Abstract: The invention provides an acid catalyst composition for alkylation of an isoparaffin with an olefin comprising from about 10 to about 90 percent of at least one acid selected from the group consisting of hydrofluoric acid and the halogen-substituted sulfonic acids, together with from about 10 to about 90 weight percent of a mono-, di-, or tri-carboxylic acid substituted member selected from the group consisting of alkanes, aromatics, haloalkanes, and haloaromatics having from about 1 to about 30 carbon atoms.

Abstract: The invention provides a substantially fail-safe HF alkylation process and reactor apparatus. The elongated reactor vessel is enclosed in a subterranean well casing and an alkylate-containing hydrocarbon layer is maintained above the hydrofluoric acid to prevent release of gaseous HF in the event of sudden depressurization. In a preferred embodiment, the hydrocarbon layer contains light hydrocarbons which vaporize upon depressurization to effect Joule-Thompson cooling of the reactor vessel.

Abstract: The invention provides a substantially fail-safe HF alkylation process and reactor apparatus. The elongated reactor vessel is enclosed in a well casing and an alkylate-containing hydrocarbon layer is maintained above the hydrofluoric acid to prevent release of gaseous HF in the event of sudden depressurization. In a preferred embodiment, the hydrocarbon layer contains light hydrocarbons which vaporize upon depressurization to effect Joule-Thompson cooling of the reactor vessel. A method for storing hazardous liquids and a penetration-resistant storage tank are also disclosed.

Abstract: The present invention includes an isoparaffin:olefin alkylation process and apparatus in which liquid acid inventory is reduced and temperature control is improved by reacting the isoparaffin:olefin feed with a thin film of liquid acid catalyst supported on a heat exchange surface.

Abstract: The present invention provides a process for alkylating an isoparaffin with an olefin comprising contacting an isoparaffin having from 4 to 8 carbon atoms with an olefin having from 2 to 12 carbon atoms in an alkylation reaction zone at temperature from about -20.degree. C. to about 200.degree. C. in the presence of a Bronsted acid and an inorganic, porous crystalline phase material having, after calcination, a d-spacing greater than about 18 Angstrom Units and having a benzene adsorption capacity of greater than 15 grams benzene per 100 grams of said material at 50 torr and 25.degree. C., wherein the molar ratio of said isoparaffin to said olefin is from about 1:1 to about 250:1 to evolve a product stream containing C.sub.5 + alkylate.

Abstract: A method of making jet fuel compositions from lower alkyl cyclopentanes and C.sub.5 -C.sub.8 olefins via a dehydrocondensation reaction in the presence of sulfuric acid or hydrofluoric acid. The reaction product contains a predominance of decalins and has high density, high heat of combustion and low freezing point.

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: An improved system for performing an alkylation process and a method for handling liquid catalyst in an alkylation process. This improvement involves method and apparatus by which liquid alkylation catalyst contained in the alkylation process equipment can be transferred into a catalyst storage vessel without the need for venting excess pressure from the storage vessel to atmosphere. Through a combination of the physical arrangement of the process equipment and the storage vessel along with the addition of a pressure equalization line, apparatus is provided whereby certain process steps can be followed which allow the transfer of catalyst from the process equipment to the storage vessel without venting the storage vessel. The improvement comprises physically locating the catalyst storage vessel at a relative elevation below the alkylation proces equipment and providing a line to connect the vapor space of the storage vessel with that of a catalyst settling vessel in the process equipment.

Abstract: A process and apparatus are disclosed for acid continuous alkylation of a hydrocarbon-containing feedstream in which the inventory of acid is reduced. The apparatus used combines a reactor, settler and heat exchanger in a single vessel. The acid phase flows out of the reactor only for acid makeup, to account for acid consumption, and regeneration.

Abstract: An HF alkylation unit incorporates a source of a proton acceptor additive which may be added to the HF alkylation acid in the event of a release of acid from the unit. The addition of the proton acceptor to the acid alters the character of HF droplets in an HF cloud to make them more easily treated by a simple water drench. The proton acceptor is maintained in a pressurized container in the unit and is connected to the reaction section of the unit by way of additive release valves under the control of an emergency controller which opens the valves and permits the additive to enter the reaction section of the unit and mix with the acid to modify its characteristics. The container may be connected to the major acid-containing process vessels in the unit, specifically the acid settler and the acid cooler (in a gravity flow unit) or the acid settler and the reactor (in a pump-around unit).

