A Review of Computational Fluid Dynamics Modeling for Isobutane Alkylation: Process Optimization, Reactor Design, and Future Perspectives
Zeinab Noorpoor, Mohammad Rahmani
Abstract
Alkylation is a refining process essential to producing clean fuels that meet the world’s most stringent air quality, carbon emissions, and vehicle efficiency standards. In this process, the reactor and catalyst are of extraordinary significance. Reactor configuration strongly affects the two determining parameters of hydrodynamics and mixing. The choice of catalyst also profoundly influences the process efficiency and environmental impact. This study presents a comparative analysis of isobutane alkylation using three distinct catalytic systems: liquid catalysts, solid catalysts, and ionic liquids. Liquid catalysts, with their well-established industrial presence, are evaluated for their efficacy in promoting the alkylation reaction. Solid catalysts, representing a potential ecofriendly alternative, are assessed for their catalytic performance. Ionic liquids, also renowned for their tunable properties and environmental sustainability, are examined as a novel catalyst option. Furthermore, this comprehensive review provides insights into the optimal reactor designs and computational modeling’s application to enhance the quality of alkylate for gasoline blending. A liquid–liquid cyclone reactor is designed to facilitate both the alkylation process and the subsequent separation of products within a single unit. This review emphasizes the importance of process optimization of isobutane alkylation using ionic liquids to improve the final product quality. It discusses the impact of various reactor designs, including different conical sections, on the mixing and separation efficiency, highlighting the potential for improvements in both areas.