Alkylation process with thermal oxidation system

A process for treating off-gas and waste effluent streams in an alkylation complex comprising:

• alkylating a C3-4 olefin stream comprising propylene and butene and an isobutane stream comprising isobutene in an liquid acid alkylation process section or an ionic liquid alkylation process section in the presence of an acid catalyst to produce a reaction mixture comprising alkylate, unreacted propylene, unreacted normal butene, acid catalyst, and spent acid catalyst, wherein the acid catalyst comprises HF, H2SO4, or an ionic liquid;
• separating the reaction mixture into at least one of:
• an alkylate stream, an acid ASO stream, an acid gas stream from the liquid acid alkylation process section, an acid liquid stream from the liquid and an acid alkylation process section;
• or an acid spent ionic liquid from an ionic liquid alkylation process section, an acid gas stream from the ionic liquid alkylation process section, an acid liquid stream from the ionic liquid alkylation process section, and a stream comprising at least one of the unreacted propylene and the unreacted normal butene;
• thermally oxidizing at least one of:
• an acid soluble oil (acid ASO) stream from a liquid acid alkylation process section of an HF alkylation process or an H2SO4 alkylation process, an acid gas stream from the liquid acid alkylation process section, an acid liquid stream from the liquid acid alkylation process section, a neutralized ASO stream from a caustic wash zone, and a spent caustic stream from an acid gas scrubber zone of the HF alkylation process or the H2SO4 alkylation process;
• or an acid spent ionic liquid from an ionic liquid alkylation process section of an ionic liquid alkylation process, an acid gas stream from the ionic liquid alkylation process section, an acid liquid stream from the ionic liquid alkylation process section, a neutralized spent ionic liquid from an ionic liquid caustic wash zone, and a spent caustic stream from an acid gas scrubber zone of the ionic liquid alkylation process;
• in a thermal oxidation section of a thermal oxidation system and thereby forming flue gas consisting essentially of at least one of H2O, CO2, N2, O2, SOx, NOx, HCl, Cl2, HF, F2, Na2O, Na2SO3, Na2SO4, Na2CO3, NaCl, NaF, CaF2, CaO, CaSO3, CaSO4, CaCO3, CaCl2, K2O, K2SO3, K2SO4, K2CO3, KCl, KF, Al2O3, NiO, FeO, FeO2, Fe2O3, Fe3O4, and CuO;
• optionally recovering waste heat from the flue gas in a waste heat recovery section of the thermal oxidizing system;
• removing at least one of SOx, HCl, Cl2, HF, F2, Na2SO3, Na2SO4, Na2CO3, NaCl, NaF, CaF2, CaSO3, CaSO4, CaCO3, CaCl2, K2SO3, K2SO4, K2CO3, KCl, KF, Al2O3, NiO, FeO, FeO2, Fe2O3, Fe3O4, and CuO from the flue gas in a contaminant removal section of the thermal oxidizing system to form a decontaminated outlet flue gas consisting essentially of at least one of H2O, CO2, N2, O2, and NOx, wherein removing the at least one of SOx, HCl, Cl2, HF, F2, Na2SO3, Na2SO4, Na2CO3, NaCl, NaF, CaF2, CaSO3, CaSO4, CaCO3, CaCl2, K2SO3, K2SO4, K2CO3, KCl, KF, Al2O3, NiO, FeO, FeO2, Fe2O3, Fe3O4, and CuO from the flue gas comprises:
• quenching the flue gas from the thermal oxidation section or from the waste heat recovery section in a quench section to form quenched flue gas;
• and
• contacting a caustic solution with the quenched flue gas in a contaminant scrubbing section of the thermal oxidizing system to form the decontaminated outlet flue gas and a liquid stream comprising at least one of H2O, NaCl, HCl, Cl2, HF, F2, Na2SO3, Na2SO4, Na2CO3, NaCl, NaF, CaF2, CaSO3, CaSO4, CaCO3, CaCl2, K2SO3, K2SO4, K2CO3, KCl, KF, Al2O3, NiO, FeO, FeO2, Fe2O3, Fe3O4, and CuO;
• or
• reacting the flue gas with a reactant in a contaminant reaction section of the thermal oxidizing system to form a reaction section flue gas consisting essentially of at least one of H2O, CO2, N2, O2, Na2SO4, Na2CO3, NaCl, NaF, CaF2, CaSO4, CaCO3, CaCl2, K2SO4, K2CO3, KCl, KF, Al2O3, NiO, FeO, FeO2, Fe2O3, Fe3O4, and CuO wherein the reactant comprises at least one of NaHCO3, NaHCO3.Na2CO3.2(H2O), CaCO3 and Ca(OH)2;
• and
• filtering the reaction section flue gas in a filtration section of the thermal oxidizing system to remove Na2SO4, Na2CO3, NaCl, NaF, CaF2, CaSO4, CaCO3, CaCl2, K2SO4, K2CO3, KCl, KF, Al2O3, NiO, FeO, FeO2, Fe2O3, Fe3O4, and CuO to form the decontaminated outlet flue gas;
• and
• optionally removing NOx from the decontaminated outlet flue gas in an NOx removal section of the thermal oxidizing system to form a de-NOx outlet flue gas consisting essentially of at least one of H2O, CO2, N2, and O2.