The present invention relates to a process for the alkylation of an isoparaffin with an olefin.

As a result of the curtailment in the use of tetraethyl lead as an octane-improving additive for gasoline, not only has the production of unleaded gasoline increased but the octane number specification of all grades of gasoline have increased as well. Isoparaffin-olefin alkylation is a key route to the production of highly branched paraffin octane enhancers which are to be blended into gasolines.

Alkylation involves the addition of an alkyl group to an organic molecule. Thus, an isoparaffin can be reacted with an olefin to provide an isoparaffin of higher molecular weight. Industrially, alkylation often involves the reaction of C--C,. olefins with isobutane in the presence of an acidic catalyst. In the past, alkylation processes have included the use of hydrofluoric acid or sulfuric acid as catalysts under controlled temperature conditions. Low temperatures are utilized in the sulfuric acid process to minimize the undesirable side reaction of olefin polymerization and the acid strength is generally maintained at 88-94 percent by the continuous addition of fresh acid and the continuous withdrawal of spent acid. The hydrofluoric acid process is less temperature-sensitive and the acid is easily recovered and purified. However, hydrofluoric acid and sulfuric acid alkylation processes, have inherent drawbacks including environmental concerns, acid consumption and disposal of corrosive materials. With the increasing demands for octane and increasing environmental concerns, it is desirable to develop an alkylation process based on a solid catalyst system.

Crystalline metallosilicates, or zeolites, have been widely investigated for use in the catalysis of isoparaffin alkylation. For example, U.S. Patent No. 3,251,902 describes the use of a fixed bed of ion-exchanged crystalline aluminosilicate having a reduced number of available acid sites for the liquid phase alkylation of ^C 4~l_20 branched-chain paraffins with patent further discloses that the C ₄ -C2Q branched-chain paraffin should be allowed to substantially saturate the crystalline aluminosilicate before the olefin is introduced to the alkylation reactor.

U.S. Patent No. 3,549,557 describes the alkylation of isobutane with C^-C, olefins using certain crystalline aluminosilicate zeolite catalysts in a fixed, moving or fluidized bed system, the olefin being preferably injected at various points in the reactor.

U.S. Patent No. 3,644,565 discloses the alkylation of a paraffin with an olefin in the presence of a catalyst comprising a Group VIII noble metal present on a crystalline aluminosilicate zeolite, the catalyst having been pretreated with hydrogen to promote selectivity.

U.S. Patent No. 3,655,813 discloses a process for alkylating C ₄ -C ₅ isoparaffins with Cj-Cg olefins using a crystalline aluminosilicate zeolite catalyst wherein a halide adjuvant is employed in the alkylation reactor. The isoparaffin and olefin are introduced into the alkylation reactor at specified concentrations and catalyst is continuously regenerated outside the alkylation reactor.

U.S. Patent No. 3,893,942 describes an isoparaffin alkylation process employing, as catalyst, a Group VIII metal-containing zeolite which is periodically hydrogenated with hydrogen in the gas phase to reactivate the catalyst when it has become partially deactivated.

U.S. Patent No. 3,236*671 discloses the use, in alkylation, of crystalline aluminosilicate zeolites having silica to alumina mole ratios above 3 and also discloses the use of various metals exchanged and/or impregnated on such zeolites. U.S. Patent No. 3,624,173 discloses the use, in isoparaffin- olefin alkylation, of zeolite catalysts containing gadolinium. U.S. Patent No. 3,738,977 discloses the alkylation of paraffins with ethylene employing a zeolite catalyst which possesses a Group VIII metal component, the catalyst having been pretreated with hydrogen.

U.S. Patent No. 3,865,894 describes the alkylation of C ₄ -C ₆ isoparaffin with C^-Cg monoolefin employing a substantially anhydrous acidic zeolite, for example acidic zeolite Y (zeolite HY), and a halide adjuvant. U.S. Patent No. 3,917,738 describes a process for alkylating an isoparaffin with an olefin using a solid, particulate catalyst capable of absorbing the olefiri. The isoparaffin and the olefin are admixed to form a reactant stream in contact with catalyst particles at the upstream end of an adsorption zone after which the reactants are passed concurrently with the catalyst so that a controlled amount of olefin is adsorbed onto the catalyst before the combination of reactants and catalyst is introduced into an alkylation zone. This controlled olefin adsorption is said to prevent polymerization of the olefin during alkylation. U.S. Patent No. 4,377,721 describes an isoparaffin-olefin alkylation-process utilizing, .Its catalyst, ZSM-20, preferably HZSM-20 or rare earth cation-exchanged ZSM-20.

