An alkylation process including an upfront isomerization zone is described. 100% n-butane or field butanes can be converted into a blend of approximately 60 wt % isobutane and 40 wt % n-butane in the isomerization zone. This blend can be used as the feed to all types of alkylation zones. It stabilizes the feed composition so that the dehydrogenation zone and alkylation zone always operate with the same feed.

An alkylation process and apparatus are described. The alkylation process includes pre-mixing a paraffin stream with an ionic liquid catalyst stream from a settler. The premixed paraffin and ionic liquid catalyst stream is mixed in a low-efficiency pump to form a paraffin and ionic liquid catalyst mixture. An olefin feed stream is introduced into a riser reactor. The paraffin and ionic liquid catalyst mixture is introduced into the riser reactor to form a reaction mixture comprising alkylate and the ionic liquid catalyst. The reaction mixture is separated in a settler into an ionic liquid catalyst stream and a hydrocarbon stream.

A process is presented for the recovery of solvent used in an alkylation process. The solvent removes heavy hydrocarbons from a C4 stream. The C4 stream is passed to an alkylation unit to generate an alkylate product. A portion of the solvent is carried over with the C4 stream and needs to be recovered to reduce the aromatics content in the C4 stream, to reduce any deleterious effects of the aromatics in downstream processing.

A process is presented for the recovery of solvent used in an alkylation process. The solvent removes heavy hydrocarbons from a C4 stream. The C4 stream is passed to an alkylation unit to generate an alkylate product. A portion of the solvent is carried over with the C4 stream and needs to be recovered to reduce the aromatics content in the C4 stream, to reduce any deleterious effects of the aromatics in downstream processing.

Improved alkylation catalysts, alkylation methods, and methods of making alkylation catalysts are described. The alkylation method comprises reaction over a solid acid, zeolite-based catalyst and can be conducted for relatively long periods at steady state conditions. The alkylation catalyst comprises a crystalline zeolite structure, a Si/Al molar ratio of 20 or less, less than 0.5 weight percent alkali metals, and further having a characteristic catalyst life property. Some catalysts may contain rare earth elements in the range of 10 to 35 wt %. One method of making a catalyst includes a calcination step following exchange of the rare earth element(s) conducted at a temperature of at least 575 C. to stabilize the resulting structure followed by an deammoniation treatment. An improved method of deammoniation uses low temperature oxidation.

Improved alkylation catalysts, alkylation methods, and methods of making alkylation catalysts are described. The alkylation method comprises reaction over a solid acid, zeolite-based catalyst and can be conducted for relatively long periods at steady state conditions. The alkylation catalyst comprises a crystalline zeolite structure, a Si/Al molar ratio of 20 or less, less than 0.5 weight percent alkali metals, and further having a characteristic catalyst life property. Some catalysts may contain rare earth elements in the range of 10 to 35 wt %. One method of making a catalyst includes a calcination step following exchange of the rare earth element(s) conducted at a temperature of at least 575 C. to stabilize the resulting structure followed by an deammoniation treatment. An improved method of deammoniation uses low temperature oxidation.

Improved alkylation catalysts, alkylation methods, and methods of making alkylation catalysts are described. The alkylation method comprises reaction over a solid acid, zeolite-based catalyst and can be conducted for relatively long periods at steady state conditions. The alkylation catalyst comprises a crystalline zeolite structure, a Si/Al molar ratio of 20 or less, less than 0.5 weight percent alkali metals, and further having a characteristic catalyst life property. Some catalysts may contain rare earth elements in the range of 10 to 35 wt %. One method of making a catalyst includes a calcination step following exchange of the rare earth element(s) conducted at a temperature of at least 575 C. to stabilize the resulting structure followed by an deammoniation treatment. An improved method of deammoniation uses low temperature oxidation.

Processes for producing neopentane are disclosed herein. Processes comprise demethylating a C.sub.6-C.sub.8 alkane within a shell and tube reactor to produce a demethylation product including at least 10 wt % neopentane based on the weight of the demethylation product.

Processes for producing neopentane are disclosed herein. Processes comprise demethylating a C.sub.6-C.sub.8 alkane within a shell and tube reactor to produce a demethylation product including at least 10 wt % neopentane based on the weight of the demethylation product.

Methods and systems for alkylate production involving a multi-zone alkylation reactor. The multi-zone alkylation reactor includes a plurality of alkylation zones spaced vertically in a series configuration and a partition splitting the plurality of alkylation zones into at least two mechanically separated catalytic volumes.