Abstract: A novel alkylation catalyst is described which is used in processes for alkylating olefin hydrocarbons with isoparaffin hydrocarbons to produce high octane alkylate products suitable for use as blending components of gasoline motor fuel. The novel catalyst comprises a mixture of a hydrogen halide, a sulfone and water and has suitable corrosion properties which permit its utilization in alkylation process systems. The novel alkylation catalyst is utilized in a novel process for alkylating olefin hydrocarbons with isoparaffin hydrocarbons.

Abstract: The present invention provides an acid catalyzed isoparaffin-olefin alkylation process which improves process stability and safety by storing the acid in an excess of an additive which reduces the fuming tendency of the mixture, for example, a sulfone. Acid is stripped from the additive and concentrated prior to charging the acid to the alkylation reaction zone. Specifically, because the stored solution of acid in the additive is more dilute than can be effectively used for isoparaffin-olefin alkylation, the acid is concentrated prior to charging the catalyst mixture to the reaction zone. The invention solves the problem of conjunct polymer accumulation by diluting the conjunct polymer with a relatively large volume of the additive and continuously regenerating a slipstream of the dilute acid/additive mixture.

Abstract: The present invention provides 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, which method provides a sulfolane recycle stream which requires no further drying before charging the stream to the alkylation reaction zone.

Abstract: The present invention provides 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, and for minimizing accumulation of conjunct polymeric byproducts in the recycled acid catalyst.

Abstract: A process for producing a low benzene content gasoline is disclosed. Catalytic reforming produces a benzene rich reformate which is fractionated to yield a benzene rich C6 fraction which is then over-alkylated, preferably with C2/C3 olefins from an FCC, to produce heavy alkylate having too high an end point for use as gasoline. Heavy alkylate is charged to an FCC reactor, along with a conventional heavy FCC feed, and converted back into a gasoline boiling range product. Heavy alkylate also produces reactive alkyl fragments in the cracking reactor which react with benzene produced during cracking of FCC heavy feed.

Abstract: An isoparaffin-olefin alkylation process is disclosed which improves alkylate quality by segregating the olefin feed into intermediate feedstreams which are enriched in propene, 1-butene, and/or 2-butenes with respect to the olefin feed, and alkylating these intermediate feedstreams in separate reaction zones at reaction temperatures specific to the olefin feed to increase the ratio of trimethylpentanes to dimethylhexanes in the resulting alkylate product.

Abstract: A continuous alkylation process for the production of high octane gasoline comprising contacting a mixture of an isoparaffin and an olefin with a catalyst complex comprising BF3:H.sub.3 PO.sub.4 in a continuous hydrocarbon downflow reactor.

Abstract: The present invention provides a method for separating conjunct polymers and sulfolane from a mixture containing conjunct polymers, sulfolane, and hydrofluoric acid comprising the sequential steps of:(a) separating hydrofluoric acid from said mixture to provide an intermediate stream containing less than about 30 percent hydrofluoric acid by weight;(b) gravitationally separating said intermediate stream into a sulfolane-enriched stream and a conjunct polymer-enriched stream;(c) contacting said sulfolane-enriched stream with a polar extraction solvent to provide an extract stream enriched in sulfolane and a raffinate stream enriched in conjunct polymers;(d) stripping the polar extraction solvent from said sulfolane-enriched extract stream; and(e) recovering sulfolane from said enriched stream of step (d).

Abstract: The present invention provides 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 the sequential steps of:(a) separating hydrofluoric acid from a mixture containing conjunct polymers, sulfolane, and hydrofluoric acid to provide a first intermediate stream containing less than about 30 percent hydrofluoric acid by weight;(b) mixing said intermediate stream with a nonpolar extraction solvent to provide a second intermediate stream; and(c) gravitationally separating said intermediate stream into a less dense extract stream enriched in conjunct polymers and a more dense liquid stream enriched in sulfolane.