U.S. Patent No. 4,384,161 describes a process of alkylating isoparaffins with olefins to provide alkylate employing as catalyst a large pore zeolite capable of absorbing 2,2,4-trimethylpentane, e.g., ZSM-4, ZSM-20, ZSM-3, ZSM-18, zeolite Beta, faujasite, mordenite, zeolite Y and the rare earth metal-containing forms thereof, and a Lewis acid such as boron trifluoride, antimony

pentafluoride or aluminum trichloride. The use of a large pore zeolite in combination with a Lewis acid in accordance with this patent is reported to greatly increase the activity and selectivity of the zeolite thereby effecting alkylation with high olefin space velocity and low isoparaffin/olefin ratio.

In accordance with the present invention there is provided a process for alkylating an isoparaffin with an olefin, which comprises reacting the isoparaffin and the olefin in the presence of, as catalyst, a synthetic porous crystalline zeolite having an X-ray diffraction pattern including values substantially as set forth in Table 1, infra.

One measure of the selectivity of an alkylation catalyst is the Cg+ yield. This fraction generally results from oligomerization of the feed olefins resulting in a loss of alkylate yield, reduced alkylate quality and the possible formation of an acidic sludge fraction. The zeolite alkylation catalyst employed in the process of this invention provides reduced C _g + yields relative to such known zeolite alkylation catalysts as zeolite HY, e.g., as disclosed in U.S. Patent No. 3,865,894 referred to above.

The alkylate produced b the process of this invention is of high quality based on both research and motor octane numbers and as such is particularly well suited for blending into the gasoline pool.

Ihe synthetic porous crystalline zeolite used in the alkylation process of this invention has, in its calcined form, an X-ray diffraction pattern including the lines listed in Table I belcw:

more specifically the lines listed in Table II below:

Most specifically, the calcined crystalline material has an X-ray diffraction pattern which includes the lines listed in Table IV below:

TABLE IV

Interplanar d-Spacing (A) Relative Intensity, I/Io x 100

W-M

W

M-VS

M-S

M-VS

W-M

M-VS

W-M

W-M

W

W

W-M

W

W-S v~s

M-VS

W-M

W-M

VS

W-M

W-M

W-M

W

W

W

W

W W

These values were determined by standard techniques. The radiation was the K-alpha doublet of copper and a diffractometer equipped with a scintillation counter and an associated computer was used. The peak heights, I, and the positions as a function of 2 theta, where theta is the Bragg angle, were determined using algorithms on the computer associated with the diffractometer. From these, the relative intensities, 100 I/I , where I is the o o intensity of the strongest line or peak, and d (obs.) the interplanar spacing in Angstroms Units (A), corresponding to the recorded lines, were determined. In Tables I-IV, the relative intensities are given in terms of the symbols W=weak, M-medium, S=strong and VS-very strong. In terms of intensities, these may be generally designated as follows:

W = 0 - 20

M = 20 - 40

S = 40 - 60

VS = 60 - 100

It should be understood that these X-ray diffraction patterns are characteristic of all species of the zeolite. The sodium form as well as other cationic forms reveal substantially the same pattern with some minor shifts in interplanar spacing and variation in relative intensity. Other minor variations can occur depending on the Y to X, e.g., silicon to aluminum mole ratio of the particular sample, as well as its degree of thermal treatment.

The zeolite employed in the present process typically has a composition involving the molar relationship: X ₂ 0 ₃ :(n)Y0 ₂ , wherein X is a trivalent element, such as aluminum, boron, iron and/or gallium, preferably aluminum, Y is a tetravalent element such as silicon and/or germanium, preferably silicon, and n is at least 10, usually from 10 to 150, more usually from 10 to 60, and even more usually from 20 to 40. In the as-synthesized form, the zeolite has a formula, on an anhydrous basis and in terms of moles of oxides per n moles of Y0 ₂ , as follows:

(0.005-0.l)Na ₂ 0:(1-4)R:X ₂ 0 ₃ :nY0 ₂ wherein R is an organic component. The Na and R components are associated with the zeolite as a result of their presence during crystallization, and are easily removed by post-crystallization methods hereinafter more particularly described.

The zeolite employed herein is thermally stable and

2 exhibits a high surface area (greater than about 400 m /gm as measured by the BET [Bruenauer, Emmet and Teller] test). In addition, the zeolite normally exhibits Equilibrium Adsorption values of greater than 4.5 wt.%, usually greater than 7 wt.%, for cyclohexane vapor, greater than 10 wt.% for n-hexane vapor and preferably greater than 10 wt.% for water vapor. As is evident from the above formula, the zeolite is synthesized nearly free of Na cations and thus possesses acid catalysis activity as synthesized.

It can, therefore, be used as alkylation catalyst herein without

having to first undergo an exchange step. To the extent desired, however, the original sodium cations of the as-synthesized material can be replaced in accordance with techniques well known in the art, at least in part, by ion exchange with other cations. Preferred replacement cations include metal ions, hydrogen ions, hydrogen precursor, e.g., ammonium, ions, hydrogen ions, hydrogen precursor, e.g., ammonium, ions and mixtures thereof. Particularly preferred cations are those which tailor the activity of the catalyst for alkylation. These include hydrogen, rare earth metals and metals of Groups IIA, IIIA, IVA, IB, IIB, IIIB, IVB and VIII of the Periodic Table of the Elements.

