Abstract: Hydrocarbons are alkylated in a fluidized riser-reactor using a solid catalyst which is regenerated within the process by contact with hydrogen. The alkylation and regeneration steps are separated to prevent the admixture of hydrogen and any olefins present in the process. Two separate modes of regeneration are performed simultaneously: a mild liquid-phase washing and a vapor-phase hot hydrogen stripping operation.

Abstract: The present invention provides a method for reclaiming HF and producing valuable gasoline blending components from the conjunct polymeric byproducts (acid soluble oil or ASO) formed as a byproduct of acid-catalyzed isoparaffin-olefin alkylation comprising the steps of:(a) reacting isoparaffin and olefin in the presence of a liquid acid alkylation catalyst to form alkylate and ASO byproduct;(b) separating alkylate, unreacted isoparaffin, and a majority of said liquid acid alkylation catalyst from said ASO;(c) reacting said separated ASO of step (b) under conditions of elevated temperature and pressure to convert the hydrocarbon portion of said ASO to gasoline boiling range hydrocarbons and to liberate HF.In a preferred embodiment, the ASO is pre-mixed with hydrogen or a hydrogen donor before reaction at elevated temperature and pressure. In a particularly preferred embodiment, the elevated temperature reaction is carried out in the presence of a catalyst such as activated carbon.

Abstract: A method for separating conjunct polymers which are formed as byproducts of acid catalyzed isoparaffin-olefin alkylation and sulfolane from a mixture containing conjunct polymers, sulfolane, and hydrofluoric acid comprising stripping HF from the spent catalyst, treating the stripped, spent catalyst with hydrogen to provide a stripped hydrotreated catalyst stream, and gravitationally separating the stripped hydrotreated catalyst stream to remove conjunct polymeric byproducts.

Abstract: A method of recovery of acid catalyst from acid soluble oil being formed in a process for alkylation of hydrocarbons and containing valuable amounts of spent acid catalyst which method comprises,treating the acid soluble oil with hydrogen in the presence of a catalyst comprising one or more metals from Group VIII of the Periodic Table supported on an acid resistant carrier; andrecycling the hydrotreated acid soluble oil to the alkylation process.

Abstract: An integrated three-column process for recovering hydrocarbon distillate products from a hydroprocessing or hydrocracking reactor effluent stream and a hydrocarbon distillate product recovery train are disclosed. According to the present recovery process, an effluent stream from the cracking reactor is cooled and separated into light and heavy phase streams. The heavy phase stream is depressurized and stripped of light end components in a steam stripping column. The light phase stream is further cooled to separate a liquid stream which is combined with the light ends from the stripper and fed to a debutanizer. A C.sub.4 -rich light end stream taken overhead from the debutanizer is condensed to produce LPG product stream(s). A C.sub.4 -lean heavy end stream removed from the bottoms of the debutanizer is combined with a heavy end bottoms stream from the stripper and fed to a fractionator for fractionation into product distillate streams such as light and heavy naphtha, jet fuel, diesel oil, and the like.

Abstract: The invention relates to an alkylation process, in which a charge incorporating at least one isoparaffin and at least one olefin containing 2 to 6 carbon atoms per molecule, is treated in the presence of a solid alkylation catalyst. In the process, catalyst present in a reaction R is contacted with the charge, recycled liquid effluent discharged from reaction zone R and liquid effluent discharged from an isobutane/n-butane/alkylate separation zone S. The process uses a specific catalyst, e.g., sulfuric acid impregnated on a porous support.

Abstract: Ethers suitable for use as high octane oxygenate additives for motor fuels are produced by a catalytic distillation process wherein a mixture of C.sub.4 -plus isoolefin(s) and an alcohol are recovered from a catalytic distillation zone as an overhead stream and charged to a packed liquid-phase reaction zone containing an etherification catalyst before being recycled to one or more portions of the overall catalytic distillation zone. The process is useful in the coprocessing of a mixture of isobutylene and isoamylene and in other hydrocarbon conversion processes such as hydration and alkylation.

