematically represents a modular reactor, as seen
from the side, in combination with a circulation loop, according to
an embodiment of the present invention;
[0016] FIGS. 6A and 6B each schematically represents a sparger for
distributing hydrocarbon feed to a modular reactor, as seen in
reverse plan view, according to embodiments of the present
invention; and
[0017] FIG. 7 schematically represents a system and process for
ionic liquid catalyzed hydrocarbon conversion, according to another
embodiment of the present invention.
DETAILED DESCRIPTION
[0018] Ionic liquid catalysts may be useful for a range of
hydrocarbon conversion reactions, including alkylation reactions
for the production of alkylate, e.g., comprising gasoline blending
components, and the like. Systems for ionic liquid catalyzed
hydrocarbon conversion according to this disclosure may comprise a
modular reactor and at least one circulation loop in fluid
communication with the modular reactor, wherein each modular
reactor may comprise a plurality of mixer modules arranged in
series.
[0019] Modular reactors as disclosed herein provide for the rapid
and thorough mixing of ionic liquid catalyst and hydrocarbon
reactants so as to generate a large surface area of ionic liquid
catalyst phase in an ionic liquid/hydrocarbon mixture, thereby
enabling highly efficient ionic liquid catalyzed hydrocarbon
conversion processes on a commercial scale.
Systems for Ionic Liquid Catalyzed Alkylation
[0020] Although systems may be described herein primarily with
reference to ionic liquid catalyzed alkylation reactions, such
systems may also be applicable to other ionic liquid catalyzed
hydrocarbon conversion reactions as well as to other processes more
generally.
[0021] In an embodiment, a system for ionic liquid catalyzed
hydrocarbon conversion processes may comprise a modular reactor
comprising a plurality of mixer modules and one or more feed
modules. Each of the plurality of mixer modules may be arranged in
series. In an embodiment, each of the mixer modules and each of the
feed modules may be arranged vertically or upright. In an
embodiment, each of the mixer modules and each of the feed modules
may be vertically aligned, and each of the mixer modules may be
arranged coaxially with each of the feed modules.
[0022] In an embodiment, the mixer modules may be arranged
alternately with the feed modules such that each feed module is
disposed between two adjacent mixer modules. The mixer modules on
top of the feed modules will therefore produce highly turbulent
flow field to allow rapid mixing in the feed modules. The mixer
modules and the feed modules may be stacked on top of each other
such that each mixer module may be in contact with at least one of
the feed modules, and each feed module may be in contact with two
adjacent mixer modules.
[0023] In an embodiment, the modular reactor may have one more
mixer module than feed module. That is to say, for a modular
reactor wherein the number of mixer modules is n, the number of
feed modules may be (n-1). In an embodiment, the number of mixer
modules per modular reactor may be in the range from two (2) to 10,
or from two (2) to six (6), or from two (2) to four (4).
[0024] In an embodiment, each mixer module and each feed module may
have a circular cross-section. In a sub-embodiment, the internal
diameter of each mixer module may be the same or essentially the
same as the internal diameter of each feed module. In an
embodiment, each mixer module may occupy essentially the entire
cross-sectional area of the modular reactor. In an embodiment, the
modular reactor may be at least substantially cylindrical.
[0025] In an embodiment, each mixer module may comprise a static
mixer. In an embodiment, each mixer module may comprise at least
one mixer element. In a sub-embodiment, the mixer element(s) may be
disposed within a cylindrical housing. In an embodiment, a surface
of the mixer element may comprise a hydrophobic material. In an
embodiment, each mixer module may comprise a material selected from
a ceramic, an engineering plastic, and a metal alloy. In a
sub-embodiment, the mixer module may comprise one or more metal
alloys, e.g., selected from Monel.RTM., Hastelloy.RTM., stainless
steel, and tantalum-coated stainless steel. In an embodiment, the
mixer module may comprise one or more engineering plastics, e.g.,
selected from polypropylene, Teflon.RTM., polyvinylidene difluoride
(PVDF), polyvinyl chloride (PVC), chlorinated polyvinyl chloride
(CPVC), and polyoxymethylene (POM). In a sub-embodiment, a mixer
module of the modular reactor may comprise a housing comprising a
metal alloy and one or more mixer elements comprising an
engineering plastic.
[0026] A system for ionic liquid catalyzed hydrocarbon conversion
processes may further comprise a feed supply line. In an
embodiment, each feed module may include a feed conduit. Each feed
conduit may be in fluid communication with the feed supply line,
and the system may be configured for delivering hydrocarbon feed to
the modular reactor via each of the feed modules. Each feed module
may be configured so as to uniformly distribute the hydrocarbon
feed over the entire cross-section of the modular reactor. In an
embodiment, the hydrocarbon feed may be introduced into the modular
reactor at high speed sufficient to allow rapid mixing of the
hydrocarbon feed stream with the liquid stream from the upper mixer
module. In an embodiment, each feed module may comprise a sparger,
such as a tree sparger or a ring sparger. In a sub-embodiment, such
a sparger may have a diameter in the range from 40 to 100% of the
internal diameter of each mixer module and of each feed module, or
from 60 to 100% of the internal diameter of each mixer module and
of each feed module, or from 90 to 99% of the internal diameter of
each mixer module and of each feed module.
[0027] In an embodiment, the modular reactor may be configured for
facile assembly and disassembly of the mixer modules to and from
the feed modules. In a sub-embodiment, each mixer module may be
configured for facile assembly to, and disassembly from, at least
one of the feed modules; and each feed module may be configured for
facile assembly to, and disassembly from, two of the mixer modules.
In an embodiment, each mixer module may comprise a mixer module
proximal flange at the mixer module proximal end and a mixer module
distal flange at the mixer module distal end.
[0028] In an embodiment, each feed module may comprise a feed
module proximal flange at the feed module proximal end and a feed
module distal flange at the feed module distal end. The mixer
module distal flange may be configured for coupling to a feed
module proximal flange, such that the mixer module distal end may
be affixed to the proximal end of an adjacent, downstream feed
module. In an embodiment, such affixation of the mixer module
distal end to the feed module proximal end may be reversible. The
feed module distal flange may be configured for coupling to the
mixer module proximal flange of an adjacent, downstream mixer
module, such that the feed module distal flange may be affixed,
e.g., reversibly, to the mixer module proximal flange.
[0029] A system for ionic liquid catalyzed hydrocarbon conversion
may further comprise a circulation loop in fluid communication with
the modular reactor. The modular reactor may have a base and a top.
The circulation loop may have a first loop end coupled to the base
of the modular reactor, and the circulation loop may further have a
second loop end coupled to the top of the modular reactor. The
system may be configured for withdrawing reactor effluent from the
modular reactor via the first loop end into the circulation loop.
The system may be further configured for delivering a recirculation
stream to the top of the modular reactor via the second loop end.
The circulation loop may comprise an ionic liquid catalyst inlet
configured for adding fresh ionic liquid catalyst to withdrawn
reactor effluent to provide the recirculation stream; for example,
the recirculation stream may comprise withdrawn reactor effluent in
combination with freshly added ionic liquid catalyst. The
circulation loop may further comprise a heat exchanger configured
for cooling the recirculation stream.
[0030] According to another embodiment of a system for ionic liquid
catalyzed hydrocarbon conversion, the system may comprise a modular
reactor comprising a plurality of mixer modules and one or more
feed modules, and a feed supply line in fluid communication with
each feed module. The mixer modules may be arranged in series. In
an embodiment, each feed module may be disposed between two mixer
modules. Each mixer module and each feed module may be vertically
aligned, and each mixer module may be coaxial with each feed
module. In an embodiment, each mixer module may occupy a volume in
the range from 10 to 50% of the total volume of the modular
reactor.
