LEWIS ACID PROMOTED TRANSITION ALUMINA CATALYSTS AND ISOPARAFFIN ALKYLATION PROCESSES USING THOSE CATALYSTS

Abstract: This invention is to: a) a catalyst system, b) a component of that system comprising certain transition aluminas promoted with a Lewis acid (preferably BF3), and c) a catalytic process for the alkylation of isoparaffin with olefins. The catalyst component is produced by contacting the transition alumina with the Lewis acid at relatively low temperatures or at those temperatures at which certain characteristic peaks appear in the component's nuclear magnetic resonance (NMR) spectrum. The catalyst system comprises that component and an additional amount of free Lewis acid. The process entails olefin/isoparaffin alkylation using the catalyst component and its allied catalyst system.

Description: LEWIS ACID PROMOTED TRANSITION ALUMINA CATALYSTS AND ISOPARAFFIN ALKYLATION PROCESSES USING THOSE CATALYSTS RELATED APPLICATIONS This is a coπtinuation-in-part of U.S. Patent Application No. 07/697,318, filed May 7, 1991, which in turn is a continuation-in-part of U.S. Patent Application No. 07/588,448, filed September 26, 1990, and also a continuation-in-part of U.S. Patent Application No. 07/697,320, filed May 7, 1991, the entirety of which are incorporated by reference. FIELD OF THE INVENTION This invention is to: a.) a catalyst system, b.) a component of that system comprising certain transition aluminas promoted with a Lewis acid (preferably BF 3 ), and c.) a catalytic process for the alkylation of isoparaffin with olefins. The catalyst component is produced by contacting the transition alumina with the Lewis acid at relatively low temperatures. The catalyst system comprises that component and an additional amount of free Lewis acid. The process entails olefin/isoparaffin alkylation using the catalyst component and its allied catalyst system. BACKGROUND OF THE INVENTION The preparation of high octane blending components for motor fuels using strong acid alkylation processes (notably where the acid is hydrofluoric acid or sulfuric acid) is well-known. Alkylation is the reaction in which an alkyl group is added to an organic molecule, typically an aromatic or olefinic molecule. For production of gasoline blending stocks, the reaction is between an isoparaffin and an olefin. Alkylation processes have been in wide use since World War II when high octane gasolines were needed to satisfy demands from high compression ratio or supercharged aircraft engines. The early alkylation units were built in conjunction with fluid catalytic cracking units to take advantage of the light end by- products of the cracking units: isoparaffins and olefins. Fluidized catalytic cracking units still constitute the major source of feedstocks for gasoline alkylation units. In spite of the mature state of strong acid alkylation technology, existing problems with the hydrofluoric and sulfuric acid technologies continue to be severe: disposal of the used acid, unintentional emission of the acids during use or storage, substantial corrosivity of the acid catalyst systems, and other environmental concerns. Although a practical alkylation process using solid acid catalysts having little or no corrosive components has long been a goal, commercially viable processes do not exist. The open literature shows several systems used to alkylate various hydrocarbon feedstocks. The American Oil Company obtained a series of patents in the mid-1950's on alkylation processes involving C 2 -C 12 (preferably C 2 or C g ) olefins and C 4 -C 8 isoparaffins. The catalysts used were BF 3 -treated solids and the catalyst system (as used in the alkylation process) also contained free BF 3 . A summary of those patents is found in the following list: BF 3 -Treated Catalyst* fwith free BF 3 ) Si0 2 stabilized Al 2 0 3 (10%-60% by weight BFa) metal pyrophosphate hydrate metal surfate hydrate metal stannate hydrate metal silicate hydrate metal orthophosphate hydrate metal tripolyphosphate hydrate metal pyroarsenate hydrate Co or Mg arsenate hydrate Co, Al, or Ni borate hydrate metal pyroantimonate hydrate salt Co or Fe molybdate hydrate Al, Co, or Ni tungstate hydrate borotungstic acid hydrate or Ni or Cd borotungstate hydrate phosphomolybdic acid hydrate solid gel alumina (5%-100% by weight of Zn or Cu fluoborate, preferably anhydrous) *may be supported on Al 2 0 3 s None of these discloses a process for alkylating olefins and isoparaffins using neat alumina treated with BF 3 . Related catalysts have been used to oligomerize olefins. U.S. Patent No. 2,748,090 to Watkins suggests the use of a catalyst made up of a Group VIII metal (preferably nickel), a phosphoric acid (preferably containing phosphorus peπtoxide), all placed on an alumina adsorbent, and pretreated with BF 3 . Alkylation of aromatics is suggested. U.S. Patent No. 2,976,338 to Thomas suggests a polymerization catalyst comprising a complex of BF 3 or H 3 P0 4 optionally on an adsorbent (such as activated carbon) or a molecular sieve optionally containing potassium acid fluoride. Certain references suggest the use of alumina-containing catalysts for alkylation of aromatic compounds. U.S. Patent No. 3,068,301 to Hervert et al. suggests a catalyst for alkylating aromatics using "olefin-acting compounds". The catalyst is a solid, silica-stabilized alumina containing up to 10% Si0 2 , ail of which has been modified with up to 100% by weight of BF 3 . None of these prior references suggest either the process nor the material used in the processes as is disclosed here. Other BF 3 -treated aluminas are known. For instance, U.S. Patent No. 3,114,785 to Hervert et al. suggests the use of a BF 3 -modified, substantially anhydrous alumina to shift the double bond of 1-butene to produce 2-butene. The preferred alumina is substantially anhydrous gamma-alumina, eta-alumina, or theta-alumina. The various aluminas will adsorb or complex with up to about 19% by