Liquid-phase alkylation and transalkylation process

Claim 2

A process for the production of alkylated aromatic hydrocarbons which comprises: (A) contacting at least a mole-excess of an aromatic hydrocarbon and a C 2 to C 4 olefin under reaction conditions including the presence of a liquid phase in an alkylation reaction zone with an alkylation catalyst comprising a composite of a steam-stabilized hydrogen Y aluminosilicate zeolite and a mineral oxide binder, said steam-stabilized hydrogen Y aluminosilicate zeolite containing less than 0.7 weight percent of Na 2 O and having a unit cell size from 24.00 Å to about 24.64 Å; (B) separating the product from step (A) into fractions comprising (1) an aromatic hydrocarbon fraction, (2) a substantially pure mono-alkylaromatic fraction, and (3) a poly alkylaromatic hydrocarbon fraction; (C) recovering the mono-alkylaromatic fraction; (D) recycling a portion of the aromatic hydrocarbon in step (B) to the alkylation reaction zone; and (E) subjecting a portion of the aromatic hydrocarbon fraction and the polyalkylaromatic hydrocarbon fraction to transalkylation in a transalkylation zone under reaction conditions including the presence of a liquid phase in contact with a transalkylation catalyst comprising the composite defined in step (A), wherein the transalkylation catalyst comprises a smaller amount by weight than the alkylation catalyst.

Claim 3

The process defined in claim 1 wherein the aromatic hydrocarbon and olefin in step (A) are contacted at a molar ratio of from about 4:1 to about 25:1.

Claim 4

The process defined in claim 1 wherein the aromatic hydrocarbon in step (A) is a member selected from the group consisting of benzene, toluene and xylene and mixtures thereof.

Claim 5

The process defined in claim 1 wherein the aromatic hydrocarbon in step (A) is benzene.

Claim 6

The process defined in claim 1 wherein the olefin in step (A) is a member selected from the group consisting of ethylene, propylene, butene-1, trans-butene-2, and cis-butene-2 and mixtures thereof.

Claim 7

The process defined in claim 1 wherein the olefin in step (A) is a member selected from the group consisting of ethylene, propylene and butene-1 and mixtures thereof.

Claim 8

The process defined in claim 1 wherein the olefin in step (A) is propylene.

Claim 9

The process defined in claim 1 wherein the reaction conditions comprise a temperature of from about 250° F. to about 550° F.; a pressure of from about 50 p.s.i.g. to about 2,000 p.s.i.g.; and a weight hourly space velocity of from 1 to about 50 pounds of aromatic hydrocarbon and olefin per pound of catalyst per hour.

Claim 10

The process defined in claim 8 including a weight hourly space velocity of from 1 to about 50 pounds of aromatic hydrocarbon and poly-alkylaromatic hydrocarbon per pound of catalyst per hour.

Claim 11

The process defined in claim 1 wherein the alkylation catalyst in step (A) and transalkylation catalyst in step (E) comprise a composite of a steam stabilized hydrogen Y aluminosilicate zeolite and a mineral oxide binder in a molar ratio of from about 50:50 to about 95:5.

Claim 12

The process defined in claim 10 wherein the mineral oxide binder is a member selected from the group consisting of alumina, silica, magnesia, beryllia, zirconia, titania, thoria, chromia and clays and mixtures thereof.

Claim 13

The process defined in claim 10 wherein the mineral oxide binder is alumina.

Claim 14

The process defined in claim 1 wherein the alkylation catalyst in step (A) and transalkylation catalyst in step (E) comprise a composite having a surface area ranging from about 500 M 2 /g to about 800 M 2 /g; a pore volume of from about 0.5 cc/g to about 0.8 cc/g; and a compacted bulk density of from about 0.45 to about 0.75.

Claim 15

The process defined in claim 1 wherein the alkylation catalyst in step (A) and transalkylation catalyst in step (E) contain a Group IA metal selected from the group consisting of lithium, potassium, rubidium and cesium and mixtures thereof.

Claim 16

The process defined in claim 14 wherein the alkylation and transalkylation catalysts contain lithium.

Claim 17

The process defined in claim 14 wherein the alkylation and transalkylation catalysts contain from about 0.1 to about 10.0 percent by weight of a Group IA metal.

Claim 18

The process defined in claim 1 wherein the alkylation catalyst in step (A) and transalkylation catalyst in step (E) contain a Group IIA metal selected from the group consisting of beryllium, magnesium, calcium, strontium and barium and mixtures thereof.

Claim 19

The process defined in claim 17 wherein the alkylation and transalkylation catalysts contain calcium and barium.

Claim 20

The process defined in claim 17 wherein the alkylation and transalkylation catalysts contain from about 0.1 to about 10.0 percent by weight of a Group IIA metal.