[0031] In an embodiment, each feed module may include a feed
conduit. Each feed conduit may be in fluid communication with the
feed supply line, and the system may be configured for delivering
hydrocarbon feed to the modular reactor via each feed module. In an
embodiment, each mixer module may be in fluid communication with,
and in contact with, at least one feed module. In an embodiment,
each feed module may be in fluid communication with, and reversibly
affixed to, two mixer modules.
[0032] In an embodiment, the system may further comprise a
circulation loop in fluid communication with the modular reactor.
The circulation loop may have a first loop end coupled to the base
of the modular reactor and a second loop end coupled to the top of
the modular reactor. The system may be configured for withdrawing
reactor effluent from the modular reactor via the first loop end
into the circulation loop. The circulation loop may comprise an
ionic liquid catalyst inlet configured for adding fresh ionic
liquid catalyst to withdrawn reactor effluent to provide a
recirculation stream. The circulation loop may further comprise a
heat exchanger configured for cooling the recirculation stream.
[0033] In an embodiment, the plurality of mixer modules may
comprise a first mixer module and at least a second mixer module
disposed downstream from the first mixer module. The first mixer
module may be in fluid communication with the second loop end for
receiving the recirculation stream from the circulation loop. In an
embodiment, the first mixer module may be configured for mixing the
recirculation stream such that the ionic liquid catalyst component
of the recirculation stream is dispersed into an ionic
liquid/hydrocarbon emulsion, wherein the emulsion may comprise
small to microscopic droplets of the ionic liquid catalyst, e.g.,
having a droplet diameter in the range from 1 to 1000 microns, or
from 5 to 500 microns, or from 10 to 250 microns. The system may be
configured for distributing the hydrocarbon feed to the modular
reactor, e.g., via each feed module, between each adjacent pair of
mixer modules. Each subsequent (downstream) mixer module may be
configured for thoroughly and rapidly mixing the distributed
hydrocarbon feed with the mixed recirculation stream emanating from
the first mixer module.
[0034] According to a further embodiment of a system for ionic
liquid catalyzed hydrocarbon conversion processes, the system may
comprise a modular reactor and a circulation loop in fluid
communication with the modular reactor. The circulation loop may
have a first loop end coupled to the base of the modular reactor
and a second loop end coupled to the top of the modular reactor.
The system may be configured for withdrawing reactor effluent from
the base of the modular reactor into the circulation loop, and the
system may be further configured for delivering a recirculation
stream to the top of the modular reactor.
[0035] The modular reactor may comprise a first static mixer, a
second static mixer, and a first feed module disposed downstream
from, and in fluid communication with, the first static mixer. The
second static mixer may be disposed downstream from, and in fluid
communication with, the first feed module. The first static mixer
may be coaxial with the first feed module and the second static
mixer.
[0036] In an embodiment, the first feed module may be reversibly
affixed to, and in contact with, each of the first static mixer and
the second static mixer. The modular reactor may further comprise a
second feed module disposed downstream from, and in fluid
communication with, the second static mixer. The modular reactor
may further comprise a third static mixer disposed downstream from,
and in fluid communication with, the second feed module. The first
static mixer may be coaxial with the second feed module and the
third static mixer. In an embodiment, each static mixer may
comprise a cylindrical housing and at least one mixer element
disposed within the cylindrical housing.
[0037] The second feed module may be reversibly affixed to, and in
contact with, each of the second static mixer and the third static
mixer. In an embodiment, the first feed module may be configured
for uniformly distributing hydrocarbon feed at an elevation between
the first static mixer and the second static mixer. The second feed
module may be configured for distributing hydrocarbon feed at an
elevation between the second static mixer and the third static
mixer. The use of multiple feed modules for introducing hydrocarbon
feed at different elevations of the modular reactor may serve to
minimize the local olefin concentration within the modular reactor
so as to provide better reactor performance and superior
product(s), e.g., alkylate.
[0038] According to yet another embodiment, a process for ionic
liquid catalyzed hydrocarbon conversion, e.g., isoparaffin/olefin
alkylation, may be practiced using systems as disclosed herein.
Such systems may comprise a modular reactor having a top and a
base, and at least one circulation loop in fluid communication with
the top and the base of the modular reactor. The modular reactor
may comprise a plurality of mixer modules. The modular reactor may
further comprise at least one feed module. Hydrocarbon feed may be
delivered to the modular reactor, e.g., between adjacent mixer
modules, via the at least one feed module. In an embodiment, each
mixer module may be disposed vertically in series. Such systems for
ionic liquid catalyzed hydrocarbon conversion may further comprise
additional elements, features, and characteristics as described
herein and as shown in the drawings.
[0039] In an embodiment, such a process for ionic liquid catalyzed
hydrocarbon conversion may include: withdrawing reactor effluent
from the modular reactor, the reactor effluent comprising unreacted
hydrocarbons from a hydrocarbon feed to the modular reactor; adding
ionic liquid catalyst to the reactor effluent to provide a
recirculation stream; introducing the recirculation stream into a
first (e.g., uppermost) mixer module of the modular reactor; via
the first mixer module, mixing the recirculation stream to provide
an ionic liquid/hydrocarbon emulsion comprising the ionic liquid
catalyst and the unreacted hydrocarbons; via a first feed module,
distributing the hydrocarbon feed at an elevation between the first
mixer module and at least a second mixer module disposed downstream
from the first mixer module; and via at least the second mixer
module, mixing the hydrocarbon feed with the ionic
liquid/hydrocarbon emulsion. In an embodiment, the ionic liquid
catalyst may be added to the reactor effluent at a rate sufficient
to maintain the overall ionic liquid catalyst volume in the modular
reactor in the range from 0.5 to 50 vol %, or from 1 to 10 vol %,
or from 2 to 6 vol %.
[0040] In an embodiment, such a process for ionic liquid catalyzed
hydrocarbon conversion may further include adding a co-catalyst, or
a catalyst promoter, or both a catalyst promoter and a co-catalyst,
to the modular reactor. In an embodiment, such a co-catalyst may
comprise an alkyl chloride. A catalyst promoter for addition to the
modular reactor may comprise a hydrogen halide, such as HCl. In an
embodiment, a co-catalyst and/or a catalyst promoter may be fed to
the modular reactor by injection into the hydrocarbon feed, or by
injection into the ionic liquid catalyst, or by direct injection
into the modular reactor.
[0041] In an embodiment, the reactor effluent may be withdrawn from
the base of the modular reactor via the circulation loop. Fresh
ionic liquid catalyst may be added to the withdrawn reactor
effluent to provide the recirculation stream, and the recirculation
stream may be cooled in the circulation loop before introducing the
cooled recirculation stream into the first mixer module of the
modular reactor. The reactor effluent may be recirculated to the
modular reactor without any attempt to separate the reactor
effluent within the circulation loop. As an example, in an
embodiment the circulation loop may lack a separation unit or other
apparatus for phase separation of the reactor effluent or the
recirculation stream. A portion of the withdrawn reactor effluent
may be removed from the circulation loop for fractionation to
provide an alkylate product.
[0042] In an embodiment, the flow rate through the circulation loop
may be much greater than the total flow rate of the hydrocarbon
feeds to reduce the temperature rise in the modular reactor and to
enhance the feed dilution in the feed modules and mixer modules. In
an embodiment, the flow rate through the circulation loop may be in
the range from 2 to 50 times the flow rate of the hydrocarbon feed,
or from 2 to 25 times the flow rate of the hydrocarbon feed, or
from 4 to 10 times the flow rate of the hydrocarbon feed.
[0043] The step of mixing the recirculation stream via the first
mixer module may comprise contacting the unreacted hydrocarbons
with the ionic liquid catalyst in the first mixer module under
alkylation conditions to provide an alkylate product. The step of
mixing the hydrocarbon feed with the ionic liquid/hydrocarbon
emulsion via at least the second mixer module may comprise
contacting the hydrocarbon feed with the ionic liquid catalyst in
at least the second mixer module under alkylation conditions to
provide an additional amount of the alkylate product. Any remaining
unreacted hydrocarbons in at least the second mixer module may also
be contacted with the ionic liquid catalyst under alkylation
conditions to provide further quantities of the alkylate product.