weight fluorine depending upon the type of alumina and the temperature of treatment. The aluminas are treated with BF 3 at elevated temperatures. Hervert §_ _. does not suggest using these catalysts in alkylation reactions. In U.S. Patent No. 4,407,731 to Imai, a high surface area metal oxide such as alumina (particularly gamma-alumina, eta-alumina, theta-alumina, silica, or a silica-alumina) is used as a base or support for BF 3 . The BF 3 treated metal oxide is used for generic oligomerization and alkylation reactions. The metal oxide is treated in a complicated fashion prior to being treated with BF 3 . The first step entails treating the metal oxide with an acid solution and with a basic aqueous y solution. The support is washed with an aqueous decomposable salt such as ammonium nitrate. The support is washed using deionized H 2 0 until the wash water shows no alkali or alkaline earth metal cations in the filtrate. The support is dried and calcined. The disclosure suggests generically that BF 3 is then introduced to the treated metal oxide support. The examples show introduction of the BF 3 at elevated temperatures, e.g. 300* C or 350* C. Similarly, U.S. Patent No. 4,427,791 to Miale et al. suggests the enhancement of the acid catalytic activity of inorganic oxide materials (such as alumina or gallia) by contacting the material with ammonium fluoride or boron fluoride, contacting the treated inorganic oxide with an aqueous ammonium hydroxide or salt solution, and calcining the resulting material. The inorganic oxides treated in this way are said to exhibit enhanced Brδnsted acidity and, therefore, are said to have improved acid activity towards the catalysis of numerous reactions (such as alkylation and isomerization of various hydrocarbon compounds). A specific suggested use for the treated inorganic oxide is as a matrix or support for various zeolite materials ultimately used in acid catalyzed organic compound conversion processes. U.S. Patent No. 4,751,341 to Rodewald shows a process for treating a ZSM-5 type zeolite with BF 3 to reduce its pore size, enhance its shape selectivity, and increase its activity towards the reaction of oligomerizing olefins. The patent also suggests using these materials for alkylation of aromatic compounds. Certain Soviet publications suggest the use of Al 2 0 3 catalysts for alkylation processes. Benzene alkylation using those catalysts (with 3 ppm to 5 ppm water and periodic additions of BF g ) is shown in Yagubov, Kh. M. et al.. Azerb. Khim. Zh,, 1984, (5) p. 58. Similarly, Kozorezov, Yu and Levitskii, E.A., Zh. Print. Khim. ( Leningrad ). 1984, ≤7 (12), p. 2681, show the use of alumina which has been heated at relatively high temperatures and modified with BF 3 at 100* C. There are no indications that BF 3 is maintained in excess. Isobutane alkylation using Al 2 0 3 /BF 3 catalysts is suggested in Neftekhimiva. 1977, J7 (3), p. 396; 1979, .19 (3), p. 385. The oiefin is ethylene. There is no indication that BF 3 is maintained in excess during the reaction. The crystalline form of the alumina is not described. U.S. Patent No. 4,918,255 to Chou et al. suggests a process for the <ό alkylation of isoparaffins and olefins using a composite described as "comprising a Lewis " acid and a large pore zeolite and/or a non-zeolitic inorganic oxide". The process disclosed requires isomerization of the olefin feed to reduce substantially the content of aipha-olefin and further suggests that water addition to the alkylation process improves the operation of the process. The best Research Octane Number (RON) product made using the inorganic oxides (in particular SiO^ is shown in Table 6 to be 94.0. Similarly, PCT published applications WO 90/00533 and 90/00534 (which are based in part on the U.S. patent to Chou et al. noted above) suggest the same process as does Chou et al. WO 90/00534 is specific to a process using boron trrfluoride-treated inorganic oxides including "alumina, silica, boria, oxides of phosphorus, titanium oxide, zirconium oxide, chromia, zinc oxide, magnesia, calcium oxide, siiica-alumina-zirconia, chromia-alumina, alumina-boria, siiica- zirconia, and the various naturally occurring inorganic oxides of various states of purity such as bauxite, clay and diatomaceous earth". Of special note is the statement that the "preferred inorganic oxides are amorphous silicon dioxide and aluminum oxide". The examples show the use of amorphous silica (and BFg) to produce alkyiates having an RON of no greater than 94. None of these disclosures shows crystalline transition aluminas which were promoted with Lewis acids at lower temperatures nor any effect upon the NMR spectrum because of such a treatment. Nor do these disclosures show their use in isoparaffin/olefin alkylation. These disclosures further do not show any benefit to the alkylation of isoparaffins and olefins using these specifically treated aluminas. BRIEF DESCRIPTION OF THE DRAWINGS Figures 1A-1D are nuclear magnetic resonance (NMR) plots of certain transition aluminas treated with BF 3 at a range of temperatures. Figure 2 is a three-dimensional graph showing octane sensitivity for the inventive process as a function of olefin feed content. SUMMARY OF THE INVENTION This invention is variously a catalyst component comprising one or more transitional aluminas which are treated with one or more Lewis acids (preferably BFa) at a fairly low temperature desirably so low that the component exhibits specific NMR spectra, a catalyst system comprising that catalyst component with excess Lewis acid, and an olefin/isoparaffin aikyation process step using that catalyst system. Use of the catalyst system, i.e., the catalyst component in conjunction with excess Lewis acid, produces high octane alkylate from isobutane and butyiene at a variety of reaction temperatures between -30 * C and 40 * C. The catalyst's high activity can result in low operating costs because of its ability