Method and device for the production of alkylates

Abstract

Disclosed is a device for the production of alkylate(s) by sulfuric acid alkylation of at least one isoparaffin such as isobutane with at least one olefin, such as butylenes. The device includes a mixing chamber for preparing a mixture of the isoparaffin with recycled reaction products. It also includes an emulsion chamber for preparing a first hydrocarbons-in-sulfuric acid emulsion, where the mixture prepared in the mixing chamber is injected in multiple parallel jets into a sulfuric acid composition. The device further includes a pre-reaction chamber for preparing a second emulsion, where a given portion of the olefin is injected in jet streams into the first hydrocarbons-in-sulfuric acid emulsion coming from the emulsion chamber. Last of all, the device includes a reaction chamber of given height and cross-section where the second emulsion coming from the pre-reaction chamber is injected through nozzles and another portion of olefin is injected in jet streams all over the cross-section and height of the reaction chamber. The reaction chamber is devised so that the second emulsion is circulated in a closed circuit and it has an outlet through which a balanced amount of reaction mixture is continuously discharged. All of said mixing chamber, emulsion chamber, pre-reaction chamber and reaction chamber are coaxially arranged one above the other in vertical position and altogether form a reactor with the prechamber being located at the bottom of the reactor and the reaction chamber on top thereof. A method for the production of alkylates by means of the above device is also disclosed.

1 . A device for mixing and reacting at least two liquid components, comprising:
 (a) a mixing chamber for preparing a mixture of two of said components;   (b) an emulsion chamber for preparing a first emulsion, where the mixture prepared in the mixing chamber (a) is injected in multiple parallel jets;   (c) a pre-reaction chamber for preparing a second emulsion, where a given portion of one of said components is injected in jet streams into the first emulsion coming from the emulsion chamber (b); and   (d) a reaction chamber of given height and cross-section where the second emulsion coming from the pre-reaction chamber (c) is injected through nozzles and one of said components is injected in jet streams all over the cross-section and height of said reaction chamber, said reaction chamber being devised so that said second emulsion is circulated in a closed circuit and comprising an outlet through which a balanced amount of reaction mixture is continuously discharged;   wherein said mixing chamber (a), emulsion chamber (b), pre-reaction chamber (c) and reaction chamber (d) are coaxially arranged one above the other in vertical position and altogether form a reactor with said mixing chamber (a) being located at the bottom of the reactor and said reaction chamber (d) on top thereof.   
     
     
         2 . The device of  claim 1 , wherein the emulsion chamber (b) includes:
 a plurality of parallel inlet branch pipes having a given internal diameter, through which the mixture prepared in the mixing chamber (a) is injected;   a cylindrical socket centrally mounted within said emulsion chamber, said socket having a height equal to 20 to 60 times to internal diameter of the parallel inlet branch pipes, said socket also having an upper outlet; and   an enlargement fitting joined to the upper outlet of said cylindrical socket.   
     
     
         3 . The device of  claim 1 , wherein the pre-reaction chamber (c) has a bottom portion provided with a feed injection unit comprising injectors having axes running upward at an angle of 0 to 30° with respect to the vertical. 
     
     
         4 . The device of  claim 1 , wherein:
 the reaction chamber (d) is separated from the pre-reaction chamber (c) by means of a baffle with nozzles mounted therein for allowing injection of the second emulsion; and   said reaction chamber (d) comprises a vertical housing and a circulation pipe which is coaxial with said housing and installed with side clearances relative to said housing.   
     
     
         5 . The device of  claim 4 , wherein the housing of the reaction chamber (d) has a bottom with at least two connecting pipes tied to it for withdrawal of the reaction mixture. 
     
     
         6 . The device of  claim 4 , wherein the circulation pipe has a top, a bottom and a given height, and other injectors are arranged near said top, said bottom and over said height in the form of tiers for injection of another feed, said other nozzles having axes running upwards at an angle of 0 to 30° with respect to the vertical. 
     
     
         7 . The device of  claim 6 , wherein each of said tiers comprises at least three injectors. 
     
     
         8 . The device of  claim 4 , wherein the nozzles in the baffle separating the pre-reaction chamber (c) from the reaction chamber (d) are arranged along a circle having a diameter that is equal 0.6 to 0.75 the inner diameter of the circulation pipe. 
     
     
         9 . The device of  claim 4 , wherein the circulation pipe has an inner diameter which is equal to 0.55 to 0.75 times the inner diameter of the housing of the reaction chamber (d). 
     
     
         10 . The device of  claim 4 , wherein the circulation pipe has a height and an inner diameter whose ratio is ranging from 3 to 9. 
     
     
         11 . The device of  claim 4 , wherein the nozzles of the baffle have inner diameters with cross-section whose total is equal to 0.04 to 0.2 times the cross-section of the circulation pipe. 
     
     
         12 . The device of  claim 1 , wherein the reaction chamber (d) is also provided with a top axial connecting outlet. 
     
     
         13 . A device for separating a reaction mixture containing immiscible liquids of different densities and some gas or vapor, wherein said device comprises a horizontal vessel incorporating:
 (a) at least one vertical overflow baffle plate that extends within said vessel and divides it into at least one settling tank and one accumulation tank;   (b) supply connecting pipes for introducing streams of said reaction mixture into the settling tank;   (c) outlet connecting pipes for discharging the liquid having the highest density from a bottom portion of the settling tank;   (d) other outlet connecting pipes for discharging liquids of lower densities from the settling tank and the accumulation tank, wherein at least one of said other connecting pipes is positioned in another bottom portion the settling tank; and   (e) at least one further outlet connecting pipe for discharging gas or vapor from an upper part of the vessel.   
     
     
         14 . The device of  claim 13 , wherein one of said other connecting pipes for discharging liquids of lower density is in the form of a perforated pipe header having an axis parallel to the overflow baffle plate, said pipe extending upwards from the bottom portion of the settling tank at a lower height than the overflow baffle plate.