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 transfer of hydrogen from a paraffin to an olefin is carried out in the presence of, as catalyst, 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: This invention is a process for the regeneration of solid acidic hydrocarbon conversion catalysts, but particularly certain transition aluminas and zeolites promoted with Lewis acids (preferably BF.sub.3) which have been used in the alkylation of isoparaffins with olefins. The process involves the removal of some portion of the reaction product residue adhering to the solid catalyst by contact with a solvent to partially recover the catalyst's initial activity.

Abstract: A process for alkylating an isoparaffin comprising reacting an isoparaffin with a monoolefin in the presence of a salt of a heteropoly-acid as a solid catalyst. The salt of the heteropoly-acid is a compound obtained by substituting a cation for a hydrogen ion of a heteropoly-acid of the formula H.sub.k.X.Y.sub.m.Z.sub.12-m.O.sub.40.nH.sub.2 O, wherein X is a hetero-atom selected from the group consisting of P, Si, Ge and As, each of Y and Z is a polyatom selected from the group consisting of W, Mo and V, k is 3 or 4, m is 0 or 1, and n is a positive number.

Abstract: A process is disclosed for regenerating a spent liquid acid catalyst comprising the steps of:(a) providing a spent liquid acid catalyst comprising HF, sulfolane, and conjunct polymeric byproducts formed during the HF-catalyzed reaction of isoparaffin and olefin to form isoparafinnic alkylate;(b) providing a finely divided solid sorbent, wherein said solid sorbent preferentially and reversibly sorbs said conjunct polymeric byproducts from a mixture containing HF, sulfolane;(c) mixing said spent liquid acid catalyst of step (a) with said solid sorbent of step (b) by charging said spent liquid acid catalyst to the driving fluid inlet of an eductor and drawing a stream containing said solid sorbent into said eductor;(d) holding said mixture of step (c) in contact for time sufficient for said solid sorbent to preferentially sorb at least a portion of said conjunct polymeric byproducts from said spent liquid acid catalyst to produce a conjunct polymer-enriched sorbent and to regenerate said liquid acid catalyst; an

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 a blending component of gasoline motor fuel. The novel catalyst comprises a mixture of a Lewis acid, a strong Bronsted acid, and a predominant amount of a weaker acid. The novel alkylation catalyst is utilized in a novel process for alkylating olefin hydrocarbons with isoparaffin hydrocarbons. Specifically the novel catalyst comprises antimony pentaflouride, trifluoromethanesulfonic acid and a predominant amount of methanesulfonic acid.

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: In one embodiment of this invention, a process for alkylating C.sub.3 -C.sub.6 alkanes (paraffins) with C.sub.3 -C.sub.6 alkenes (monoolefins) employs a catalyst composition which has been prepared by heating a mixture consisting essentially of aluminum chloride, at least one metal sulfate (CuSO.sub.4, FeSO.sub.4, NiSO.sub.4, MgSO.sub.4, CaSO.sub.4 or combinations thereof), at least one inorganic refractory support material (alumina, silica, silica-alumina, aluminum phosphate, aluminum phosphate/oxide or combinations thereof), and at least one chlorinated hydrocarbon (preferably carbon tetrachloride). In another embodiment of this invention, a process for alkylating C.sub.3 -C.sub.6 alkanes with C.sub.3 -C.sub.6 alkenes employs a catalyst which has been prepared by heating a mixture consisting essentially of aluminum chloride, aluminum phosphate, silica, and at least one chlorinated hydrocarbon (preferably carbon tetrachloride).

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: An integrated process for converting C.sub.4 /C.sub.5 hydrocarbons contained in a gasoline feedstock to more valuable motor fuel components includes various distillation steps, a hydroisomerization step, an etherification step (for producing t-amyl methyl ether), and an alkylation step. In a preferred embodiment, this process additionally includes a dehydrogenation step and a step of using formed debydrogenated hydrocarbons in the etherification step.

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

Abstract: New catalyst compositions comprise sulfated and calcined mixtures of (1) a support comprising an oxide or hydroxide of a Group IV-A element, (2) an oxide or hydroxide of a Group VI, VII or VIII metal, (3) an oxide or hydroxide of a Group I-B, II-B, III-A, III-B, IV-B, V-A or VI-A metal and (4) a metal of the Lanthanide Series of the Periodic Table. A process for alkylation of acyclic saturated compounds with acyclic unsaturated compounds utilizing such catalyst compositions.

Abstract: New catalyst compositions comprise sulfated and calcined mixtures of (1) a support comprising an oxide or hydroxide of a Group IV-A element, (2) an oxide or hydroxide of molybdenum, and (3) an oxide or hydroxide of a Group I-B, II-B, III-A, III-B, IV-B, V-A or VI-A metal other than molybdenum or a metal of the Lanthanide Series of the Periodic Table. A process for alkylation of acyclic saturated compounds with acyclic unsaturated compounds utilizing such catalyst compositions.

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: 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: The invention provides a catalyst complex for promoting alkylation of an isoparaffin with an olefin, said catalyst complex comprising the reaction product of Lewis acid and at least one fluorophosphoric acid; and, additionally, excess Lewis acid in concentration of from about 10 ppm (weight) to about 10000 ppm by weight of the total isoparaffin and olefin feed. The invention further provides a process for the alkylation of an isoparaffin with an olefin by contacting a mixture of isoparaffin and olefin with the catalyst complex of the invention.