Prior to its use as alkylation catalyst herein, the zeolite should be subjected to thermal treatment to remove part or all of any organic constituent present therein. The zeolite alkylation catalyst herein can also be used in intimate combination with a hydrogenating component such as tungsten, vanadium, molybdenum, rhenium, nickel, cobalt, chromium, manganese, or a noble metal such as platinum or palladium where a hydrogenation-dehydrogenation function is to be performed. Such component can be associated chemically and/or physically with the zeolite and/or matrix with which the zeolite may be optionally composited. Thus, e.g., the hydrogenating component can be introduced into the catalyst composition by way of co- crystallization, exchanged into the composition to the extent a Group IIIA element, e.g., aluminum, is in the structure, impregnated therein or intimately physically admixed therewith. Such component can be impregnated in, or on, the zeolite such as, for example, by, in the case of platinum, treating the zeolite with a solution containing the platinum metal-containing ion. Thus, suitable platinum compounds for this purpose include chloroplatinic acid, platinous chloride and various compounds containing the platinum amine complex.

Prior to its use as alkylation catalyst in the process of this invention, the present zeolite should be at least partially dehydrated. This can be accomplished by heating the crystals to a

temperature in the range of from 200°C to 595°C in an atmosphere such as air, nitrogen, etc., and at atmospheric, subatmospheric or superatmospheric pressures for a period of from between 30 minutes to 48 hours. Dehydration can also be performed at room temperature merely by placing the crystalline material in a vacuum but a longer time will be required to achieve a suitable degree of dehydration.

The zeolite employed in the present process can be prepared from a reaction mixture containing sources of alkali or alkaline earth metal (M), e.g., sodium or potassium, cation, an oxide of trivalent element X, e.g., aluminum, an oxide of tetravalent element Y, e.g., silicon, an organic (R) directing agent, hexamethyleneimine, and water, said reaction mixture having a composition, in terms of mole rations of oxides, within the following ranges: Reactants Useful Preferred

In a preferred synthesis method the Y0 ₂ reactant contains a substantial amount of solid Y0 ₂ , e.g., at least 30 wt.% solid 0 ₂ . Where Y0 ₂ is silica, the use of a silica source containing at least 30 wt.% solid silica, e.g., Ultrasil (a precipitated, spray dried silica containing 90 wt.% silica) or HiSil (a precipitated hydrated Si0 ₂ containing 87 wt.% silica, 6 wt.% free H ₂ 0 and 4.5 wt.% bound H ₂ 0 of hydration and having a particle size of 0.02 micron) favors crystal formation from the above mixture. If another source of oxide of silicon, e.g., ^J Q-Brand (a sodium silicate comprised of 28.8 wt.% of Si0 ₂ , 8.9 wt.% Na ₂ 0 and 62.3 wt.%

H ₂ 0) is used, crystallization may yield little of the required zeolite and impurity phases of other crystal structures, e.g., ZSM-12, may be produced. Preferably, therefore, the Y0 ₂ , e.g., silica, source contains at least 30 wt.% solid Y0 ₂ , e.g., silica, and more preferably at least 40 wt.% solid Y0 ₂ , e.g., silica.

Crystallization of the required zeolite can be carried out at either static or stirred conditions in a suitable reactor vessel such as, e.g., polypropylene jars or teflon-lined or stainless steel autoclaves. Crystallization is generally conducted at a temperature of 80 to 225°C for 25 hours to 60 days. Thereafter, the crystals are separated from the liquid and recovered.

Crystallization is facilitated by the presence of at least 0.01 percent, preferably 0.10 percent and still more preferably 1 percent, seed crystals based on the total weight of the crystalline product formed.

Prior to use in the process of the invention, the present zeolite is preferably combined with another material, i.e, a binder, which is resistant to the temperataures and other conditions employed in the isoparaffin alkylation process of this invention. Suitable binder materials include active and inactive materials and synthetic or naturally occurring zeolites as well as inorganic materials such as clays, silica and/or metal oxides such as alumina. The latter can be either naturally occurring or provided in the form of gelatinous precipitates or gels including mixtures of silica and metal oxides. Use of a binder material in conjunction with the present zeolite, i.e., combined therewith or present during its synthesis, which itself is catalytically active may change the conversion and/or selectivity of the catalyst. Inactive materials suitably serve as diluents to control the amount of conversion so that isoparaffin alkylation products can be obtained economically and in controlled fashion without having to employ other means for controlling the rate of reaction. These materials can be incorporated into naturally occurring clays, e.g., bentonite and kaolin, to improve the crush strength of the zeolite under commercial isoparaffin alkylation operating conditions. Good crush strength is an advantageous attribute for commercial use since it prevents or delays breaking down of the catalyst into powder-like materials.

