Abstract: A process for converting natural gas to a liquid includes heating the gas to a selected range of temperature to convert a fraction of the gas stream to reactive hydrocarbons, primarily acetylene, and reacting methane and the reactive hydrocarbons in the presence of an acidic catalyst to produce a liquid, predominantly pentane. Hydrogen resulting from the reactions is used to heat the incoming natural gas, either with a hydrogen furnace or by electrical energy generated from the hydrogen. Little or no use of methane is required to supply energy for the process.

Abstract: The invention provides an improved alkylation process and reactor apparatus. The invention utilizes a vessel containing a riser-reactor conduit, an acid settler and an acid cooler. Hydrocarbons are introduced beneath said riser-reactor conduit, mixed with acid catalyst, and passed generally upwards through the riser-reactor conduit to enter the acid settler. Within the acid settler, alkylate is separate from the acid catalyst and is removed from the vessel. Acid catalyst from the acid settler is cooled in the internal acid coolers and returned to the region beneath the riser-reactor conduit.

Abstract: Zeolite/clay/phosphate catalysts can be prepared by a process wherein a composition of zeolite-clay-phosphate is brought to a pH level of about 7.0 to about 14.0. The resulting slurry is then age reacted for about 0.5 to about 24 hours. Thereafter the slurry is dried to produce a zeolite/clay/phosphate catalyst particles that are particularly characterized by their high levels of zeolite stability.

Abstract: The invention concerns the catalytic alkylation of at least one isoparaffin selected from the group formed by isobutane and isopentane in the presence of at least one olefin containing 3 to 6 carbon atoms per molecule, using a catalyst comprising 40% to 99% by weight of an acid selected from acids with formula R--SO.sub.3 H where R is fluorine or an alkyl group or a fluorinated alkyl group, R preferably being F or CF.sub.3, and more preferably CF.sub.3, and 1% to 60% by weight of a solvent selected from the group formed by sulpholane, dimethylsulphoxide and dioxanes, preferably sulpholane.

Abstract: A method is disclosed for producing branched aliphatic ketones in hydrocarbon mixtures from isoalkanes by a superacid catalyzed formylation-rearrangement reaction. The method can be used to simultaneously isomerize, if necessary, and formylate hydrocarbons in complex hydrocarbon mixtures such as refinery streams, alkylate mixtures, and natural gas liquids. Natural gas liquids of low octane number are upgraded and oxygenated by adding to the natural gas liquids or reactively producing in the liquids branched aliphatic ketones.

Abstract: The invention pertains to a process for alkylating hydrocarbons in which an alkylatable organic compound is reacted with an alkylation agent to form an alkylate in the presence of a catalyst comprising a hydrogenating function and a solid acid constituent, with the catalyst being subjected intermittently to a regeneration step by being contacted with a feed containing a saturated hydrocarbon and hydrogen, said regeneration being carried out at 90% or less of the active cycle of the catalyst, with the active cycle of the catalyst being defined as the time from the start of the feeding of the alkylation agent to the moment when 20% of the alkylation agent leaves the catalyst-containing reactor section without being converted, not counting isomerization inside the molecule. The process according to the invention is especially attractive for the alkylation of isobutane with one or more butenes to form an alkylate with a high RON.

Abstract: A method of converting an HF alkylation process into a solid catalyst alkylation process is disclosed. In this method, an HF alkylation unit having an HF stripper downstream of the HF alkylation reactor is modified to a benzene rectifier. By modifying the HF stripper, this invention not only makes use of the existing HF stripper but also allows the entire downstream product recovery section, which comprises four fractionation columns, to be used in the modified process with only relatively minor modifications. Thus this invention maximizes the use of existing equipment and minimizes the investment necessary to eliminate the use of HF in detergent alkylation.

Abstract: A process for preparing high-octane gasoline components consists in that a feed stock, composed of isobutane and olefins, preferably butylenes, in a molar ratio between 1 and 40, is contacted at temperatures of from about 50 to about 160.degree. C. and at pressures of from about 1 to about 40 atm. with a heterogeneous acid catalyst, whose active component is a metal-complex or metaloxopolymeric compound of the general formula H.sub.k (Me.sup.1); (Me.sup.2).sub.m O.sub.n X.sub.p wherein k=1-6; j=1-3; m=1-5; n=1-10, p=2-10, dispersed in a porous organic or inorganic matrix, followed by the extraction regeneration of the deactivated catalyst with an organic or inorganic solvent.