to operate at high space velocities. DESCRIPTION OF THE INVENTION This invention is: A) a catalyst component comprising certain Lewis add treated transition aluminas, B) a catalyst system comprising the catalyst component in combination with at least a minor amount of free Lewis acid, and C) an alkylation process for producing branched paraffinic products from olefins and isoparaffins using that catalyst system. The Catalyst Component The catalyst component of this invention comprises or consists essentially of a major amount of transition aluminas (preferably eta- or gamma-alumina) which has been treated with a Lewis acid, preferably BF 3 . The catalyst component is acidic in nature and contains substantially no metals (except, of course, aluminum and the semi-metal boron) in catalytic amounts capable of hydrogenating the hydrocarbons present in the feeds except those metals may be present in trace amounts in the Lewis acid or the alumina. Alumina Aluminum oxide (alumina) occurs abundantly in nature, usually in the form of a hydroxide in the mineral bauxite, along with other oxidic impurities such as Ti0 2 , Fe 2 0 3 , and Si0 2 . The Bayer process is used to produce a reasonably pure Al 2 0 3 having a minor amount of Nap. The Bayer process may be used to produce a variety of alumina hydroxides: The aluminum hydroxides may then be treated by heating to produce various activated or transition aluminas. For instance, the aluminum hydroxide known as boehmite may be heated to form a sequence of transition phase aluminas: gamma, delta, theta, and finally, alpha (see Wefers et al.. "Oxides and Hydroxides of Alumina", Technical Paper No. 19, Aluminum Company of America, Pittsburgh, PA, 1972, pp.1-51). Transition aluminas (and their crystalline forms) include: Activated aluminas and aluminum hydroxides are used in various chemical processes as catalyst and adsorbents. The aluminas suitable for use in this process include the noted transition aluminas: gamma, delta, eta, theta, chi, kappa, or lambda. Especially preferred r are gamma- and eta-aluminas. Mixtures of the two are also desireable. Since it is difficult to produce a substantially pure single phase transition alumina, mixtures of various aluminas are tolerable so long as a major amount of the specified alumina is present in the catalyst. For instance, in the production of eta-alumina, gamma-alumina is often concurrently present in the resulting product. Indeed, x-ray diffraction analysis can only difficultly detect the difference between the two phases. Aluminum hydroxides (boehmite, gibbsite, etc.) may be present in the predominately transition phase product in more than trivial amounts so long as they do not substantially affect the desired alkylation reaction. The alumina may be produced in any appropriate form such as pellet, granules, bead, sphere, powder, or other shape to facilitate its use in fixed bed, moving bed, slurry, or fluidized bed reactors. Lewis Acids The catalyst component of this invention contains one or more Lewis acids in conjunction with the alumina noted above. A Lewis acid is a molecule which can form another molecule or an ion by forming a complex in which it accepts two electrons from a second molecule or ion. Typical strong Lewis acids include boron halides such as BF 3> BCI 3 , BBr 3 , and Bl 3 ; antimony peπtafluoride (SbF^; aluminum halides (AICI 3 and AIBr- j ); titanium halides such as TiBr 4 , TiCI 4 , and TiCI 3 ; zirconium tetrachloride (ZrCI 4 ); phosphorus pentafluoride (PF^; iron halides such as FeCI 3 and FeBr 3 ; and the like. Weaker Lewis acids such as tin, indium, bismuth, zinc, or mercury halides are also acceptable. Preferred Lewis acids are boron containing materials (BF 3 , BCI 3 , BBr 3 , and By, SbF 5 , and AICI 3 ; most preferred is BF 3 . The Lewis acid typically forms complexes or surface compounds with the alumina substrate. For instance, BF 3 forms aluminum fluoroborate sites with the hydroxyi groups found at the alumina surface and additionally is physi-sorbed at the alumina surface. The total amount of Lewis acid in the alumina surface is between 0.5% and 40% by weight of the catalyst depending in large measure on two factors: the Lewis acid chosen and the susceptibility of the alumina surface to accepting the ? Lewis acid by chemisorption or by physisorption. In the case of BF 3 , we believe that 5-20% of the weight of the alumina catalyst component is attributable to BF 3 products (e.g., the production of aluminum fluoroborate or similar compounds) and the remainder is physi-sorbed BF 3 . To maintain the presence of sufficient Lewis add on the catalyst composition, we have found it desirable to maintain at least a minor amount of the Lewis acid in the proximity of the alumina surface, preferably in the reaction fluid. This amount is an amount at least sufficient to maintain the concentration of the Lewis add specified above on the alumina. At the WHSV ranges specified above with regard to the alkylation reaction, we have found that generally an amount of at least 0.5% of Lewis acid (based on the hydrocarbon) is sufficient to maintain the Lewis acid level on the alumina. On an alumina basis, the ratio of free Lewis acid (that is, Lewis acid in t e proximity of the alumina but not associated with the alumina by chemisorption or physisorption) to alumina is in the range of 0.05 to 25 g Lewis acid/g Al 2 0 3 . For BF 3 the preferred range is 0.15 to 20 g BF g /g AJ 2 0 3 , is more preferably in the range of 0.20 to 15 g BF 3 /g Al 2 0 3 , and is most preferably in the range of 0.10 to 15 g BF 3 /g Al 2 0 3 . Catalyst Component Preparation The catalyst component may be prepared in situ in, e.g., an alkylation reactor by passing the Lewis acid in gaseous form through the vessel containing the transition alumina. Alternatively, the alumina may be contacted with the Lewis acid and later introduced into the reactor. In any case, the alumina may be substantially