AlkyClean catalyst

The AlkyClean catalyst contains no halogens, has acid sites with sufficient strength for alkylation, yields high quality alkylate with minimal side reactions, and exhibits the required activity, stability and regenerability characteristics necessary for a successful process. It is promoted with a low Pt content to assist regeneration and hydrogen transfer. 

Figure 12.15 is a photograph of the installed demo reactor section. The demo reactors are sufficiently large and proportioned to allow for reliable scale-up. As such, each demo reactor represents a core of a much larger reactor and provides for the necessary hydrodynamic similarity (e.g., equivalent superficial velocities) to a full commercial-scale reactor system. Equally important, these reactors use AlkyClean catalyst produced in commercial manufacturing trials, not developmental-scale catalyst with characteristics that may not be fully duplicable under commercial-scale production conditions. 

In 1999, Akzo Nobel (which later sold its catalyst division to Albemarle) patented a new technology for alkylating hydrocarbons based on a zeolite acid catalyst [193]. This new process, AlkyClean, was then designed by ABB Lummus and Albemarle, and a 10 barrels per stream day (BPSD) demonstration unit came online in Finland in 2002. AlkyClean produces a high-quality sulfur-free alkylate (96 octane), eliminating all the drawbacks of the liquid acid catalyst technologies. There are no add-soluble oil waste streams, the reactor operates at 50-90 °C, and the catalyst is a solid, noncorrosive material, which is easily transported and stored. 

Figure4.31 A simplified design scheme ofthe AlkyClean process, using three reactors in a cyclic configuration. At any given time, two reactors are used for alkylation, while the catalyst in the third reactor is regenerated.

Like the AVADA and the AlkyClean processes, these two processes also replace the liquid acid/base catalysts with solid acids and bases [192]. Although the reaction mechanism for the heterogeneous acid-catalyzed esterification is similar to the homogeneously catalyzed one [207,208], there is an important difference concerning the relationship between the surface hydrophobicity and the catalyst s activity. This is especially true for fatty acids, which are very lipophilic compounds. One can envisage three cases First, if there are isolated Bronsted acid sites surrounded by a... 

This chapter discusses alkylation and its evolution into a modern refining process. We review the basic chemistry of alkylation, assess the properties and other merits of H F versus H2SO4, identify key drivers in the process and discuss the evolution of one particular process - the AlkyClean solid acid catalyst alkylation process. 

AlkyClean Alkylation Process A True Solid Acid Catalyst (SAC) Process... 

In contrast, the AlkyClean solid acid catalyst contains no halogens and it is very robust with regard to water and other potential feed impurities. This was observed even after exposure of the catalyst to high concentrations of oxygenates (250-700 ppmw), sulfur compounds (200-1200 ppmw) and butadiene (400-1800 ppmw). Moreover, after any observed deactivation from these impurities, the catalyst could always be restored to full activity via HTR (i.e., treatment with H2 at 250 °C). Furthermore, in... 

The process flow scheme for the AlkyClean process is similar to that employed for current liquid acid technologies. As illustrated in the block flow diagram in Figure 12.12, the process consists of four main sections feedstock pretreatment (optional, depending on contaminant level), reactor system, catalyst regeneration and product distillation. 

Key to the AlkyClean technology s superior performance is the coupling of a newly developed catalyst with a novel alkylation reactor system, which minimizes the peak... 

D Amico, V.J. et al. (2002) The AlkyClean process a new solid add catalyst gasoline alkylation technology. 

The recent application of AlkyStar catalyst has reduced the number of reactors required in the AlkyClean process from five to three, owing to its extended service lifetime. In addition, higher olefin space velocities are allowed, while a lower I/O ratio can be employed, with the consequent savings in distillation and recirculation of isobutane. 

AlkyClean [Alkylate Clean] An alkylation process using a solid acid catalyst. Developed by CB I, Albemarle, and Neste Oil in the 1990s. 

AlkyStar Not a process but a zeolite-based alkylation catalyst claimed to be safer than the traditional acid alkylation catalysts. Used in the AlkyClean process. Developed by Albemarle, ABB Lummus Global, and Neste Oil. 

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