Nano-Porous Catalyst for Refinery Alkylation

The removal of MTBE (methyl tert-butyl ether) from many gasoline blends necessitates the increased use of other high-octane components. Alkylate represents a clean high-quality alternative; however, alkylate is produced using hazardous and increasingly expensive liquid acid catalysts. A safe, economical alternative to liquid acids is needed. Solid acid catalysts offer a safe and clean alternative to liquid acids, but suffer from rapid deactivation under industrial conditions. This project will develop an engineered catalyst that resists deactivation by creating a network of nanopores in the catalyst particle, thereby enhancing diffusion. Phase I will prove the feasibility of this concept in bench-scale reactors. The nano-porous catalyst will be developed and tested to quantify the improvement in performance. An economic evaluation will also be conducted to ensure the nano-porous catalyst will be cost effective. Commerecial Applications and Other Benefits as described by the awardee: An economically viable solid-acid catalyst for isoparaffin alkylation would produce a lower-cost higher-quality gasoline. The result would be a cleaner, safer process and clean-burning high-octane fuels, without objectionable additives like MTBE.