Abstract: Paraffin alkylation using solid, particulate catalyst is carried out by preparing an alkane-catalyst mixture in a wash zone, passing the alkane-catalyst mixture to a plug flow reactor where a minor amount of olefin is introduced to contact the alkane-catalyst mixture and react to form alkylate and the alkane-catalyst-alkylate mixture is passed through the reactor with a minimum of back mixing to restrict the reaction of alkylate with olefin, thus substantially preventing polymerization. The alkane-catalyst-alkylate mixture, substantially free of olefin is passed to a disengaging zone where the liquid is removed and the solid particulate catalyst is recovered and returned to the wash zone for recycle. The alkane is present in the reactor in sufficient molar excess to react substantially all of the olefin. Any unreacted isoalkane is recycled to the reactor with make-up isoalkane added to maintain the molar excess.

Abstract: A catalytic distillation structure which comprises a catalyst component having a porous container having disposed therein, solid particulate catalytic material which swells in use intimately admixed with from 5 to 60 volume % of a deformable material. The catalyst component may be in intimate association with or surrounded by a resilient component, which is comprised of at least 70 volume % open space.

Abstract: A liquid phase process for oligomerization of C.sub.4 and C.sub.5 isoolefins or the etherification thereof with C.sub.1 to C.sub.6 alcohols wherein the reactants are contacted in a reactor with a fixed bed acid cation exchange resin catalyst at an LHSV of 5 to 20, pressure of 0 to 400 psig and temperature of 120.degree. to 300.degree. F. wherein the improvement is the operation of the reactor at a pressure to maintain the reaction mixture at its boiling point whereby at least a portion but less than all of the reaction mixture is vaporized. By operating at the boiling point and allowing a portion of the reaction mixture to vaporize, the exothermic heat of reaction is dissipated by the formation of more boil up and the temperature in the reactor is controlled.

Abstract: Aromatic compounds are alkylated in a combination reactor/distillation column comprising a vessel suitable for operating between 70.degree. C. and 500.degree. C. and from 0.5 to 20 atmospheres pressure; an inert distillation packing in the lower one-third of said vessel; solid acidic catalytic material such as zeolites or an acidic cation exchange resin supported in the middle one-third of said vessel; and inert distillation packing in the upper one-third of said vessel. A benzene inlet is located near the upper end of the vessel; an olefin inlet is juxtaposed with said solid acidic catalytic material; a bottoms outlet is positioned near the bottom of said vessel for removing said cumene and ethyl benzene; and an overhead outlet is placed at the top of said vessel for removing any unreacted benzene and olefin.

Abstract: Paraffin alkylation using solid, particulate catalyst is carried out by preparing an alkane-catalyst mixture in a wash zone, passing the alkane-catalyst mixture to a plug flow reactor where a minor amount of olefin is introduced to contact the alkane-catalyst mixture and react to form alkylate and the alkane-catalyst-alkylate mixture is passed through the reactor with a minimum of back mixing to restrict the reaction of alkylate with olefin, thus substantially preventing polymerization. The alkane-catalyst-alkylate mixture, substantially free of olefin is passed to a disengaging zone where the liquid is removed and the solid particulate catalyst is recovered and returned to the wash zone for recycle. The alkane is present in the reactor in sufficient molar excess to react substantially all of the olefin. Any unreacted isoalkane is recycled to the reactor with make-up isoalkane added to maintain the molar excess.

Abstract: A method and apparatus is provided for removing catalyst from a distillation column reactor and replacing the catalyst with fresh or regenerated catalyst. More specifically a small particulate catalyst is supported by wire mesh or screen or filter medium on trays in a conventional distillation column and substantially submerged by the liquid on the trays. The vapor rising through the liquid tends to keep the catalyst in suspension in the liquid. A draw-off is provided for each tray having catalyst supported thereon whereby liquid containing the suspended or slurried catalyst can be removed to a separator during operation. The catalyst is separated, as in a settling tank separator, from the liquid recycled to the tray until all the catalyst has been removed. The separated catalyst is removed for either regeneration or discarding. Fresh catalyst can then be added to the separator where it is slurried into the liquid again being recirculated from the tray.

