U.S. patent number 3,653,835 [Application Number 04/870,728] was granted by the patent office on 1972-04-04 for specific gravity analyzer for control of an alkylation process.
This patent grant is currently assigned to Chevron Reasearch Company. Invention is credited to Albert John Brandel.
United States Patent |
3,653,835 |
Brandel |
April 4, 1972 |
SPECIFIC GRAVITY ANALYZER FOR CONTROL OF AN ALKYLATION PROCESS
Abstract
The acid strength of a process stream associated with an
alkylation process using a mineral acid catalyst, such as sulfuric
acid, can be conveniently and continuously measured by determining
the specific gravity of a sample of acid taken from the main
process stream. The sample is pumped under positive and fixed flow
rates into and from an analysis chamber by means of first and
second pumping means, connected, respectively, to the inlet and
outlet of the chamber. Prior to determining the gravity of the acid
within the chamber, dissolved volatile hydrocarbons and high
molecular weight, normally liquid, hydrocarbons are removed from
the sample by stripping and settling chambers within the analysis
chamber, the high molecular weight hydrocarbons flowing from the
chamber by means of an overflow tube positioned in the settling
chamber. The weight percent of the carbonaceous matter removed from
the sample including the high molecular weight hydrocarbons is
controlled by maintaining said second pumping means at a pumping
rate less than that of said first pumping means.
Inventors: |
Brandel; Albert John (Long
Beach, CA) |
Assignee: |
Chevron Reasearch Company (San
Francisco, CA)
|
Family
ID: |
25355973 |
Appl.
No.: |
04/870,728 |
Filed: |
October 20, 1969 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
|
699108 |
Jan 19, 1968 |
3513220 |
|
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Current U.S.
Class: |
436/100; 73/445;
422/211; 585/701; 73/32R; 73/452; 436/119; 585/730 |
Current CPC
Class: |
G01N
9/36 (20130101); Y10T 436/18 (20150115); Y10T
436/15 (20150115) |
Current International
Class: |
G01N
9/00 (20060101); G01N 9/36 (20060101); G01n
009/18 (); G01n 009/36 (); C07c 003/14 () |
Field of
Search: |
;23/230,253
;73/32,445-447,452-453 ;260/683.43,683.59 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Wolk; Morris O.
Assistant Examiner: Katz; Elliott A.
Claims
I claim:
1. In an apparatus for continuously determining the concentration
of sulfuric acid in an aliquot continuously sampled from a
pressurized alkylation system line and said aliquot having
hydrocarbons therein, in which said determination occurs after said
hydrocarbons have been removed from said acid, the improvement
comprising, in combination, a sampling line connected to said
pressurized alkylation system line for continuously removing a
sample of said acid from said system line, chamber means including
overflow tube means, input pumping means having a suction side
connected to said sampling line and a discharge side connected to
said chamber means and operating to flow said sample to said
chamber means at a substantially constant flow rate, output pumping
means connected to the discharge side of said chamber means for
flowing said sample from said chamber at an output pumping rate
less than that of said input pumping means, said pumping rates of
said input and output pumping means adapted to define a
differential pumping rate therebetween, the ratio of said
differential pumping rate over the input pumping rate being at
least as large as the weight fraction of said hydrocarbons to be
removed from said original acid sample, and means in said chamber
means for measuring a specific gravity characteristic of said
sample at a constant temperature after removal of said hydrocarbons
so as to indicate the concentration of said acid.
2. Apparatus in accordance with claim 1 in which said chamber means
includes a stripping chamber, a settling chamber in direct fluid
communication with said stripping chamber, and heating means in
contact with said stripping and settling chambers, said stripping
chamber including vent means, wall means and substantially
horizontal extending planar bottom base means, said side wall and
bottom base means adapted to convey said input sample of acid
flowing from said discharge side of said first input pumping means
in open channel heat transfer contact with said heating means so as
to remove volatile hydrocarbons within said acid sample.
3. Apparatus in accordance with claim 2 in which said stripping
chamber includes baffling means connected to said wall and bottom
base means and adapted to cause said acid sample to be conveyed in
serpentine fashion through said stripping chamber so as to improve
heat transfer between said heating means and said sample.