In an embodiment, each mixer module of the modular reactor may
serve as an ionic liquid alkylation zone. Furthermore, in an
embodiment each feed module of the modular reactor may also serve
as an ionic liquid alkylation zone.
[0044] In an embodiment, the first feed module may be disposed
between the first and second mixer modules, such that the first
feed module is disposed downstream from the first mixer module and
the second mixer module is disposed downstream from the first feed
module. Flow through the modular reactor may be downward, e.g.,
from the first mixer module to the first feed module and the second
mixer module. The first feed module may be coaxial with both the
first mixer module and the second mixer module. In an embodiment,
the modular reactor may comprise additional mixer modules and
additional feed modules. The mixer modules may be arranged
alternately with the feed modules. Each feed module may be disposed
between two mixer modules such that when the number of mixer
modules is n, the number of feed modules is (n-1), wherein n may be
in the range from two (2) to 10, or from two (2) to six (6), or
from two (2) to four (4). In an embodiment, mixer modules of the
modular reactor, e.g., the first mixer module and the second mixer
module, may each comprise a static mixer. In an embodiment, at
least one feed module of the modular reactor, e.g., the first feed
module, may comprise a sparger.
[0045] In an embodiment, the ionic liquid/hydrocarbon emulsion
formed by mixing the recirculation stream in the first mixer module
may comprise small to microscopic droplets of the ionic liquid
catalyst, e.g., having a droplet diameter in the range from 1 to
1000 microns, or from 5 to 500 microns, or from 10 to 250 microns.
Different combinations of static mixer elements and liquid linear
velocities may be chosen to achieve the said range of droplet size
for the ionic liquid catalyst. For example, both helical type- and
plate type static mixers that are able to produce high turbulence
and achieve good radial mixing may be used.
[0046] The system may be configured for distributing the
hydrocarbon feed to the modular reactor, e.g., via each feed
module, between each adjacent pair of mixer modules. The second
mixer module and any subsequent (downstream) mixer module(s) may be
configured for thoroughly mixing the distributed hydrocarbon feed
with the mixed recirculation stream emanating from the first mixer
module so as to maintain the ionic liquid catalyst droplet diameter
within the ranges cited hereinabove.
[0047] A range of the ionic liquid catalyzed hydrocarbon conversion
processes may be practiced using systems, apparatus, and processes
as disclosed herein. As non-limiting examples, such hydrocarbon
conversion processes may include or be selected from: paraffin
alkylation, paraffin isomerization, olefin oligomerization,
cracking of olefins or paraffins, and aromatic alkylation.
[0048] In an embodiment of a process for ionic liquid catalyzed
paraffin alkylation, the hydrocarbon feed may comprise at least one
C.sub.2-C.sub.10 olefin and at least one C.sub.4-C.sub.10
isoparaffin. In an embodiment, the ionic liquid catalyst may
comprise a chloroaluminate ionic liquid. In an embodiment, the
alkylation conditions may comprise a temperature in the range from
-40.degree. C. to 150.degree. C., and a pressure in the range from
atmospheric pressure to 8000 kPa. In an embodiment, the overall
ionic liquid catalyst volume in the modular reactor may be
maintained in the range from 0.5 to 50 vol %, or from 1 to 10 vol
%, or from 2 to 6 vol %. Hydrocarbon feeds, ionic liquid catalysts,
and conditions for ionic liquid catalyzed alkylation are described
hereinbelow.
[0049] Systems and apparatus for ionic liquid catalyzed hydrocarbon
conversion, including alkylation for gasoline production, will now
be described with reference to the drawings.
[0050] FIG. 1A schematically represents a system for ionic liquid
catalyzed hydrocarbon conversion processes. System 100 may comprise
at least one modular reactor 200 and at least one circulation loop
400. Modular reactor 200 provides for the rapid and thorough mixing
of ionic liquid catalyst and hydrocarbon reactants. As an example,
modular reactor 200 may generate a large surface area of the ionic
liquid catalyst phase in an ionic liquid/hydrocarbon mixture,
thereby providing for the highly efficient performance of ionic
liquid catalyzed hydrocarbon conversion processes.
[0051] Modular reactor 200 may have a reactor top 202 and a reactor
base 203. In an embodiment, modular reactor 200 may be vertically
aligned having a height greater than its width. In an embodiment,
modular reactor 200 may be substantially cylindrical. In an
embodiment, system 100 may comprise a plurality of mixer modules
210 per modular reactor 200 (see, for example, FIGS. 2, 3, and
4A-4B). Circulation loop 400 may be in fluid communication with
modular reactor 200 for withdrawing liquid (e.g., reactor effluent)
from modular reactor 200 into circulation loop 400. Circulation
loop 400 may further be in fluid communication with modular reactor
200 for recirculating at least a portion of the withdrawn liquid to
the reactor top 202 of modular reactor 200. Although only one
circulation loop 400 is shown in FIG. 1A, in an embodiment system
100 may comprise a plurality of circulation loops 400 per modular
reactor 200, wherein each circulation loop 400 may be in fluid
communication with modular reactor 200.
[0052] FIG. 1B schematically represents a system for ionic liquid
catalyzed hydrocarbon conversion processes, wherein system 100 may
comprise a plurality of modular reactors 200 per circulation loop
400. In an embodiment, the plurality of modular reactors 200 may be
arranged in parallel. Each modular reactor 200 in the embodiment of
FIG. 1B provides for the rapid and thorough mixing of ionic liquid
catalyst and hydrocarbon reactants, substantially as described with
reference to FIG. 1A, thereby providing for the highly efficient
performance of ionic liquid catalyzed hydrocarbon conversion
processes.
[0053] Each modular reactor 200 in the embodiment of FIG. 1B may
have features, elements, and characteristics as described, for
example, with reference to FIGS. 1A, 2, 3, and 4A-4B. Although two
modular reactors 200 are shown in FIG. 1B, larger numbers of
modular reactors may also be used per circulation loop 400. In an
embodiment, the use of multiple modular reactors 200 per
circulation loop 400 may serve to increase the overall reactor
throughput. In an embodiment, reactor scale-up may be conveniently
achieved by the addition of modular reactors 200 to system 100.
[0054] FIG. 2 schematically represents a system 100 for ionic
liquid catalyzed hydrocarbon conversion, wherein system 100
comprises a modular reactor 200 and a circulation loop 400. Modular
reactor 200 may comprise a plurality of mixer modules 210 and one
or more feed modules 300. Each mixer module 210 may be configured
for mixing liquid(s), e.g., comprising two or more immiscible
liquids, flowing through modular reactor 200. Although three mixer
modules 210 are shown in FIG. 2, modular reactor 200 may comprise
other numbers of mixer modules 210 (see, for example, FIG. 3).
[0055] Circulation loop 400 may comprise a first loop end 400a
coupled to reactor base 203 and a second loop end 400b coupled to
reactor top 202. Circulation loop 400 may further comprise a loop
outlet 402, an ionic liquid catalyst inlet 404, a circulation pump
406, and a heat exchanger 408. In embodiments having a plurality of
circulation loops 400 per modular reactor 200, each circulation
loop 400 may have a dedicated circulation pump 406 and heat
exchanger 408.
[0056] System 100 may further comprise a feed supply line 302. Each
feed module 300 may include a feed conduit 304 in fluid
communication with feed supply line 302. In an embodiment, each
feed module 300 may be configured for introducing a hydrocarbon
feed 301 into modular reactor 200, e.g., at an elevation between
two adjacent, vertically stacked mixer modules 210. In an
embodiment, each feed module 300 may be configured for uniformly
distributing the hydrocarbon feed 301 over the entire
cross-sectional area of modular reactor 200. In an embodiment, the
hydrocarbon feed 301 may comprise an olefin feed stream, an
isoparaffin feed stream, or a mixed olefin/isoparaffin feed, for
ionic liquid catalyzed alkylation, e.g., as described hereinbelow.