Abstract: Disclosed is an alkylation process which ultilizes a mixture of sulfolane and hydrogen fluoride as an alkylation catalyst. The process provides for the removal of water from the alkylation catalyst that accumulates within the alkylation process system as a result of the incoming water which accompanies the catalyst mixture make-up components.

Abstract: A process for isoparaffin-olefin alkylation is provided that permits the use of solid acid catalysts which require frequent regeneration and high isoparaffin/olefin ratios. The process comprises circulating in a reactor a slurry comprising solid acid zeolite catalyst particles (20-2000 microns) and feed of liquid reactants comprising isoparaffins and olefins in an isoparaffin to olefin molar ratio of less than 100, recycling a first portion of said slurry to provide an isoparaffin to olefin molar ratio in the reactor of at least 500, passing a second portion of the slurry to a separating means to separate alkylate product from said solid catalyst particles, and regenerating the catalyst particles.

Abstract: Disclosed is a process for removing acid soluble oils, produced as an undesirable by-product of an acid catalyzed alkylation reaction, from a mixture containing a strong acid and methanesulfonic acid. The process includes the use of water to induce the formation of the two immiscible liquid phases of ASO and methanesulfonic acid with water. The two immiscible phases can subsequently be separated from each other.

Abstract: A method for converting HF alkylation unit to a sulfuric acid alkylation unit comprising the steps of retaining a reactor, an acid settler and a fractionation section from the HF alkylation unit and modifying at least a portion of the HF alkylation unit to produce a converted alkylation unit that is adapted to use sulfuric acid as a reaction catalyst.

Abstract: An improved alkylation recontactor is provided, wherein the recontactor utilizes an internal mixer for mixing hydrocarbon effluent from an alkylation zone with an acid catalyst from an acid inventory vessel in fluid flow communication with the interior of the recontactor.

Abstract: An improved method and apparatus for the safe handling of alkylation catalyst. The method and apparatus comprises a process vessel which serves a dual function of storing alkylation catalyst and of recontacting alkylation hydrocarbon product with alkylation catalyst. Alkylate product is passed through an eductor-mixer device which intimately mixes alkylate with catalyst. This mixture flows into the dual function recontacting vessel where a phase separation of the catalyst and alkylation hydrocarbon product takes place. Conduits are provided to connect the process reactor, cooling heat exchanger, settler, and interconnecting piping so as to allow the quick release of pressure from the combination storage-recontacting vessel and subsequent draining of catalyst into the vessel by use of gravitational force.

Abstract: A process and apparatus for recovering propane product from HF alkylation process that is substantially free of HF acid. The invention allows for the improvement in the operation of an HF alkylation propane stripper by utilizing a bottoms recycle stream.

Abstract: The present invention provides a Lewis acid-catalyzed isoparaffin/olefin alkylation process in which acid consumption and energy costs are decreased by employing an acid sorption stage to separate the Lewis acid catalyst from the alkylate product stream, or from a selected fraction of the alkylate product stream, and desorbing the Lewis acid from the sorption stage with an isoparaffin-containing alkylation process feedstream.

Abstract: In an alkylation process wherein the amount of hydrogen fluoride (HF) acid catalyst required to maintain a desired HF acid/hydrocarbon ratio in a plurality of alkylation reactors is contained in the lower portion of a common settler vessel, the improvement comprises: dividing the lower portion of the common settler vessel into a plurality of chambers for containing the desired amount of HF acid catalyst, such that a leak affecting the catalyst handling system for one of the plurality of reactors would only spill the amount of liquid HF acid contained in one of the chambers, and would not affect the liquid HF acid level in a non-leaking chamber.

Abstract: Unsaturated .alpha.-olefin oligomers are topped to remove monomer and dimer and then distilled to remove a trimer fraction leaving a residue of tetramer, pentamer and higher oligomers. The trimer fraction is hydrogenated to form saturated .alpha.-olefin oligomer suitable for use as a lubricant.