4. Apparatus in accordance with claim 2 in which said settling
chamber includes wall means defining a settling cavity therein for
receiving said sample from said stripping chamber and an output
means connected to said output fluid pumping means at a remote end
thereof for flowing said sample from said chamber means under
pressure after said sample has passed through said stripping
chamber and said settling chamber,
overflow tube means adapted to be positioned within said settling
cavity so as to define a skimming level therein for removing high
molecular weight hydrocarbons from said sample,
said means for measuring said specific gravity characteristic also
being positioned in said settling cavity below said skimming
level.
5. Apparatus in accordance with claim 4 in which said overflow tube
means is positioned to establish said skimming level at a datum
plane above said bottom base means of said stripping chamber
thereby regulating the depth of said sample of acid in said
stripping chamber in open channel heat transfer contact with said
heating means.
6. The method of determining the concentration of sulfuric acid
catalyst in an alkylation process system which comprises:
1. continuously flowing at a selected pumping rate a sample of said
acid to an analysis chamber,
2. removing volatile hydrocarbons from said sample by heating said
sample within said chamber,
3. after removal of said volatile hydrocarbons, removing high
molecular weight hydrocarbons from said sample by establishing a
predetermined skimming level within said chamber, said high
molecular weight hydrocarbons being removed from said chamber by
means of an overlow tube therein,
4. after removal of said volatile and high molecular weight
hydrocarbons, flowing at a second pumping rate said acid sample
from said chamber, the pumping rate of said flow from said chamber
adapted to be less than that into said chamber to establish a
differential pumping rate therebetween, the ratio of said
differential pumping rate over the input flow rate being at least
as large as the total weight fraction of said volatile and high
molecular weight hydrocarbons to be removed from said sample,
5. after removal of said hydrocarbons but prior to flowing said
sample from said chamber, measuring a specific gravity
characteristic of said acid sample at a known temperature to
provide a continuous indication of the concentration of said acid
sample.
7. Method of claim 6 wherein said differential pumping rate is
adapted to be adjusted so that said ratio exceeds the expected
weight fraction of both said volatile and said high molecular
weight hydrocarbons within said sample.
Description
The present invention is concerned with a method and apparatus for
the determination of the concentration of solutions. In particular,
the present invention is directed to the determination and control
of acid strength in chemical processes dependent on acid catalysis
by means of measuring the specific gravity of the solution. More
particularly, the invention is directed to the determination and
control of acid strength in a sulfuric acid catalyzed alkylation
reaction in which isoparaffin hydrocarbons and olefin hydrocarbons
are reacted in contact with a sulfuric acid catalyst. Still more
particularly, this invention relates to a method and means for
measuring the concentration of spent sulfuric acid by continuously
measuring the specific gravity of a sample of such acid.
The present invention may be briefly described as a method for
maintaining catalyst activity in the aforementioned sulfuric acid
catalyzed alkylation reaction in which the sulfuric acid gradually
loses its strength for the alkylation reaction thereby requiring
the withdrawal of a portion of the sulfuric acid in the system and
the replacement of the withdrawn portion with sulfuric acid of a
predetermined alkylation strength.
The method of alkylating isoparaffins and olefins in the presence
of a concentrated sulfuric acid catalyst is well known in the
petroleum refining art. Typically, in this process, isobutane and
butylenes are alkylated using a concentrated sulfuric acid catalyst
which may range upward in strength from about 85 weight percent
H.sub.2 SO.sub.4. The acid strength tends to decrease during the
operation of the process due to dilution with carbonaceous matter
such as sulfonated hydrocarbons, i.e., catalyst-hydrocarbon
complexes and esters, and with water. As the acid is diluted, its
activity decreases. In the typical instance, the alkylation
reaction is carried out in a series of mixing zones without the
addition of acid to the materials passed through the zones. For
satisfactory operation the acid strength in the last reactor must
be maintained above a certain minimum concentration. When the acid
strength drops below an established minimum, the acid is discarded.
It is usual to recycle a portion of the spent alkylation acid
inasmuch as is possible to reduce the operating costs of the
process, since the cost of acid used is important. Thus, it is
desirable to minimize the amount of spent acid discarded because of
the drop in acid strength. However, the determination of the acid
strength is time consuming and expensive when carried out in the
laboratory, and laboratory methods do not provide sufficient
rapidity for close operational control of the process.
Since almost all commercial processes which utilize an acid
catalyst involve continuous recycling of the acid catalyst through
the reaction, it is of great importance to be able to continuously
and accurately determine the acid strength. When the acid strength
falls below the minimum amount necessary, additional fresh acid can
be added. However, if the analytical technique is not accurate,
then either too much acid may be added, resulting in a wasting of
this expensive material, or else too little may be added, resulting
in poor product yields.