Claim 21

The process defined in claim 1 wherein the aromatic hydrocarbon in fraction (1) and polyalkyl aromatic in fraction (3) of step (E) are contacted at a molar ratio of from about 1:1 to about 50:1.

Claim 22

A process for producing isopropylbenzene which comprises: (A) contacting at least a mole-excess of benzene with propylene under reaction conditions including the presence of a liquid phase in an alkylation reaction zone with an alkylation catalyst comprising a composite of a steam-stabilized hydrogen Y aluminosilicate zeolite and a mineral oxide binder, said steam-stabilized hydrogen Y aluminosilicate zeolite containing less than 0.7 weight percent of Na 2 O and having a unit cell size from 24.00 Å to about 24.64 Å; (B) separating the product from step (A) into fractions comprising (1) a benzene fraction, (2) a substantially pure isopropylbenzene fraction, and (3) a poly-isopropylbenzene fraction; (C) recovering the isopropylbenzene fraction; (D) recycling a portion of the benzene in step (B) to the alkylation zone; and (E) recycling a portion of the benzene and polyisopropylbenzene to transalkylation in a transalkylation zone under reaction conditions including the presence of a liquid phase in contact with a transalkylation catalyst comprising the composite defined in step (A), wherein the transalkylation catalyst comprises from about 25 to about 90 weight percent less than the alkylation catalyst.

Claim 23

A process for producing isopropylbenzene which comprises: (A) contacting at least a mole-excess of benzene with propylene under reaction conditions including the presence of a liquid phase in an alkylation reaction zone with an alkylation catalyst comprising a composite of a steam-stabilized hydrogen Y aluminosilicate zeolite and a mineral oxide binder, said steam-stabilized hydrogen Y aluminosilicate zeolite containing less than 0.7 weight percent of Na 2 O and having a unit cell size from 24.00 Å to about 24.64 Å; (B) separating the product from step (A) into fractions comprising (1) a benzene fraction, (2) a substantially pure isopropylbenzene fraction, and (3) a poly-isopropylbenzene fraction; (C) recovering the isopropylbenzene fraction; (D) recycling a portion of the benzene in step (B) to the alkylation zone; and (E) recycling a portion of the benzene and polyisopropylbenzene to transalkylation in a transalkylation zone under reaction conditions including the presence of a liquid phase in contact with a transalkylation catalyst comprising the composite defined in step (A), wherein the transalkylation catalyst comprises from about 25 to about 90 weight percent less than the alkylation catalyst.

Claim 24

The process defined in claim 21 wherein the benzene and propylene are contacted at a molar ratio of from about 4:1 to about 25:1.

Claim 25

The process defined in claim 21 wherein the reaction conditions comprise a temperature of from about 250° F. to about 550° F.; a pressure of from about 50 p.s.i.g. to about 2,000 p.s.i.g.; and a weight hourly space velocity of from about 1 to about 50 pounds of benzene and propylene per pound of catalyst per hour.

Claim 26

The process defined in claim 23 including a weight hourly space velocity of from about 1 to about 50 pounds of benzene and poly-isopropylbenzene per pound of catalyst per hour.

Claim 27

The process defined in claim 21 wherein the mineral oxide binder is a member selected from the group consisting of alumina, silica, magnesia, beryllia, zirconia, titania, thoria, chromia and clays and mixtures thereof.

Claim 28

The process defined in claim 21 wherein the mineral oxide binder is alumina.

Claim 29

The process defined in claim 21 wherein the alkylation catalyst in step (A) and transalkylation catalyst in step (E) comprise a composite having a surface area ranging from about 500 M 2 /g to about 800 M 2 /g; a pore volume of from about 0.5 cc/g to about 0.8 cc/g; and a compacted bulk density of from about 0.45 to about 0.75.

Claim 30

The process defined in claim 21 wherein the alkylation catalyst in step (A) and transalkylation catalyst in step (E) contain a Group IA metal selected from the froup consisting of lithium, potassium, rubidium and cesium and mixtures thereof.

Claim 31

The process defined in claim 28 wherein the alkylation and transalkylation catalysts contain lithium.

Claim 32

The process defined in claim 28 wherein the alkylation and transalkylation catalysts contain from about 0.1 to about 10.0 percent by weight of a Group IA metal.

Claim 33

The process defined in claim 21 wherein the alkylation catalyst in step (A) and transalkylation catalyst in step (E) contain a Group IIA metal selected from the group consisting of beryllium, magnesium, calcium, strontium and barium and mixtures thereof.

Claim 34

The process defined in claim 31 wherein the alkylation and transalkylation catalysts contain calcium and barium.

Claim 35

The process defined in claim 31 wherein the alkylation and transalkylation catalysts contain from about 0.1 to about 10.0 percent by weight of a Group IIA metal.

