US 11,891,347 B2
Catalyzed alkylation, alkylation catalysts, and methods of making alkylation catalysts
Mitrajit Mukherjee, Livingston, NJ (US); Eric Daniel Gauthier, Succasunna, NJ (US); and Kelly Ann Coley, Warren, NJ (US)
Assigned to Exelus Inc., Fairfield, NJ (US)
Filed by Exelus Inc., Fairfield, NJ (US)
Filed on Jan. 26, 2022, as Appl. No. 17/584,610.
Application 17/584,610 is a division of application No. 16/590,328, filed on Oct. 1, 2019, granted, now 11,261,139.
Application 16/590,328 is a division of application No. 15/190,063, filed on Jun. 22, 2016, granted, now 10,464,863, issued on Nov. 5, 2019.
Claims priority of provisional application 62/183,037, filed on Jun. 22, 2015.
Prior Publication US 2022/0144724 A1, May 12, 2022
Int. Cl. B01J 29/06 (2006.01); C07C 2/58 (2006.01); B01J 29/08 (2006.01); B01J 29/70 (2006.01); B01J 37/30 (2006.01); B01J 37/02 (2006.01); C01B 39/20 (2006.01); C01B 39/02 (2006.01); C01B 39/46 (2006.01); C10G 29/20 (2006.01); B01J 29/90 (2006.01); B01J 29/12 (2006.01); B01J 38/10 (2006.01); B01J 29/74 (2006.01); C07C 2/56 (2006.01); C07C 2/54 (2006.01); C07C 9/14 (2006.01); C07C 9/16 (2006.01); B01J 29/14 (2006.01); B01J 37/08 (2006.01); C10G 99/00 (2006.01)
CPC C07C 2/58 (2013.01) [B01J 29/08 (2013.01); B01J 29/082 (2013.01); B01J 29/084 (2013.01); B01J 29/087 (2013.01); B01J 29/088 (2013.01); B01J 29/123 (2013.01); B01J 29/126 (2013.01); B01J 29/143 (2013.01); B01J 29/7007 (2013.01); B01J 29/7057 (2013.01); B01J 29/7407 (2013.01); B01J 29/90 (2013.01); B01J 37/0201 (2013.01); B01J 37/024 (2013.01); B01J 37/08 (2013.01); B01J 37/30 (2013.01); B01J 38/10 (2013.01); C01B 39/026 (2013.01); C01B 39/20 (2013.01); C01B 39/46 (2013.01); C07C 2/54 (2013.01); C07C 2/56 (2013.01); C07C 9/14 (2013.01); C07C 9/16 (2013.01); C10G 29/205 (2013.01); B01J 2229/10 (2013.01); B01J 2229/18 (2013.01); B01J 2229/186 (2013.01); B01J 2229/20 (2013.01); B01J 2229/40 (2013.01); C07C 2529/08 (2013.01); C07C 2529/12 (2013.01); C07C 2529/14 (2013.01); C07C 2529/70 (2013.01); C10G 99/00 (2013.01); C10G 2300/104 (2013.01); C10G 2300/1081 (2013.01); C10G 2300/1092 (2013.01); C10G 2300/305 (2013.01); C10G 2300/70 (2013.01); C10G 2400/02 (2013.01); Y02P 20/584 (2015.11)] 9 Claims
 
1. A solid-acid alkylation catalyst, comprising:
a zeolite structure comprising sodalite cages and supercages, a Si/Al molar ratio of 20 or less, less than 0.5 weight percent alkali metals, rare earth elements in the range of 10 to 35 wt %; and
characterizable by a Catalyst Lifetime of 2 or greater where the Catalyst Lifetime parameter is defined as the catalyst age when olefin conversion falls below 90% using a test reaction where the solid-acid catalyst is loaded in a fixed-bed reactor such that the dT/dP>10 (diameter of tube to diameter of catalyst particles) and L/dP>50 (length of catalyst bed to diameter of catalyst particles) and exposed to a flow comprising a feed of 10:1 molar ratio of isobutane:n-butenes at 60° C. and 300 psig with a recycle ratio (R=volumetric flow rate of recycle stream/volumetric flow rate of feed stream) of 50, wherein the n-butenes comprise the olefin, where VS/VC is 7 (the ratio of system volume to catalyst volume), without regeneration of the solid-acid alkylation catalyst, and wherein a product of the test reaction has a RON of at least 92.