Solid Catalyst Alkylation of C2–C3 Olefins with Isobutane in the Presence of Hydrogen Using a Slurry Transport Reactor–Hydrocyclone-Regenerator System and PtSO4TiZr/SiO2 Catalyst: Part 1. Alkylation in Continuous Pilot Plant Operation and Simulation of a Slurry Transport Reactor–Hydrocyclone Settler System

A continuous alkylation plant was simulated to evaluate the capability of a newly designed acid solid catalyst PtSO4TiZr/SiO2 to convert light olefins (C2 and C3) and isobutane into alkylate in the presence of hydrogen. This part of the process consists in a three-phase slurry transport reactor (STR) and a hydrocyclone settler (HCS) operating in series with the recycling of unconverted reactant and regenerated and fresh catalysts. Data for alkylation were obtained in batch reactor and in pilot plant tests at different gas flow rates, temperatures, pressures, and catalyst particle sizes. Kinetic and deactivation rates and fluid dynamic data were obtained using the pilot plant continuous operation. Fresh, spent, and regenerated catalyst were characterized using different techniques to explain its selectivity and deactivation. Commercial size plant was designed and then simulated to determine the impacts STR operating variables in the alkylate cost. The study determined the kinetic and deactivation rates parameter for the main reactions as well as the effect of operating variables and particle size in the performance of the catalysts. Simulation provides information with which to discuss the behavior of STR reactor and the impacts of the operating variables in the cost of alkylate. The rates of apparent in-series alkylate production depend on order 1 in intermediates and olefin concentration, catalyst activity, and rate of diffusion in mesopores; the rates of soluble coke production depend on order 1 in intermediaries and 1.5 in olefin concentration and is inversely proportional to hydrogen partial pressure. The kinetic and deactivation model is independent of the reactor used. Catalyst aged with the number of cycles of alkylation and regeneration; its activity is inversely proportional to the soluble coke content. Inlet temperature, olefins-to-isobutene mole ratio, hydrogen-to-olefins mole ratio, and catalyst makeup are the main operational variables that impact the cost of alkylate. Sensitivity to kinetic rate parameters, fluid dynamic model, and particle size are analyzed. There is an optimal coke build-up in solid alkylation that minimizes the alkylate cost.