Abstract: The invention concerns a catalyst comprising a porous organic or inorganic support and at least one active phase comprising at least one acid selected from acids with formula R--SO.sub.3 H, where R is fluorine or an alkyl group or a fluorinated alkyl group, and at least one weakly basic aprotic organic solvent, the support having been impregnated with the active phase, the catalyst being such that it is essentially constituted by particles with an average diameter in the range 0.1 .mu.m to 150 .mu.m, and being such that before impregnation with the active phase, the support has a total pore volume in the range 0.5 cm.sup.3 /g to 6 cm.sup.3 /g. The invention also concerns the use of the catalyst for aliphatic alkylation.

Abstract: Improved isoparaffin-olefin alkylation solid catalyst processes are provided which are characterized by low coke laydown and catalyst deactivation rates and production of valuable branched chain, high octane number alkylates. The processes of the invention involve providing a starting reactant mixture comprising an isoparaffin, an olefin and a co-solvent or diluent (carbon dioxide in molar excess, methane, hydrogen or mixtures thereof), and contacting the reactant mixture with an alkylation catalyst at near-critical or preferably supercritical conditions for the reaction mixture. The carbon dioxide serves as a co-solvent and reduces the critical temperature (T.sub.c) of the reaction mixture, thereby allowing lower reaction temperatures. The isoparaffin and olefin reactants are preferably pretreated to minimize moisture, peroxide and oxygenate impurities therein.

Abstract: A solid state insoluble salt catalyst system for the carbocationic polymerization of olefin monomer in the presence of a polar or non-polar reaction medium, which comprises (a) solid state catalyst component comprising at least one salt of a strong acid and a carbocationically active transition metal selected from Groups III A, IV A, V A and VI A of the Periodic Table of Elements, wherein said salt is insoluble in the reaction medium; and (b) cocatalyst component effective for promoting the carbocationic polymerization.

Abstract: Paraffins or other hydrocarbons are alkylated in a process featuring a reaction zone containing a pool of liquid maintained at its boiling point and containing a suspended solid catalyst, which allows the heat of reaction to vaporize a portion of the liquid phase feed hydrocarbon. The vapor phase withdrawn from the top of the reaction zone is at least partially recycled to the reaction zone either as vapor or liquid. The feed hydrocarbons are introduced to the bottom of the reaction zone as a vapor phase stream, which may contain hydrogen. The catalyst is suspended within the liquid in the reaction zone.

Abstract: A zirconium catalyzed transesterification process for preparing synthetic wax monomers is disclosed. The monomers are useful in a wide range of polymers.

Abstract: The invention concerns the catalytic alkylation of at least one isoparaffin selected from the group formed by isobutane and isopentane in the presence of at least one olefin containing 3 to 6 carbon atoms per molecule, using a catalyst comprising 40% to 99% by weight of an acid selected from acids with formula R--SO.sub.3 H where R is fluorine or an alkyl group or a fluorinated alkyl group, R preferably being F or CF.sub.3, and more preferably CF.sub.3, and 1% to 60% by weight of a solvent selected from the group formed by sulpholane, dimethylsulphoxide and dioxanes, preferably sulpholane.

Abstract: Hydrocarbons are alkylated using slowly moving cylindrical beds of solid catalyst in a process featuring a cooling zone within the reaction zone and a moving bed catalyst regeneration zone. The catalyst passes downward through both zones, which may be stacked upon one another. The reaction zone is operated at liquid-phase conditions, and the catalyst is periodically subjected to a regeneration procedure employing a hydrogen-containing stream. Direct heat exchange within the reaction zone removes the heat of the reaction.

