A new alkylate production process

Abstract

A new technology for alkylation on solid AlkiRAN-GPN catalyst with process performance characteristics and an attained material balance competitive with existing sulfuric and hydrofluoric acid alkylation technologies is presented. Data on the effect such parameters as temperature, pressure, iso-butane: olefin ratio, and feedstock hourly space velocity (FHSV)) have on the process’s performance characteristics are given, and their optimum values are recommended. It is shown that using a sectioned reactor at a constant inlet iso-butane: olefin ratio ensures a higher internal ratio of these components and an increase in the total concentration of alkylate in the reaction products at a specified internal iso-butane: olefin ratio. This also lengthens the period of catalyst interregeneration with no losses in the process’s productivity and selectivity. The use of a zeolite based on faujasite in the rare-earth element–calcium form (REECaHY) and ultrastable zeolites as catalysts is substantiated. Higher values of olefin conversion and the alkyl gasoline yield are observed when these zeolites are used. To test the new technology, a demonstration plant of iso-butane alkylation with olefins on heterogeneous catalysts with an alkylate production capacity of 1 t/day is constructed. The results from studies are to be used in developing the basic design of an industrial plant. The construction of the first industrial plant of alkylation on a heterogeneous catalyst with an alkyl gasoline production capacity of 100000 t/year is planned at AO Gazprom Neft Moscow Oil Refinery.