A process for sulfuric acid catalyzed alkylation involving the use of surfactants which form bi-continuous micro-emulsions with the sulfuric acid and the hydrocarbon is described. The bi-continuous phase facilitates and improves the sulfuric acid catalyzed alkylation reactions. The concentration of the surfactant is selected based on the type of olefin feed. Easy to alkylate feeds, such as 2-butene, use lower concentrations of surfactant, while feeds which are harder to alkylate, such as propene or isobutene, use higher concentrations of the surfactant. In addition, increasing the concentration of sulfuric acid when a surfactant is included resulted in higher calculated RON. The use of a surfactant and a high concentration of sulfuric acid can provide a calculated RON over 100 and close to theoretical yields.

A process for sulfuric acid catalyzed alkylation involving the use of surfactants which form bi-continuous micro-emulsions with the sulfuric acid and the hydrocarbon is described. The bi-continuous phase facilitates and improves the sulfuric acid catalyzed alkylation reactions. The concentration of the surfactant is selected based on the type of olefin feed. Easy to alkylate feeds, such as 2-butene, use lower concentrations of surfactant, while feeds which are harder to alkylate, such as propene or isobutene, use higher concentrations of the surfactant. In addition, increasing the concentration of sulfuric acid when a surfactant is included resulted in higher calculated RON. The use of a surfactant and a high concentration of sulfuric acid can provide a calculated RON over 100 and close to theoretical yields.

A dividing wall column is used in an alkylation process flow scheme to fractionate an alkylate reactor effluent to produce an iso-butane-rich stream as a recycle feed for the alkylation reactor while also separating iso-butane, normal butane and alkylate as separate product streams depending on the reactor effluent composition. In an optional embodiment, the scheme may contain propane.

A dividing wall column is used in an alkylation process flow scheme to fractionate an alkylate reactor effluent to produce an iso-butane-rich stream as a recycle feed for the alkylation reactor while also separating iso-butane, normal butane and alkylate as separate product streams depending on the reactor effluent composition. In an optional embodiment, the scheme may contain propane.

This invention describes methods of alkylating isobutane which include a catalytic reaction system comprising a crystalline zeolite catalyst and a rare earth-modified molecular sieve adsorbent (RE—MSA). The crystalline zeolite catalyst comprises sodalite cages and supercages, a Si/Al molar ratio of 20 or less, less than 0.5 weight percent alkali metals; and up to 5 wt% of Pt, Pd and or Ni, and acid-site density (including both Lewis and Brønsted acid sites) of at least 100 .Math.mole/gm. The RE-modified molecular sieve adsorbent (Re—MSA) comprising sodalite cages and supercages, a Si/Al molar ratio of 20 or less, less than 1 wt% of alkali metals, RE (rare earth elements) in the range of 10 to 30 wt% and transition metals selected from groups 9-11 in the range from 2 wt% to 10 wt; and acid-site density of no more than 30 .Math.mole/gm. The invention also includes methods of making RE—MSA.

This invention describes methods of alkylating isobutane which include a catalytic reaction system comprising a crystalline zeolite catalyst and a rare earth-modified molecular sieve adsorbent (RE—MSA). The crystalline zeolite catalyst comprises sodalite cages and supercages, a Si/Al molar ratio of 20 or less, less than 0.5 weight percent alkali metals; and up to 5 wt% of Pt, Pd and or Ni, and acid-site density (including both Lewis and Brønsted acid sites) of at least 100 .Math.mole/gm. The RE-modified molecular sieve adsorbent (Re—MSA) comprising sodalite cages and supercages, a Si/Al molar ratio of 20 or less, less than 1 wt% of alkali metals, RE (rare earth elements) in the range of 10 to 30 wt% and transition metals selected from groups 9-11 in the range from 2 wt% to 10 wt; and acid-site density of no more than 30 .Math.mole/gm. The invention also includes methods of making RE—MSA.

A process for sulfuric acid catalyzed alkylation involving the use of surfactants which form bi-continuous micro-emulsions with the sulfuric acid and the hydrocarbon is described. The bi-continuous phase facilitates and improves the sulfuric acid catalyzed alkylation reactions. The concentration of the surfactant is selected based on the type of olefin feed. Easy to alkylate feeds, such as 2-butene, use lower concentrations of surfactant, while feeds which are harder to alkylate, such as propene or isobutene, use higher concentrations of the surfactant. In addition, increasing the concentration of sulfuric acid when a surfactant is included resulted in higher calculated RON. The use of a surfactant and a high concentration of sulfuric acid can provide a calculated RON over 100 and close to theoretical yields.

A process for sulfuric acid catalyzed alkylation involving the use of surfactants which form bi-continuous micro-emulsions with the sulfuric acid and the hydrocarbon is described. The bi-continuous phase facilitates and improves the sulfuric acid catalyzed alkylation reactions. The concentration of the surfactant is selected based on the type of olefin feed. Easy to alkylate feeds, such as 2-butene, use lower concentrations of surfactant, while feeds which are harder to alkylate, such as propene or isobutene, use higher concentrations of the surfactant. In addition, increasing the concentration of sulfuric acid when a surfactant is included resulted in higher calculated RON. The use of a surfactant and a high concentration of sulfuric acid can provide a calculated RON over 100 and close to theoretical yields.

A process for sulfuric acid catalyzed alkylation involving the use of surfactants which form bi-continuous micro-emulsions with the sulfuric acid and the hydrocarbon is described. The bi-continuous phase facilitates and improves the sulfuric acid catalyzed alkylation reactions. The concentration of the surfactant is selected based on the type of olefin feed. Easy to alkylate feeds, such as 2-butene, use lower concentrations of surfactant, while feeds which are harder to alkylate, such as propene or isobutene, use higher concentrations of the surfactant. In addition, increasing the concentration of sulfuric acid when a surfactant is included resulted in higher calculated RON. The use of a surfactant and a high concentration of sulfuric acid can provide a calculated RON over 100 and close to theoretical yields.

A process for producing high octane bio-based alkylate is provided. The process involves reacting isobutane and bio-ethylene using an ionic liquid catalyst. Reaction conditions can be chosen to assist in attaining, or to optimize, desirable alkylate yields and/or properties.