Abstract: Disclosed are various embodiments for alkylating olefins and isoparaffins in the presence of an acid to reduce and/or control acid consumption or maximize and/or control the octane number of the produced alkylate product. One embodiment includes alkylation by controlling the C.sub.3 /C.sub.5 olefin ratio to reduce acid consumption. Another embodiment includes alkylation of C.sub.3 and C.sub.5 olefins in separate alkylation zones to maximize alkylate octane number. Even another embodiment includes propylene alkylation followed by C.sub.4 and/or C.sub.5 olefin alkylation, with the spent propylene acid used in the C.sub.4 and/or C.sub.5 olefin alkylation. Still another embodiment includes alkylation of C.sub.3, C.sub.4 and C.sub.5 olefins in separate alkylation zones, with the spent propylene acid used in the C.sub.4 alkylation, and the spent butylene acid used in the C.sub.5 alkylation. Yet another embodiment includes alkylation by controlling the C.sub.3 /C.sub.

Abstract: Improved acid catalyzed alkylation reactions occur for the addition of a hydrocarbyl reactant to an alkene, by the optimized addition of an oxidizing agent, such as a peroxide, molecular oxygen, ozone, peracid, and one or more of the peroxide, molecular oxygen, ozone, or peracid mixed with at least one material selected from the group consisting of the hydrocarbyl reactant, and the alkene. The hydrocarbyl reactant contains at least one tertiary carbon atom attached to hydrogen, such as isobutane. The alkene is preferably an alkene of at least 2 carbon atoms. Suitable peroxides are found in the group consisting of: tert-butyl peroxyneopentanoate ((CH.sub.3).sub.3 C--O--OCO--C(CH.sub.3).sub.3); acetyl peroxide (CH.sub.3 CO--O--OCOCH.sub.3); di-tert-butyl peroxide ((CH.sub.3).sub.3 C--O--O--C(CH.sub.3).sub.3); hydrogen peroxide (H.sub.2 O.sub.2) and peracids of carboxylic acid having up to 10 carbon atoms, and a general chemical formula C.sub.n H.sub.2n O.sub.3, where n has values in the range 2-10.

Abstract: The use of flow restrictors at the inlet of reactor cooling tubes significantly improves heat transfer and process performance in an acid catalyzed alkylation reaction process. Improved vaporization of the stream is achieved by equalizing the liquid distribution and the ratio of liquid and vapor entering each tube to overcome poor boiling film heat transfer. The invention relocates available pressure drop for equally subdividing the flow entering the heat exchanger into a plurality of heat exchanger inlet streams. Flow restrictors provide pressure drop at the inlets to each tube. This method and apparatus is particularly useful in contactors for the sulfuric acid catalyzed alkylation of olefinic and isoparaffinic hydrocarbons.

Abstract: For recovering acetylene from hydrocarbons, the hydrocarbons are thermally cracked in the presence of CO.sub.2 as a diluent gas. Suitable for thermal cracking for acetylene generation is a ratio, by weight, of CO.sub.2 to hydrocarbon, of between 3:1 and 1:3, and preferably between 2:1 and 1:2. It is preferred for the CO.sub.2 to be mixed with the hydrocarbons before thermal cracking which is thereafter conducted at average reaction temperatures of between 800.degree. and 1200.degree. C., preferably between 900.degree. and 1100.degree. C. An average residence time of between 5 and 500 milliseconds (ms) of the hydrocarbons during thermal cracking has proven to be effective. As the hydrocarbon feedstock for the thermal cracking, basically C.sub.2+ alkanes, especially ethane, propane and/or butane, can be used advantageously. After the cracked gas is cooled, higher alkynes are removed from the cracked gas, then the acetylene is separated preferably by scrubbing with an absorption agent selective for acetylene.

Abstract: A process for converting at least one olefin and at least one isoparaffin to a diesel fuel blending component comprising the steps of contacting the olefin and the isoparaffin with a catalyst comprising an acidic solid comprising a Group IVB metal oxide modified with an oxyanion of a Group VIB metal to provide a diesel fuel. Process conditions can be varied to favor the formation of gasoline, distillate, lube range products or mixtures thereof.

Abstract: The invention concerns a supported catalyst in the form of packing and constructed on an open-pore support material on whose external and internal surfaces a macro-porous ion exchange resin is mechanically and/or chemically affixed.