Claim 36

The process defined in claim 31 wherein the aromatic hydrocarbon and polyalkyl aromatic in step (E) are contacted at a molar ratio of from about 1:1 to about 50:1.

Claim 37

A process for producing ethylbenzene which comprises: (A) contacting at least a mole-excess of benzene and ethylene at a molar ratio of from about 4:1 to about 25:1, in an alkylation zone with an alkylation catalyst comprising a composite of a steam-stabilized hydrogen Y aluminosilicate zeolite admixed with an aluminum oxide binder in a molar ratio of from about 70:30 to about 90:10, under reaction conditions comprising a temperature of from about 300° F. to about 500° F., at a pressure of from about 150 p.s.i.g. to about 700 p.s.i.g., a weight hourly space velocity of from about 1 to about 50 pounds of benzene and ethylene per pound of catalyst per hour, said reaction conditions including the presence of a liquid phase and said steam-stabilized hydrogen Y aluminosilicate zeolite containing less than 0.7 weight percent of Na 2 O and having a unit cell size from about 20.00 Å to about 24.64 Å; (B) separating the product from step (A) into fractions comprising (1) a benzene fraction, (2) a substantially pure ethylbenzene fraction, and (3) a poly-ethylbenzene fraction; (C) recovering the ethylbenzene fraction; (D) recycling a portion of the benzene in step (B) to the alkylation zone, and (E) subjecting a portion of benzene and the poly-ethylbenzene to transalkylation in a transalkylation zone under reaction conditions including the presence of a liquid phase in contact with a transalkylation catalyst comprising the composite defined in step (A); wherein the transalkylation catalyst comprises from about 25 to about 90 weight percent less than the alkylation catalyst.

Claim 38

A process for producing ethylbenzene which comprises: (A) contacting at least a mole-excess of benzene and ethylene at a molar ratio of from about 4:1 to about 25:1, in an alkylation zone with an alkylation catalyst comprising a composite of a steam-stabilized hydrogen Y aluminosilicate zeolite admixed with an aluminum oxide binder in a molar ratio of from about 70:30 to about 90:10, under reaction conditions comprising a temperature of from about 300° F. to about 500° F., at a pressure of from about 150 p.s.i.g. to about 700 p.s.i.g., a weight hourly space velocity of from about 1 to about 50 pounds of benzene and ethylene per pound of catalyst per hour, said reaction conditions including the presence of a liquid phase and said steam-stabilized hydrogen Y aluminosilicate zeolite containing less than 0.7 weight percent of Na 2 O and having a unit cell size from about 20.00 Å to about 24.64 Å; (B) separating the product from step (A) into fractions comprising (1) a benzene fraction, (2) a substantially pure ethylbenzene fraction, and (3) a poly-ethylbenzene fraction; (C) recovering the ethylbenzene fraction; (D) recycling a portion of the benzene in step (B) to the alkylation zone, and (E) subjecting a portion of benzene and the poly-ethylbenzene to transalkylation in a transalkylation zone under reaction conditions including the presence of a liquid phase in contact with a transalkylation catalyst comprising the composite defined in step (A); wherein the transalkylation catalyst comprises from about 25 to about 90 weight percent less than the alkylation catalyst.

Claim 39

A process for producing isopropylbenzene which comprises: (A) contacting at least a mole-excess of benzene and propylene at a molar ratio of from about 4:1 to about 25:1, in an alkylation zone with an alkylation catalyst comprising a composite of a steam-stabilized hydrogen Y aluminosilicate zeolite admixed with an aluminum oxide binder in a molar ratio of from about 70:30 to about 90:10, under reaction conditions comprising a temperature of from about 300° F. to about 500° F., at a pressure of from about 150 p.s.i.g. to about 700 p.s.i.g., a weight hourly space velocity of from about 1 to about 50 pounds of benzene and ethylene per pound of catalyst per hour, said reaction conditions including the presence of a liquid phase, and said steam-stabilized hydrogen Y aluminosilicate zeolite containing less than 0.7 weight percent of Na 2 O and having a unit cell size from about 24.00 Å to about 24.64 Å; (B) separating the product from step (A) into fractions comprising (1) a benzene fraction, (2) a substantially pure isopropylbenzene fraction, and (3) a poly isopropylbenzene fraction; (C) recovering the isopropylbenzene fraction; (D) recycling a portion of the benzene in step (B) to the alkylation zone; and (E) subjecting a portion of benzene and the poly isopropylbenzene to transalkylation in a transalkylation zone under reaction conditions, including the presence of a liquid phase, in contact with a transalkylation catalyst comprising the composite defined in step (A), wherein the transalkylation catalyst comprises from about 25 to about 90 weight percent less than the alkylation catalyst.