Heretofore, the acidity of the alkylation acid could be determined
spectrophotometrically, but this technique suffers from several
disadvantages:
1. it requires the use of relatively expensive
spectrophotometers;
2. it requires a continuous addition of an indicator compound such
as alizarin blue in known amounts to the sample. Accordingly, a
complicated and expensive control and metering system for the
indicator compound is needed.
In a further prior art method, the acidity function of an
alkylation acid could be determined by continuously measuring the
specific gravity of a sample of acid by means of a hydrometer after
removal of carbonaceous matter from the sample. Experience has
shown that in flowing the sample to the hydrometer clogging often
occurs due to the deposit of carbonaceous matter in
pressure-reducing elements of the system such as orifice
restrictors.
It is therefore an object of the present invention to provide a
useful and novel method and apparatus for the accurate and
continuous determination of the specific gravity of reaction
process streams utilizing only relatively simple and inexpensive
instruments which will not require the addition of indicators or
other reagents and which do not clog even though the sample
contains carbonaceous matter. It is a further object to provide
such a method and apparatus which can be adapted to provide
automatic control over a continuous acid catalyzed chemical process
so as to maintain maximum product yields with minimal acid
losses.
It has been found that the specific gravity and especially changes
in the specific gravity of a recycle process acid stream associated
with an alkylation process using a mineral acid catalyst, such as
sulfuric acid, can be conveniently and continuously measured to
determine the concentration of the aforementioned recycle stream. A
sample of the stream is pumped under positive and fixed flow rates
into and from an analysis chamber by means of first and second
pumping means, connected, respectively, to the inlet and outlet of
the chamber. Prior to determining the gravity of the acid within
the chamber, dissolved volatile hydrocarbons and high molecular
weight, normally liquid hydrocarbons are removed from the sample by
stripping and settling chambers within the analysis chamber, the
high molecular weight hydrocarbons flowing from the chamber by
means of an overflow tube positioned in the settling chamber. The
weight percent of the carbonaceous matter removed from the sample
including the high molecular weight hydrocarbons is controlled by
maintaining said second pumping means at a pumping rate less than
that of said first pumping means.
In a specific embodiment of the invention, a continuous sample of
the recycle process stream is pumped, by means of an input acid
pump, to the stripping chamber. To maintain a pumping head for the
pump, a pressure-sensitive relief valve may be fitted between the
discharge side of the pump and the stripping chamber operated to
open on the discharge stroke of the pump when a working pressure
above the process pressure is achieved. The pump and sequentially
operated valve provide a constant rate of flow to the separation
chamber without the use of restrictors. In the stripping chamber
the sample is heated to the desired temperature say, 105.degree.
F., by means of a temperature-controlled hot water bath. While
within the bath, the sample flows through the stripping chamber
which preferably includes a substantially horizontal extending
planar base adapted to convey the input sample in open channel heat
transfer contact with the bath so as to strip the volatile
hydrocarbons from the sample. The volatile hydrocarbons are vented
to the atmosphere from the top of the stripping chamber as vapors.
Baffles on the planar base of the stripping chamber provide a
sinuous flow pattern to the sample. Within the settling chamber
located at one end of the base in fluid communication with the
stripping chamber, the high molecular weight hydrocarbons including
the alkylate are skimmed off by an overflow tube. An outlet near
the bottom of the settling chamber is connected to the second fluid
pumping means for removing the stripped acid sample from the
chamber after the sample has passed through both the stripping and
the settling chambers. Preferably, the overflow outlet tube within
the stripper chamber is adapted to be positioned above the plane of
the base of the stripping chamber, the amount of the projection
thereby regulating the thickness of the sample stream within the
stripping chamber to a predetermined relatively small magnitude
whereby uniform heat contact between the stripping and the heating
chamber readily occurs. Prior to removal of the stripped acid from
the settling chamber, the specific gravity of the acid is
determined by means of a displace meter of constant volume in which
the buoyant force is measured by means of a strain gage-type
transducer so as to indicate the specific gravity of the acid
sample.
By suitably controlling the pumping rates of the input and output
pumping means, a ratio of fluids removed by the overflow tube and
by the second fluid pumping means can be controlled which assures
that substantially all volatile and high molecular weight
hydrocarbons of the sample are removed prior to the gravity
determinations.
