Novel alkylation catalyst and its use in alkylation

Abstract

The invention pertains to a catalyst comprising catalyst particles comprising a hydrogenation function and a solid acid, wherein the ratio between (i) the volume in catalyst pores with a diameter in the range of 40-8000 nm and (ii) the specific length of the catalyst particles is in the range of 0.01-0.90 ml/(g*mm) and wherein the catalyst has a total pore volume of at least 0.20 ml/g and the volume in the catalyst pores with a diameter in the range of 40-8000 nm is below 0.30 ml/g. The invention further pertains to the use of this catalyst in the alkylation of hydrocarbons.

We claim:  
     
         1 . A catalyst suitable for use in the alkylation of hydrocarbons which comprises catalyst particles comprising a hydrogenation function and a solid acid, wherein the ratio between (i) the volume in catalyst pores with a diameter in the range of about 40-8000 nm and (ii) the specific length of the catalyst particles is in the range of about 0.01-0.90 ml/(g*mm) and wherein the catalyst has a total pore volume of at least about 0.20 ml/g and the volume in the catalyst pores with a diameter in the range of about 40-8000 nm is below about 0.30 ml/g.  
     
     
         2 . The catalyst of  claim 1  wherein the ratio between (i) the volume in catalyst pores with a diameter in the range of about 40-8000 nm and (ii) the specific length of the catalyst particles is at least about 0.20 ml/(g*mm).  
     
     
         3 . The catalyst of  claim 1  wherein the catalyst has a total pore volume of at least about 0.23 ml/g.  
     
     
         4 . The catalyst of  claim 1  wherein the hydrogenation function consists essentially of a Group VIII noble metal.  
     
     
         5 . The catalyst of  claim 1  wherein the solid acid is a Y-zeolite with a unit cell size in the range of about 24.34-24.72 angstroms.  
     
     
         6 . The catalyst of  claim 5  wherein the solid acid is a Y zeolite with a unit cell size in the range of about 24.40-24.61 angstroms.  
     
     
         7 . The catalyst of  claim 6  wherein the solid acid is a Y zeolite with a unit cell size in the range of about 24.45-24.58 angstroms.  
     
     
         8 . The catalyst of  claim 1  wherein the catalyst additionally comprises a matrix material.  
     
     
         9 . The catalyst of  claim 8  wherein the matrix material comprises alumina.  
     
     
         10 . The catalyst of  claim 1  wherein the catalyst is free of rare earth metals and Group VIII non-noble metals.  
     
     
         11 . A process for the alkylation of hydrocarbons wherein a hydrocarbon feedstock and an olefin are contacted with the catalyst of  claim 1  at alkylation process conditions.  
     
     
         12 . A process for the alkylation of saturated hydrocarbons wherein a saturated hydrocarbon feedstock and an olefin are contacted with the catalyst of  claim 1  at alkylation process conditions.