Alkylate octane number

Some normal butane is also produced from butylenes but this is estimated at only 4-6%. The higher octane isobutylene alkylate and a claimed yield increase must be contrasted with normal paraffin production from olefins and a higher isobutane requirement. The typical mixed 03 = 704= feed can be made to produce a high octane alkylate with either acid catalyst by the optimization of other variables. The highest alkylate octane numbers reported are produced with sulfuric acid catalyst, alkylating with a typical cat cracker butylene olefin. 

Figure 12.2 Alkylate octane number versus I/O ratio for an HF unit [7].

The preceding information indicates the paths to follow in order to obtain stocks of high octane number by refining. The orientation must be towards streams rich in aromatics (reformate) and in isoparaffins (isomerization, alkylation). The olefins present essentially in cracked gasolines can be used only with moderation, considering their low MONs, even if their RONs are attractive. 

Their production in a refinery begins with base stocks having narrow boiling ranges and high octane numbers iso C5 cuts (used in small concentrations because of their high volatility) or alkylates are sought for such formulations. 

Refiners will turn to reformulated motor fuels where the octane number will be increased by alkylate or oxygenated compounds. It has indeed been shown for a long time that oxygenated compounds, alcohols, ethers and ketones Improved the octane number of hydrocarbon-based blends (Whitcomb, 1975). 

As a complementary process to reforming, isomerization converts normal paraffins to iso-paraffins, either to prepare streams for other conversions nCi —> /C4 destined for alkylation or to increase the motor and research octane numbers of iight components in the gasoiine pooi, i.e., the C5 or Cs-Ce fractions from primary distillation of the crude, or light gasoline from conversion processes, having low octane numbers. 

Alkylation is a process that produces high octane number (RON and MON) components from light olefins ( 3=, 4=, 05=) by addition of isobutane. 

We cite isomerization of Cs-Ce paraffinic cuts, aliphatic alkylation making isoparaffinic gasoline from C3-C5 olefins and isobutane, and etherification of C4-C5 olefins with the C1-C2 alcohols. This type of refinery can need more hydrogen than is available from naphtha reforming. Flexibility is greatly improved over the simple conventional refinery. Nonetheless some products are not eliminated, for example, the heavy fuel of marginal quality, and the conversion product qualities may not be adequate, even after severe treatment, to meet certain specifications such as the gasoline octane number, diesel cetane number, and allowable levels of certain components. 

All lation. The combination of olefins with paraffins to form higher isoparaffins is termed alkylation (qv). Alkylate is a desirable blendstock because it has a relatively high octane number and serves to dilute the total aromatics content. Reduction of the olefins ia gasoline blendstocks by alkylation also reduces tail pipe emissions. In refinery practice, butylenes are routinely alkylated by reaction with isobutane to produce isobutane—octane (26). In some plants, propylene and/or pentylenes (amylenes) are also alkylated (27). 

Alkylate is composed of a mixture of isoparaffins whose octane numbers vary with the olefins from which they were made. Butylenes produce the highest octane numbers, propylene the lowest, and amylenes (pentylenes) the iatermediate values. AH alkylates, however, have high (>87) octane numbers that make them particularly valuable. 

Butylenes. Butylenes are the primary olefin feedstock to alkylation and produce a product high in trimethylpentanes. The research octane number, which is typically in the range of 94—98, depends on isomer distribution, catalyst, and operating conditions. 

Isomerization. Isomerization of any of the butylene isomers to increase supply of another isomer is not practiced commercially. However, their isomerization has been studied extensively because formation and isomerization accompany many refinery processes maximization of 2-butene content maximizes octane number when isobutane is alkylated with butene streams using HF as catalyst and isomerization of high concentrations of 1-butene to 2-butene in mixtures with isobutylene could simplify subsequent separations (22). One plant (Phillips) is now being operated for this latter purpose (23,24). The general topic of isomerization has been covered in detail (25—27). Isomer distribution at thermodynamic equiUbrium in the range 300—1000 Kis summarized in Table 4 (25). 

Polymer Gasoline. Refinery trends tend to favor alkylation over polymerisation. Unlike the alkylation process, polymerisation does not require isobutane. The catalyst is usually phosphoric acid impregnated on kieselghur pellets. Polymerisation of butylenes is not an attractive alternative to alkylation unless isobutane is unavailable. The motor octane number of polymer gasoline is also low, and there is considerable shrinkage ia product volume. The only commercial unit to be built ia recent years is at Sasol ia South Africa. The commercial process was developed by UOP ia the 1940s (104). 

The term alkylation generally is applied to the acid catalyzed reaction hetween isohutane and various light olefins, and the product is known as the alkylate. Alkylates are the best of all possible motor fuels, having both excellent stability and a high octane number. 

As has been mentioned in Chapter 3, isobutane is mainly used as an alkylating agent to produce different compounds (alkylates) with a high octane number to supplement the gasoline pool. Isobutane is in high... 

The motor octane number jc7 was a function of the external isobutane-to-olefin ratio jc8 and the acid strength by weight percent x6 (for the same reactor temperatures and acid strengths as for the alkylate yield x4)... 

The main components of FCC catalysts are Zeolite Y, e.g., REY orUSY as the major active component (10 to 50%), and a binder that is typically an amorphous alumina, silica-alumina, or clay material. In addition to these main components, other zeolite components, e.g., ZSM-5, and other oxide or salt components are quite frequently used additives in the various FCC catalysts available on the market. The addition of 1 to 5% ZSM-5 increases the octane number of the gasoline. ZSM-5 eliminates feed compounds with low octane numbers because it preferentially center-cracks n-paraffins producing butene and propene [14], These short-chain olefins are then used as alkylation feedstocks... 

A clear example of the possible use of acid and/or superacid solids as catalysts is the alkylation of isobutane with butenes. Isobutane alkylation with low-molecular-weight olefins is one of the most important refining process for the production of high-octane number (RON and MON), low red vapor pressure (RVP) gasoline. Currently, the reaction is carried out using H2SO4 or HF (Table 13.1), although several catalytic systems have been studied in the last few years. 

Olefins, unlike paraffins, do not show significant gains in octane number with skeletal isomerization (see Table 14.2). As a result, olefin isomerization is not a useful octane boosting strategy. However, tertiary olefins (olefins with three alkyl substituents on the double bond), do react fairly readily with olefins to form ethers, which do have good octane numbers-for example, methyl tert-butyl ether (MTBE). 

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