dry or anhydrous prior to contact with the Lewis acid and maintained in a state of dryness, i.e., maintained at a very low free H 2 0 content. The alumina phase chosen in conjunction with proper treatment of the alumina to maintain the presence of hydroxyl groups (usually by maintaining the alumina at temperatures below 450 * C during pretreatment) allows the presence of about 4-10 hydroxyl groups per 100 A 2 of alumina surface area. Preferred is 6-10 hydroxyl groups per 100 A 2 of alumina surface area. The alumina is preferably completely hydroxylated since that hydroxylation, in turn, permits the formation of the maximum amount of the AI-OH- /0 Lewis add complex, believed to be one element of the active alkylation catalyst at the alumina surface. The alumina may be partially or substantially dehydroxylated but the catalyst is not as efficacious. Additionally, free water (in distinction to the water which may be identified as hydroxyl groups on the alumina surface) may be present in limited amounts in the alumina. The free water content in the alumina may range between 0.0 and 10% by weight but preferably is between about 0.0 and about 5.0 %. If the Lewis add chosen is BF 3 , the free water content of the alumina may be between 0.0 and 4.0 % (by weight), preferably between 1.0 and 3.5 %, and most preferably between 2.5 and 3.5 %. Higher amounts of water appear both to degrade the catalyst and to impair the effectiveness of the catalyst in the practice of the alkylation reaction. Higher amounts of water also tend to form compounds, such as BF 3 hydrates, which are corrosive and therefore undesirable. Contact temperatures between -25* C and less than about 150 * C are acceptable; a temperature between -25* C and 100*C is desirable; a temperature between -30 * C and 30 * C is preferred. The partial pressure of gaseous Lewis acid added to the alumina is not particularly important so long as a sufficient amount of Lewis acid is added to the alumina. We have found that treatment of the alumina with BF 3 at the noted temperatures will result in an alumina-BF 3 complex containing BF 3 sufficient to carry out the alkylation. The alumina contains between 0.5% and 30% by weight of BF 3 . We have observed that solid state boron-nuclear magnetic resonance ( 11 B-NMR) analysis of the catalyst component provides evidence (a pronounced peak at about -21.27 ppm relative to boric add) of tetragonal boron in the catalyst composite produced at the lower temperatures. Aluminas treated at temperatures of 150 * C and higher do not show these spectra but instead show evidence of trigonal symmetry about the boron. Acceptably active catalysts are those in which the relative amounts of trigonal boron:tetragonal boron (as calculated by the integration of the respective 11 B-NMR spectra) are in the range of 0 to 0.5. The lower the value of the ratio, the more effective the catalyst has been found to be in alkylation reactions. More preferred is the range of 0.0 to 0.25; most preferred is 0.0 to 0.1. Additionally, we have observed that when the alumina substrates are heated at temperatures above about 400 * C before they are contacted with the Lewis acid BF 3 , that certain areas of the infrared spectra are modified. The Fourier Transform Infrared (FTIR) absorbances at about 1557 and 1510 cm *1 which we observe when the alumina is treated at temperatures below that level disappear above this temperature. Although we believe that the disappearance of those IR spectral absorbances is somehow related to the decomposition of the key surface intermediates involved in the catalytic function, we do not wish to be bound to this theory. Obviously, the alumina may be incorporated into a binder prior to its treatment with Lewis acid. The binders may be days (such as montmorillonite and kaolin) or silica based materials (such as gels or other gelatinous precipitates). Other binder materials include carbon and metal oxides such as alumina, silica, titania, zirconia, and mixtures of those metal oxides. The composition of the binders is not particularly critical but care must be taken that they not substantially interfere with the operation of the alkylation reaction. The preferred method for incorporating the catalytic alumina into the binder is by mixing an aluminum hydroxide precursor (such as boehmite) with the binder precursor, forming the desired shape, and calcining at a temperature which both converts the aluminum hydroxide precursor into the appropriate transition phase and causes the binder precursor to bind the alumina particles. The absolute upper temperature limit for this calcination is about 1150*C. Temperatures below about 1000 * C may be appropriate. Alkylation Process The inventive catalyst component and the allied catalyst composition are especially suitable for use in alkylation processes involving the contact of an isoparaffin with an olefin. The catalyst component should be used in conjunction with an amount of free Lewis acid. Specifically, the catalyst system (the inventive catalyst component in combination with a free Lewis acid) is active in alkylation reactions at low temperatures (as low as -30 * C) as well as at higher temperatures (nearing 50' C). Lower temperatures (-5'C to 15 * C) are preferred because of the enhanced octane of the alkylate produced and are particularly preferred if the feedstream contains more than about 1% isobutylene. Higher temperatures also tend to produce larger amounts of polymeric materials. The pressure used in this process may be between atmospheric pressure and about 750 psig. Higher pressures within the range allow recovery of excess reactants by flashing after the product stream leaves the alkylation reactor. The amount of catalyst used in this process depends upon a wide variety of disparate variables. Nevertheless, the Weight Hourly Space Velocity ("WHSV" = weight of olefin feed/hour + weight of catalyst) may effectively be between 