Abstract: Disclosed is a process for the alkylation of an olefin with an isoparaffin using sulphuric acid as a catalyst. In this process, a finely-dispersed emulsion of isoparaffin and sulphuric acid is prepared first, in a separate emulsion preparation zone. This preparation is carried out by injecting the isoparaffin into the acid through a set of nozzles, thereby allowing the isoparaffin to "scavenge" at high speed through the acid and thus to form an extremely homogeneous emulsion. This makes it possible to achieve proper mixing without need of impellers or other similar mixing devices that usually call for substantial maintenance and operating costs. Then, the emulsion that was so prepared and which forms an already "finished" phase per se, is fed into a reaction zone which is separate from the emulsion preparation zone and in which the olefin is injected preferably at a plurality of points and in directions perpendicular to the emulsion flow.

Abstract: A process for cooling unreacted hydrocarbon substrate that is recycled to an alkylation reactor and for minimizing the concentration of lower boiling hydrocarbons in such recycle.

Abstract: A process for the alkylation of at least one isoparaffin by at least one olefin in the presence of at least one solid acidic catalyst, characterized in that the major portion of the olefin is initially brought into contact with the catalyst in a complexing zone to form an olefin-catalyst complex in the presence of the isoparaffin, and in that the suspension of the complex in the isoparaffin is then sent to at least one alkylation reaction zone.

Abstract: A novel catalyst for alkylating an alkene with an alkane to give an alkylate product has been developed. The catalyst comprises a refractory inorganic oxide on which is dispersed a Group VIII metal, a metal cation and the reaction product of a metal halide and bound surface hydroxyl groups of the refractory inorganic oxide. The catalyst is characterized in that the Group VIII metal is concentrated in an outer layer of the catalyst particle.

Abstract: Gasoline range olefins such as trimethyl pentene are saturated to the corresponding paraffins such as trimethylpentane by hydrogen transfer from lower molecular weight paraffins using a catalyst comprising platinum supported on a large pore borosilicate zeolite which has been partially neutralized by the addition of alkali cations.

Abstract: Hydrocarbon conversion processes, e.g., alkylation, are disclosed and claimed which use as the catalyst novel fluoride containing substituted smectite clays. The clay has the formulaA.sub.x (M.sub.y M'.sub.4-y)(Si.sub.8-x M.sub.t M'.sub.v)O.sub.20 (OH).sub.4-u F.sub.uwhere A is a cation, M and M' are metals having a +3 oxidation state, each selected from the group consisting of aluminum, gallium, iron and chromium, x is the moles of A, y is the moles of M, t and v are the moles of M and M' in the tetrahedral layer and t+v=x and u is the moles of F. The clay composition may be used as is or after pillaring to catalyze hydrocarbon conversion processes such as alkylation.

Abstract: The present invention concerns a catalyst comprising a porous organic or mineral support, preferably silica, and an acidic phase containing B(OSO.sub.2 CF.sub.3).sub.3 and at least one acid selected from the group formed by sulphuric acid (H.sub.2 SO.sub.4) and trifluoromethane sulphonic acid (CF.sub.3 SO.sub.3 H), the support having been impregnated by said acidic phase, said catalyst being such that it is constituted essentially by particles with an average diameter of between 0.1 and 150 .mu.m, such that the support, prior to its impregnation with said acidic phase, has a total pore volume of between 0.5 and 6 cm.sup.3 per gram and said catalyst being characterized in that said acidic phase contains:between 0.1 and 70% by weight of B(OSO.sub.2 CF.sub.3).sub.3 ;between 0 and 90% by weight of H.sub.2 SO.sub.4 ;between 0 and 90% by weight of CF.sub.3 SO.sub.3 H.

Abstract: An improved process for alkylation of isoparaffins with olefins to yield a product which includes a high proportion of highly branched alkylates for blending into gasolines is disclosed. The catalyst comprises a large pore zeolite such as USY which may be partially or fully exchanged with a cation or cations selected from the rare-earth metals.

Abstract: A hydrocarbon stream is cracked to produce a hot gaseous stream which is compressed and cooled to condense almost all of the hydrocarbons contained in the stream. A noncondensed stream remaining after the condensation step, comprised predominantly of hydrogen and C.sub.1 to C.sub.3 hydrocarbons, is subjected to pressure swing adsorption or temperature swing adsorption at an adsorption temperature of about 0.degree. to about 250.degree. C. in a bed of adsorbent which selectively adsorbs ethene and propene, thereby adsorbing substantially all of the ethene and propene from the gas stream. The ethene and/or propene is recovered upon bed regeneration. Higher alkenes are separated from alkanes by various methods.

