Catalytic Distillation Technologies

William M Cross

Lawrence A Smith, Jr

Lawrence A Smith

Abraham P Gelbein

Gary G Podrebarac

Mitchell E Loescher

Christopher C Boyer

Arvids Judzis, Jr

A process for the dimerization of isoolefins, including: contacting an isoolefin with a solid catalyst composition passivated with at least one of an ether, an alcohol, and water; wherein the solid catalyst composition comprises at least one of a solid phosphoric acid catalyst and a resin of a macroporous matrix of polyvinyl aromatic compound crosslinked with a divinyl compound and having thereon from about 3 to 5 milli equivalents of sulfonic acid groups per gram of dry resin; and wherein at least 50% to less than 100% of acid groups in the solid catalyst composition are neutralized with a metal of Al, Fe, Zn, Cu, Ni, or mixtures thereof. The catalyst may be metalized prior to placement in a reactor or may be metalized in situ.

Selectivated isoolefin dimerization using metalized resins

A process for producing an alkylate having a low Reid vapor pressure, the process including: contacting a C-containing hydrocarbon stream with a mixture of isopentane and isobutane in the presence of an acid catalyst in an alkylation reactor to form a dilute alkylate product, wherein the C-containing hydrocarbon stream includes at least one of oligomers of Cto Colefins and a dilute alkylate produced by contacting an isoparaffin with at least one of Cto Colefins and oligomers of Cto Colefins; fractionating the dilute alkylate product to form an isobutane-rich fraction, a n-butane-rich fraction, a fraction containing isopentane, and an alkylate product having a Reid vapor pressure less than 0.35 bar (5 psi); recycling at least a portion of the fraction containing isopentane to the alkylation reactor.

Gasoline alkylate RVP control

A process for treating an alkylation feedstock comprising olefins, n-alkanes, iso-alkanes, and impurities including one or more of butadiene, oxygenates, nitrogen-containing compounds, and sulfur-containing compounds, the process including: contacting an alkylation feedstock containing at least one of oxygenates and nitrogen-containing compounds with water to produce a hydrocarbon fraction having a reduced concentration of the at least one of oxygenates and nitrogen-containing compounds and an aqueous fraction comprising at least a portion of the at least one of oxygenates and nitrogen-containing compounds; separating water from the hydrocarbon fraction having a reduced concentration to produce a hydrocarbon fraction having a reduced water content; contacting the hydrocarbon fraction having a reduced water content with an oligomerization catalyst in a first oligomerization reaction zone under oligomerization conditions to react at least a portion of the olefins to form a reactor effluent comprising olefin oligomers; and feeding at least a portion of the reactor effluent to an alkylation unit.

Preparation of alkylation feed

A process for the regeneration of spent sulfuric acid including contacting spent sulfuric acid containing acid soluble oils (ASO) with sulfur dioxide to extract at least a portion of the ASO from the spent sulfuric acid into the sulfur dioxide. The sulfuric acid phase having a reduced ASO content and a sulfur dioxide phase containing at least a portion of the ASO may be recovered. The resulting sulfuric acid and sulfur dioxide phases may be further separated to recover ASO, sulfur dioxide, and sulfuric acid.

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A process for alkylation of propylene, the process including: contacting a stream comprising propylene and propane with sulfuric acid in a first reaction zone under conditions to form propylene sulfate esters; contacting the propylene sulfate esters with isoparaffin and sulfuric acid in an alkylation reaction zone under conditions to react the propylene sulfate esters and the isoparaffin to form a reactor effluent comprising an acid phase and a hydrocarbon phase comprising unreacted isoparaffin and alkylate product; separating the hydrocarbon phase from the sulfuric acid; separating the hydrocarbon phase to form a fraction comprising unreacted isoparaffin and a fraction comprising the alkylate product.

Process for the alkylation of isobutane with dilute propylene

A process for treating an alkylation feedstock comprising olefins, n-alkanes, and iso-alkanes, the process including: contacting at least a portion of the alkylation feedstock with sulfuric acid in a reaction zone under conditions to form sulfate esters of the olefins; separating the n-alkanes and the iso-alkanes from the sulfuric acid and the sulfate esters; recovering the n-alkanes and the iso-alkanes in a first product stream; and recovering the sulfate esters in a second product stream; wherein the sulfuric acid has a strength titrating as below 75 weight percent HSO/water mixtures.

A process for the removal of aromatic compounds from an olefin feed to a paraffin alkylation is disclosed. The process may include feeding a olefin and aromatic containing hydrocarbon stream and a dilute alkylate product stream comprising alkylate product and unreacted material from the paraffin alkylation to a distillation zone and removing the unreacted material as overheads and removing a more concentrated alkylate product stream and a portion of the aromatic compounds as bottoms resulting in an improved alkylation process.

Treatment of olefin feed to paraffin alkylation

A process for the alkylation of isobutane is disclosed wherein isobutane is fed to two separate alkylation systems. The effluent from the first alkylation system is fed to an interim debutanizer where the C's are separated from the alkylate product. The overhead Cproduct is then fed to the second alkylation system to provide the isobutane. The effluent from the second alkylation system is fed to a traditional deisobutanizer to prevent any build up of normal butanes in the system.

Paraffin alkylation process

A selected boiling range fluid catalytically cracked naphtha stream is subjected to simultaneous splitting, thioetherification of a light boiling range naphtha and selective hydrogenation of the dienes in a medium boiling range naphtha.

Process for treating cracked naphtha streams

A method of operating a multi-phase downflow reactor so as to induce a pulsing flow regime is disclosed. The pulse may be induced by increasing the gas rate while maintaining the liquid rate until a pressure drop sufficient to induce the pulse flow is achieved. The method is particularly useful in the sulfuric acid catalyzed alkylation of olefins in a reactor packed with a stainless steel/polypropylene mesh.

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Seabrook, TX, United States of America

William M Cross