0.1 and 120, especially between 0.5 and 30. The overall molar ratio of isoparaffin to olefin may be between about 1.0 and 50.0. Preferred ranges include 2.0 and 25.0; the more preferred include 3.0 and 15.0. The feedstreams introduced to the catalyst are desirably chiefly isoparaffins having from four to ten carbon atoms and, most preferably, four to six carbon atoms. Isobutane is most preferred because of its ability to make high octane alkylate. The olefins desirably contain from three to twelve and preferably from three to five carbon atoms, i.e., propylene, cis- and trans-butene-2, butene-1, and amylene(s). Preferably, the olefin stream contains little (if any) isobutylene. Similarly, for the inventive catalysts the process works better in producing high octane alkylate if the feedstream contains little or no butadiene (preferably less than 0.2% to 0.3% molar of the total olefins) and a minimal amount of isobutylene, e.g., less than about 2.5% molar based on the olefins. Although the catalyst alkylates butene-1, it is preferred to operate with a minimum of butene-1, e.g., less than about 10% by mol, since it lowers the octane values of the resulting alkylate. Of course, if it is desired to operate a process with high throughput rather than with highest octane, a higher level of butene-1 is tolerable. An excellent source of a feedstock containing a low level of isobutylene is the raffinate from a process which produces methyl-t-butylether (MTBE). The water content of the feedstocks may vary within wide limits, but preferably is at a low level. The water content should be less than about 200 ppmw and most preferably less than about 50 ppmw. Higher levels of water content tend to lower the octane value of the resulting alkylate and form corrosive hydrates or reaction products with the Lewis acids. " The feedstocks should contain a minimum of oxygenates such as ethers and alcohols. Oxygenates appear to lessen substantially the effectiveness of the catalyst system. The products of this alkylation process typically contain a complex mixture of highly branched alkanes. For instance, when using isobutane as the alkane and n-butylene as the olefin, a mixture of 2,2,3-; 2,2,4-; 2,3,3-; and 2,3,4- trimethylpentane (TMP) will result often with minor amounts of other isomeric or polymeric products. The 2,3,4-TMP isomer is the lowest octane isomer of the noted set. The 2,2,3- and 2,2,4-TMP isomers are higher octane components. Calculated average octane values (RON plus Motor Octane Number [MON]/2) of The process may be carried out in the liquid, vapor, or mixed liquid and vapor phase. Liquid phase operation is preferred. The invention has been disclosed by direct description. Below may be found a number of examples showing various aspects of the invention. The examples are only examples of the invention and are not to be used to limit the scope of the invention in any way. EXAMPLES Example 1 : Catalyst Testing This example shows the preparation of a number of alumina-based catalysts in situ and their subsequent use in an alkylation reaction using model /¥ feeds. It is used to evaluate catalyst activity and selectivity. The alumina samples were dried at 150 * C overnight and charged to a semi-batch reactor having an internal volume of about 500 cc. The reactor temperature was controllable over the range of -5 * C to 40 * C. For initial catalyst treatment, the reactor containing the catalyst was purged with an inert gas and cooled to about 0 * C. About 275 cc of isobutane was added to the reactor. After a brief degassing, BF 3 was added batchwise. After BF 3 is added, the pressure typically drops as the alumina adsorbs or reacts with the BF 3 . Additional infusions of BF 3 are made until the pressure in the reactor no longer drops. The BF 3 saturation equilibrium pressure was about 40 psig. The liquid phase concentration of BF 3 was about 1.5%. At that point the alumina had adsorbed or reacted with all of the BF 3 possible at that temperature and the catalyst was in its most active form. A 4/1 molar mixture of isobutane and trans-2-butene was added to the reactor at a WHSV of 3.5 until the paraffin to olefin ratio reached 25. The product alkylate was then removed from the reactor vessel and analyzed using gas-liquid chromatography. The results of those runs are shown in Table I. Table 1 It is clear from these preliminary screening data that the transition (gamma and delta) aluminas produce significantly higher percentages of C 8 in the product alkylate than do the other aluminum hydroxide catalysts. The result did not appear to correlate to the specific surface area of the catalyst. Example 2: Catalyst Screening This example compares the performance of eta-alumina (a preferred form of the inventive catalyst) with representative samples of other addic oxides each combined with BF 3 for the reaction of isobutane with butenes to produce alkylate. The eta-alumina sample was prepared by a controlled thermal treatment of bayerite (Versal B from LaRoche Chemical) for 15 hours at 250 * C and 24 hours at 500 * C under a N 2 atmosphere. The comparative oxidic materials were: silica-alumina, synthetic mordenite zeolite, and fumed silica. The silica-alumina (obtained from Davisoπ Chemical) contained 86.5% Si0 2 and had a surface area of 392 m 2 /gm. It was used without further treatment. The mordenite was a hydrogen form zeolite and was obtained from Toyo Soda. It was prepared from Na-mordenite and subjected to ion exchange, steam treatment, and calcination to achieve a Si/AI ratio of 28. Each of the samples was dried at 150* C overnight and introduced into the semi-batch reactor described in Example 1. The samples were purged with a dry inert gas and cooled to 0' C. Isobutane was added to the reactor to an initial volume of 100 cc. BF 3 was added with stirring until an equilibrium pressure of 30 psig was obtained. A mixture of isobutane/t-2-butene was fed to the reactor. At the completion of the reaction, alkylate was removed and analyzed by gas-liquid chromatography. The RON were calculated from the gas-liquid chromatography data using the well- known correlations in Hutson and Logan, "Estimate Alky Yield and Quality", Hydrocarbon Processing, September, 1975, pp. 107-108. The summary of the experiments and results is shown in the table below: /& Table 2 Eta- Siiica- Dealuminated A!