Abstract: A continuous process for alkylating an alkylatable hydrocarbon in the presence of a acid-type catalyst. The reaction product is separated in a first separation zone into an alkylate product phase, located in the upper portion and a catalyst phase located in the lower portion. The catalyst phase is separated into a first portion and second portion, the first portion is cooled and recycled for use in the alkylation reaction zone, and the second portion is passed into a second separation zone, wherein the second portion catalyst phase is further separated into a hot rerun catalyst stream and an acid soluble oil stream. The rerun catalyst stream is passed into the alkylate product phase of the first separation zone. In order to prevent excessive pressure in the first separation zone as a result of the hot rerun catalyst stream, two liquid hydrocarbon drawoffs from the first separation zone are employed.

Abstract: The present invention is directed to an improvement in an alkylation process involving effluent refrigeration in which an enhanced boiling surface heat exchanger is utilized in the alkylation reaction zone so as to carry out the reaction at its optimum reaction temperature and at a positive compressor suction pressure.

Abstract: An improved method for processing the effluent of a hydrocarbon conversion zone. The invention is particularly useful in a catalytic reforming reaction, wherein practice of the invention results in an increased recovery of butane and propane. The effluent is separated into vapor and liquid components, which are then recontacted at a higher pressure. Several recontacting steps may be employed. Liquid product is then subjected to fractionation. Overhead vapor from the fractionation zone is recycled back to a recontacting step in order to recover a portion of the hydrocarbons contained therein, instead of routing the vapor to the plant fuel gas system.

Abstract: A process for recovering HF catalyst and acid soluble oil from an HF alkylation unit acid stream containing HF and acid soluble oils. The acid stream is charged to a distillation column, wherein free HF acid, and stripping fluid added to the column, are removed as an overhead fraction. A bottoms fraction is removed from this column containing acid soluble oil and some HF. This bottoms fraction is cooled and mixed with a light hydrocarbon, and the mixture is allowed to settle. The mixture separates into an HF-lean acid soluble oil, plus solvent upper phase and an HF-rich acid soluble oil lower phase. The HF-lean phase may be withdrawn from the process as a product or upgraded to improve its quality, permitting recycle of the HF-rich phase with reduced acid soluble oil content, to the alkylation unit.

Abstract: A method is disclosed for fractionating a hydrocarbon conversion zone effluent stream comprising at least three components which are to be isolated into separate streams. A two-column system for fractionating the effluent of a benzene alkylation zone is employed. The overhead vapor of a downstream second column is condensed in a side reboiler of a preceding recycle column. This side reboiler is located between the feed point to the recycle column and a separate reboiler located at the bottom of the recycle column. The utilities cost of performing the fractionation is reduced.

Abstract: A slip stream of system HF from HF alkylation is charged to propane stripping of the fractionation system to purify the HF for recycle to the alkylation. Bottoms yield from propane stripping is fractionated to separate propane from the acid soluble oil separated from the slip stream of HF.

Abstract: In an HF alkylation process, ASO is separated from HF acid catalyst in a fractionation zone by heating the fractionation zone with a condensible stream comprising liquid and vaporous components. In the process of condensation, latent heat is evolved which is used to effectuate the separation of ASO and HF acid catalyst and dilution of the separated ASO is achieved with the use of the produced condensate.

Abstract: A process combination, with inter-cooperation, for producing high-octane alkylates comprising(a) dehydrogenating isopentane to isopentenes (amylenes),(b) introducing the mixture of said amylenes and unconverted isopentane into an HF alkylation unit for reaction with fresh or recycled isobutane,(c) separating the alkylation products into high octane alkylates, isopentane (for recycling to the dehydrogenation reactor) and isobutane (for recycling to the alkylation reactor).

Abstract: A method for utilizing low level or waste heat in a petroleum refinery through absorption refrigeration of isoparaffinic hydrocarbons, e.g., isobutane. In an alkylation process, an olefin is contacted with a molar excess of isoparaffinic hydrocarbons to produce an alkylate. A portion of unreacted isoparaffinic hydrocarbons is vaporized to provide refrigeration. They are cooled and condensed by contact with a lean oil absorbent. They are recovered from the absorbent by use of low level heat in a distillation step and returned to the reaction zone.

Abstract: Acid soluble oils recovered from the acid phase from an HF alkylation unit are processed with hydrocarbon phase from the same or a different unit.

