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Solid Catalyzed Isoparaffin Alkylation at Supercritical Fluid and Near-Supercritical Fluid Conditions

Idaho National Laboratory

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Technology Marketing Summary

INL has developed a solid catalyst process for the alkylation reaction of isoparaffins with olefins over solid catalysts. The process includes contacting a mixture of an isoparaffin, an olefin and a phase-modifying material with a solid acid catalyst member under alkylation conversion conditions at either supercritical fluid, or near-supercritical fluid conditions. Temperature and pressure conditions are important in relation to the critical temperature (Tc) and the critical pressure (Pc) of the reaction mixture. The phase-modifying material is employed to promote the reaction's achievement of either a supercritical fluid state or a near-supercritical state, while simultaneously allowing for decreased reaction temperature and longer catalyst life.

Description

INL has developed a solid catalyst process for the alkylation reaction of isoparaffins with olefins over solid catalysts. The process includes contacting a mixture of an isoparaffin, an olefin and a phase-modifying material with a solid acid catalyst member under alkylation conversion conditions at either supercritical fluid, or near-supercritical fluid conditions. Temperature and pressure conditions are important in relation to the critical temperature (Tc) and the critical pressure (Pc) of the reaction mixture. The phase-modifying material is employed to promote the reaction's achievement of either a supercritical fluid state or a near-supercritical state, while simultaneously allowing for decreased reaction temperature and longer catalyst life.

Benefits

Environmentally improved process for producing distillate alkylates for use in transportation fuels.  Avoids the use of hydro-fluoric and concentrated sulfuric acids.  Solid catalysts can be reactivated to reduce catalyst costs in alkylate process.

Applications and Industries

Production of alkylates for use in distillate transportation fuels; Oil & gas industry.

More Information

Patent number 6,103,948; 6,579,821; 6,887,813; 7,407,905; 7,592,282

Patents and Patent Applications
ID Number
Title and Abstract
Primary Lab
Date
Patent 6,103,948
Patent
6,103,948
Solid catalyzed isoparaffin alkylation at supercritical fluid and near-supercritical fluid conditions
This invention relates to an improved method for the alkylation reaction of isoparaffins with olefins over solid catalysts including contacting a mixture of an isoparaffin, an olefin and a phase-modifying material with a solid acid catalyst member under alkylation conversion conditions at either supercritical fluid, or near-supercritical fluid conditions, at a temperature and a pressure relative to the critical temperature(T.sub.c) and the critical pressure(P.sub.c) of the reaction mixture. The phase-modifying phase-modifying material is employed to promote the reaction's achievement of either a supercritical fluid state or a near-supercritical state while simultaneously allowing for decreased reaction temperature and longer catalyst life.
Idaho National Laboratory 08/15/2000
Issued
Patent 6,887,813
Patent
6,887,813
Method for reactivating solid catalysts used in alkylation reactions
A method for reactivating a solid alkylation catalyst is provided which can be performed within a reactor that contains the alkylation catalyst or outside the reactor. Effective catalyst reactivation is achieved whether the catalyst is completely deactivated or partially deactivated. A fluid reactivating agent is employed to dissolve catalyst fouling agents and also to react with such agents and carry away the reaction products. The deactivated catalyst is contacted with the fluid reactivating agent under pressure and temperature conditions such that the fluid reactivating agent is dense enough to effectively dissolve the fouling agents and any reaction products of the fouling agents and the reactivating agent. Useful pressures and temperatures for reactivation include near-critical, critical, and supercritical pressures and temperatures for the reactivating agent. The fluid reactivating agent can include, for example, a branched paraffin containing at least one tertiary carbon atom, or a compound that can be isomerized to a molecule containing at least one tertiary carbon atom.
Idaho National Laboratory 05/03/2005
Issued
Patent 7,407,905
Patent
7,407,905
Method for reactivating catalysts and a method for recycling supercritical fluids used to reactivate the catalysts
A method of reactivating a catalyst, such as a solid catalyst or a liquid catalyst. The method comprises providing a catalyst that is at least partially deactivated by fouling agents. The catalyst is contacted with a fluid reactivating agent that is at or above a critical point of the fluid reactivating agent and is of sufficient density to dissolve impurities. The fluid reactivating agent reacts with at least one fouling agent, releasing the at least one fouling agent from the catalyst. The at least one fouling agent becomes dissolved in the fluid reactivating agent and is subsequently separated or removed from the fluid reactivating agent so that the fluid reactivating agent may be reused. A system for reactivating a catalyst is also disclosed.
Idaho National Laboratory 08/05/2008
Issued
Patent 7,592,282
Patent
7,592,282
Enhancement of alkylation catalysts for improved supercritical fluid regeneration
A method of modifying an alkylation catalyst to reduce the formation of condensed hydrocarbon species thereon. The method comprises providing an alkylation catalyst comprising a plurality of active sites. The plurality of active sites on the alkylation catalyst may include a plurality of weakly acidic active sites, intermediate acidity active sites, and strongly acidic active sites. A base is adsorbed to a portion of the plurality of active sites, such as the strongly acidic active sites, selectively poisoning the strongly acidic active sites. A method of modifying the alkylation catalyst by providing an alkylation catalyst comprising a pore size distribution that sterically constrains formation of the condensed hydrocarbon species on the alkylation catalyst or by synthesizing the alkylation catalyst to comprise a decreased number of strongly acidic active sites is also disclosed, as is a method of improving a regeneration efficiency of the alkylation catalyst.
Idaho National Laboratory 09/22/2009
Issued
Technology Status
Technology IDDevelopment StageAvailabilityPublishedLast Updated
LIT-PI-076, LIT-PI-597, LIT-PI-597C1, B-113, B-482DevelopmentAvailable04/14/201104/14/2011

Contact INL About This Technology

To: Ryan Bills<Ryan.Bills@inl.gov>