^ Alumina Mordenite Silica Catalyst charge (g) 3.5 3.7 2.4 1.8 Temperature ( * C) 0 0 0 0 i-C 4 charge ml (initial) 180 180 180 375 i-C 4 /C 4 "feed ratio (molar) 5.2 5.9 5.9 9.5 Space velocity (WHSV) 2.6 2.0 3.3 2.8 Run time (minutes) 36 34 28 58 i-C 4 /C 4 , (final) 23.5 30.3 34.0 57 Butene conversion (%) 100 100 100 100 Product analysis (weight %): m Clearly, for the eta-alumina catalyst, the yield of C 8 's was significantly higher; th overall yield and RON were much better. Example 3 This example shows that the addition of either water or methanol produ no appreciable improvement on the alkylation of butene-2 with isobutane using inventive alumina catalyst. Indeed, water and methanol appear to be detriment Three separate semi-batch reactors were dried and flushed with nitroge A sample of 2.5 gm of a gamma-alumina (LaRoche VGL) was loaded into each bottle. The alumina samples had been previously dried at 110 * C overnight. A amount of 0.278 gms of deionized water was added dropwise to one reactor. amount of 0.988 gms of methanol was added to another reactor. These amou were calculated to be 10% of the catalyst plus water equivalent. The remainin reactor was used as a control reactor. Isobutane (246 cc) was added to each bottle; BF 3 was added (with stirring) until the pressure reached a constant 30 A feedstock of 2/1 : isobutane/2-butene was continuously added at a rate of 1. /7 cc/minute. The reaction continued for about 75 minutes after which samples of the reactor liquids were extracted and analyzed using a gas-liquid chromatograph. The conversion of olefin was more than 99% in each case. Other reaction conditions and a summary of reaction results are shown in the following table: Reaction Conditions Alumina Alumina w/H ; Q Alumina Reaction temperature ( * C) 0 0 0 Pressure (psig) 30.0 30.0 30.0 WHSV 5.653 5.526 5.526 I/O (w/w) 10.3 10.63 10.63 Product C 8 (saturated) <v TMP/C 8 Yield (w/w) RON R+M/2 It is clear that neither water nor methanol created any advantage in the operation of the process in producing a gasoline alkylate. The gross amounts of C 8 produced were smaller than for the inventive alumina; the amount of undesirable C 12 + were two to four times higher than for the inventive alumina. The yields were lower and, probably most importantly, the octane values of the comparative products were significantly lower. Example 4 This example shows the suitability of the inventive catalyst (gamma-alumina, LaRoche GL) for a variety of olefin feedstocks. The following reaction conditions were used for the test series: A semi-batch reactor was utilized in each run. The olefin feedstocks were mixtures which were chosen to allow us to identify desirable and undesirable combinations of feed materials. The mixtures were: /f The products made were analyzed using gas-liquid chromatography and their respective octane numbers calculated as follows: These data show that increases in isobutene and propylene feed concentrations directionally cause the inventive alkylation process to produce lower alkylate C 8 content. As shown in Figure 1, smaller amounts of either C 3 " or i-C 4 " cause no more harm to alkylate quality but are generally undesirable if extremely high octane alkylates are necessary. Example 5 This example demonstrates the performance of the transition alumina/BF 3 catalysts in reacting isobutane with butenes to form high octane product under conditions of high space velocity and low paraffin/olefin feed ratios. 0 A sample of gamma-alumina (VGL, LaRoche) was dried overnight at 110 * C and loaded into the semi-continuous reactor unit described in Example 1. The catalyst was purged with dry inert gas and cooled to 0 * C. Isobutane was added to the reactor and then the system was exposed to BF 3 under stirring conditions until an equilibrium pressure of 30 psig was achieved. A feed comprising pure trans-2-butene was then pumped into the reactor under vigorous stirring conditions over a period of 60 minutes; samples were obtained periodically during the run. The results are summarized in the table below: Example 6 This example shows, the utility of the catalyst system on a feed obtained from a refinery MTBE unit. The feed, containing minor amounts of butadiene and isobutene, was introduced into a bed of a commercial hydroisomerization catalyst (0.3% Pd on Al jj Og) at 400 cc/hr, 80 * C, and 350 psig along with 14 seem H 2 . The molar ratio of H 2 :butadiene was 6:1. The thusly treated feed, containing no butadiene and 0.52 % (molar) of isobutene, was mixed with an appropriate amount of isobutane. The mixture had the following approximate composition: <*/ This mixture had an isoparaffin/olefin ratio of 6.10 and an isobutane/olefin ratio of 5.69. The mixture was then admitted to a pair of continuous laboratory reactors each containing 280 cc of liquid and containing 5.04 g of catalyst. The temperature was maintained at 0 * F. The WHSV for the reactor was 4.3 hr '1 and the LHSV was 1.07 hr *1 . The catalyst was a gamma alumina (LaRoche VGL) and was prepared by adding the proper amount to the reactors along with a small amount of isobutane, pressuring the reactor to about 40 psig of BF 3 , and maintaining that pressure for the duration of the test. The test was run for 41 hours total time. The catalyst was regenerated four times during the run by rinsing the catalyst in 200cc of trimethyl pentane, heating to 150 * C in air for 45 minutes to volatilize a portion of the reaction product on the catalyst, and heating the catalyst to 600* C in air for 