Abstract: Vent gases containing propane and HF obtained from a hydrocarbon alkylation operation are treated together with an alkylate either before or after it has been debutanized thus to remove HF from said vent gases and/or the vent gases are combined with a normal butane stream before it is treated to remove HF therefrom thus to remove HF from said vent gases. In any event described, the propane in the vent gases is advantageously recovered in the normal butane containing stream.

Abstract: The reactor effluent hydrocarbon phase from an alkylation zone in which isoparaffin and olefin are contacted in the presence of HF catalyst to form alkylate product is treated by (1) separating a hydrocarbon phase from the reaction effluent; (2) separating the hydrocarbon phase in a first fractionator to produce a bottoms stream containing isoparaffin and alkylate; (3) flashing this bottoms stream to produce a flashed vapor enriched in isoparaffin and a flashed liquid enriched in alkylate; (4) subjecting this flashed liquid to a high pressure, high temperature fractionation in a second fractionator to produce isoparaffin overhead and alkylate from the kettle; and (5) passing the isoparaffin overhead as heat exchange fluid to at least one of (a) the indirect reboiling of the first fractionator kettle, (b) the indirect heating of the bottoms stream being fed from the first fractionator to the flashing step and (c) the indirect heating of the flashed liquid being fed to the second fractionator.

Abstract: Improvements in heat exchanging of distillation steps in sulfuric acid alkylation processes; removing water from the vaporous overhead fraction of a sulfuric acid alkylation process distillation step or deisobutanizer to enable mixing thereof with the vaporous hydrocarbon effluent from the reaction zone which contains sulfur dioxide vapors sulfur trioxide and H.sub.2 SO.sub.4 mist, thus permitting mixing of the vaporous fraction and effluent for compression before use as a compressed heat exchanging medium in the alkylation process; sulfuric acid alkylation with deisobutanizer tower overhead effluent acid wash.

Abstract: The reactor effluent hydrocarbon phase from an alkylation zone in which isoparaffin and olefin are contacted in the presence of HF catalyst to form an alkylate product is treated by (1) separating a hydrocarbon phase from the reacton effluent; (2) separating the hydrocarbon phase in a fractionator to produce a bottoms stream containing isoparaffin, paraffin, and alkylate and an overhead stream containing HF, isoparaffin, and paraffin; (3) flashing this bottoms stream to produce a flashed vapor enriched in isoparaffin and a liquid enriched in alkylate as compared to the bottoms stream; (4) cooling this flashed vapor to produce a condensed liquid; and (5) indirectly contacting this condensed liquid with the overhead stream thereby cooling the overhead stream and heating the condensed liquid.

Abstract: A process for the separation of isobutane from an alkylation reaction zone hydrocarbon effluent stream comprising isobutane, n-butane, propane and alkylate is disclosed. The hydrocarbon effluent stream is charged to an isostripper column. An isobutane vapor stream from the column is condensed in indirect heat exchange with the lower liquid stream from said column comprising n-butane. The lower liquid stream is flashed in indirect heat exchange with said vapor stream at conditions to provide a vapor phase, said vapor phase being compressed and recycled to said column at a temperature to promote vapor formation therein.

Abstract: A settler-soaking apparatus for treating the effluent from an acid-catalyzed alkylation reaction is disclosed which comprises three interconnected vertically aligned chambers. The uppermost chamber possesses a hydrocarbon outlet means above an acid hydrocarbon inlet means and a downspout having an acid transfer means extending through and ending in the lower end of the middlemost chamber. The latter possesses a hydrocarbon outlet means at an elevated position with respect to the end of the acid transfer means in the downspout and a lower situated acid outlet means. The lowermost chamber possesses a multitude of spaced horizontal perforate trays and an acid hydrocarbon inlet means, which is in connection with the hydrocarbon outlet means of the uppermost chamber. The middle and lowermost chamber are in open communication via a chimney which extends upwardly into said middle chamber to provide a hydrocarbon outlet means at a point above the end of said downspout.

Abstract: Propylene and butylenes are separately acid alkylated with at least one isoparaffin. Expansion and liquid-vapor separation is utilized to separate the propylene from the butylenes. The use of expansion and separation improves the energy efficiency of the alkylation process. The energy efficiency of the alkylation process is further improved by utilizing the bottoms product from the acid stripper associated with the isostripper to cool the acid being supplied to the riser reactor. The size requirements of the isostripper are also reduced by using liquid-vapor separation to remove at least a portion of the unreacted isoparaffin from the alkylated butylenes.