Abstract: An etherification process combines an alkylation zone with a skeletal olefin isomerization zone in an arrangement that rejects isoalkanes and normal alkanes with only minor loss of valuable olefin isomers. The invention also provides a balanced feed to an alkylation zone for the production of high octane gasoline components. This invention can be used to provide ethers and gasoline boiling range alkylates from either C.sub.4 or C.sub.5 feedstocks. The invention fully utilizes all olefin isomers improve octane and vapor pressure charactristics of the gasoline components.

Abstract: This invention relates to catalysts for alkylation reactions and their preparation. More particularly, the invention relates to an alkylation process using a hydrogen fluoride-containing alkylation catalyst, which catalyst may be safely and easily handled, transported, and stored.

Abstract: Method of producing alkylates in which an isoparaffin, olefin, a diffusing agent and a solid, acid catalyst are combined to form a three phase reaction mixture; a hydrocarbon phase containing primarily isoparaffin, a diffusing agent phase containing the diffusing agent, olefin and diffuse isoparaffin and a solid, acid catalyst phase, the diffusing agent being a polar solvent in which the olefin and aromatics are soluble.

Abstract: A method and apparatus for indirectly heating a mixed phase stream by contact with a boiling surface located on the inside of the plurality of heat exchange tubes. Improved vaporization of the stream is achieved by equalizing the liquid distribution and the ratio of liquid and vapor entering each tube to overcome poor boiling film heat transfer. The invention uses a means for subdividing the flow entering the heat exchanger into a plurality of streams with each of the divided streams discharging directly into a heat exchange tube. The means for dividing the stream can include baffle arrangements or plugs providing pressure drop at the inlets to the tubes. This method and apparatus is particularly useful in contactors for the sulfuric acid catalyzed alkylation of hydrocarbons.

Abstract: A process for converting at least one olefin and at least one isoparaffin to a diesel fuel blending component comprising the steps of contacting the olefin and the isoparaffin with a catalyst comprising MCM-58 to provide a diesel fuel. Process conditions can be varied to favor the formation of gasoline, distillate, lube range products or mixtures thereof.

Abstract: Disclosed is an alkylation process in which C.sub.3 to C.sub.5 olefins are reacted with an isoparaffin mixture of isobutane and isopentane in the presence of a catalyst. Varying the amount of isopentane present in the mixture can control and/or eliminate the amount of isopentane produced in the alkylation reaction. The disclosed reaction has an improved alkylation yield, and also produces an alkylate having a lowered Reid Vapor Pressure and results in lowered olefin content for reformulated gasoline.

Abstract: A process for the alkylation of aliphatic hydrocarbons with olefins catalyzed by a silica-based material, characterised in that the surface Si--OH groups of said silica are esterified with a fluoroalkylsulphonic acid of formula CF.sub.3 (CF.sub.2).sub.n SO.sub.3 H, where n is a whole number between 0 and 11, said material having a Hammett acidity Ho.ltoreq.-11.4.

Abstract: This invention relates to use of synthetic layered material MCM-56 as a sorbent and as a catalyst component in catalytic conversion of organic compounds. Examples of sorbent use include rapid sorption of hydrocarbons and separating at least one hydrocarbon component from a mixture of hydrocarbon components having differential sorption characteristics with respect to MCM-56. Examples of catalytic use include acid catalyzed reactions, such as cracking, aromatic compound alkylation, and isoalkane alkylation.

Abstract: This invention relates to use of synthetic porous crystalline MCM-58 as a catalyst component in catalytic conversion of organic compounds.

Abstract: Hydrocarbons such as isobutane and benzenes are alkylated using a solid catalyst in a process which simulates the cocurrent movement of the catalyst bed versus the reactants. This has been found to greatly reduce the rate of catalyst deactivation compared to simulated countercurrent flow. The process may be performed using five or more beds of catalyst, with two undergoing regeneration at any one time. One bed is subjected to a short term liquid-phase regeneration while the other is subjected to long term vapor-phase regeneration. The catalyst preferably contains a metal hydrogenation function effective to selectively hydrogenate C.sub.6 -plus materials trapped on the used catalyst.

