Simulation of three-phase spouted bed reactor for solid catalyst alkylation

A process simulator was developed to afford better understanding of the performance of the isobutane–butene alkylation plant that uses a three-phase spouted bed-reactor hydrocyclon and a super acid solid catalyst. The system was simulated by using correlations developed in the cold model and apparent kinetic constants measured in a batch reactor for 1-butene–isobutene alkylation. A new type of catalyst, PtSO4Zr/TiO2, was used in the presence of recycled alkylate and hydrogen. The computer simulator numerically solved the mass and energy balance equations for the riser and downcomer. It was determined that a gas–liquid–solid with similar properties to the system under study do not shown a charm regime of flow and that the new design of the gas disengaging zone at the end of the riser prevent the undesired recirculation of large bubble and provide stability. New gas hold-up, linear velocity of the liquid, recycle ratio, and mass transfer correlations obtained reproduce the result within a ±10% error. The result of the alkylation plant simulation indicated a large influence of linear velocity and temperature on activity, selectivity, and stability of catalytic system. The other important operating parameters are alkylate/olefin and isobutane/olefin ratios. The optimal operating conditions were determined for a particular catalyst and set of cost.