Abstract: A process for alkylating an aliphatic hydrocarbon having isobutane with an alkenyl hydrocarbon with isobutylene in the presence of a liquid onium polyhydrogen fluoride complex as the reaction medium and catalyst at a temperature between -20.degree. and 70.degree. and pressure between atmospheric and 200 psi and at a time sufficient to form a high octane alkylate thereof.

Abstract: The thermal stability of synthetic lubricants composed of alpha-olefin oligomers is improved by reaction with an olefin such as decene or the lower molecular weight, non-lubricant range olefins produced in the course of the oligomerization of 1-alkenes. The alkylation of the lube range oligomer is carried out using acidic alkylation catalyst such as solid, open-pore catalyst, e.g., fluorided alumina.The improved lubricant compositions of the present invention comprise a high viscosity index liquid lubricant oligomer composition containing C.sub.30 -C.sub.1300 hydrocarbons with at least one higher alkyl branch per oligomer molecule, said alkyl branch containing between 12 and 40 carbon atoms. In a preferred embodiment the novel alkylated lubricant composition has a methyl to methylene branch ratio of less than 0.19 and pour point below -15.degree. C.

Abstract: High viscosity index, low pour point lubricants are produced by reacting an iso-paraffinic component, preferably with significant mono- and di-methyl chain branching, with an olefinic reactant in the presence of a free radical generator such as an organic peroxide, preferably ditertiary butyl peroxide. The isoparaffinic reactant is preferably obtained by the isomerization of a waxy feed such as slack wax over a zeolite beta isomerization catalyst, preferably Pt/zeolite beta. The olefinic reactant is preferably a distillate fraction produced by the oligomerization of low molecular weight olefins e.g., C.sub.3 to C.sub.5 olefins, produced by oligomerization over an intermediate pore size zeolite oligomerization catalyst such as ZSM-5.

Abstract: A method of containing a hydrofluoric acid spill which includes the steps of detecting the spill, drenching the hydrofluoric acid spill area with an aqueous drench, drenching the hydrofluoric acid area with an aqueous solution composed of at least one foam generating surfactant, a foam stabilizer and a phase transfer agent. The drenching steps may be performed in sequence or concurrently.

Abstract: An apparatus and a method are disclosed for transferring acid catalyst from a transport vehicle where liquid acid is carried under a relatively low vapor pressure level to a process vessel in an alkylation process where liquid acid is contained at a higher pressure level, while minimizing the loss of acid vapor to the environment. The acid transfer is accomplished without venting the process vessel by employing a relatively small volume pressure lock chamber between the transport vessel and the storage vessel. In a preferred embodiment the small volume pressure lock chamber also serves as a storage vessel for make-up acid which is added to the alkylation process as required.

Abstract: A novel liquid acid catalyzed alkylation process utilizing a liquid acid catalyst comprising a surfactant and a liquid acid is disclosed which incorporates a fixed bed of contact material to improve the alkylation reaction zone efficiency. The fixed bed of contact material also allows the process to be efficiently operated at lower acid to olefin mole/mole feed ratios than normally used.

Abstract: A cooling fluid is utilized to withdraw heat from a KOH treater. The passing of the cooling fluid in heat exchange with the KOH treater is controlled so as to maintain desired operating pressures and also substantially maximize heat transfer. Bypassing of the feed around the KOH treater is utilized only if sufficient cooling cannot be provided to prevent a temperature runaway.

Abstract: A novel liquid acid catalyzed alkylation process is disclosed which incorporates a fixed bed of contact material to improve the alkylation reaction zone efficiency. The fixed bed of contact material also allows the process to be efficiently operated at lower acid to olefin mole/mole feed ratios than normally used.