Naturally occurring clays which can be composited with the present zeolite include the montmorillonite and kaolin family, which

—11—

families include the subbentonites, and the kaolins commonly known as Dixie, McNaraee, Georgia and Florida clays or others in which the main mineral constituent is halloysite, kaolinite, dickite, nacrite, or anauxite. Such clays can be used in the raw state as originally mined or initially subjected to calcination, acid treatment or chemical modification. Binders useful for compositing with the zeolite also include inorganic oxides, notably alumina.

Apart from or in addition to the foregoing binder materials, the present zeolite can be composited with an inorganic oxide matrix such as silica-thoria, silica-beryllia, silica-titania as well as ternary compositions such as silica-alumina-thoria, silica-alumina- zirconia, silica-aluraina-magnesia and silica-magnesia-zirconia. It may also be advantageous to provide at least a part of the foregoing matrix materials in colloidal form so as to facilitate extrusion of the bound catalyst components(s).

The relative proportions of zeolite and inorganic oxide matrix can vary widely with the zeolite content ranging from 1 to 95 percent by weight and more usually, particularly when the composite is prepared in the form of beads, in the range of 2 to 80 weight precent of the composite.

The stability of the alkylation catalyst of the invention may be increased by steaming, which is conveniently effected by contacting the zeolite with, e.g., 5-100% steam at a temperature of at least 300°C (e.g., 300-650°C) for at least one hour (e.g., 1-200 hours) at a pressure of 101-2,500 kPa. In a more particular embodiment, the catalyst can be made to undergo steaming with 75-100% steam at 315-500°C and atmospheric pressure for 2-25 hours.

The alkylation catalyst employed in the process of this invention may comprise a Lewis acid promoter in addition to the zeolite described above. A Lewis acid is generally considered to be a molecule which is capable of combining with another molecule or ion by forming a covalent chemical bond with two electrons from the second molecule or ion, which is to say, a Lewis acid is an electron acceptor. Examples of Lewis acids include boron trifluoride ( ^BF 3^' antimony pentafluoride (SbFr) and aluminum chloride

(AlCl,). The present invention contemplates the use of these and other Lewis acids including those disclosed in "Friedel-Crafts and Related Reactions", Interscience Publishers, Chapters III and IV (1963). BF, is a preferred Lewis acid for use in the alkylation process of this invention. In the case of BF,, this promoter is preferably present in the alkylation zone in an amount which exceeds that required to saturate the zeolite catalyst component considered not only as the zeolite per se but as any other material, e.g., binder or matrix material, which might be associated therewith. The operating temperature of the alkylation process herein can extend over a broad range, e.g., from -40 to 400°C, with lower temperatures being used when Lewis acid promoter is present. Thus with a Lewis acid promoter the temperature will generally be from -40 to 250°C and preferably -20 to 100°C. When no Lewis acid promoter is employed, the temperature will generally be from -25 to

400°C, and preferably 75 to 200°C. The practical upper operating temperature will often be dictated by the need to avoid an undue occurrence of undesirable side reactions.

The pressures employed in the present process can extend over a wide range, e.g., from subatmospheric to 34580 kPa (5000 psig), preferably from 100 to 7000 kPa (1 atomsphere to 1000 psig).

The amount of zeolite used in the present alkylation process can be varied over relatively wide limits. In general, the amount of zeolite as measured by the weight hourly space velocity (WHSV) of the olefin can range from 0.01 to 100, preferably from 0.1 to 20.

The isoparaffin reactant used in the present alkylation process generally possesses up to 20 carbon atoms and preferably 4 to 8 carbon atoms, such as, for example, isobutane, 3-methylhexane, 2-methylbutane, 2,3-dimethylbutane and 2,4-dimethylhexane. The olefin reactant employed herein generally contains from 2 to 12 carbon atoms. Representative examples are ethylene, propylene, butene-1, butene-2, isobutylene, pentenes, hexenes, heptenes and octenes. Particlarly preferred are C- and C, olefins and mixtures thereof. In general, the mole ratio of total isoparaffin to total olefin

alkylating agent in the combined hydrocarbon feed can be from 0.5:1 to 500:1, preferably from 3:1 to 50:1. The isoparaffin and/or olefin reactants can be in either the vapor phase or the liquid phase and can be neat, i.e., free from intentional admixture of dilution with other material, or the reactants can be brought into contact with the catalyst composition with the aid of carrier gases or diluents such as, for example, nitrogen.

The reactants can be introduced to the alkylation reaction zone together with one or more other materials which serve to enhance the overall conversion operation. Thus, for example, relatively small quantities of hydrogen and/or hydrogen donors can be present in the reaction zone to suppress catalyst aging. Water and/or materials such as alcohols which provide water under the alkylation conditions selected can also be introduced into the reaction zone for this purpose. Oxygen and/or other materials which tend to suppress oligomerization of the olefin feed can also be present.