If desired, the process from which the sample is taken may be
controlled by utilizing the specific gravity determinations to
control valves which withdraw spent acid from the system and admit
new acid of correct strength to the system to maintain the strength
of the acid at a proper setpoint level. When the acid strength and
therefore the specific gravity falls below a preselected level, the
control equipment connected to the valves may be automatically
actuated in response to the deviation of the measured specific
gravity until the optimum level within the system is again reached.
It is thus possible to utilize such a system to maintain the acid
strength equilibrating about the optimum level thereby achieving a
high process efficiency.
The invention may be used to control the catalyst activity of a
single or a plurality of alkylation reactors using common
isoparaffin and olefin reactants in the presence of a mineral acid
catalyst such as sulfuric acid, hydrofluoric acid, etc.
The present invention will be further illustrated by reference to
the drawings in which:
FIG. 1 is an illustrative flow diagram of a typical hydrocarbon
sulfuric acid alkylation process in which the system of the present
invention can be utilized;
FIG. 2 is an elevational view partially cut away of the apparatus
of FIG. 1 for processing a sample of the recycle stream in
accordance with the present invention to determine the specific
gravity of the sample;
FIG. 3 is a plan view, partially cut away, of the apparatus of FIG.
2 illustrating in detail the flow of a sample within the stripping
and settling chambers of the apparatus of FIG. 2.
Referring to FIG. 1, there is illustrated diagrammatically a
specific form of alkylation process conventionally used in the
hydrofining art for the purpose of illustrating the use of the
present invention. In operation, a large stream of hydrocarbons
undergoes alkylation in the presence of an acid catalyst such as
sulfuric acid. The hydrocarbons and catalysts are continuously
circulated by pump 10, through cooler 11, system line 12, reactor
13 and return line 14. Thorough mixing of the hydrocarbons with the
acid is maintained by the mixing action of the pump and also by
baffling (not shown) within the reactor. A side stream of the
mixture is continuously withdrawn from a convenient point of the
system, say through line 17, to settler 18 where the acid is
permitted to settle from the alkylated and nonreacted hydrocarbons.
The settled acid is returned to the system through line 19 and the
hydrocarbons are withdrawn through line 20 for neutralization and
fractionation into alkylate products as well as recycle products.
Makeup hydrocarbons including the recycle products from
fractionation are introduced to the system at a convenient point,
as near the intake of pump 10, as illustrated by line 22.
The strength of the acid circulated in the system gradually
decreases until a point is reached where its strength is
uneconomically low for the production of good quality alkylate. If
not corrected, the acid strength may become so low that various
undesirable side reactions occur. To maintain the acid strength at
an economic optimum, spent acid is withdrawn from time to time
through valve 24 and strong makeup acid at the alkylation
concentration is introduced through valve 25. If the strength of
the acid within the reactor is not accurately and continuously
determinable, determinations as to the amount of spent acid to be
withdrawn and the amount of alkylation acid to be added to the
system cannot be made. In withdrawing a sample of the acid from the
system for such determination, several factors must be considered
including reducing, to a minimum, the time lag between withdrawal
of the sample of the acid and the determination of the strength of
the acid. Further difficulties can occur due to the pressure and
temperature prevailing within the system. For example, upon release
of pressure, a sample withdrawn immediately becomes foamy and must
be allowed to settle. Further, volatile and high molecular
hydrocarbons must be removed from the sample if the gravity
determinations are to have any reproducible significance. Still
further difficulties occur in the use of orifice restrictors in
withdrawing a sample of the acid from the system. Not only is the
acid difficult to handle, the carbonaceous matter within the
withdrawn sample frequently clogs the restrictors requiring the
installation of an attendant control system for cycling steam
through the sampling system.
In accordance with the present invention, the spent alkylation acid
is sampled by means of sampling line 31 and flows at a constant
rate through valve 32 to first stage acid pump 33 and
pressure-sensitive relief valve 34. The acid pump 33 discharges at
a substantially constant flow rate through the valve 34; typically
the flow rate is low so as to be compatible with the size of the
sampling system, say about 1.5 gallons per hour.