Abstract: To achieve good liquid-vapor contact and at the same time better utilize the heat of reaction in a distillation column reactor a system is provided wherein a reaction tray and distillation tray are "coupled" by a continuous liquid level between the two. A reaction tray, containing the appropriate catalyst, is situated directly below a distillation tray. A vapor riser is provided through the reaction tray as a by-pass which carries the vapor from a lower distillation tray to a vapor distribution area underneath the "coupled" distillation tray. Liquid flows downward through a downcomer by-passing the "coupled" distillation tray, and onto and across the "coupled" reaction tray immersing the catalyst and rises upward, onto and across the "coupled" distillation tray where it is intimately contacted with the rising vapor effecting fractional distillation.

Abstract: A method and apparatus for conducting a catalytic distillation process is provided which allows for maintaining a liquid level in selected portions of the catalyst bed. Three particular processes disclosed are the production of methyl tertiary butyl ether, tertiary butyl alcohol and cumene.

Abstract: A process is provided for etherification of essentially pure IC.sub.4.sup.= with MeOH to form MTBE in a distillation column reactor containing a fixed bed acid cation exchange resin as a catalytic distillation structure in an a distillation reaction zone. An inert C.sub.4 hydrocarbon is initially fed to the distillation column reactor to act as a diluent and a heat sink which boils at the desired temperature range for the reaction. Additionally the inert C.sub.4 diluent acts as an azeotroping agent for the MeOH in the lower end of the column carrying more of the MeOH back up into the reaction distillation zone. After start up and circulation the inert C.sub.4 hydrocarbon feed is stopped and that in the system is retained therein by total reflux of the overheads and judicious operation of the lower portion of the distillation column reactor.

Abstract: There is provided a new process for conducting heterogeneous chemical reactions in which a particulate catalyst is slurried in one of the reactant streams and fed into a distillation column reactor in a distillation reaction zone. The distillation reaction zone contains inert packing which provides the distillation structure for separation. The slurried catalyst trickles downward through the inert packing and is removed with the bottoms and separated therefrom for regeneration or replacement.

Abstract: A process for the isomerization of butenes in a mixed hydrocarbon stream containing butene-1, butene-2 and small amounts of butadiene in which the mixed hydrocarbon stream is fed to distillation column reactor containing an alumina supported palladium oxide catalyst as a distillation structure. As butene-1 is produced it is distilled off upsetting the equilibrium and allowing for a greater than equilibrium amount of butene-1 to be produced. Additionally, any butadiene in the feed is hydrogenated to butenes. The bottoms, which is rich in butene-2 may be recycled to the reactor column for more complete conversion of butene-2 to butene-1. Alternatively, a portion or essentially all of the bottoms, substantially free of butadiene, may be used for feed to an HF alkylation unit.

Abstract: A process for the catalytic distillation production of alkylated aromatic compounds is provided wherein the vapor pressure of the olefin may be increased while maintaining the same olefin feed rate and aromatic to olefin ratio. In one embodiment a side stream from the vapor from the second column below the catalyst and olefin feed is condensed and rerouted to the aromatic make up stream from the reflux drum. The vapor pressure of the olefin in the lower end of the first column in the catalyst bed is thus increased which increases the equilibrium concentration of the olefin in the liquid phase. In another embodiment of the invention the effective driving force for the reaction is increased by injecting the olefin at different heights within the catalyst bed. If additional olefin is injected more catalyst bed height would be required, but the additional catalyst is more that offset by the increased throughput at the same overall olefin conversion.

Abstract: Organic aromatic compounds are alkylated in a Reactive Distillation.TM. reactor, wherein the solid particulate catalyst is slurried in the aromatic feed stream and fed to a reaction zone containing inert distillation packing. Olefin is vaporized and fed to the bottom of the reaction zone and agitates the catalyst while reacting the olefin with the aromatic to form an alkylation product. The alkylation product is removed from the lower end of the reaction zone and recovered. Any unreacted aromatic is distilled overhead and recycled or recovered. Recycling the aromatic controls the molar ratio of aromatic to olefin to the extent that substantially all of the olefin is reacted.