Where water is to be introduced into the alkylation reactor, it is conveniently co-fed at a rate of O.lppmw to 1 wt.%, preferably O.lppmw to 500ppmw, based upon the total hydrocarbon feed rate. Alternatively, water can be,preintroduced into the zeolite catalyst, conveniently in an amount ranging from 0.5 to 25%, preferably 1-10%, by weight of the catalyst. .

The alkylation proςess of the present invention can be carried out as a batch-type, semi-continuous or continuous operation utilizing a fixed or moving bed of the zeolite catalyst component. A preferred embodiment entails use of a catalyst zone wherein the hydrocarbon charge is passed concurrently or countercurrently through a moving bed of the zeolite catalyst. The latter, after use, is conducted to a regeneration zone where coke is removed, e.g., by burning in an oxygen-containing atmosphere (such as air) at elevated temperature or by extracting with a solvent, after which the regenerated catalyst is recycled to the conversion zone for further contact with the organic reactants.

The invention will now be more particularly described with reference to the Examples and the accompanying drawings, in which:

Figures 1-5 are X-ray diffraction patterns of the calcined crystalline material products of Examples 1, 3, 4, 5 and 7, respectively.

In the Examples, whenever sorption data are set forth for comparison of sorptive capacities for water, cyclohexane and/or n-hexane, they were Equilibrium Adsorption values determined as follows:

A weighed sample of the calcined adsorbent was contacted with the desired pure adsorbate vapor in an adsorption chamber, evacuated to less than 1 mm Hg and contacted with 1.6 kPa (12 Torr) of water vapor or 5.3 kPa (40 Torr) of n-hexane or 5.3 kPa (40 Torr) of cyclohexane vapor, pressures less than the vapor-liquid equilibrium pressure of the respective adsorbate at 90°C. The pressure was kept constant (within about _+ 0.5 mm Hg) by addition of adsorbate vapor controlled by a manostat during the adsorption period, which did not exceed about 8 hours. As adsorbate was adsorbed by the crystalline zeolite, the decrease in pressure caused the manostat to open a valve which admitted more adsorbate vapor to the chamber to restore the above control pressures. Sorption was complete when the pressure change was not sufficient to activate the manostat. The increase in weight was calculated as the adsorption capacity of the sample in g/100 g of calcined adsorbant. The zeolite employed herein always exhibits Equilibrium Adsorption values of greater than 10 wt.% for water vapor, greater than 4.5 wt.%, usually greater than 7 wt.% for cyclohexane vapor and greater than 10 wt.% for n-hexane vapor.

When Alpha Value is examined, it is noted that the Alpha Value is an approximate indication of the catalytic cracking activity of the catalyst compared to a standard catalyst and it gives the relative rate constant (rate of normal hexane conversion per volume of catalyst per unit time). It is based on the activity of a highly active silica-alumina cracking catalyst taken as an Alpha of 1 (Rate Constant = 0.016 sec ^" ). The Alpha Test which is used herein is described in J. Catalysis, 61, pp. 390-396 (1980). It is noted that intrinsic rate constants for many acid-catalyzed reactions are

F-5248C5283) - 15 -

proportional to the Alpha Value for a particular crystalline silicate catalyst, i.e., the rates for toluene isproportionation, xylene isomerization, alkene conversion and methanol conversion (see "The Active Side of Acidic Aluminosilicate Catalysts," Nature, Vol. 309, No. 5969, pp. 589-591, 14 June 1984.)

EXAMPLE 1 1 part of sodium aluminate (43.5% A O^, 32.2% Na-0, 25.6% H ₂ 0) was dissolved in a solution containing 1 part of 50% NaOH solution and 103.13 parts H ₂ 0. To this was added 4.50 parts hexamethyleneimine. The resulting solution was added to 8.55 parts of Ultrasil, a precipitated, spray-dried silica (about 90% SiO-). The reaction mixture had the following composition, in mole ratios:

Si0 ₂ /Al ₂ 0 ₃ = 30.0 0H ^" /Si0 ₂ = 0.18

H ₂ 0/Si0 ₂ = 44.9

Na/Si0 ₂ = 0.18

R/Si0 ₂ = 0.35

where R is hexamethyleneimine. The πiixture was crystallized in a stainless steel reactor, with stirring, at 150°C for 7 days. The crystalline product was filtered, washed with water and dried at 120°r. After a 20 hour calcination at 538°C, the X-ray diffraction pattern contained the major lines listed in Table V. Figure 1 shows the X-ray diffraction pattern of the calcined product. The sorption capacities of the calcined material were measured to he:

H ₂ 0 15.2 wt.%

Cyclohexane 14.6 wt.% n-Hexane 16.7 wt.% The surface area of the zeolite was measured to be 494 m /g.