The function of the pump 33 and relief valve 34 is to dissipate
system pressure in passing the sample from process line 19 where,
say, a pressure of 120 p.s.i.g. exists, to analysis chamber 35
where, say, a pressure of about zero psig exists while
simultaneously maintaining the sample at a substantially constant
flow rate. Relief valve 34 is shown connected to the discharge side
of pump 33 and is adapted to be biased to a full open position when
a preselected discharge pressure above the system pressure occurs
in line 36. The full open position of the valve is adapted to be
large enough so that carbonaceous matter in the sample does not
accumulate at the valve seat. The discharge pressure of the acid
pump 33 periodically rises above the setpoint level of the valve 34
to allow flow of the sample through the valve 34. The bypass line
37 which includes valve 38 is placed in parallel with the relief
valve 34. Valve 38 is normally closed but can be open to facilitate
additional flow from the acid pump 33.
As an alternative modification, the system pressure can also be
dissipated at the suction side of acid pump 33. For example, a
pressure-sensitive valve may be positioned on the suction side of
the acid pump 33 and be adapted to incrementally open to maintain a
given pressure drop between the valve and a pressure-sensing means
on the discharge side of the pump. Accordingly, as carbonaceous
matter accumulates within the valve, the valve plug is
incrementally released to thereby maintain a given flow rate
through the acid pump.
The discharge of pump 33 through valve 34 is then passed by way of
line 39 to the inlet of analysis chamber 35. As shown, chamber 35
is positioned within a constant temperature bath 40 and includes
stripping chamber 41 and settling chamber 42. Bath 40 is employed
to maintain the sample within the chamber 35 at a substantially
constant temperature, say about 105.degree. F. For this purpose,
steam is passed into the bath by way of line 43 through temperature
responsive valve 44. The bath is also preferably agitated by air
introduced to the chamber 35 through line 45. The sample is first
preheated by exchanger 46 in contact with bath 40 and is then
passed into stripping chamber 41.
Stripping chamber 41 includes a planar base 47, upright walls 48
attached to the base 47 and baffle plates 49. As the sample
circulates through the stripping chamber, the volatile hydrocarbons
are heated to a gaseous phase. The vapors exit through vent tube
50. Discharge of the stripping chamber is by way of the settling
chamber 42. Settling chamber 42 is provided with an overflow tube
51 and a receiving cavity 52. As shown, cavity 52 is positioned
below the skimming level established by inlet 51A of the overflow
tube 51. Within the settling chamber 42, the high molecular weight
hydrocarbons in the sample are skimmed off by the overflow tube 51
and are passed from the settling chamber by way of line 53. The
stripped sample passes through the cavity 52 toward outlet 55 near
the floor of the settling chamber. Within cavity 52 is the displace
meter 56 weighted, i.e. with mercury, to a higher density than the
maximum sample density to be measured, and connected by a wire line
57 to a buoyancy force reading transducer 58. Transducer 58
converts the magnitude of the buoyancy force acting on the displace
meter 56 to an electrical signal indicating a specific gravity of
the stripped sample. The gravity-indicating signal is then recorded
by recorder 59 to provide a record indicating the concentration of
the alkylation acid.
Second stage acid pump 60 attaches to outlet 55 of cavity 52 for
pumping the stripped sample from the settling chamber via line 61.
The discharge side of the acid pump 60 attaches via line 62 to a
hydrometer pot 63. Specific gravity determinations of the stripped
sample are made by a hydrometer in hydrometer pot 63 from time to
time to calibrate transducer 58. Thus by monitoring the record of
recorder 59, the operator may be readily advised of the strength of
the acid in the alkylation system. Desired corrections in the
alkylation process can be made manually or automatically by adding
alkylation acid and withdrawing spent acid from the process.
To automatically control the addition of alkylation acid, recorder
59 may be provided with mechanical linkages 64 which control spent
acid valve 24. As deviations from a setpoint level within the
recorder-controller occur, valve 24 is adjusted to withdraw spent
acid from the process. To control the admission of strong
alkylation acid, to compensate for the removal of the spent acid,
settler 18 may be provided with a level-indicating controller 65
for operating valve 25. Accordingly, as the acid hydrocarbon
interface level within settler 18 deviates from the preselected
setpoint level, the valve 25 is actuated to admit alkylation acid
to the process. When an optimum concentration of alkylation acid is
achieved within the alkylation process, valves 24 and 25 are biased
to a closed position. Alternatively, the recorder-controller which
includes recorder 59 and linkages 64 may operate spent acid valve
25 instead of valve 24. Accordingly, level-indicating controller 65
of settler 18 operates spent acid valve 24.
