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.

What is claimed is: 
     
         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 2 -C 10  olefin and at least one C 4 -C 10  isoparaffin,   the ionic liquid catalyst comprises a chloroaluminate ionic liquid, and   the alkylation conditions comprise a temperature in the range from −40° C. to 150° 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.