The chemical composition of the uncalcined material was determined to be as follows:

A portion of the calcined crystalline product of Example 1 was tested in the Alpha Test and was found to have an Alpha Value of 224.

11412

-17-

EXA PLES 3-5

Three separate synthesis reaction mixtures were prepared with compositions indicated in Table VI. The mixtures were prepared with sodium aluminate, sodium hydroxide, Ultrasil, hexamethyleneimine (R) and water. The mixtures were maintained at 150°C, 143°C and 150°C, respectively, for 7, 8 and 6 days respectively in stainless steel autoclaves at autogenous pressure. Solids were separated from any unreacted components by filtration and then water washed, followed by drying at 120°C. The product crystals were subjected to X-ray

* diffraction, sorption, surface area and chemical analyses. The results of the sorption, surface area and chemical analyses are presented in

Table VI and the X-ray diffraction patterns are presented in Figures 2, 3 and 4, respectively. The sorption and surface area measurements were of the calcined product.

TABLE VI

Example

EXAMPLE 6

Quantities of the calcined (538°C for 3 hours) crystalline silicate products of Examples 3, 4 and 5 were tested in the Alpha Test and found to have Alpha Values of 227, 180 and 187, respectively.

EXAMPLF 7 To demonstrate a larger preparation of the reαuired zeolite 1200g of hexamethyleneimine was added to a solution containing 268g of sodium aluminate, 267g of 50% NaOH solution and ll,800g of H ₂ 0. To the combined solution was added 2,280g of Ultrasil silica. The mixture was crystallized with agitation (about 200 rpm) at 145°C in a 5 gallon reactor. Crystallization time was 59 hours. The product was water washed and dried at 120°C.

The X-ray diffraction pattern of the dried product crystals is presented in Figure 5 and demonstrates the product to be the crystalline material of this invention. Product chemical composition, surface area and adsorption analyses results were as set forth in Table VII:

Surface Area, m ² /g 479

^■ 19-

EXAMPLE 8

25g grams of solid crystal product from Example 7 were calcined in a flowing nitrogen atmospheres at 538°C for 5 hours, followed by purging with 51 oxygen gas (balance N ₂ ) for another 16 hours at 538°C.

Individual 3g samples of the calcined material were ion-exchanged with 100 ml of 0.IN TEABr, TPABr and LaCl _j solution separately. Each exchange was carried out at ambient temperature for 24 hours and repeated three times. The exchanged samples were collected by filtration, water-washed to be halide-free and dried. The compositions of the exchanged samples are tabulated below demonstrating the exchange capacity of the present crystalline silicate for different ions.

The La-exchanged sample from Example 8 was sized to 14 to

25 mesh and then calcined in air at 538°C for 3 hours. The calcined material had an Alpha Value of 173.

EXA1PLE 10 The calcined sample La-exchanged material from Example 9 was severely steamed at 649°C in 100% steam for 2 hours. The steamed sample had an Alpha Value of 22, demonstrating that the zeolite had very good stability under severe hydrothermal treatment.

EXAMPLE 11 This example illustrates the preparation of the present zeolite where X in the general formula, supra, is boron. Boric

PCI7US90/01926 12

- 20 -

acid, 2.59 parts, was added to a solution containing 1 part of 45% KOH solution and 42.96 parts H ₂ 0. To this was added 8.56 parts of Ultrasil silica, and the mixture was thoroughly homogenized. A 3.88 parts quantity of hexamethyleneimine was added to the mixture. The reaction mixture had the following composition in mole ratios:

H ₂ 0/Si0 ₂ = 19.0 K/Si0 ₂ = 0.06

R/Si0 ₂ = 0.30 where R is hexamethyleneimine.

The mixture was crystallized in a stainless steel reactor, with agitation, at 150°C for 8 days. The crystalline product was filtered, washed with water and dried at 120°C. A portion of the product was calcined for 6 hours at 540°C and found to have the following sorption capacities:

H ₂ 0 11.7 wt.%

Cyclohexane 7.5 wt.% n-Hexane 11.4 wt.%

The surface area of the calcined crystalline material was measured (BET) to be.405 m ² /g.

12

- 21 -

EXAMPLE 12 A portion of the calcined crystalline product of Example 11 was treated with NH ₄ C1 and again calcined. The final crystalline product was tested in the Alpha test and found to have an Alpha Value of 1.

EXAMPLF 1 This example illustrates another preparation of t e zeolite in which X of the general formula, supra, is boron. Boric acid, 2.23 parts, was added to a solution of 1 part of 50% NaOH solution and 73.89 parts H ₂ 0. To this solution was added 15.29 parts of FiSi silica followed by 6.69 parts of hexamethyleneimine. The reaction mixture had the following composition in mole ratios: Si0 ₂ /B ₂ 0 ₃ = 12.3

0H ^" /Si0 ₂ = 0.056 H ₂ 0/Si0 ₂ = 18.6

K/Si0 ₂ = 0.056

R/Si0 ₂ = 0.30 where R is hexamethyleneimine.