Abstract: A process for the hydrofluoric acid-catalyzed alkylation of an isoparaffin with an olefin in a gravity-flow hydrofluoric acid alkylation reaction system. The process is effected without benefit of an acid regenerator. Regeneration is effected an isostripper column, and catalyst-contaminating polymeric products of the alkylation are recovered in the normally liquid alkylate product substantially free of hydrofluoric acid.

Abstract: A continuous process for alkylating an alkylatable hydrocarbon with an alkylating agent in the presence of an acid-type catalyst in which the alkylatable hydrocarbon is contacted with the alkylating agent in the presence of the catalyst at a temperature and for a time sufficient to alkylate the alkylatable hydrocarbon, the reaction product is separated into an alkylate product phase and a catalyst phase, containing catalyst-soluble oil, the catalyst phase is cooled to maintain a preselected temperature in the exothermic alkylation zone, the cooled catalyst phase is recycled to the alkylation reaction and a predetermined concentration of catalyst-soluble oil is maintained in the catalyst phase by at least periodically heating an alkylating agent to a temperature above the reaction temperature, contacting the heated alkylating agent with one of the separated recycle catalyst, separated rerun catalyst, fresh catalyst or mixture thereof and combining the resultant reaction product with separated recycle catalyst

Abstract: An improvement is disclosed in a process for the acid-catalyzed alkylation of an isoparaffin with an olefin alkylating agent. The improvement relates to an alkylation process wherein the hydrocarbon phase of the alkylation reaction mixture is introduced into a common fractionation column with a field butane stream comprising olefinic materials. The improvement comprises initially clay-treating said field butane stream.

Abstract: A process is provided for the simultaneous and separate alkylation of an isoparaffin such as isobutane with different olefins, e.g., propylenes and butylenes in different zones with an HF acid catalyst comprising separating the hydrocarbon phase from each of the alkylation effluents, subjecting each hydrocarbon phase to separate HF stripping, fractionating the liquid phases removed from each of the HF stripping zones, pressurizing the vaporous isoparaffin stream recovered from fractionation and utilizing the pressurized vaporous streams for indirect heat exchange with HF strippers and fractionation zones prior to recycling through alkylation.

Abstract: A process is provided for the alkylation of isoparaffins with olefins in the presence of an HF acid catalyst comprising separating a liquid hydrocarbon phase from the alkylation effluent, subjecting the hydrocarbon phase to HF stripping, separating the stripped hydrocarbon into a liquid and a vapor phase, fractionating the liquid phase into product streams, and pressurizing the vaporous stream prior to separation of C.sub.3 and lighter materials. The HF alkylation process utilizes indirect heat exchange of various streams and compression of HF-free vapors.

Abstract: A process for the acid-catalyzed alkylation of an alkylatable hydrocarbon with an olefin-acting alkylating agent is disclosed. The alkylation reactor effluent is treated in a unitary settler-soaker vessel whereby a substantial reduction in the acid catalyst inventory of the system is effected. A novel combination soaking-settling apparatus is also disclosed.

Abstract: Improvements in alkylation effluent flash vaporization systems used in processes of alkylating isoparaffinic hydrocarbons with olefinic hydrocarbons in the presence of acid catalyst and an excess of isoparaffinic hydrocarbons; improvements in heat sources used in such alkylation effluent flash vaporization systems, specifically utilizing hot and compressed isoparaffinic hydrocarbon vapors generally available in such systems from such sources as fractionation (deisobutanizer) overhead or vapor flashing processes utilized in cooling the reaction step or both; improvements in alkylation effluent flash vaporization systems which reduce the load on the conventional step of retrieving excess isoparaffinic hydrocarbons from the alkylation reaction effluent for recycle to the reaction step.