FIGS. 2 and 3 illustrate the use of the gravity-indicating
apparatus of the present invention in marked detail. In FIG. 2, a
frame 70 is seen to be fitted with lateral channel bars 71 at the
upper end of the frame to which analysis chamber 35 is attached. At
the lower periphery, channel bars 72 and support base 73 provide
support for acid pumps 33 and 60. Hydrometer pot 63 is positioned
at one side of the frame 70 while recorder 59 is positioned at an
opposite side, as shown, or remotely, as in a control room.
In flowing an acid sample under pressure to the apparatus of the
present invention, the first stage acid pump 33 periodically
creates a discharge pressure at discharge side 74 above the
setpoint bias of relief valve 34 as previously mentioned.
Accordingly, acid pump 33 is preferably of the piston or diaphragm
type and may be operated as shown by a motor-driven system also
used to drive second stage acid pump 60. In such a drive system, a
single motor 76 drives both pumps 33 and 60 through shafts 76A and
76B to separately driven gear boxes 77A and 77B within each pump.
Duplex version, Model No. SL-3, Lapp Insulator Company, Inc., Le
Roy, New York, has been found to be a satisfactory, commercially
available, tandem pump.
Bath 40 of analysis chamber 35 is enclosed within a support housing
78. Water comprising the bath is placed in heat transfer contact
with the pre-heat exchanger 46 as well as stripping chamber 41 and
settling chamber 42. The temperature of the bath is controlled by
steam entering the analysis chamber through the inlet line 43. The
flow rate of the steam is controlled by temperature-sensitive
diaphragm valve 44 controlled by temperature-measuring element 79.
An exterior indicating dial 80 provides visual indication of the
temperature of the bath.
The temperature within the analysis chamber 35 must be maintained
at a uniform temperature during operations. If the temperature
remains constant, substantially the same amount of hydrocarbons are
removed from the acid sample within the analysis chamber. A single
bath 40 for both heating the sample to remove volatile hydrocarbons
as well as maintaining the settling chamber at a constant
temperature as a specific gravity characteristic of the acid is
measured, has been found to be an important advantage of the
present invention.
However, the temperature selected must be high enough to separate
substantially all of the volatile hydrocarbons within the stripping
chamber without too much troublesome foam. It should not be so
high, however, as to substantially decompose the high molecular
weight hydrocarbons, normally in the liquid phase, removed by
skimming within the settling chamber. A selected temperature of
about 105.degree. F. has proven to be satisfactory although a range
somewhere between 90.degree. - 150.degree. F. should prove to be
satisfactory in the average installation.
As shown best in FIG. 2, the stripping chamber 41 is positioned at
an elevated location above the floor of the bath housing 78. It is
attached in the elevated position by welding its planar base 47 and
side walls 48 to adjacent portions of the bath housing 78 in the
settling chamber 42, as shown. When the level of the heater within
bath housing 78 is adjusted to a level so that contact is made both
with the side walls 48 and the base 47 of the stripping chamber, as
shown, heating of the sample occurs at the sides as well as the
base of the stripping chamber.
FIG. 3 illustrates the flow pattern of the acid sample within the
stripping chamber 41 in more detail. As shown, the stripping
chamber 41 is provided with a series of upright plates 49 attached
to base 47 and the side walls 48. After the acid sample has passed
into the stripping chamber by way of inlet 76 and helically wound
pre-heating tube 46, the plates 49 direct the sample in the sinuous
flow pattern as shown. The incremental time period that the sample
contacts bath 40 is thus increased. Accordingly, substantially all
of the volatile hydrocarbons are stripped from the sample. The
vapors vent to atmosphere by way of vent tube 50.
As shown in FIG. 2, settling chamber 42 includes side walls 81
attached to the bath housing 78 in fluid communication with the
stripping chamber 48 through aperture 82 in the base 47. The planar
base 83 is attached to the floor of the bath housing. Base 83 is
provided with openings by which overflow tube 51 and outlet 55 are
rigidly positioned so as to contact the fluid within the settling
chamber 42. After the sample has entered the settling chamber, the
high molecular weight hydrocarbons are stripped from the sample at
a skimming level established at the inlet 51A of the overflow tube
51. The skimmed hydrocarbons are disposed to drain via line 53
attached to the overflow tube 51. The stripped acid sample is then
passed through cavity 52 below the skimming level established by
the overflow tube and then is conveyed from the settling chamber by
way of outlet 55 to the second stage pump 60.
