Exelus, Inc.

Exclus, Inc.

Kelly Ann Coley

Mitrajit Mukherjee

Eric Daniel Gauthier

George D Suciu

John Young

James P Nehlsen

John F Young

James Nehlsen

Improved alkylation catalysts, alkylation methods, and methods of making alkylation catalysts are described. The alkylation method comprises reaction over a solid acid, zeolite-based catalyst and can be conducted for relatively long periods at steady state conditions. The alkylation catalyst comprises a crystalline zeolite structure, a Si/Al molar ratio of 20 or less, less than 0.5 weight percent alkali metals, and further having a characteristic catalyst life property. Some catalysts may contain rare earth elements in the range of 10 to 35 wt %. One method of making a catalyst includes a calcination step following exchange of the rare earth element(s) conducted at a temperature of at least 575° C. to stabilize the resulting structure followed by an deammoniation treatment. An improved method of deammoniation uses low temperature oxidation.

Catalyzed alkylation, alkylation catalysts, and methods of making alkylation catalysts

Improved alkylation catalysts, alkylation methods, and methods of making alkylation catalysts are described. The alkylation method comprises reaction over a solid acid, zeolite-based catalyst and can be conducted for relatively long periods at steady state conditions. The alkylation catalyst comprises a crystalline zeolite structure, a Si/Al molar ratio of 20 or less, less than 0.5 weight percent alkali metals, and further having a characteristic catalyst life property. Some catalysts may contain rare earth elements in the range of 10 to 35 wt %. One method of making a catalyst includes a calcination step following exchange of the rare earth element(s) conducted at a temperature of at least 575&#xb0; C. to stabilize the resulting structure followed by an deammoniation treatment. An improved method of deammoniation uses low temperature oxidation.

A method of producing a high octane alkylate from ethylene and isobutane by reacting ethylene and isobutane under catalytic conversion conditions. The ethylene and isobutane are contacted with a first catalytic material comprising a dimerization catalyst (i.e, for dimerizing ethylene) and a second catalytic material comprising an alkylation catalyst. The first and second catalytic materials are separate and distinct from each other. A high octane alkylate is recovered as a result of reacting the ethylene and isobutane in the presence of the first and second catalytic materials.

Production of a high octane alkylate from ethylene and isobutene

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Warren, NJ, United States of America

Kelly Ann Coley