In an embodiment, the hydrocarbon feed 301 introduced into modular
reactor 200 may comprise a liquid feed.
[0057] System 100 may be configured for withdrawing reactor
effluent 206 from base 203 of modular reactor 200 into circulation
loop 400. Reactor effluent 206 may comprise ionic liquid catalyst
that has previously contacted the hydrocarbon feed 301 in modular
reactor 200. Fresh ionic liquid catalyst 403 may be added to
reactor effluent 206, within circulation loop 400, via ionic liquid
catalyst inlet 404 to provide a recirculation stream 412. A portion
of withdrawn reactor effluent 206 may be removed from circulation
loop 400, via loop outlet 402, e.g., for fractionation thereof to
provide an alkylate product.
[0058] Although only one modular reactor 200 is shown in FIG. 2, in
an embodiment a plurality of modular reactors 200 may be used per
circulation loop 400 (see, for example, FIG. 1B). Loop outlet 402
and ionic liquid catalyst inlet 404 may be disposed at various
locations within circulation loop 400 other than as shown in FIG.
2. In an embodiment, system 100 may be configured for ionic liquid
catalyzed alkylation reactions and processes. Feeds, ionic liquid
catalysts, and reaction conditions for ionic liquid catalyzed
alkylation are described hereinbelow.
[0059] FIG. 3 schematically represents a modular reactor as seen
from the side. Modular reactor 200 may have a reactor top 202 and a
reactor base 203. Modular reactor 200 may be in fluid communication
with a first loop end 400a and a second loop end 400b of
circulation loop 400 (see, for example, FIG. 2). In an embodiment,
modular reactor 200 may comprise a plurality of mixer modules
210a-210n and a plurality of feed modules 300a-300n. Modular
reactor 200 may receive recirculation stream 412 at the first
(uppermost) mixer module 210a via second loop end 400b.
[0060] In an embodiment, mixer modules 210a-210n may be arranged
alternately with feed modules 300a-300n such that each feed module
300 is disposed between two mixer modules 210. In an embodiment,
all mixer modules 210a-210n and all feed modules 300a-300n may be
arranged in series. In an embodiment, each of modular reactor 200,
mixer modules 210a-210n, and feed modules 300a-300n may be arranged
vertically or upright. In an embodiment, each mixer module
210a-210n and each feed module 300a-300n may be vertically aligned,
and each of mixer modules 210a-210n may be arranged coaxially with
each of feed modules 300a-300n.
[0061] In an embodiment, mixer modules 210a-210n and feed modules
300a-300n may be stacked on top of each other, such that each mixer
module 210a-210n may be in contact (contiguous) with at least one
of feed modules 300a-300n, and each feed module 300a-300n may be in
contact (contiguous) with two of mixer modules 210a-210n. In an
embodiment, modular reactor 200 may have one more mixer module 210
than feed module 300. As an example, for a modular reactor 200
having n mixer modules 210a-210n, the number of feed modules 300
may be (n-1). In an embodiment, each modular reactor 200 may
typically comprise from two (2) to 10 mixer modules 210, or from
two (2) to six (6) mixer modules 210, or from two (2) to four (4)
mixer modules 210.
[0062] FIG. 4A schematically represents components of a modular
reactor in exploded view as seen from the side; FIG. 4B
schematically represents a modular reactor as seen from the side;
FIG. 4C schematically represents a modular reactor as seen along
the line 4C-4C of FIG. 4B; and FIG. 4D schematically represents a
modular reactor as seen along the line 4D-4D of FIG. 4B. With
reference to FIGS. 4A-4D, modular reactor 200 may comprise a
plurality of vertically aligned mixer modules 210. Although two
mixer modules 210 are shown in FIGS. 4A-4B, other numbers of mixer
modules 210 may also be used (see, e.g., FIG. 3). In an embodiment,
a feed module 300 may be disposed between each adjacent pair of
mixer modules 210 such that when the number of mixer modules 210 is
n, the number of feed modules 300 is (n-1).
[0063] In an embodiment, modular reactor 200 may be configured such
that all mixer modules 210 and feed module(s) 300 are coaxial. A
common axis of modular reactor 200, mixer modules 210, and feed
module(s) 300 is indicated in FIG. 4A by the line labeled
A.sub.MM/A.sub.FM (wherein the mixer module axis and the feed
module axis are designated as A.sub.MM and A.sub.FM,
respectively).
[0064] With further reference to FIGS. 4A-4D, in an embodiment each
mixer module 210 may include a mixer module housing 218 and each
feed module 300 may include a feed module housing 318. In an
embodiment, each mixer module 210 of modular reactor 200 may have a
circular cross-section, and each mixer module 210 may have the same
or essentially the same internal diameter, D.sub.MM. In an
embodiment, each feed module 300 of modular reactor 200 may have a
circular cross-section, and each feed module 300 may have the same
or essentially the same internal diameter, D.sub.FM. In a
sub-embodiment, the internal diameter, D.sub.MM, of each mixer
module of a given modular reactor 200 may be the same or
essentially the same as the internal diameter, D.sub.FM, of each
feed module. In an embodiment, each mixer module 210 may occupy
essentially the entire cross-sectional area of modular reactor
200.
[0065] Each mixer module 210 may have a mixer module proximal end
211a and a mixer module distal end 211b. Each mixer module 210 may
be configured for facile assembly to, and disassembly from, at
least one feed module 300; and each feed module 300 may be
configured for facile assembly to, and disassembly from, two mixer
modules 210. In an embodiment, each mixer module 210 may comprise a
mixer module proximal flange 212a at the mixer module proximal end
211a and a mixer module distal flange 212b at the mixer module
distal end 211b.
[0066] In an embodiment, each feed module 300 may comprise a feed
module proximal flange 312a at the feed module proximal end 311a
and a feed module distal flange 312b at the feed module distal end
311b. Mixer module distal flange 212b may be configured for
coupling to feed module proximal flange 312a, such that mixer
module distal end 211b may be affixed to the proximal end 311a of
an adjacent, downstream feed module 300. In an embodiment, such
affixation of mixer module distal end 211b to feed module proximal
end 311a may be reversible. Feed module distal flange 312b may be
configured for coupling to mixer module proximal flange 212a of an
adjacent, downstream mixer module 210, e.g., such that feed module
distal end 311b may be reversibly affixed to mixer module proximal
end 211a. Flanged couplings for pipes and cylindrical housings
comprising metal(s), plastics or other materials, and the like are
known in the art.
[0067] In an embodiment, at least one mixer module 210 of modular
reactor 200 may comprise a static mixer. In a sub-embodiment, each
mixer module 210 of modular reactor 200 may comprise a static
mixer. In an embodiment, each mixer module 210 may comprise at
least one mixer element disposed within mixer module housing 218
(see, for example, FIG. 5). Various static mixers having a broad
range of characteristics may be obtained commercially.
[0068] In an embodiment, mixer modules 210 for modular reactor 200
may be selected such that a total pressure drop across modular
reactor 200, from reactor top 202 to reactor base 203, is in the
range from 15 to 115 psig, or from 20 to 100 psig. System 100 and
modular reactor 200 may be configured to produce small to
microscopic droplets of ionic liquid catalyst within mixer modules
210 of modular reactor 200. In an embodiment, such droplets of
ionic liquid catalyst may have a diameter in the range from 1 to
1000 microns, or from 5 to 500 microns, or from 10 to 250 microns.
