Nano-Porous Catalyst for Refinery Alkylation

The phase-out of methyl tertiary-butyl ether (MTBE) from the US gasoline pool has created an excess supply of isobutylene. Substituting ethanol for MTBE also has resulted in a rise in the vapor pressure of gasoline blends and has increased the need for high-octane, low vapor pressure blendstocks. This project aims to create a safe and economical solid acid catalyst suitable for refinery alkylation using isobutylene or mixed butene feeds. The catalyst will be designed with a unique nanometer-scale pore structure to improve its performance with these feeds. In Phase I, this new family of alkylation catalysts was synthesized and tested to demonstrate their enhanced properties and performance. Significant benefits were found at commercially viable reaction conditions. Phase II will optimize the performance of the catalyst while reducing its cost. Also, the long-term stability of the catalyst will be demonstrated. Commercial Applications and Other Benefits as described by the awardee: The production of a high-value gasoline blending component from excess low-value material should improve refining efficiency and increase gasoline supply, while still enabling refiners to meet clean-fuel regulations. The technology also would replace dangerous liquid acid catalysts, thereby improving safety and reducing the vulnerability of alkylation units.