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: A process using selective hydrogenation and HF alkylation in combination that employs a multifunction alkylation stripper for removal of light ends from the selective hydrogenation and a alkylation operations. The process combines the effluent from the selective hydrogenation operation, an isobutane feed stream and a bottoms stream from the HF stripper in the alkylation feed stripper. The feed stripper provides a C.sub.4 -plus bottoms stream that serves as the feed to the alkylation zone and a C.sub.3 -minus overhead that can be recovered as fuel gas. Significant benefit is obtained from this process when processing a mixed olefin feed of C.sub.3 /C.sub.4 hydrocarbons and recovering a high purity C.sub.3 product stream ahead of the selective hydrogenation zone. Another variation of this process allows a C.sub.3 product stream to be withdrawn from the alkylation feed stripper either directly as a sidecut or downstream of an overhead condensor.

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: Alkylate is produced by catalytically converting oxygenate feedstock, such as methanol, to lower olefins comprising C.sub.2 -C.sub.4 olefins. Ethene is separated by interstage sorption of C.sub.3 + components and an isoparaffin is alkylated with C.sub.3 -C.sub.4 olefins.The improved technique comprises fractionating an olefinic feedstream containing ethene and C.sub.3 + olefinic components by contacting the olefinic feedstream in a sorption zone with a liquid hydrocarbon sorbent to selectively sorb C.sub.3 + components; reacting C.sub.3 + olefins with excess isoparaffin in a catalytic alkylation reactor to produce C.sub.7 + alkylate hydrocarbons; fractionating the alkylation reactor effluent to provide a liquid hydrocarbon fraction rich in C.sub.4 + isoparaffin for recycle to the sorption zone as lean sorbent; and recovering C.sub.7 + alkylate product from the process.

Abstract: A continuous process for upgrading C.sub.3 -C.sub.4 hydrocarbon feed containing olefins to produce heavier liquid hydrocarbons comprising converting a major portion of C.sub.3 -C.sub.4 olefins in an oligomerization zone by contacting a shape selective medium pore zeolite catalyst at elevated temperature and pressure to make distillate and olefinic gasoline; fractionating the oligomerization stage effluent to provide distillate and gasoline product and a C.sub.3 -C.sub.4 intermediate stream containing isobutane and unconverted propene and butylene; and combining the C.sub.3 -C.sub.4 intermediate stream with a portion of C.sub.3 -C.sub.4 feed and further converting the combined streams in an alkylation zone to make heavier paraffinic hydrocarbons.The olefin feed may be produced by catalytically converting methanol or similar oxygenated hydrocarbons in a known process.

Abstract: Alkylate is produced by catalytically converting oxygenate feedstock, such as methanol, to lower olefins comprising C.sub.2 -C.sub.4 olefins. Ethene is separated by interstage sorption of C.sub.3 + components and an isoparaffin is alkylated with C.sub.3 -C.sub.4 olefins derived from sorbate.The improved technique comprises fractionating an olefinic feedstream containing ethene and C.sub.3 + olefinic components by contacting the olefinic feedstream in a sorption zone with a liquid hydrocarbon sorbent to selectively sorb C.sub.3 + components; reacting C.sub.3 + olefins with excess isoparaffin in a catalytic alkylation reactor to produce C.sub.7 + alkylate hydrocarbons; fractionating the alkylation reactor effluent to provide a liquid hydrocarbon fraction rich in C.sub.7 +, alkylate for recycle to the sorption zone as lean sorbent; and recovering C.sub.7 + alkylate product and C.sub.5 + gasoline from the process.

Abstract: Alkylate is produced by catalytically converting oxygenate feedstock, such as methanol, to lower olefins comprising C.sub.2 -C.sub.4 olefins. Ethene is separated for recycle and an isoparaffin is alkylated with C.sub.3 -C.sub.4 olefins.

Abstract: Alkylate is produced by catalytically converting oxygenate feedstock, such as methanol, to lower olefins comprising dominantly C.sub.2 -C.sub.4 olefins. Ethene is separated from primary stage effluent by interstage sorption of C.sub.3 + components which may be upgraded. Isoparaffin may be alkylated with C.sub.3 -C.sub.4 olefins in a secondary stage.The improved technique comprises fractionating an olefinic feedstream containing ethene and C.sub.3 + olefinic components by contacting the olefinic feedstream in a sorption zone with a liquid hydrocarbon sorbent to selectively sorb C.sub.3 + components;wherein the sorbent is obtained by condensing C.sub.5 + aliphatic and aromatic hydrocarbon from the primary stage.