Abstract: The present invention provides 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 the sequential steps of:(a) separating hydrofluoric acid from said mixture to provide an intermediate stream containing less than about 30 percent hydrofluoric acid by weight;(b) gravitationally separating said intermediate stream into a more dense sulfolane-enriched stream and a less dense conjunct polymer-enriched stream;(c) distilling said more dense sulfolane-enriched stream of step (b) to provide an overhead stream containing a higher sulfolane concentration than said more dense sulfolane-enriched stream of step (b) and a bottom stream enriched in conjunct polymers.

Abstract: This invention provides a method for separating ASO from a mixture containing ASO, HF and sulfolane comprising the steps of:(a) contacting said mixture with a sorbent to selectively sorb HF and water from said mixture to evolve an intermediate product containing less than 5 weight percent HF;(b) charging said intermediate product to a gravitational separation zone;(c) holding said intermediate product in said gravitational separation zone for time sufficient to evolve two at least partially immiscible liquid phases in said gravitational separation zone; and(d) withdrawing a less-dense phase enriched in ASO and a more-dense phase enriched in sulfolane from said gravitational separation zone.

Abstract: The present invention provides a method for separating sulfolane from a mixture containing conjunct polymers, sulfolane, and hydrofluoric acid comprising the sequential steps of:(a) removing HF from said mixture to provide an intermediate stream containing less than about 30 weight percent HF;(b) contacting said intermediate stream with water;(c) contacting said intermediate stream with an aliphatic hydrocarbon co-solvent having from about 3 to about 20 carbon atoms concurrently with said water-contacting step (b);(d) recovering an extract stream enriched in sulfolane and hydrofluoric acid; and(e) recovering a raffinate stream enriched in conjunct polymers.

Abstract: A single path process for alkylating a hydrocarbon feedstock containing an olefin and an isoparaffin is disclosed. The process includes dispersing an acid-based liquid alkylation catalyst into a reaction zone for contact with a continuous hydrocarbon phase. The process further includes separating the hydrocarbon phase from the acid catalyst upon completion of the alkylation reaction and providing a continuous on-line regeneration of the entire volume of catalyst once it has been separated from the hydrocarbon phase.

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: A method for separating conjunct polymers and sulfolane from a mixture containing conjunct polymers, sulfolane, and hydrofluoric acid is disclosed, which method comprises the sequential steps of separating hydrofluoric acid from said mixture to provide an intermediate stream containing less than about 30 percent hydrofluoric acid by weight and gravitationally separating said intermediate stream into a sulfolane-enriched stream and a conjunct polymer-enriched stream.

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: A process for alkylation of isoparaffins and olefins employing a fixed bed of catalyst. The catalyst composition includes an unpromoted synthetic zeolite. The alkylate product contains highly branched paraffins and has an octane suitable for blending into motor gasolines. Alternatively multiple fixed beds can be employed with direct effluent recycle or split olefin feeds.

Abstract: A reactor system and process for conducting exothermic or endothermic chemical reactions achieves greater kinetic efficiency through transfer of heat between adjacent feed temperature modification and reaction zones.

Abstract: Oxides of nitrogen (NO.sub.x) emissions from an FCC regenerator are reduced by adding a DeNO.sub.x catalyst to the FCC regenerator in a form whereby the DeNO.sub.x catalyst remains segregated within the FCC regenerator. This permits use of a DeNO.sub.x catalyst without regard to the effect of the DeNO.sub.x catalyst on the catalytic cracking reaction. Floating hollow spheres, or catalyst fines, containing the DeNO.sub.x catalyst are preferred.

Abstract: A process for production of alcohol or ether by hydration of olefinic feedstock containing at least one lower alkene by contacting the olefinic feedstock and water in a hydration zone with porous solid metal oxide acidic olefin hydration catalyst under olefins hydration conditions. The process is characterized by the step of pretreating porous solid catalyst, such as acid zeolite, prior to contacting with the olefinic feedstock with a wetting agent containing at least one polar aliphatic oxygenated hydrocarbon to substantially wet said solid catalyst and sorb said wetting agent into pores of said solid catalyst. After initiating hydration reaction by feeding the olefinic feedstock and water, increased catalytic activity is obtained. The process is particularly useful for making isopropanol and DIPE from propene and water.