Such droplets may provide not only an ionic liquid catalyst surface
area that will produce a high rate of reaction and a high quality
product (e.g., alkylate), but also a hydrocarbon/ionic liquid mixed
phase that is conducive to subsequent phase separation downstream.
The size or size range of ionic liquid droplets produced by modular
reactor 200 may be selected, for example, by adjusting the flow
rate across modular reactor 200 and by mixer element design.
[0069] FIG. 5 schematically represents a modular reactor as seen
from the side. Modular reactor 200 may have a reactor top 202 and a
reactor base 203. In an embodiment, modular reactor 200 may
comprise a first mixer module 210a, a second mixer module 210b, and
a third mixer module 210c. Mixer modules 210a-210c may comprise
mixer elements 220a-220c, respectively, disposed within mixer
module housing 218. Such mixer modules 210a-210c comprising one or
more mixer elements may be referred to herein as static mixers.
Static mixers may also be known as motionless mixers. Systems and
apparatus as disclosed herein are not limited to any specific
static mixer type, configuration, or design.
[0070] In an embodiment, mixer module housing 218 may comprise a
cylindrical housing. In an embodiment, each of mixer modules
210a-210c may have a separate mixer module housing 218, and modular
reactor 200 may be configured such that each of mixer modules
210a-210c may be removed separately (see, for example, FIGS.
4A-4B). Such modular construction of modular reactor 200 allows for
the facile assembly and disassembly of modular reactor 200. Mixer
modules 210a-210c may additionally include various elements,
features and characteristics as described herein, for example, with
reference to FIGS. 3 and 4A-4D.
[0071] With further reference to FIG. 5, modular reactor 200 may be
in fluid communication with first loop end 400a of circulation loop
400 at reactor base 203 for withdrawing reactor effluent from
modular reactor 200. Modular reactor 200 may further be in fluid
communication with second loop end 400b of circulation loop 400 at
reactor top 202 for delivering recirculation stream 412 to modular
reactor 200. First mixer module 210a may be coaxial with second
mixer module 210b and third mixer module 210c.
[0072] With still further reference to FIG. 5, a first feed module
300a may be disposed between first and second mixer modules, 210a
and 210b, respectively, such that first feed module 300a is
disposed downstream from, and in fluid communication with, first
mixer module 210a. Second mixer module 210b may be disposed
downstream from, and in fluid communication with, first feed module
300a. First feed module 300a may be configured for distributing
hydrocarbon feed between first mixer module 210a and second mixer
module 210b. First feed module 300a may be reversibly affixed to,
and in contact (contiguous) with, each of first mixer module 210a
and second mixer module 210b.
[0073] A second feed module 300b may be disposed between second and
third mixer modules, 210b and 210c, respectively, such that second
feed module 300b is disposed downstream from, and in fluid
communication with, second mixer module 210b. Third mixer module
210c may be disposed downstream from, and in fluid communication
with, second feed module 300b. First mixer module 210a may be
coaxial with first feed module 300a and second feed module 300b.
Second feed module 300b may be configured for distributing
hydrocarbon feed between second mixer module 210b and third mixer
module 210c. Second feed module 300b may be reversibly affixed to,
and in contact with, each of second mixer module 210b and third
mixer module 210c.
[0074] First feed module 300a and second feed module 300b may
comprise a first feed conduit 304a and a second feed conduit 304b,
respectively. First feed module 300a and second feed module 300b
may further comprise a first sparger 320a and a second sparger
320b, respectively. First sparger 320a and second sparger 320b may
be in fluid communication with first feed conduit 304a and second
feed conduit 304b, respectively. Each of first feed conduit 304a
and second feed conduit 304b may be in fluid communication with
feed supply line 302 (see, for example, FIG. 2) for providing
hydrocarbon feed to modular reactor 200. Although, FIG. 5 shows
three mixer modules 210a-210c and two feed modules 300a, 300b,
other numbers of mixer modules and feed modules are also possible
(see, for example, FIG. 3).
[0075] FIGS. 6A and 6B each schematically represents a sparger, as
seen in reverse plan view, for distributing hydrocarbon feed 301 to
a modular reactor 200. FIG. 6A schematically represents a tree
sparger 320' in combination with a feed conduit 304. FIG. 6B
schematically represents a ring sparger 320'' in combination with a
feed conduit 304. In an embodiment, one or more feed modules 300 of
modular reactor 200 (e.g., feed modules 300a-300n, FIG. 3) may each
comprise tree sparger 320' or ring sparger 320''.
[0076] Feed conduit 304 may be in fluid communication with spargers
320'/320'' and with feed supply line 302 (see, e.g., FIG. 2) for
providing hydrocarbon feed 301 to spargers 320'/320''. Each of
spargers 320'/320'' may be configured for distributing hydrocarbon
feed 301 at a location upstream from an adjacent downstream mixer
module 210 (see, for example, FIG. 5). In an embodiment, spargers
320'/320'' may be configured for uniformly distributing the
hydrocarbon feed over the entire cross-sectional area of modular
reactor 200. In an embodiment, spargers 320'/320'' may have a
circular cross-section and a diameter D.sub.S. In an embodiment,
the diameter, D.sub.S, of spargers 320'/320'' may be in the range
from 40 to 100% of the mixer module internal diameter, D.sub.MM, or
from 60 to 100% of the mixer module internal diameter, D.sub.MM, or
from 90 to 99% of the mixer module internal diameter, D.sub.MM. In
an embodiment, the mixer module internal diameter, D.sub.MM, may be
the same or essentially the same as the feed module internal
diameter, D.sub.FM.
[0077] In an embodiment, system 100 as disclosed herein may be used
for ionic liquid catalyzed alkylation processes. In an embodiment,
the ionic liquid catalyst may comprise, e.g., a chloroaluminate
ionic liquid as described hereinbelow. In an embodiment, the
hydrocarbon feed may comprise at least one of an olefin feed
stream, an isoparaffin feed stream, and a mixed olefin/isoparaffin
feed, for ionic liquid catalyzed alkylation, e.g., as also
described hereinbelow.
[0078] FIG. 7 schematically represents a system and process for
ionic liquid catalyzed hydrocarbon conversion, according to another
embodiment. System 100' of FIG. 7 may comprise a modular reactor
200 having a reactor top 202, a reactor base 203, and a reactor
outlet 204. Modular reactor 200 may comprise a plurality of mixer
modules and one or more feed modules (see, for example, FIGS. 3-5).
System 100' may have elements and features in common with system
100 (see, for example, FIGS. 1A-1B and 2). In modular reactor 200,
at least one isoparaffin and at least one olefin may be contacted
with ionic liquid catalyst under ionic liquid alkylation
conditions. Ionic liquid alkylation conditions, feedstocks, and
ionic liquid catalysts that may be suitable for performing ionic
liquid alkylation reactions are described, for example,
hereinbelow.
[0079] In an embodiment, a process for ionic liquid catalyzed
hydrocarbon conversion may include adding a co-catalyst, or a
catalyst promoter, or both a catalyst promoter and a co-catalyst,
to modular reactor 200. In an embodiment, such a co-catalyst may
comprise an alkyl chloride. A catalyst promoter for addition to the
modular reactor may comprise a hydrogen halide, such as HCl. In an
embodiment, a co-catalyst and/or a catalyst promoter may be fed to
modular reactor 200 via the hydrocarbon feed, or via the ionic
liquid catalyst feed, or by separate direct injection into modular
reactor 200. The addition of co-catalyst(s) and/or catalyst
promoter(s) to modular reactor 200 is not shown in the Drawings.
Various methods and techniques for introducing co-catalyst(s)
and/or catalyst promoter(s) to modular reactor 200 will be apparent
to the skilled artisan.
[0080] System 100' may further comprise a circulation loop 400.