Abstract: An improved method is disclosed for regenerating adsorbents used in an integrated process for the production of ethers such as methyl tertiary butyl ether by the reaction of an alcohol with an isoolefin. The sorbents are used to remove such compounds as the product ether and the feed alcohol from a hydrocarbon-rich stream withdrawn from the etherification zone. The regeneration procedure includes contacting the sorbent with a heated portion of the treated hydrocarbon stream. The resultant contaminated hydrocarbon stream is passed into a stripping column used to remove light ends from the effluent of a dehydrogenation zone in which the isoolefin fed to the etherification zone is produced. The hydrocarbonaceous compounds collected on the sorbent are thus recycled rather than being destroyed or lost in low purity effluent streams.

Abstract: An improved method is disclosed for regenerating adsorbents used in an integrated process for the production of ethers such as methyl tertiary butyl ether by the reaction of an alcohol with an isoolefin. The sorbents are used to remove oxygenated compounds such as the product ether and the feed alcohol from a hydrocarbon-rich stream withdrawn from the etherification zone. The regeneration procedure includes contacting the sorbent with a heated hydrocarbon stream. The resultant contaminated hydrocarbon stream is passed into a stripping column used to remove light ends from the effluent of a dehydrogenation zone in which the isoolefin fed to the etherification zone is produced. The oxygenated compounds collected on the sorbent are thus selectively recycled or rejected rather than being destroyed or lost in low purity effluent streams.

Abstract: In a combination alkylation-methyltertiary butyl ether (MTBE) operation, isobutane vapor side-draw and bottoms product yield from the alkylation fractionation, respectively, are used to indirectly heat the mid-section and reboil section of the methyltertiary butyl ether fractionator for heat conservation, beneficiating both the alkylation operation and the MTBE operation.

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: This invention relates to a new process for the direct conversion of natural gas or methane into gasoline-range hydrocarbons (i.e., synthetic transportation fuels or lower olefins) via catalytic condensation using superacid catalysts.

Abstract: MTBE is recovered from an ether containing effluent by fractionation. When driers are not used on the hydrocarbon feed to MTBE manufacture, a separate water-methanol phase occurs in the fractionation overhead which is separately processed in a methanol fractionator and the water recovered is used to water wash the separated hydrocarbon phase from the overhead while methanol is recycled to MTBE and when driers are used on the hydrocarbon feed a separate methanol phase occurs in the fractionation overhead which can be recycled to MTBE manufacture and the hydrocarbon phase is directly passed to a drier preceding alkylation.

Abstract: Introduction of undesirable materials through liquid containing vessels of an ether forming unit into an alkylation unit is prevented by pressurizing one or more of these liquid containing vessels of the ether forming unit with a gas which is compatible with both the ether forming reaction and the alkylation reaction and which has a boiling point to keep it in essentially the gas phase in the pressurized vessel and to keep it in the liquid or dissolved form in the overhead accumulator associated with the fractionator of the alkylation unit (if said gas is present in the accumulator at all).

Abstract: This invention relates to a new process for the direct conversion of natural gas or methane into gasoline-range hydrocarbons (i.e., synthetic transportation fuels or lower olefins) via catalytic condensation using superacid catalysts.

Abstract: In an HF alkylation process the HF phase leaving the reaction zone is introduced into a separate resaturation zone wherein this HF phase is contacted with isobutane to resaturate the HF with isobutane. In the main hydrocarbon fractionator only a very small quantity of isobutane has to be evaporated and this isobutane can be withdrawn as a side stream and recycled.

Abstract: This invention relates to a new process for the direct conversion of natural gas or methane into gasoline range hydrocarbons (i.e., synthetic transportation fuels or lower olefins) via catalytic condensation using superacid catalysts.

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 process is described for paraffin-olefin alkylation under strong acid conditions in which an adamantylalkyl carboxylic acid or sulfonic acid is used to substantially improve the efficiency of reaction.