Abstract: A process for the acid-catalyzed alkylation of an isoparaffinic hydrocarbon with an olefinic hydrocarbon is disclosed. The alkylation is effected at alkylation reaction conditions resulting in an alkylation reaction mixture containing a vapor phase generated by the exothermic heat of reaction. The vapor phase so generated has a cooling effect permitting the alkylation reaction to be effected at lower temperatures more conducive to higher quality alkylation product.

Abstract: An improved isoparaffin/olefin HF alkylation process designed to function absent the commonly-utilized acid regenerator. Polymer products, formed during the alkylation reaction, are recovered with the normally liquid alkylate product, substantially free from HF, without effecting degradation in the product quality. In addition to enhanced economic considerations stemming from a reduction in equipment costs, the operational stability of the process is significantly improved.

Abstract: In an acid catalyzed alkylation system, a prefractionated reactor hydrocarbon effluent bottoms stream, substantially free of HF, is passed to a propane concentrator in order to provide for a more concentrated and desirable feed for the depropanizer. Due to the highly concentrated propane stream fed to the depropanizer, the size of the depropanizer can be much smaller thereby saving in energy. Hot overhead vapor from the isostripper is also passed in an indirect heat exchange relationship with various feed streams and fractionators in order to supply heat for the preheating of the feed streams and the reboiling of the fractionators. The bottoms fraction of the isostripper can also be passed in an indirect heat exchange relationship with various feed streams and fractionators. The alkylation process, therefore, maximizes the use of available waste heat and reduces the pressure and utilities on the depropanizer thereby saving greatly on energy costs.

Abstract: In the recovery of ethane and propane from an alkylation of an isoparaffin with an olefin to prevent buildup of ethane and propane in the system, the ethane and propane are taken as a side draw from the conventional HF stripper instead of being vented from the depropanizer or the fractionator overhead accumulator. Considerable ethane, propane and HF are thus saved and equipment costs reduced, especially because fractionator wall thickness can be reduced and because of the elimination of the equipment attendant the venting of the accumulator.

Abstract: An HF alkylation-fractionation system for the separation of the hydrocarbon phase separated from the HF alkylation effluent by passing the hydrocarbon phase first to a prefractionation zone operated at low pressure, followed by fractionation of both overhead and bottoms from the prefractionation zone at higher pressures and temperatures, and utilization of the high temperature streams obtained from the higher pressure fractionations as sources of heat for indirect heat exchange of the prefractionation zone and feed to at least one of the subsequent fractionations.

Abstract: An olefin and isoparaffin are contacted in the presence of an acid alkylation catalyst to form an alkylate-containing alkylation effluent. The effluent is separated with the hydrocarbon phase passing to a prefractionation zone. A side stream from the prefractionation zone is passed in indirect heat exchange relationship with an interheater of an isostripper thereby providing a majority of the heat necessary to reboil the isostripper.

Abstract: An alkylation process wherein isoparaffin hydrocarbons are alkylated with olefin hydrocarbons in the presence of an alkylation catalyst comprising H.sub.2 SO.sub.4 to yield alkylated hydrocarbons suitable for use in motor fuels. Such process includes an isoparaffin pretreatment step wherein isoparaffin charge is contacted with spent alkylation catalyst to remove contaminants from the isoparaffin which are reactive with sulfuric acid under alkylation conditions.

Abstract: Field butanes, otherwise introduced into an isostripping column, also utilized to recover alkylate product from unreacted isobutane, are separately fractionated to provide an isobutane concentrate and a normal butane concentrate. The former is increased in pressure and reacted with the olefinic feed stream in admixture with HF-acid catalyst. The latter is introduced into the reaction zone wherein it is vaporized via indirect contact with the reaction mixture. Vaporous normal butane is introduced into the fractionation facility wherein the exothermic heat of reaction serves to separate the field butane stream. Alkylation reactions can thus be conducted at sub-ambient temperatures which results in an alkylate product of improved quality. This technique also obviates the necessity for a cooling water system, thus eliminating the possibility of HF-acid contamination of water bodies.

Abstract: Liquid propane containing HF is admixed in an eductor or sparger with aqueous alkaline solution, e.g., 2-5 percent aqueous NaOH maintained in a treating vessel, the eductor or sparger being located within a body of said alkaline treating agent in said vessel, thus to avoid explosion.