Circulation loop 400 may comprise a first loop end 400a coupled to
vessel outlet 204 and a second loop end 400b coupled to reactor top
202. In an embodiment, a first mixer module 210a may be disposed at
reactor top 202 (see, for example, FIG. 3), and second loop end
400b may be coupled to, and in fluid communication with, first
mixer module 210a. Circulation loop 400 may further comprise a
circulation pump 406, and a heat exchanger 408. Circulation loop
400 may still further comprise at least one circulation loop
conduit 410, e.g., for coupling components of circulation loop 400
to vessel outlet 204 and reactor top 202.
[0081] System 100' may still further comprise an ionic
liquid/hydrocarbon (IL/HC) separator 500 in fluid communication
with circulation loop 400, and a fractionation unit 600 in fluid
communication with IL/HC separator 500. Reactor effluent 206 may be
withdrawn from modular reactor 200 into circulation loop 400 via
vessel outlet 204. A portion of the reactor effluent 206 may be fed
from circulation loop 400, via a line 501, to IL/HC separator 500
for separation of the portion of reactor effluent into a
hydrocarbon phase 502 and an ionic liquid phase 403'. Non-limiting
examples of separation processes that can be used for such phase
separation include coalescence, phase separation, extraction,
membrane separation, and partial condensation. IL/HC separator 500
may comprise, for example, one or more of the following: a settler,
a coalescer, a centrifuge, a cyclone, a distillation column, a
condenser, and a filter. In an embodiment, IL/HC separator 500 may
comprise a gravity based settler and a coalescer disposed
downstream from the gravity based settler.
[0082] It can be seen from FIG. 7 that IL/HC separator 500 may be
external to circulation loop 400. In an embodiment, circulation
loop 400 may lack a unit or apparatus for phase separation of
reactor effluent 206 or the external recirculation stream, R.sub.E.
Accordingly, reactor effluent 206 may be recirculated to modular
reactor 200 without any attempt to separate reactor effluent 206,
or the external recirculation stream, within circulation loop 400.
System 100' having IL/HC separator 500 external to circulation loop
400 allows IL/HC separator 500 to be smaller than that for a system
in which a separator may be used for phase separation of 100% of
the withdrawn reactor effluent within a hydrocarbon recycle
loop.
[0083] The hydrocarbon phase 502 from IL/HC separator 500 may be
fed via a line 503 to fractionation unit 600. The hydrocarbon phase
from IL/HC separator 500 may comprise alkylate components
(product), as well as unreacted components of hydrocarbon feed 301,
including isobutane. The alkylate components may comprise, e.g.,
C.sub.5-C.sub.11 alkanes, such as C.sub.7-C.sub.8 isoparaffins. The
hydrocarbon phase from IL/HC separator 500 may be fractionated via
fractionation unit 600 to provide one or more products 602a-n and
an isobutane fraction. In an embodiment, products 602a-n may
comprise alkylate, n-butane, and propane. In an embodiment,
fractionation unit 600 may comprise one or more distillation
columns.
[0084] At least a portion of the isobutane stream from
fractionation unit 600 may be recycled via a line 604 to modular
reactor 200. In an embodiment, the recycle isobutane may be
premixed with at least one of an olefin feed stream 301a and a
make-up isobutane feed stream 301b to provide a mixed hydrocarbon
feed 301 for introduction into modular reactor 200. In an
embodiment, modular reactor 200 may comprise a plurality of feed
modules, and each feed module may separately receive hydrocarbon
feed 301, e.g., via their respective feed conduit 304 (see, for
example, FIG. 5). Although two inputs for hydrocarbon feed 301 to
modular reactor 200 are shown in FIG. 7, other numbers and
configurations are possible. In an embodiment, the number of feed
modules per modular reactor 200 may be in the range from one (1) to
9, or from one (1) to five (5), or from one (1) to three (3).
[0085] The ionic liquid phase 403' from IL/HC separator 500 may be
recycled to circulation loop 400 via a line 505. Make-up (e.g.,
fresh) ionic liquid catalyst 403 may be combined with the recycled
ionic liquid catalyst via a line 509. The combined fresh and
recycled ionic liquid catalyst may be injected into the reactor
effluent within circulation loop 400 to provide an external
recirculation stream, R.sub.E, which may be cooled via heat
exchanger 408. The cooled external recirculation stream may be
recirculated to modular reactor 200 via circulation loop 400. In an
embodiment, the ionic liquid catalyst may be added to system 100'
at a rate sufficient to maintain the overall ionic liquid catalyst
volume in modular reactor 200 in the range from 0.5 to 50 vol %, or
from 1 to 10 vol %, or from 2 to 6 vol %.
[0086] In an embodiment, the ionic liquid phase 403' may be
recycled to circulation loop 400 either directly or indirectly
through a catalyst surge vessel (the latter not shown). In an
embodiment, a portion of the ionic liquid phase 403' from IL/HC
separator 500 may be purged or withdrawn to other vessels (not
shown), via a line 507, for ionic liquid catalyst regeneration,
e.g., as described hereinbelow.
Feedstocks for Ionic Liquid Catalyzed Alkylation
[0087] In an embodiment, feedstocks for ionic liquid catalyzed
alkylation may comprise various olefin- and isoparaffin containing
hydrocarbon streams in or from one or more of the following: a
petroleum refinery, a gas-to-liquid conversion plant, a
coal-to-liquid conversion plant, a naphtha cracker, a middle
distillate cracker, a natural gas production unit, a LPG production
unit, and a wax cracker, and the like.
[0088] Examples of olefin containing streams include FCC off-gas,
coker gas, olefin metathesis unit off-gas, polyolefin gasoline unit
off-gas, methanol to olefin unit off-gas, FCC light naphtha, coker
light naphtha, Fischer-Tropsch unit condensate, and cracked
naphtha. Some olefin containing feed streams may contain at least
one olefin selected from ethylene, propylene, butylenes, pentenes,
and up to C.sub.10 olefins, i.e., C.sub.2-C.sub.10 olefins, and
mixtures thereof. Such olefin containing streams are further
described, for example, in U.S. Pat. No. 7,572,943, the disclosure
of which is incorporated by reference herein in its entirety.
[0089] Examples of isoparaffin containing streams include, but are
not limited to, FCC naphtha, hydrocracker naphtha, coker naphtha,
Fisher-Tropsch unit condensate, natural gas condensate, and cracked
naphtha. Such streams may comprise at least one C.sub.4-C.sub.10
isoparaffin. In an embodiment, such streams may comprise a mixture
of two or more isoparaffins. In a sub-embodiment, an isoparaffin
feed to the alkylation reactor during an ionic liquid catalyzed
alkylation process may comprise isobutane.
Paraffin Alkylation
[0090] In an embodiment, the alkylation of a mixture of
hydrocarbons may be performed in a modular reactor vessel under
conditions known to produce alkylate gasoline. The modular reactor
may be referred to herein as an alkylation reactor, and the modular
reactor may comprise at least one alkylation zone. The alkylation
conditions in the alkylation reactor are selected to provide the
desired product yields and quality. The alkylation reaction in the
alkylation reactor is generally carried out in a liquid hydrocarbon
phase, in a batch system, a semi-batch system, or a continuous
system. The catalyst volume in the alkylation reactor may be in the
range of 0.5 to 50 vol %, or from 1 to 20 vol %, or from 2 to 6 vol
%. In an embodiment, vigorous mixing can be attained by using one
or more mixing devices per reactor, e.g., as described hereinabove,
to provide contact between the hydrocarbon reactants and ionic
liquid catalyst over a large surface area per unit volume of the
reactor. The alkylation reaction temperature can be in the range
from -40.degree. C. to 150.degree. C., such as -20.degree. C. to
100.degree. C., or -15.degree. C. to 50.degree. C. The alkylation
pressure can be in the range from atmospheric pressure to 8000 kPa.
In an embodiment the alkylation pressure is maintained at a level
at least sufficient to keep the reactants in the liquid phase. The
residence time of reactants in the reactor can be in the range of a
second to 60 hours.