Abstract: An energy recovery method is disclosed for use on acid catalyzed alkylation processes which produce motor fuel blending components. The method is used on alkylation processes in which a light hydrocarbon, such as isobutane, is withdrawn from an elevated pressure fractionation column as a vapor-phase stream which is preferably a sidecut stream, condensed and then recycled to the reaction zone of the alkylation process. In the subject method, the vapor-phase stream is first depressurized to recover useful energy and is then condensed.

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: Hydrocarbon vapors containing HF, as from an HF alkylation refrigerated vent gas yield, the reactor settler, and the like are charged to a liquid knock-out drum to remove entrained liquid therefrom, the recovered liquid being pumped to storage in response to liquid level control on the knock-out drum. Recovered vapors are charged to a circulating aqueous caustic treater to yield HF-free vapors, as to a flare. The circulating caustic solution is indirectly heated in response to a preselected caustic solution temperature to prevent freezing. A high pressure rupture disc, upstream from the knock-out drum, affords a vapor relief safety by-pass of the treater. Dry gas, such as nitrogen or sweet, natural gas, continuously sweeps the relief line to maintain this line open and operable.

Abstract: A process for maintaining HF acid soluble oils (ASO) in an HF alkylation reaction zone in an amount sufficient to ensure formation of an alkylate containing a high octane number is provided by returning to the reaction zone a portion of acid soluble oil recovered from an HF catalyst rerun system.

Abstract: An alkylation process comprising an isoparaffin feed fractionation zone, an alkylation zone, and an alkylation product fractionation zone wherein a normal paraffin stream separated from the product fractionation zone is charged, preferably after defluorination, to the feed fractionation zone at a locus between interheating and high purity normal paraffin withdrawal, and wherein interheating is effected by use of isoparaffin vapor separated from the product fractionation prior to return to the alkylation zone.

Abstract: A apparatus for the catalytic alkylation of an isoparaffin with one or more olefins. Reactant hydrocarbons are passed in contact with a liquid catalyst such as hydrofluoric acid in a reaction zone. The hydrocarbon phase is allowed to separate from the catalyst phase in a settling zone, and a portion of the hydrocarbon phase is cooled and reintroduced to the reaction zone in a separate stream from that of the feed hydrocarbons. The alkylation apparatus by which the process is carried out includes a vertical reaction vessel, which in a preferred embodiment is 2 to 6 feet in height, a settling vessel, means for fluid flow from the reaction vessel to the settling vessel, a conduit for fluid flow between the upper part of the settling vessel and the reaction zone, and means for cooling fluid in this conduit.

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: A combination process for production of HF alkylate motor fuel and HF alkylate solvent wherein the alkyl fluoride impurities present in the produced motor fuel are removed therefrom by treatment with a relatively clean HF stream (emulsion) containing the produced HF alkylate solvent. Makeup, relatively clean, HF catalyst for the motor fuel alkylation is secured from the solvent HF alkylate alkylation system.The invention produces motor fuel alkylate substantially free of organic fluoride contaminates as well as substantially organic fluoride-free isoparaffin solvent alkylate, using only one HF rerun column.

Abstract: An alkylation process comprising fractionating the hydrocarbon phase separated from the alkylation effluent into an overhead condensate comprising at least three portions wherein one portion is subjected to depropanization, another portion is used as reflux for the fractionating, and another portion is recycled to the alkylation.

Abstract: An improved multiconversion zone process which results in an increased yield of motor fuel blending stocks from butanes is disclosed. A butane mixture is fractionated into isobutane-rich and normal butane-rich process streams, with the normal butane-rich stream being passed into an isomerization zone. All of the C.sub.4 's in the isomerization zone effluent and the normal butane-rich process stream are passed through a dehydrogenation zone. The entire dehydrogenation zone effluent stream is passed into an alkylation zone, and the alkylation zone effluent is fractionated. An alkylate-containing normal butane stream is recycled to the feed fractionator, and alkylate from the feed fractionator is admixed with an alkylate stream from the alkylation zone product fractionator to produce a product stream.

Abstract: A process is described for paraffin-olefin alkylation under strong acid conditions in which an adamantane hydrocarbon is used to substantially increase the reaction rate of the alkylation.

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.