Novel System for Solid Catalyzed Isobutane/Olefin Alkylation

Isobutane/olefin alkylation is a major refinery process in which light hydrocarbons (isobutene and mainly C3 and C4 olefins) are converted to a high octane gasoline feedstock. Environmental and safety concerns have led to interest in the potential for increasing the amount of alkylate used in gasoline. This project will develop an approach for limiting olefin polymerization in the alkylation of isobutane with olefins, thereby limiting solid polymer formation on the catalyst surface. In particular, zeolite coatings will be used to obtain not only reduced polymer formation but high conversions of isobutene to alkylate. This will enable higher quality alkylate gasoline, an important contributor to the gasoline pool and an ideal core component for reformulated gasoline. Phase I will demonstrate the validity of the system to limit olefin polymerization and produce high quality alkylate via the reaction of isobutane with butenes. The basic parameters of the system ¿ including coatings, reactor configuration, and operating conditions ¿ will be defined, and stable operation will be documented. Phase II will further explore extended cycle life, including techniques to exploit the physical properties of these unique reactor designs. A commercially feasible system will be designed, built, and demonstrated in Phase II. Commercial Applications and other Benefits as described by the awardee: The technology should enable a potential breakthrough in the replacement of hazardous, liquid-acid-based HF and sulfuric acid processes. This replacement would eliminate the environmental and safety complications of liquid acids, simplify plant design (e.g. by avoiding acids handling and refrigeration steps), reduce capital costs, and reduce energy consumption and operating costs.