[0091] In one embodiment, the molar ratio of isoparaffin to olefin
in the alkylation reactor can vary over a broad range. Generally
the molar ratio of isoparaffin to olefin is in the range of from
0.5:1 to 100:1. For example, in different embodiments the molar
ratio of isoparaffin to olefin is from 1:1 to 50:1, from 1.1:1 to
10:1, or from 1.1:1 to 20:1. Lower isoparaffin to olefin molar
ratios will tend to produce a higher yield of higher molecular
weight alkylate products, and thus can be selected when operating
the alkylation reactor in a distillate mode, such as described in
U.S. Patent Publication No. US20110230692A1.
Other Hydrocarbon Conversion Processes
[0092] Systems comprising a modular reactor as disclosed herein can
be used for other hydrocarbon conversion processes using an acidic
ionic liquid catalyst. Some examples of the hydrocarbon conversion
processes include isomerization of C.sub.4-C.sub.8 paraffin where
normal paraffins are converted to isoparaffins, oligomerization of
C.sub.3-C.sub.30 olefins to produce higher molecular weight
olefins, isomerization of C.sub.3-C.sub.30 olefins to shift the
location of the double bond in the molecule (double bond
isomerization) or shift the back-bone of the olefin molecules
(skeletal isomerization), cracking of high molecular weight olefins
and paraffins to low molecular paraffins and olefins, and
alkylation of olefins with aromatics to form alkylaromatics.
Ionic Liquid Catalysts for Hydrocarbon Conversion Processes
[0093] In an embodiment, a catalyst for hydrocarbon conversion
processes may be a chloride-containing ionic liquid catalyst
comprised of at least two components which form a complex. A first
component of the chloride-containing ionic liquid catalyst can
comprise a Lewis Acid selected from components such as Lewis Acidic
compounds of Group 13 metals, including aluminum halides, alkyl
aluminum halides, gallium halides, and alkyl gallium halides,
indium halides, and alkyl indium halides (see International Union
of Pure and Applied Chemistry (IUPAC), version 3, October 2005, for
Group 13 metals of the periodic table). Other Lewis Acidic
compounds, in addition to those of Group 13 metals, can also be
used. In one embodiment the first component is aluminum halide or
alkyl aluminum halide. For example, aluminum trichloride can be the
first component of the chloride-containing ionic liquid
catalyst.
[0094] A second component comprising the chloride-containing ionic
liquid catalyst is an organic salt or mixture of salts. These salts
can be characterized by the general formula Q.sup.+A.sup.- wherein
Q.sup.+ is an ammonium, phosphonium, boronium, iodonium, or
sulfonium cation and A.sup.- is a negatively charged ion such as
Cl.sup.-, Br.sup.-, ClO.sub.4.sup.-, NO.sub.3.sup.-,
BF.sub.4.sup.-, BCl.sub.4.sup.-, PF.sub.6.sup.-, SbF.sub.6.sup.-,
AlCl.sub.4.sup.-, TaF.sub.6.sup.-, CuCl.sub.2.sup.-,
FeCl.sub.3.sup.-, HSO.sub.3.sup.-, RSO.sub.3.sup.- (wherein R is an
alkyl group having from 1 to 12 carbon atoms),
SO.sub.3CF.sub.3.sup.-, and 3-sulfurtrioxyphenyl. In one
embodiment, the second component is selected from those having
quaternary ammonium or phosphonium halides containing one or more
alkyl moieties having from 1 to 12 carbon atoms, such as, for
example, trimethylamine hydrochloride, methyltributylammonium
halide, trialkylphosphonium hydrochloride, tetraalkylphosphonium
chlorides, methyltrialkylphosphonium halide or substituted
heterocyclic ammonium halide compounds, such as hydrocarbyl
substituted pyridinium halide compounds, for example,
1-butylpyridinium halide, benzylpyridinium halide, or hydrocarbyl
substituted imidazolium halides, such as for example,
1-ethyl-3-methyl-imidazolium chloride.
[0095] In one embodiment the chloride-containing ionic liquid
catalyst is selected from the group consisting of hydrocarbyl
substituted pyridinium chloroaluminate, hydrocarbyl substituted
imidazolium chloroaluminate, quaternary amine chloroaluminate,
trialkyl amine hydrogen chloride chloroaluminate, alkyl pyridine
hydrogen chloride chloroaluminate, and mixtures thereof. For
example, the chloride-containing ionic liquid catalyst can be an
acidic haloaluminate ionic liquid, such as an alkyl substituted
pyridinium chloroaluminate or an alkyl substituted imidazolium
chloroaluminate of the general formulas A and B, respectively.
##STR00001##
[0096] In the formulas A and B, R, R.sub.1, R.sub.2, and R.sub.3
are H, methyl, ethyl, propyl, butyl, pentyl or hexyl group, and X
is a chloroaluminate. In the formulas A and B, R, R.sub.1, R.sub.2,
and R.sub.3 may or may not be the same. In one embodiment the
chloride-containing ionic liquid catalyst is N-butylpyridinium
chloroaluminate. Examples of highly acidic chloroaluminates are
Al.sub.2Cl.sub.7.sup.- and Al.sub.3Cl.sub.10.sup.-.
[0097] In another embodiment the chloride-containing ionic liquid
catalyst can have the general formula RR'R''NH.sup.+
Al.sub.2Cl.sub.7.sup.- wherein R, R', and R'' are alkyl groups
containing from 1 to 12 carbons, and where R, R', and R'' may or
may not be the same.
[0098] In another embodiment the chloride-containing ionic liquid
catalyst can have the general formula RR'R''R'''P.sup.+
Al.sub.2Cl.sub.7.sup.- wherein R, R', R'' and R''' are alkyl groups
containing from 1 to 12 carbons, and where R, R', R'' and R''' may
or may not be the same.
[0099] The presence of the first component should give the
chloride-containing ionic liquid a Lewis or Franklin acidic
character. Generally, the greater the mole ratio of the first
component to the second component, the greater is the acidity of
the chloride-containing ionic liquid catalyst. The molar ratio of
the first component (metal halide) to the second component
(quaternary amine or quaternary phosphorus) is in the range of 2:1
to 1.1:1.
[0100] In one embodiment, the chloride-containing ionic liquid
catalyst is mixed in the alkylation reactor with a hydrogen halide
and/or an organic halide. The hydrogen halide or organic halide can
boost the overall acidity and change the selectivity of the
chloride-containing ionic liquid catalyst. The organic halide can
be an alkyl halide. The alkyl halides that can be used include
alkyl bromides, alkyl chlorides, alkyl iodides, and mixtures
thereof. A variety of alkyl halides can be used. Alkyl halide
derivatives of the isoparaffins or the olefins that comprise the
feed streams in the alkylation process are good choices. Such alkyl
halides include, but are not limited to, isopentyl halides,
isobutyl halides, butyl halides (e.g., 1-butyl halide or 2-butyl
halide), propyl halides and ethyl halides. Other alkyl chlorides or
halides having from 1 to 8 carbon atoms can be also used. The alkyl
halides can be used alone or in combination or with hydrogen
halide. The alkyl halide or hydrogen halide is fed to the unit by
injecting the alkyl halide or hydrogen halide to the hydrocarbon
feed, or to the ionic liquid catalyst or to the alkylation reactor
directly. The amount of HCl or alkyl chloride usage, the location
of the injection and the injection method may affect the amount of
organic chloride side-product formation. The use of alkyl halides
to promote hydrocarbon conversion by chloride-containing ionic
liquid catalysts is taught in U.S. Pat. No. 7,495,144 and in U.S.
Patent Publication No. 20100298620A1.
