A New Process for Synthesis of Alkylate

A new technology for alkylation over the AlkyRAN-GPN catalyst was developed. The performance and the mass balance achieved using the developed technology is competitive to the parameters of currently employed processes for alkylation with sulfuric acid and hydrogen fluoride. The data on the influence of temperature, pressure, isobutane : olefin ratio, feed flow rate on the process parameters are reported and the optimal conditions recommended. The use of a sectional reactor is shown to allow the isobutane : olefin ratio and the total alkylate concentration in the reaction products to be increased at the constant inlet isobutane : olefin ratio. The service cycle of the catalyst also increases while the process productivity and selectivity does not decrease. The use of faujasite-based zeolites in their calcium-rare-earth and ultrastable forms is rationalized: they provide the highest conversions of olefin and the best yield of alkylgasoline. The construction of a demonstration setup (1 t of alkylate per day) for testing the new technology of isobutane alkylation with olefins over heterogeneous catalysts is in progress. The results obtained will be used for preparation of the engineering bases of the large-scale unit. The first industrial unit for alkylation over a heterogeneous catalyst (100,000 t of alkylgasoline/y) is to be erected at JSC Gazpromneft-Moscow Refinery.

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