In addition to establishing a skimming level for removing the high
molecular weight hydrocarbons, the overflow tube 51 also performs
another important function in the operation of the
gravity-indicating apparatus of the present invention.
As shown in FIG. 2, the skimming level established by overflow tube
51 only slightly exceeds the plane of base 47 of the stripping
chamber 41, say by the incremental distance d as shown. The depth
of the sample within the stripping chamber is, of course, equal to
the incremental distance d since the pressure in the stripping and
settling chambers is the same. Accordingly, the depth of the sample
can be easily reduced to a relatively small magnitude, say
one-eighth to one-half inch without introducing inaccuracies in the
gravity measurements later performed in the settling chamber. As
the removal of the hydrocarbons from the acid sample is enhanced by
the apparatus of the present invention, measurements of the
specific gravity characteristic of the stripped sample within
cavity 52 of the settling chamber 42 result in a true and easily
reproducible indication of the specific gravity of the acid.
The pumping rates of the acid pumps 33 and 60 closely control the
gravity-indicating apparatus of the present invention so that the
pumping rate of the input, or first stage, acid pump 33 is always
greater than that of the output, or second stage, acid pump 60.
Accordingly, not only is the original acid sample pumped under
positive flow conditions into the analysis chamber 35 by means of
acid pump 33, thereby reducing clogging in the measuring system to
a minimum, but the stripped sample is also seen to be pumped under
positive flow conditions from the settling chamber 42 by means of
second stage acid pump 60.
Furthermore, it can be seen that the differential pumping rate
established by the first stage and second stage pumps can easily be
varied to values that assure that all of the hydrocarbons are
removed from the acid sample prior to measuring the specific
gravity characteristic of the stripped sample within cavity 52 of
the settling chamber 42. The skimming level of the fluid within the
analysis chamber is preferably constructed to remain fixed during
operations. Accordingly, the percentage by weight of the
hydrocarbons removed from the acid sample is a direct function of
the differential pumping rates of the first stage and second stage
acid pumps. Stated mathematically, for the minimum case: Weight
Percentage hydrocarbons (W.sub.R) = PR/R.sub.Input
where
PR is the differential flow rate of the first stage and second
stage acid pumps and
R.sub.Input is the flow rate of the first stage acid pump.
In actual practice, the pumping differential is always adjusted so
that the ratio defined above is always greater than the expected
weight percentage of hydrocarbons within the sample to be removed.
For example, where the acid to be monitored is thought to contain
about 5 percent by weight volatile and high molecular weight
hydrocarbons, the percentage of removal established by the acid
pumps is set at a much higher level, say 30 percent. Accordingly,
25 percent of the stripped acid would also be removed via overflow
tube 51.
To establish optimum pumping rates for the acid pumps 33 and 60,
several operating parameters of the gravity-indicating apparatus of
the present invention must be taken into consideration, among which
are: the capacity of the gravity-indicating apparatus, the size of
the sample stream, the maximum time lag permitted to measure the
sample, as well as the weight percent of hydrocarbons within the
sample. For a maximum time lag of 12 minutes, an input flow rate of
1.5 gallons per hour, a total apparatus capacity of about one-half
gallon, a second stage pumping rate of about 1.0 gallons per hour
provides removal of about 30 percent by weight of the input sample.
Accordingly, as the weight percent of volatile and high molecular
weight hydrocarbons within the sample increases, the differential
flow rate of the acid pumps can be readily adjusted to facilitate
their removal.
Removal of the hydrocarbons from the sample in the aforementioned
manner has been found to provide stripped samples that are not only
substantially free of hydrocarbons, but the hydrocarbons that
remain, if any, are substantially constant. Accordingly, the
gravity-indicating apparatus of the present invention has been
found to provide results that can be repeated within very small
tolerances.
The invention has been described above in conjunction with a
specific type of alkylation process for which it was particularly
designed. However, it is useful in conjunction with other forms of
sulfuric acid alkylation process and also with other processes
wherein strong sulfuric acid is contacted under pressure with
normally gaseous hydrocarbons. In such processes it is generally
desirable to withdraw a sample of the acid from time to time for
control purposes. The invention provides a ready means of obtaining
such sample without the customary difficulties arising from the
sudden volatilization of the hydrocarbons in the withdrawn
sample.
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