The mixture was crystallized in a stainless steel reactor, with agitation, at 300°C for 9 days. The crystalline product was filtered, washed with water and dried at 120°C. The sorption capacities of the calcined material (6 hours at 540°C) were measured: H ₂ 0 14.4 wt.%

Cyclohexane 4.6 wt.% n-Hexane 14.0 wt.%

The surface area of the calcined crystalline material was measured to be 438m /g.

The chemical composition of the uncalcined material was determined to be as follows:

A portion of the calcined crystalline product of Example 13 was tested in the Alpha Test and found to have an Alpha Value of 5.

EXAMPLE 15 This example compares the catalytic performance of the zeolite of the invention with that of zeolite HY for the alkylation of isobutane with 2-butene.

A. Preparation of the Zeolite of the Invention The zeolite of the invention was produced by adding 4.50 parts of hexamethyleneimine to a mixture containing 1.01 parts sodium aluminate, 1.00 part 50% NaOH, 8.56 parts Ultrasil, VN3 and 44.29 parts deionized H ₂ 0. The reaction mixture was heated to

143°C (290°F) and stirred in an autoclave at that temperature for crystallization. After full crystallinity was achieved, the majority of the hexamethyleneimine was removed from the autoclave by controlled distillation and the zeolite crystals were separated from the remaining liquid by filtration, washed with deionized H ₂ 0, exchanged with ammonium and dried. A portion of this zeolite was further exchanged with aqueous solution of ammonium nitrate. The material was then dried overnight at 120°C (250°F), calcined at 480°C (900°F) for three hours in 3v/v/min N ₂ , then treated with 50 vol,% air/50 vol.* N ₂ at 3v/v/min, also at 480°C (900°F) for one hour. The calcination was completed by raising the temperature to 540°C (1000°F) at 3°C (5°F)/min and finally switching to 100% air

(3v/v/min) and holding at this temperature for six hours. The resultant zeolite had an alpha activity of 323, a surface area of

2 455 m /g and contained 28 ppm sodium.

B. Preparation of Zeolite HY The HY catalyst was prepared by exchanging 60g of NaY with

IN NH^NO- _j for one hour at room temperature. The catalyst was filtered, washed, and the exchange procedure was repeated. The ammonium exchanged Y zeolite was calcined in air for three hours at

540°C (1000°F). The final material had an alpha activity of 61, a

2 surface area of 721 m /g, and contained 3.0 wt.% sodium.

C. Alkylation of Isoputane With 2-Butene

To assess the catalytic properties of the above zeolites, separate alkylation runs were carried out batch-wise in an autoclave. The start-up procedure included the charging of 10 grams of catalyst into the reactor followed by sealing of the vessel.

Approximately 350 grams of isobutane/2-butene were then introduced into the autoclave and the slurry was stirred during the subsequent nitrogen pressure test. To commence the reaction, nitrogen pressure was lowered to 1135 kPa (150 psig), and the system heated at a rate of 3°C (5°F)/minute. The final reaction conditions in each run were a temperature of 120°C (250°F), autogeneous pressure 3410 kPa or (480 psig), and a stirring speed of 500 rpm.

The results of the alkylation runs are set forth in Table VIII as follows:

Conversion (%) 95 73 99 85

Product Distribution

c ₉ +

Distribution of Cp Products 2,2,4-trimeth lpropanol 2,3,3-trimethylpropane 2,3,4-trimeth lpropane

Dimethylhexanes Other product(s)

Trimethylpropanes/ Dimethexanes Mole Ratio

As these data show, the use of the alkylation catalyst of the invention resulted in substantially more trimethylpropane alkylate and significantly less Cg+ products compared to the use of zeolite HY catalyst under equivalent conversion conditions.

EXAMPLE 16

This example compares the alkylation performance of a BF ₃ -promoted zeolite alkylation catalyst composition in accordance with this invention and a BF ₃ -promoted silica alkylation catalyst

composition. The catalyst of the invention was prepared by adding a 4.49 parts quantity of hexamethyleneimine to a mixture containing 1.00 parts sodium aluminate, 1.00 parts 50% NaOH, 8.54 parts Ultrasil VN3 and 44.19 parts deionized H ₂ 0. The reaction mixture was heated to 143°C (290°F) and stirred in an autoclave at that temperature for crystallization. After full crystallinity was achieved, the majority of the hexamethyleneimine was removed from the autoclave by controlled distillation and the zeolite crystals were separated from the remaining liquid by filtration, washed with deionized H ₂ 0 and dried. The zeolite was activated by calcining N at 1000°F for six hours, followed by aqueous ammonium nitrate exchange and calcining in air at 1000°F for six hours.

