Process for preparing high-octane gasoline components, and a cat

Details Process for preparing high-octane gasoline components, and a cat Process for preparing high-octane gasoline components, and a cat

1997-02-13

1999-07-20

Caldarola, Glenn A.

Chemistry of hydrocarbon compounds

Saturated compound synthesis

By condensation of a paraffin molecule with an olefin-acting...

585709, 585730, 585731, 585732, 502208, 502216, 502217, 502224, 502226, 502227, 502231, C07C 258, B01J 2714, B01J 27053

Patent

active

059258012

DESCRIPTION:

BRIEF SUMMARY
TECHNICAL FIELD

The present invention relates to catalytic chemistry, more particularly, to processes for preparing high-octane gasoline components in the oil refining and petrochemical industries.
The present invention relates to an alkylation process which is based on reaction of isoparaffins with olefins to form isoparaffin hydrocarbons having a higher molecular weight.


PRIOR ART

Alkylation of isobutane with butylenes is traditionally used in industry to form a mixture of isoparaffin hydrocarbons, a so-called alkylate with an octane number of from 82 to 92 MM. Typical catalysts of industrial alkylation processes are sulfuric acid or fluorinated derivatives thereof (EP 0 433 954 A1) and hydrofluoric acid. Artificial cold is used a process involving sulfuric acid to maintain low reaction temperatures at 3 to 8.degree. C., at acid concentrations from about 88 to about 94% by weight by continuously adding a fresh acid to the reaction system and removing the spent one.
Hydrofluoric and sulfuric acid alkylation plants are being used in the world. However, hydrofluoric acid is more dangerous than sulfuric acid, that is why some countries refuse the construction of plants using this catalyst. A choice between these processes depends on an amount of operating costs and/or safety in operations.
A hydrofluoric acid alkylation process usually uses 0.5 to 0.8 kg of acid per ton of alkylate, whereas a sulfuric acid alkylation process uses a much greater amount of acid, namely 60-100 kg per ton of alkylate.
High acid consumption necessitates the use of acid regeneration plants which should be used in combination with an alkylation plant.
The world annual production of alkylate amounts to 51 mln. tons and is expected to grow by 5 times before the year of 2000 due to more rigid ecological norms for motor gasoline with respect to the content of tetraethyl lead, benzene and a total amount of aromatic hydrocarbons.
The widely known industrial alkylation technologies are disadvantageous in:
high toxicity and corrosive aggression of sulfuric and hydrofluoric acids,
problems of utilization of the spent acid,
necessity for recovering a catalyst from a product mixture and subsequently making it alkaline, these factors cause a high ecological danger and insufficient economic efficiency from the industrial point of view.
In solving these problems, the last decade has witnessed intensive investigations on developing solid acid catalysts and carrying out an alkylating process in a gas (raw material)--solid (catalyst) or liquid (raw material)--solid (catalyst) heterogeneous system. This makes the process ecologically safer.
It is advisable to single out several approaches to the development of solid alkylation catalysts.
The first approach suggests improving an alkylation catalyst by applying (heterogenizing) an (traditional) active component that has been known for a long time to inorganic supports. The peculiar feature of this approach is using, as active components, both proton-containing acids (H.sub.2 SO.sub.4 ; HF; CF.sub.3 SO.sub.3 H) and Lewis acids (AlCl.sub.3, BF.sub.3, BCl.sub.3, SbF.sub.5, and the like). The nature of patented supports is much more variegated. Two large groups of supports may be singled out.
1. Non-zeolite ones represented by oxides or a mixture of Group III or IV metal oxides modified with the additives of elements of from Groups I to VIII, more often than not with the oxides of rare-earth elements.
2. Wide-pore zeolites of X, Y, ZSM, or Beta, etc. types. This approach is illustrated by a number of the patented catalytic systems and processes based thereon.
In U.S. Pat. No. 2,804,491 the catalyst is represented by an alumina gel stabilized with silica and containing boron trifluoride. Solid inorganic Group IV metal oxides modified with sulfuric acid, represent the subjects of the inventions in Japanese Patents No. 51-63386; No. 57-3650; No. 59-40056, No. 59-6181 and also in U.S. Pat. No. No. 3,251,902; No. 3,655,813; No. 4,377,721 for a process for alkylating isoparaffin hydrocarbons with olefins.
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