60 minutes to oxidize the remaining hydrocarbonaceous materials. Small amounts of the catalyst were added as necessary with the regenerated catalyst to restore the catalyst to its proper amount upon return to the reactor (0.41 g @ cycle 2, 0.97 g @ cycle 3, 0.0 g @ cycle 4, and 0.47 g @ cycle 5). About 4.5 liters (3.2 kg) of stripped C 5+ alkylate was collected having about 7.6% C^, 81.2% C 8 , 4.4% C g .,,, and 6.8% C 12 (all by weight). Using the Hutson method discussed above, the octanes were calculated to be: RON = 96.6, MON = 93.3, and the (R+M)/2 = 94.95. The product was then engine-tested using API methodology and the octanes were measured to be: RON = 98.7, MON = 93.85. The resulting (R+M)/2 = 96.28. The Hutson method clearly underestimated the RON octane values for this process. Example 7 This example shows the preparation of a number of BF 3 /alumina-based catalyst components. One is made in accord with this invention and three are comparative samples. Each of the samples was then tested in an alkylation reaction using model feeds and isobutane and butenes. All four gamma-alumina samples (LaRoche-Versal GL) were infused with BF 3 in a Cahn balance. Use of a Cahn balance allowed close control of the temperature at which the alumina contacted the BF 3 and further allowed the weight gain to be measured during the treatment. The four samples were treat with BF 3 respectively at 25 * C, 150*C, 250* C, and 350* C. The amount of BF 3 i the samples was 17.4%, 17.3%, 13.7% and 13.6% (by weight). A sample of e of the catalyst components was removed and analyzed using "B-MAS-NMR. T results of these analyses are shown in the figures: Figure 1A shows the treate alumina; Figures 1B, 1C, and 1D show the respective data from the 150 * C, 250 * C, and 350 * C treated aluminas. In Figure 1A, there is a pronounced sharp peak at about -21.27 ppm (relative to boric acid) suggesting significant tetrago boron content. The other three NMR plots do not show such a sharp peak. Instead, the data suggest the presence of substantial trigonal boron. The four gamma-alumina samples (LaRoche-Versal GL) were then char to a semi-batch reactor having an internal volume of about 500 cc. The reacto temperature was controllable over the range of -5* C to 40 * C. For initial cataly treatment, the reactor containing the catalyst was purged with an inert gas and cooled to about 0 * C. About 275 cc of isobutane were added to the reactor. a brief degassing, BF 3 was added batchwise. Additional infusions of BF 3 are made until the pressure in the reactor no longer drops. The BF 3 saturation equilibrium pressure was about 40 psig. The liquid phase concentration of BF o^ Λ '3> was about 1.5%. A mixture of isobutane/trans-2-butene was fed to the reactor. At the completion of the reaction, alkylate was removed and analyzed by gas-liquid chromatography. The RON'S were calculated from the gas-liquid chromatography data using the well-known correlations in Hutson and Logan, "Estimate Alky Yield and Quality", Hydrocarbon Processing, September, 1975, pp. 107-108. The summary of the experiments and results is shown in the table below: It is clear from the data that the catalyst component treated with BF 3 at the lower temperature is superior in operation in most practical aspects (conversion, C 8 production, alkylate yield, RON, MON, etc.) than the other materials. It should be clear that one having ordinary skill in this art would envision equivalents to the processes found in the claims that follow and that these equivalents would be within the scope and spirit of the claimed invention.

Claims: »-Z6> WE CLAIM AS OUR INVENTION: 1. A catalyst component comprising a transition alumina which has been contacted with a Lewis add at a treatment temperature below about 150' C to produce a catalyst component containing Lewis add. 2. The catalyst component of claim 1 where the transition alumina is selected from gamma-alumina, eta-alumina, theta-alumina, chi- alumina, rhc-alumina, and mixtures. 3. The catalyst component of claim 2 where the transition alumina is selected from gamma-alumina, eta-alumina, and mixtures. 4. The catalyst component of claim 1 where the treatment temperature is below about 100 * C. 5. The catalyst component of claim 4 where the treatment temperature is below about 30 * C. 6. The catalyst component of claim 1 where the Lewis acid is selected from BF 3 , BCI 3 , BBr 3 , Bl 3 , SbF 5 , AICI 3 , AIBr 3 , TϊBr 4 , TiCI 4 , TϊCI 3 , ZrCI 4 , PF 5 , FeCI 3 , and FeBr 3 . 7. The catalyst component of claim 1 where the Lewis acid is selected from SbF 5 , AICI 3 , and BF 3 . 8. The catalyst component of claim 7 where the Lewis acid is BF 3 . 9. The catalyst component of claim 2 where the Lewis acid is selected from SbF 5 , AICI 3 , and BF 3 . 10. The catalyst component of claim 9 where the Lewis acid is BF 3 . 11. The catalyst component of claim 3 where the Lewis acid is selected from SbF 5 , AICI 3 , and BF 3 . 12. The catalyst component of claim 11 where the Lewis acid is BF 3 . 13. The catalyst component of claim 4 where the Lewis acid is selected . from SbF 5 , AICI 3 , and BF 3 . 14. The catalyst component of claim 13 where the Lewis acid is BF 3 . 15. The catalyst component of claim 5 where the Lewis acid is selected from SbF 5 , AICI 3 , and BF 3 . 16. The catalyst component of claim 15 where the Lewis acid is BF 3 . 17. The catalyst component of claim 1 containing substantially no metal or semi-metals in catalytic amounts other than aluminum and the semi-metal boron. 18. A catalyst component comprising a transition alumina which has been contacted with a boron containing-Lewis acid at a treatment temperature below about 150*C to produce a catalyst component containing the boron-containing Lewis acid. 19. The catalyst component of claim 18 where the transition alumina is selected from gamma-alumina, eta-alumina, theta-alumina, chi- alumina, rho-aiumina, and mixtures. 