Abstract: The present invention provides catalytic distillation structures which are useful in the concurrent reaction and distillation of a reaction mixture. The distillation structures are provided as rigid containers having a volume substantially smaller than the volume of conventional distillation column reactors. The catalyst component is loaded into the containers and the containers are closed. Openings are provided to allow vapor and liquid passage into and out of the containers. The surfaces of the containers provide the necessary/vapor liquid contact surfaces for the distillation. The rigidity of the containers provides for spacing the structures and the necessary free space for the distillation.

Abstract: Cumene is produced in a catalyst bed under 0.25 to 50 atmospheres of pressure and at temperatures in the range of 50.degree. C. to 500.degree. C., using as the catalyst a mole sieve characterized as acidic by feeding propylene to the catalyst bed while benzene is conveniently added through the reflux to result in a molar excess present in the reactor to that required to react with propylene, thereby reacting substantially all of the propylene and recovering benzene as the principal overhead and cumene and diisopropyl benzene in the bottoms. The bottoms are fractionated, the cumene recovered and the bottoms are contacted with benzene in the liquid phase in a fixed bed straight pass reactor under conditions to transalkylate the benzene thereby converting most of the diisopropyl benzene to cumene which is again separated and recovered.

Abstract: Organic aromatic compounds are alkylated in a Reactive Distillation.TM. reactor, wherein the solid particulate catalyst is slurried in the aromatic feed stream and fed to a reaction zone containing inert distillation packing. Olefin is vaporized and fed to the bottom of the reaction zone and agitates the catalyst while reacting the olefin with the aromatic to form an alkylation product. The alkylation product is removed from the lower end of the reaction zone and recovered. Any unreacted aromatic is distilled overhead and recycled or recovered. Recycling the aromatic controls the molar ratio of aromatic to olefin to the extent that substantially all of the olefin is reacted.

Abstract: A liquid phase process for oligomerization of C.sub.4 and C.sub.5 isoolefins or the etherification thereof with C.sub.1 to C.sub.6 alcohols wherein the reactants are contacted in a reactor with a fixed bed acid cation exchange resin catalyst at an LHSV of 5 to 20, pressure of 0 to 400 psig and temperature of 120 to 300.degree. F. wherein the improvement is the operation of the reactor at a pressure to maintain the reaction mixture at its boiling point whereby at least a portion but less than all of the reaction mixture is vaporized. By operating at the boiling point and allowing a portion of the reaction mixture to vaporize, the exothermic heat of reaction is dissipated by the formation of more boil up and the temperature in the reactor is controlled.

Abstract: A process for the production of tertiary alcohols by the reaction of the corresponding isoolefin and water is disclosed. In particular the production of tertiary butyl alcohol and tertiary amyl alcohol is disclosed. The isoolefin and water are contacted over an acid cation exchange resin catalyst in a distillation column reactor where the products and reactants are separated by fractional distillation. In one embodiment a liquid level is maintained in the catalyst bed.

Abstract: A method and apparatus for conducting a catalytic distillation process is provided which allows for maintaining a liquid level in selected portions of the catalyst bed. Three particular processes disclosed are the production of methyl tertiary butyl ether, tertiary butyl alcohol and cumene. A method for the production of methyl tertiary butyl ether by reaction of isobutene with methanol in a distillation reaction column is disclosed wherein a liquid level maintained in the distillation reaction zone.

Abstract: A liquid phase process for oligomerization of C.sub.4 and C.sub.5 isoolefins or the etherification thereof with C.sub.1 to C.sub.6 alcohols wherein the reactants are contacted in a reactor with a fixed bed acid cation exchange resin catalyst at an LHSV of 5 to 20, pressure of 0 to 400 psig and temperature of 120.degree. to 300.degree. F. wherein the improvement is the operation of the reactor at a pressure to maintain the reaction mixture at its boiling point whereby at least a portion but less than all of the reaction mixture is vaporized. By operating at the boiling point and allowing a portion of the reaction mixture to vaporize, the exothermic heat of reaction is dissipated by the formation of more boil up and the temperature in the reactor is controlled.