[0101] It is believed that the alkyl halide decomposes under
hydrocarbon conversion conditions to liberate Bronsted acids or
hydrogen halides, such as hydrochloric acid (HCl) or hydrobromic
acid (HBr). These Bronsted acids or hydrogen halides promote the
hydrocarbon conversion reaction. In one embodiment the halide in
the hydrogen halide or alkyl halide is chloride. In one embodiment
the alkyl halide is an alkyl chloride, for example t-butyl
chloride. Hydrogen chloride and/or an alkyl chloride can be used
advantageously, for example, when the chloride-containing ionic
liquid catalyst is a chloroaluminate.
Ionic Liquid Catalyst Regeneration
[0102] As a result of use, ionic liquid catalysts become
deactivated, i.e. lose activity, and may eventually need to be
replaced. However, ionic liquid catalysts are expensive and
replacement adds significantly to operating expenses. Thus it is
desirable to regenerate the ionic liquid catalyst on-line and reuse
in the alkylation process. The regeneration of acidic ionic liquid
catalysts is taught in U.S. Pat. No. 7,651,970, U.S. Pat. No.
7,674,739, U.S. Pat. No. 7,691,771, U.S. Pat. No. 7,732,363, and
U.S. Pat. No. 7,732,364.
[0103] Alkylation processes utilizing an ionic liquid catalyst form
by-products known as conjunct polymers. These conjunct polymers are
highly unsaturated molecules and deactivate the ionic liquid
catalyst by forming complexes with the ionic liquid catalyst. A
portion of used ionic liquid catalyst from the alkylation reactor
is sent to the regenerator reactor which removes the conjunct
polymer from the ionic liquid catalyst and recovers the activity of
the ionic liquid catalyst. The regeneration reactor contains metal
components that saturates the conjunct polymers and releases the
saturated polymer molecules from the ionic liquid catalyst. The
regeneration can be performed either in a stirred reactor or a
fixed bed reactor. For ease of operation, a fixed bed reactor is
preferred even though the fixed bed regenerator reactor is more
susceptible to plugging from coking, deposits of corrosion products
and decomposition products derived from feed contaminants. A guard
bed vessel containing adsorbent material with appropriate pore size
may be added before the regeneration reactor to minimize
contaminants going into the regeneration reactor.
Product Separation and Finishing
[0104] The hydrocarbon effluent product from the reactor containing
ionic liquid catalyst and hydrogen halide co-catalyst may contain
trace amounts of hydrogen halides or organic halides or inorganic
halides. When aluminum chloride containing catalyst is used, then
trace amounts of HCl, organic chlorides and inorganic chlorides may
be present in the reactor effluent. HCl and organic chlorides are
preferred to be captured and recycled to the alkylation reactor.
Inorganic chlorides such as corrosion products or decomposition
product may be captured with a filter.
[0105] The separated hydrocarbon product may still contain trace
amounts of HCl, organic chlorides and inorganic chlorides. Removal
of HCl and inorganic chlorides from the product are typically done
by caustic washing. Chloride selective adsorbent may be used to
capture the residual chlorides. Organic chloride may be converted
to HCl and organic hydrocarbon by hydrogenation, cracking or hot
caustic treating. Treating of products for chloride reduction is
taught, for example, in U.S. Pat. No. 7,538,256, U.S. Pat. No.
7,955,498, and U.S. Pat. No. 8,327,004.
EXAMPLES
Example 1
[0106] N-butylpyridinium chloroaluminate
(C.sub.5H.sub.5NC.sub.4H.sub.9Al.sub.2Cl.sub.7) ionic liquid
catalyst (1:2 molar ratio of N-butyl pyridinium chloride and
AlCl.sub.3) was used to produce alkylate shown in Example 2. The
acidic ionic liquid catalyst had aluminum chloride as a metal
halide component. The catalyst had the following elemental
composition.
TABLE-US-00001 Wt % Al 12.4 Wt % Cl 56.5 Wt % C 24.6 Wt % H 3.2 Wt
% N 3.3
Example 2
[0107] The acidic ionic liquid catalyst described in Example 1 was
used to alkylate C.sub.3-C.sub.4 olefins with isobutane in a
process unit. The alkylation was performed in a static mixer
reactor system containing three mixer modules and two feed modules
arranged in the sequence shown in FIG. 2. Each feed module had
three spargers for hydrocarbon feed introduction. An 18:1 molar
ratio of isobutane to total olefin mixture was fed to the reactor
via the two feed modules. Reactor effluent was withdrawn from the
base of the reactor and recirculated to the top of the reactor via
a circulation loop containing the recycle flow). The relative rate
of the recycle flow to the fresh hydrocarbon feed was 17:1. The
pressure drop across the reactor was 50 psi. The acidic ionic
liquid catalyst was fed to the circulation loop to occupy 7 vol %
in the reactor. A small amount of anhydrous n-butyl chloride
corresponding to 120:1 molar ratio of olefin to n-butyl chloride
was added to the acidic ionic liquid catalyst in the reactor. The
average residence time of the combined feeds (isobutane/olefin
mixture and catalyst) in the reactor and loop was about four
minutes. The outlet pressure was maintained at 190 psig and the
reactor temperature was maintained at 35.degree. C. (95.degree. F.)
using external cooling. The reactor effluent was separated with a
coalescing separator into a hydrocarbon phase and an acidic ionic
liquid catalyst phase.
[0108] The bulk of the separated ionic liquid catalyst was recycled
back to the alkylation reactor through the circulation loop. A
portion of the separated acidic ionic liquid catalyst phase was
sent to a catalyst regeneration unit to maintain the conjunct
polymer level in the alkylation catalyst in the range from 3 to 5
wt %.
[0109] The hydrocarbon phase was then sent to a series of three
distillation columns to separate C.sub.5.sup.+, n-butane,
C.sub.3.sup.- offgas and isobutene recycle streams. The
C.sub.5.sup.+ alkylate stream was analyzed using D86 laboratory
distillation. Research and Motor Octane numbers were measured with
an engine test. ASTM D86 distillation of the C.sub.5.sup.+ stream
showed the initial boiling point of 102.degree. F. (39 degree
Celsius), T.sub.50 boiling point of 213.degree. F. (101 degree
Celsius), T.sub.90 boiling point of 346.degree. F. (174 degree
Celsius) and the end boiling point of 433.degree. F. (223 degree
Celsius). The resulting C.sub.5 stream was an alkylate gasoline
having a 89 RON and 89 MON. These results indicate that the in-line
mixer reactor can produce high quality alkylate gasoline that can
be readily blended to the refinery gasoline pool.
[0110] For the purposes of this specification and appended claims,
unless otherwise indicated, all numbers expressing quantities,
percentages or proportions, and other numerical values used in the
specification and claims, are to be understood as being modified in
all instances by the term "about." Furthermore, all ranges
disclosed herein are inclusive of the endpoints and are
independently combinable. Whenever a numerical range with a lower
limit and an upper limit are disclosed, any number falling within
the range is also specifically disclosed.
[0111] Any term, abbreviation or shorthand not defined is
understood to have the ordinary meaning used by a person skilled in
the art at the time the application is filed. The singular forms
"a," "an," and "the," include plural references unless expressly
and unequivocally limited to one instance.
[0112] All of the publications, patents and patent applications
cited in this application are herein incorporated by reference in
their entirety to the same extent as if the disclosure of each
individual publication, patent application or patent was
specifically and individually indicated to be incorporated by
reference in its entirety.
[0113] The drawings are representational and may not be drawn to
scale. Modifications of the exemplary embodiments disclosed above
may be apparent to those skilled in the art in light of this
disclosure. Accordingly, the invention is to be construed as
including all structure and methods that fall within the scope of
the appended claims. Unless otherwise specified, the recitation of
a genus of elements, materials or other components, from which an
individual component or mixture of components can be selected, is
intended to include all possible sub-generic combinations of the
listed components and mixtures thereof.
* * * * *