20. The catalyst component of claim 19 where the transition alumina is selected from gamma-alumina, eta-alumina, and mixtures. 21. The catalyst component of claim 18 where the treatment temperature is below about 100 * C. 22. The catalyst component of claim 21 where the treatment temperature is below about 30 * C. 23. The catalyst component of claim 18 where the boron-containing Lewis acid is selected from BF 3 , BCI 3 , BBr 3 , and Bl 3 . 24. The catalyst component of claim 23 where the boron-containing Lewis acid is BF 3 . 25. The catalyst component of any of claims 18-24 in which the 1 B- MAS-NMR exhibits a trigonal boron: tetragonal boron ratio between 0.0 and 0.5. 26. A catalyst component comprising a transition alumina selected from gamma-alumina, eta-alumina, theta-alumina, chi-alumina, rho- alumina, and mixtures which has been contacted with a boron containing-Lewis acid to produce a catalyst component containing between 0.5% and 30% by weight of the boron-containing Lewis add and which the "B-MAS-NMR of the catalyst component exhibits evidence of tetragonal boron. 27. . The catalyst component of daim 26 where the transition alumina is selected from gamma-alumina, eta-alumina, and mixtures. 28. The catalyst component of claim 26 where the boron-containing Lewis acid is selected from BF 3 , BCI 3 , BBr 3 , and Bl 3 . 29. The catalyst component of claim 28 where the boron-containing Lewis acid is BF 3 . 30. The catalyst component of any of claims 26-29 in which the 11 B- MAS-NMR exhibits a trigonal boron: tetragonal boron ratio between 0.0 and 0.5. ^ 9 31. An alkylation catalyst system comprising a. an alumina alkylation catalyst component of a transition alumina which has been contacted under substantially anhydrous conditions with a Lewis add to produce an alkylation catalyst containing Lewis add, and b. an amount of that free Lewis add sufficient to maintain the Lewis acid concentration of the alumina alkylation catalyst component. 32. The catalyst system of claim 31 where the transition alumina is selected from gamma-alumina, eta-alumina, theta-alumina, chi- alumina, rho-alumina, and mixtures. 33. The catalyst of claim 32 where the transition alumina is selected from gamma-alumina, eta-alumina, and mixtures. 34. The catalyst system of claim 31 where the Lewis acid is selected from BF 3 , BCI 3 , BBr 3 , Bl 3 , SbF 5 , AICI 3 , AIBr 3 , TiBr 4> TiCI 4 , TiCI 3 , ZrCI 4 , PF 5 , FeCI 3 , and FeBr 3 . 35. The catalyst system of claim 31 where the Lewis acid is selected from SbF 5 , AICI 3 , and BF 3 . 36. The catalyst system of claim 35 where the Lewis acid is BF 3 . 37. The catalyst system of claim 32 where the Lewis acid is selected from SbF 5 , AICI 3 , and BF 3 . 38. The catalyst system of claim 37 where the Lewis acid is BF 3 . 39. The catalyst system of claim 33 where the Lewis acid is selected from SbF 5 , AICI 3 , and BF 3 . 40. The catalyst system of daim 39 where the Lewis acid is BF 3 . 41. The catalyst system of daim 34 containing substantially no metals or semi-metals in catalytic amounts other than aluminum and the semi- metal boron. 42. The catalyst system of daim 36 additionally comprising isobutane and butylene. 43. An alkylation process comprising the steps of: a. contacting a mixture comprising isoparaffins and olefins with an acidic alkylation catalyst system comprising: a.) a transition alumina which has been previously contacted under substantially anhydrous conditions with a Lewis add and b.) an amount of free Lewis add, under alkylation conditions to produce an alkylate stream, and b. separating the alkylate stream from the acidic alumina based alkylation catalyst. 44. The process of claim 43 where the transition alumina is selected from gamma-alumina, eta-alumina, theta-alumina, chi-alumina, rho- alumina, and mixtures. 45. The process of claim 44 where the transition alumina is selected from gamma-alumina, eta-alumina, and mixtures. 46. The process system of claim 43 where the Lewis acid is selected from BF 3> BCI 3 , BBr 3 , Bl 3 , SbF 5 , AICI 3> AIBr 3 , TiBr 4 , TiCI 4 , TiCI 3 , ZrCI 4 , PF 5 , FeCI 3 , and FeBr 3 . 47. The process system of daim 43 where the Lewis acid is selected from SbF 5 , AICl 3 , and BF 3 . 48. The process system of claim 47 where the Lewis acid is BF 3 . 49. The process system of claim 44 where the Lewis acid is selected from SbF s , AICI 3 , and BF 3 . 50. The process system of claim 49 where the Lewis acid is BF 3 . 51. The process system of claim 45 where the Lewis acid is selected from SbF 5 , AICI 3 , and BF 3 . 52. The catalyst system of claim 51 where the Lewis add is BF 3 . 53. The process of daim 46 where the alumina based alkylation catalyst additionally contains substantially no metals or semi-metals in catalytic amounts other than aluminum or boron. 54. The process of claim 43 where alkylation conditions indude a temperature in the range of -30 * C to 50* C. 55. The process of claim 43 where the mixture comprises 2-butene and isoparaffin. 56. The process of claim 43 where the contacting step is carried out in the substantial absence of isobutylene. 57. The process of claim 43 where the isoparaffin comprises isobutane. 58. The process of claim 55 where the isoparaffin comprises isobutane. 59. The process of claim 56 where the isoparaffin comprises isobutane. 60. The process of claim 43 where alkylation conditions include a WHSV between 0.5 to 30.0. 61. The process of claim 43 where the ratio of C 4 -C 10 isoparaffins to C 3 - C 5 olefins is in the range of one to 50. 62. The process of claim 43 including the step of mixing the alkylate stream with other hydrocarbons to produce a gasoline blending component or gasoline.

Inventors: COOPER MICHAEL D, KING DAVID L, SANDERSON WILLIAM A, COOPER, MICHAEL, D., KING, DAVID, L., SANDERSON, WILLIAM, A.
Applicants: CATALYTICA INC, CATALYTICA, INC.
Application year: 1991
Main classification: B01J27
IPC codes: B01J21, B01J27, B01J38, C07B61, C07C2, C07C9, C10G35