Process for producing high octane alkylated hydrocarbons substantially free of alkyl fluoride compounds

Claim 2

The process according to claim 1 wherein said isoparaffin-olefin admixture is formed from isobutane and butylene.

Claim 3

The process according to claim 1 wherein said isoparaffin-olefin admixture is passed into said reaction cooler through a plurality of inlet loci comprising from two to six inlet points longitudinally spaced intermediate the ends of said reaction cooler.

Claim 4

The process according to claim 1 wherein at least a portion of the unreacted hydrocarbons of step (k) is recycled to the reaction cooler.

Claim 5

The process according to claim 1 wherein at least a portion of the catalyst of step (h) after passing into said acid regeneration zone is recycled to the settler-contactor.

Claim 6

The process according to claim 1 wherein said catalyst is recycled to the settler-contactor in admixture with fresh hydrogen fluoride catalyst.

Claim 7

A process for producing high-octane alkylated hydrocarbons substantially free of alkyl fluoride compounds which comprise the steps of: a. introducing an isoparaffin-olefin admixture into an elongated reaction cooler, said reaction cooler having internally placed heat exchange means and having a predetermined number of spaced baffle means to furnish a pressure drop of from 5 to about 25 p.s.i. in order to maintain a homogenous reaction mass through said cooler; b. contacting said admixture with hydrogen fluoride alkylation catalyst in said reaction cooler; c. continuously removing heat of reaction from said reaction cooler using said internally placed heat exchange means and turbulence derived therefrom to maintain regulated isothermal reaction conditions in said reaction cooler; d. passing a reaction cooler effluent comprising said catalyst alkylated hydrocarbons, unreacted hydrocarbons and alkyl fluoride compounds to a reaction soaker having a predetermined number of spaced perforated plates therein to furnish a pressure drop of from 5 to about 25 p.s.i. in order to maintain a homogeneous reaction mass through said soaker zone; e. maintaining said effluent in said reaction soaker for a time sufficient to complete the alkylation reaction; f. passing from said reaction soaker to a settler-contactor zone a reactor soaker effluent comprising high octane alkylated hydrocarbons, said catalyst, unreacted hydrocarbons and alkyl fluoride compounds; g. separating in a lower portion of said settler-contactor zone said hydrogen fluoride catalyst from high-octane alkylated hydrocarbons, unreacted hydrocarbons and alkyl fluoride compounds; h. contacting in an intermediate portion of said settler-contactor said high-octane alkylated hydrocarbons, unreacted hydrocarbons and alkyl fluoride compounds with concentrated hydrogen fluoride under conditions sufficient to react the alkyl fluoride compounds with said concentrated hydrogen fluoride; i. further separating in an upper portion of said settler-contactor said hydrogen fluoride of step (h) from said high-octane alkylated hydrocarbons and from said unreacted hydrocarbons; j. withdrawing and passing a portion of said hydrogen fluoride of step (g) and said hydrogen fluoride of step (i) from a bottom portion of said settler-contactor zone into said reaction cooler without intervening cooling thereof and passing the remaining portion of said hydrogen fluoride into an acid regeneration zone; k. removing as overhead from said settler-contactor said high-octane alkylated hydrocarbons and unreacted hydrocarbons substantially free of alkyl fluoride compounds for further separation and recovery in a fractionation zone; and, l. recycling the unreacted hydrocarbons of step (k) to said reaction cooler in admixture with the isoparaffin-olefin admixture of step (a).

Claim 8

The process according to claim 8 wherein said concentrated hydrogen fluoride has a concentration of at least 95 percent by weight hydrogen fluoride.