Scale-up strategy applied to solid-acid alkylation process

Recently, a new isoparaffin alkylation process using a solid-acid catalyst has been scaled up and proven in a pilot plant using an improved strategy. Two components; a solid-acid catalyst and a simple fixed-bed reactor are the key factors to this new process. Catalyst performance and stability were demonstrated on a pilot-scale reactor that closely matched the commercial reactor design. Tests showed that product quality and catalyst lifetime is identical in the bench scale and pilot-scale reactors when operated at the same temperature, feed composition and olefin space velocity. Using this scale-up strategy and a fully integrated catalyst development technique resulted in a high product octane rating, simple process operation, and efficient and inexpensive process and reactor schemes.