Claim 40

A process for producing isopropylbenzene which comprises: (A) contacting at least a mole-excess of benzene and propylene at a molar ratio of from about 4:1 to about 25:1, in an alkylation zone with an alkylation catalyst comprising a composite of a steam-stabilized hydrogen Y aluminosilicate zeolite admixed with an aluminum oxide binder in a molar ratio of from about 70:30 to about 90:10, under reaction conditions comprising a temperature of from about 300° F. to about 500° F., at a pressure of from about 150 p.s.i.g. to about 700 p.s.i.g., a weight hourly space velocity of from about 1 to about 50 pounds of benzene and ethylene per pound of catalyst per hour, said reaction conditions including the presence of a liquid phase, and said steam-stabilized hydrogen Y aluminosilicate zeolite containing less than 0.7 weight percent of Na 2 O and having a unit cell size from about 24.00 Å to about 24.64 Å; (B) separating the product from step (A) into fractions comprising (1) a benzene fraction, (2) a substantially pure isopropylbenzene fraction, and (3) a poly isopropylbenzene fraction; (C) recovering the isopropylbenzene fraction; (D) recycling a portion of the benzene in step (B) to the alkylation zone; and (E) subjecting a portion of benzene and the poly isopropylbenzene to transalkylation in a transalkylation zone under reaction conditions, including the presence of a liquid phase, in contact with a transalkylation catalyst comprising the composite defined in step (A), wherein the transalkylation catalyst comprises from about 25 to about 90 weight percent less than the alkylation catalyst.

Claim 41

A process for the production of alkylated aromatic hydrocarbons which comprises: (A) contacting at least a mole-excess of an aromatic hydrocarbon and a C 2 to C 4 olefin under reaction conditions, including the presence of a liquid phase, in an alkylation reaction zone with an alkylation catalyst comprising a composite of a steam-stabilized hydrogen Y aluminosilicate zeolite and a mineral oxide binder, said steam-stabilized hydrogen Y aluminosilicate zeolite containing less than 0.7 weight percent of Na 2 O, having a unit cell size from 24.00 Å to about 24.64 Å, and containing a Group IA metal or a Group IIA metal of the Periodic Table; (B) separating the product from step (A) into fractions comprising (1) an aromatic hydrocarbon fraction, (2) a substantially pure mono-alkylaromatic fraction, and (3) a poly alkylaromatic hydrocarbon fraction; (C) recovering the alkylaromatic fraction; (D) recycling a portion of the aromatic hydrocarbon in step (B) to the alkylation reaction zone; and (E) subjecting a portion of the aromatic hydrocarbon and the polyalkylaromatic hydrocarbon to transalkylation in a transalkylation zone under reaction conditions, including the presence of a liquid phase, in contact with a transalkylation catalyst comprising the composite defined in step (A), wherein the transalkylation catalyst comprises from about 25 to about 90 weight percent less than the alkylation catalyst.

Claim 42

A process for the production of alkylated aromatic hydrocarbons which comprises: (A) contacting at least a mole-excess of an aromatic hydrocarbon and a C 2 to C 4 olefin under reaction conditions, including the presence of a liquid phase, in an alkylation reaction zone with an alkylation catalyst comprising a composite of a steam-stabilized hydrogen Y aluminosilicate zeolite and a mineral oxide binder, said steam-stabilized hydrogen Y aluminosilicate zeolite containing less than 0.7 weight percent of Na 2 O, having a unit cell size from 24.00 Å to about 24.64 Å, and containing a Group IA metal or a Group IIA metal of the Periodic Table; (B) separating the product from step (A) into fractions comprising (1) an aromatic hydrocarbon fraction, (2) a substantially pure mono-alkylaromatic fraction, and (3) a poly alkylaromatic hydrocarbon fraction; (C) recovering the alkylaromatic fraction; (D) recycling a portion of the aromatic hydrocarbon in step (B) to the alkylation reaction zone; and (E) subjecting a portion of the aromatic hydrocarbon and the polyalkylaromatic hydrocarbon to transalkylation in a transalkylation zone under reaction conditions, including the presence of a liquid phase, in contact with a transalkylation catalyst comprising the composite defined in step (A), wherein the transalkylation catalyst comprises from about 25 to about 90 weight percent less than the alkylation catalyst.

Claim 43

The process defined in claim 37 wherein the alkylation catalyst in step (A) and transalkylation catalyst in step (E) contain a Group IA metal selected from the group consisting of lithium, potassium, rubidium and cesium and mixtures thereof.

Claim 44

The process defined in claim 37 wherein the alkylation catalyst in step (A) and transalkylation catalyst in step (E) contain a Group IIA metal selected from the group consisting of beryllium, magnesium, calcium, strontium and barium and mixtures thereof.