In separate runs, lOg of each of the foregoing catalyst compositions and 300 ml isobutane were charged to a reactor. Following cooling of the reactor contents to the desired alkylation temperature accompanied by constant stirring at 1900 rpm, BF ₃ gas was introduced to the reactor at a flow rate of 3 wt.% of the total hydrocarbon feed. The feed olefin was then continuously introduced into the reactor to initiate alkylation. The mole ratio of isobutanes to total olefin was 10:1, the reaction temperatures were 0 or 20°C as indicated below, and the WHSV (based on total olefin) was 1.3. The composition of the feed is given in Table IX and results of the alkylation operations for both catalyst compositions are set forth in Table X as follows: TABLE IX

Composition of Paraf ^' fin-Olefin Feed

Olefin Propylene + Butenes

Isobutane:01efin Mole Ratio 12:1

Feed Component Wt.% propylene 3.30 isobutylene 1.24

1-butene 1.01

2-butene 2.14 isobutane 92.31

TABLE X BF3-Promoted Siθ2 BF^-Promoted Zeolite

Alkylation Temp., °C 0 20 0 20 C-+ Product wt.%

TMP = trimethylpentanes

DM3 = dimethylhexanes

EXAMPLE 17 Example 16 was substantially repeated but with a feed having the composition set forth in Table XI as follows:

TABLE XI

Composition of Paraffin-Olefin Feed

Olefin Propylene + Butenes

Isobutane:01efin Mole Ratio 5.7:1

Feed Component Wt.% propylene 5.60 isobutylene 2.90

1-butene 2.00

2-butene 4.45 isobutane 84.40 n-butane 0.65 .

The results of the alkylation operations are set forth in Table XII as follows:

TABLE XII

Example 16 was substantially repeated but with a feed having the composition set forth in Table XIII as follows:

TABLE XIII

Composition of Paraffin-Olefin Feed

Olefin Propylene + Butenes

Isobutane:01efin Mole Ratio 10:1

Feed Component Wt.% isobutylene 5.73

1-butene 0.26

2-butene 2.98 isobutane 90.93 n-butane 0.10

The results of the alkylation operations are set forth in

Table XIV as follows:

TABLE XIV

Example 16 was substantially repeated but with a feed having the composition set forth in Table XV as follows:

TABLE XV

Composition of Paraffin-Olefin Feed

Olefin Propylene + Butenes

Isobutane:01efin Mole Ratio 12.9:1

Feed Component Wt.% propylene ^" 37∑2 isobutylene 2.74

1-butene 0.15

2-butene 1.24 isobutane 92.50 n-butane 0.15

The results of the alkylation operation are set forth in Table XVI as follows:

TABLE XVI

Example 16 was substantially repeated but with a feed having the composition set forth in Table XVII as follows:

TABLE XVII

Composition of Paraffin-Olefin Feed

Olefin Butene

Isobutane:01efin Mole Ratio 9.6:1

Feed Component Wt.% 2-butene 9.4 isobutane 90.60

The results of the alkylation operation are set forth in Table XVIII as follows:

TABLE XVIII BFy Promoted SiO? BFyPromoted Zeolite

Alkylation Temp. , °C 0 20 0 20 C-+ Product, wt. %

3.6 3.2 3.9 86.8 2.6 3.4

94.8 93.3

—31—

EXAMPLES 21 - 24

The procedure of Example 16 was repeated with a BF ₃ -promoted zeolite alkylation catalyst of the invention (Example 21) and the results were compared with those obtained with a similar catalyst to which water had been added (Examples 22 and 23) and with a BF ₃ /H ₂ 0 catalyst system. The results are su___narized in Table XIX.

From Table XIX, it will be seen that, at identical process conditions, the BF./zeolite/H-O system was more active than the catalyst without H ₂ 0 (100 vs. 57% olefin conversion) and produced a higher quality of alkylate product (6.2 vs. 71.7 wt% C _g+ ). In addition, the alkylate produced by the BF./zeolite/H-O catalyst was superior (higher C _g and lower C _g> ) to the product from the BF ₃ /H ₂ 0 system.

23 24 BF ₃ /Zeolite H ₂ 0 1/1 BF3/H2O (No Solid)

10

Teep. (°C) 10 10 20 20

Pressure, psig (kPa) 150 (1135) 150 (1135) 150 (1135) 150 (1135) BF ₃ Rate (wt.l of feed) 2.0 2.0 3.0 3.0 Olefins in Feed 2-Butenes

10 2-Butenes Mixed C3, C4 Mixed C ₃ , C4 iC ₄ /01efins Feed Ratio 10 10 10 Olefin WHSV 1.35 1.35 2.24 2.24

Olefin Conv. (t) 57 100 100 Yield 100 1.2 2.0 2.0 2.2 ι->

>

Total Product Distribution (wt.l)