Sulfuric acid alkylation reactor system and conversion of a hydrogen fluoride alkylation unit to a sulfuric acid alkylation unit

A split sulfuric acid alkylation reactor system comprising:

• (a) a closed horizontal reactor vessel comprising a shell, a vapor outlet, a first emulsion outlet, a second emulsion outlet, a first partition baffle, a first coalescing media, a second partition baffle, a second coalescing media, a spent acid outlet, and a net effluent outlet;
• (b) a first distributor located at the lower portion of the reactor vessel;
• (c) a second distributor located at the lower portion of the reactor vessel;
• (d) a first mixer fluidly connected with the first distributor;
• (e) a second mixer fluidly connected with the second distributor;
• (f) a first emulsion pump fluidly connected with the first mixer, the first emulsion outlet, and the spent acid outlet;
• and
• (g) a second emulsion pump fluidly connected with the second mixer, the second emulsion outlet, and the spent acid outlet;
• wherein the first partition baffle, the second partition baffle, the first coalescing media, and the second coalescing media extend upwardly from the bottom of the reactor vessel respectively, the first coalescing media is downstream of the first partition baffle, the second coalescing media is downstream of the second partition baffle, the first coalescing media and the second coalescing media define a first reaction zone, a second reaction zone and an acid settling zone inside the reactor vessel, the first reaction zone is upstream of the first coalescing media, the second reaction zone is upstream of the second coalescing media, the acid settling zone is between the first coalescing media and the second coalescing media, the first distributor is located at the first reaction zone, the second distributor is located at the second reaction zone, the first emulsion pump and the second emulsion pump are located outside the reactor vessel.