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: This invention deals with a hydrocarbon conversion process using a crystalline oxysulfide composition. The crystalline oxysulfide composition has a three-dimensional microporous framework structure of at least MO.sub.2, MS.sub.2, and MOS tetrahedral units, having an intracrystalline pore system and an empirical formula expressed in molar ratios:(M.sub.s Al.sub.t P.sub.u Si.sub.v)S.sub.w O.sub.2-wwhere M is at least one metal selected from the group consisting of metals which: 1) can be incorporated into the framework structure of a microporous molecular sieve and 2) form hydrolytically stable sulfides; s, t, u, v and w are the mole fractions of M, Al, P, Si and S respectively. The values of s, t, u and v are chosen such that when t is greater than zero u is greater than zero, s+t+u+v=1 and when s=1, M is only a combination of gallium and germanium.

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: Compositions containing sulfuric acid and one or more of certain chalcogen-containing compounds in which the chalcogen compound/H.sub.2 SO.sub.4 molar ratio is below 2 contain the mono-adduct of sulfuric acid which is catalytically active for promoting organic chemical reactions. Suitable chalcogen-containing compounds have the empirical formula ##STR1## wherein X is a chalcogen, each of R.sub.1 and R.sub.2 is independently selected from hydrogen, NR.sub.3 R.sub.4, and NR.sub.5, at least one of R.sub.1 and R.sub.2 is other than hydrogen, each of R.sub.3 and R.sub.4 is hydrogen or a monovalent organic radical, and R.sub.5 is a divalent organic radical. Such compositions are useful for catalyzing organic reactions such as oxidation, oxidative addition, reduction, reductive addition, esterification, transesterification, hydrogenation, isomerication (including racemization of optical isomers), alkylation, polymerization, demetallization of organometallics, nitration, Friedel-Crafts reactions, and hydrolysis.

Abstract: A process is described in which methane is reacted with acetylene in the presence of a solid acid catalyst containing fluoride to produce isobutene in high yields. The process may take place at room temperature or lower and atmospheric pressure. The conversion of acetylene typically approaches 100% and the methane conversion has been found to surpass stoichiometric requirements.

Abstract: The invention relates to a novel process for the synthesis of zeolites of the ferrisilicate type called ferrizeosilites, to the products obtained by this process as well as their uses. Ferrizeosilite according to the invention is characterized by (a) a chemical formula close to the following:M.sub.2/n O, Fe.sub.2 O.sub.3, x SiO.sub.2whereM represents a proton and/or a metal cationn is the valence of said cationx is a number between 40 and 1000(b) an x-ray diffraction diagram, and (c) a fluorine content between about 0.01% and 16% by weight. Uses are in processes for the conversion of methanol into hydrocarbons, alkylation of toluene with methanol and catalytic cracking of hydrocarbons.

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: A process control technique 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. The oligomerization stage effluent is fractionated to provide distillate and gasoline product and a C.sub.3 -C.sub.4 intermediate stream containing isobutane and unconverted propene and butylene. The C.sub.3 -C.sub.4 intermediate stream is combined under control 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.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: 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: Normal butane withdrawn from the main fractionator in an acid alkylation process is recycled to the main fractionator as required to insure that the actual alkylate to normal butane ratio in the alkylate product withdrawn from the main fractionator does not go below a desired ratio. Maintenance of the actual ratio at or above the desired ratio substantially minimizes the concentration of isobutane in the alkylate product stream.

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: 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 method and apparatus for high volume distillation of impure liquid, particularly of binary mixtures of relatively low boiling organic substances and water, comprises fractionally distilling the impure liquid to form a vapor of a low boiling organic substance; compressing the vapor; passing at least a portion of the compressed vapor through a vapor composition adjustment zone wherein the organic substance may catalytically or otherwise react or merely stabilize following compression; compressing the vapor exiting the adjustment zone to form a recompressed vapor; cooling the recompressed vapor in heat transfer relation with the impure liquid whereby the vapor at least partially condenses, transferring sufficient heat to the impure liquid for evaporating the liquid and to form the aforementioned low boiling organic vapor; and collecting the condensed low boiling organic vapor.

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: 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 stream comprising isobutylene and n-butenes is processed to effect dimerization of the isobutylene, and the resulting isobutylene dimer is fed to an alkylation step.

Abstract: Utilization of isoparaffin is maximized in an alkylation of isoparaffin with olefin by variously detecting and/or measuring change in amount of hydrocarbon effluent, the alkylation zone and supplying a sufficient amount of olefin to said alkylation zone to keep the amount of hydrocarbon effluent said alkylation zone substantially constant, in one embodiment sensing the level of hydrocarbon in a settling zone in which alkylation zone effluent is settled, said level being representative of the amount of hydrocarbon being formed, and increasing the amount of olefin when effluent the alkylation zone is increasing, and vice versa.

Abstract: A process for producing high octane DIP (2,3-dimethylbutane) from mixed C.sub.4 olefins comprising the steps of subjecting the mixed C.sub.4 olefines to double bond isomerization, skeletal isomerization, olefin disproportionation, olefin hydrogenation and fractionation to yield DIP.