Abstract: There are provided a catalyst, a method for making this catalyst, and a process for using this catalyst in the alkylation of an isoparaffin with an olefin to provide an alkylate. The catalyst may be made from an as-synthesized material which, upon calcination, is capable of generating zeolites designated MCM-22. The as-synthesized material is then combined with a binder material, such as alumina, by an extrusion process. The uncalcined bound material may then be ammonium exchanged, followed by a calcination treatment. The as-synthesized material may also be swollen with a suitable swelling agent, such as a cetyltrimethylammonium compound, prior to the binding process.

Abstract: The invention provides a process for alkylating an olefin with an isoparaffin comprising contacting an olefin-containing feed in the presence of a thermally stable composition comprising a non-swellable layered chalcogenide of an element having an atomic number of 4, 5, 12 to 15, 20 to 33, 38 to 51, 56 to 83 and greater than 90, inclusive, said layered metal chalcogenide comprising an interspathic polymeric chalcogenide of an element selected from Groups IB, IIB, IIIA, IIIB, IVA, IVB, VA, VB, VIA, VIIA, and VIIIA of the Periodic Table.

Abstract: Alkyl alcohols are added to the effluent from hydrocarbon reactions using phosphoric acid based catalysts to prevent corrosion in metallic pipes and vessels downstream of the reactor. The alcohol is believed to react with phosphoric acid present in the hydrocarbon stream to produce a mixture of phosphate esters which act as corrosion filmers to prevent corrosion. The high boiling points of the phosphate esters allow for the separation of useful product from the phosphate ester corrosion inhibitors.

Abstract: The disproportionation of isopentane(s) in the presence of hydrogen fluoride as the catalyst is improved by adding at least one C.sub.6 -C.sub.18 (preferably C.sub.6 -C.sub.8) isoalkane to the isopentane feed.

Abstract: A process for catalytic cracking and C3/C4 olefin alkylation with phosphorus stabilized faujasite catalyst is disclosed. Catalytic cracking produces C3 and C4 olefins, which are alkylated using phosphorus stabilized and water activated cracking catalyst. Spent alkylation catalyst may be discharged into the FCC unit.

Abstract: The transfer of hydrogen from a paraffin to an olefin is provided. This reaction may be carried out in the presence of a catalyst, such as MCM-36. Especially when the paraffin reactant is an isoparaffin, the olefin produced from the reacted isoparaffin may react with unreacted isoparaffin to also produce an alkylate product.

Abstract: Hydrocarbon conversion processes are disclosed which are catalyzed by novel pillared clay compositions. The clay contains pillars which are at least partially fluorided. These pillars are metal fluoro hydroxy cations where the metal can be Al, Zr, Si/Al, Ti or Cr. The clays which can be pillared with these pillars are the smectite clays which include hectorite and beidellite along with synthetically prepared smectite clays. These clays are prepared by pillaring the clay, followed by calcination and then treatment with a fluoride salt such as ammonium bifluoride.

Abstract: Ethers suitable for use as high octane oxygenate additives for motor fuels or other compounds such as alcohols or alkylates are produced in a catalytic distillation process wherein a C.sub.4 -plus isoolefin(s) and an alcohol present in the catalytic distillation zone overhead stream are charged to a packed liquid-phase reaction zone containing an etherification catalyst before being recycled to the overall catalytic distillation zone. The effluent of the liquid-phase reactor is returned to the catalytic distillation zone at a point above the catalyst in this zone. The feed(s) to the process passes directly into the catalytic distillation zone, without passage through a prereactor, at a point located below a majority of catalyst bed in the catalytic distillation zone.

Abstract: A method of minimizing or controlling the production of synthetic isopentane during the catalyzed alkylation reaction of amylenes and isoparaffins by providing a concentration of isopentane in the alkylation reactor feed material.

Abstract: Synthetic lubricant base stocks having improved properties are disclosed. The base stocks may be obtained by a two-step process, comprising the steps of (1) co-reacting vinylcyclohexene and long-chain linear olefin with a free-radical initiator; and (2) further reacting the mixture resulting from step (1) in the presence of an acidic montmorillonite clay.