Abstract: This disclosure relates to SA alkylation reactor systems. The reactor system involves a closed reactor vessel comprising a shell, a vapor outlet, and an emulsion outlet. The reactor system also involves a distributor located at the lower portion of the reactor vessel, a mixer fluidly connected with the distributor, and an emulsion pump fluidly connected with the mixer and the emulsion outlet, wherein the emulsion pump is located outside the reactor vessel. This disclosure also relates to a split SA alkylation reactor system wherein a single horizontal reactor vessel is divided to accommodate two reactor systems. This disclosure also relates to alkylation processes using the reactor systems. This disclosure also relates to methods of converting an HF alkylation unit to a SA alkylation unit. This disclosure also relates to converted SA alkylation units and alkylation processes performed in the converted SA alkylation units.

Abstract: This disclosure relates to methods of converting an HF alkylation unit which utilizes HF as a reaction catalyst to a sulfuric acid alkylation unit which utilizes sulfuric acid as a reaction catalyst. This disclosure also relates to a segmented sulfuric acid settler for separating a sulfuric acid phase from a hydrocarbon phase. This disclosure also relates to methods of converting a vertical HF acid settler to a segmented sulfuric acid settler. This disclosure also relates to converted sulfuric acid alkylation units and alkylation processes performed in the converted sulfuric acid alkylation units.

Abstract: This disclosure relates to SA alkylation reactor systems. The reactor system involves a closed reactor vessel comprising a shell, a vapor outlet, and an emulsion outlet. The reactor system also involves a distributor located at the lower portion of the reactor vessel, a mixer fluidly connected with the distributor, and an emulsion pump fluidly connected with the mixer and the emulsion outlet, wherein the emulsion pump is located outside the reactor vessel. This disclosure also relates to a split SA alkylation reactor system wherein a single horizontal reactor vessel is divided to accommodate two reactor systems. This disclosure also relates to alkylation processes using the reactor systems. This disclosure also relates to methods of converting an HF alkylation unit to a SA alkylation unit. This disclosure also relates to converted SA alkylation units and alkylation processes performed in the converted SA alkylation units.

Abstract: This disclosure relates to alkylation processes. The process involves providing two or more reaction zones disposed in sequence. In at least the first two reaction zones, olefin mixture comprising C3 and C4 olefins is contacted with isoparaffin comprising isobutane in the presence of sulfuric acid solution under effective alkylation conditions to produce a product mixture comprising spent acid solution and alkylate product, wherein the molar ratio of C3 to C4 olefins in the olefin mixture decreases in each subsequent reaction zone. In the process, the sulfuric acid solution present in a reaction zone contains the spent acid solution produced in the immediately preceding reaction zone.

Abstract: This disclosure relates to methods of converting an HF alkylation unit which utilizes HF as a reaction catalyst to a sulfuric acid alkylation unit which utilizes sulfuric acid as a reaction catalyst. This disclosure also relates to a segmented sulfuric acid settler for separating a sulfuric acid phase from a hydrocarbon phase. This disclosure also relates to methods of converting a vertical HF acid settler to a segmented sulfuric acid settler. This disclosure also relates to converted sulfuric acid alkylation units and alkylation processes performed in the converted sulfuric acid alkylation units.