Abstract: The present disclosure relates to a method and an apparatus for self-heat-extracting flash evaporation of a sulfuric acid alkylation reaction product. There is provided a method for self-heat-extracting flash evaporation of a sulfuric acid alkylation reaction product. One step is to coalesce and vaporize a preliminarily distributed sulfuric acid alkylation reaction product to cause preliminary vaporization of a hydrocarbon therein, thereby taking heat away and preliminarily separating the hydrocarbon from sulfuric acid. Another step is to subject the preliminarily separated alkylation reaction to reinforced separation, where the hydrocarbon is further vaporized to take heat away and further separate the hydrocarbon from the sulfuric acid. There is also provided an apparatus for self-heat-extracting flash evaporation of a sulfuric acid alkylation reaction product.

Abstract: One exemplary embodiment can be a method of modifying an alkylation unit to increase capacity. The method may include combining a first alkylation zone with a second alkylation zone. Generally, the first alkylation zone includes a first settler having a height and a width. Typically, the width is greater than the height. In addition, the second alkylation zone may have a second settler having a height and a width. Usually, the height is greater than the width.

Abstract: The present invention provides a process for preparing an alkylate, comprising: contacting in a reaction zone a hydrocarbon mixture comprising at least isoparaffin and an olefin with an acidic ionic liquid catalyst under alkylation conditions to obtain an alkylate; withdrawing an alkylate-comprising effluent from the reaction zone; separating at least part of the alkylate-comprising effluent into an hydrocarbon-rich phase and an ionic liquid catalyst-rich phase; fractionating part of the hydrocarbon-rich phase into at least an alkylate-comprising product and a isoparaffin-comprising stream; mixing another part of the hydrocarbon-rich phase with an olefin-comprising stream to form the hydrocarbon mixture; and providing the hydrocarbon mixture to the reaction zone.

Abstract: An improved process for removing polymeric by-product (ASO) from the HF alkylation acid in an HF alkylation unit used for the production of gasoline boiling range alkylate product by olefin/iso-paraffin alkylation, comprises fractionating a portion of the circulating HF alkylation acid inventory of the unit with a portion of hot alkylate product in a fractionation zone to from an overhead product comprising HF alkylation acid and water and a bottoms fraction comprising the polymeric by-product and alkylate. The bottoms fraction is sent to the isoparaffin stripper of the unit to remove trace HF alkylation acid as overhead and form a product stream of hot alkylate as a bottoms fraction.

Abstract: One exemplary embodiment can be a method of modifying an alkylation unit to increase capacity. The method may include combining a first alkylation zone with a second alkylation zone. Generally, the first alkylation zone includes a first settler having a height and a width. Typically, the width is greater than the height. In addition, the second alkylation zone may have a second settler having a height and a width. Usually, the height is greater than the width.

Abstract: A process for separating an ionic liquid from hydrocarbons employs a coalescer material having a stronger affinity for the ionic liquid than the hydrocarbons. The coalescer material can be a high surface area material having a large amount of contact area to which ionic liquid droplets dispersed in the hydrocarbons may adhere. The process includes feeding a mixture comprising ionic liquid droplets dispersed in hydrocarbons to a coalescer comprising the coalescer material. The process further includes a capture step involving adhering at least a portion of the ionic liquid droplets to the coalescer material to provide captured droplets and a coalescing step involving coalescing captured droplets into coalesced droplets. After the capture and coalescence steps, the coalesced droplets are allowed to fall from the coalescer material to separate the ionic liquid from the hydrocarbons and provide a hydrocarbon effluent.

Abstract: A process for the sulfuric acid catalyzed alkylation of C3-C5 olefins with isobutane is disclosed wherein the requisite mixing is accomplished by the use of eductors within the reactor. In addition the alkylate product is subjected to primary and secondary coalescers for removal of entrained sulfuric acid. The vaporized unreacted C4's are recovered as liquid by absorption and desorption in an absorber oil.

Abstract: A liquid acid process is disclosed in which a hydrocarbon component containing an olefin, an olefin precursor or mixture and an isoalkane and a liquid acid catalyst is fed to a downflow reaction zone containing a disperser, under conditions to induce pulse flow at or near the outlet to react the isoalkane and olefin to produce a reaction product and feeding the reaction product to a vaporization zone containing a disperser under conditions to induce pulse flow at or near the outlet of the vaporization zone. A pressure drop across the disperser in the vaporization zone causes partial vaporization of the hydrocarbon which quench es the heat reaction and cooling the unvaporized portion of said reaction product, which is recovered and allowed to separate into an acid phase and hydrocarbon phase containing the alkylate. The acid catalyst and hydrocarbons may be fractally fed to the reaction zone.

Abstract: An improvement in the alkylation of olefins with isoalkanes in the presence of sulfuric acid wherein the sulfuric acid is removed from the product by a mechanical coalescer means prior to fractionation. No water wash or caustic treatment is required. Any sulfonates or sulfonic esters are removed by hydrodesulfurization or decomposition catalyst in a separate reactor or in either the deisobutanizer (DIB) or debutanizer (DB) column.

Abstract: A process for the removal of organic sulfur compounds, primarily oxygenated organic compounds, such as sulfates and sulfonic esters from a hydrocarbon liquid is disclosed which comprises contacting the hydrocarbon liquid with a coalescer comprising a mesh material which has been wetted by sulfuric acid. The hydrocarbon liquid may be the product from a sulfuric acid catalyzed alkylation process and contain sufficient sulfuric acid to remove the sulfates and sulfonic esters. Sulfuric acid may be added to the coalescer vessel counter current to the hydrocarbon liquid to improve the efficiency of the contacting and removal.

Abstract: An improvement in the alkylation of olefins with isoalkanes in the presence of sulfuric acid wherein the sulfuric acid is removed from the product by a mechanical coalescer means prior to fractionation. No water wash or caustic treatment is required. Any sulfonates or sulfonic esters are removed by hydrodesulfurization or decomposition catalyst in a separate reactor or in either the deisobutanizer (DIB) or debutanizer (DB) column.

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

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: 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: A process for alkylating isoparaffin hydrocarbon with olefin hydrocarbon in the presence of a sulfuric acid alkylation catalyst wherein hydrocarbon effluent from an alkylation reaction zone is treated in the liquid phase with bauxite or similar adsorbent for removing acid alkyl sulfates, neutral alkyl sulfate and other corrosive species, wherein treated alkylation effluent is flashed at reduced pressure in indirect heat exchange contact with alkylation reaction mixture in said alkylation reaction zone for refrigerating said reaction mixture, and wherein flashed vapors and unflashed liquid are fractionated for recovery of isoparaffin recycle and alkylated hydrocarbon product.