Development and introduction of a highly efficient catalyst for the butane–butylene fraction oligomerization process for the production of a high-octane automobile gasoline compound

Abstract

The main stages in developing a technology for the production of high-silica ZSM-5 zeolite-based catalyst for the butane–butylene fraction (BBF) oligomerization process are described. The application of a new zeolite surface modification procedure allows the attainment of higher selectivity and target product yields (compared to familiar analogs) and the synthesis of more branched (and thus more high-octane) oligomers at lower pressures. The introduction of promoting metal Ga raises the target gasoline fraction yield by 0.9%, compared to the unpromoted catalyst. Comparative pilot tests of industrial (BAK-70U) and the developed (Ga-ZSM-5/Al₂O₃) BBF oligomerization catalysts are performed under the following conditions: pressure, 1.5 MPa; initial working temperature, 300°C; feedstock hourly space velocity (FHSV), 1.5 mL BBF/(mL cat h). It is shown that using modified ZSM-5 based catalyst results in a gasoline fraction yield 7% higher than with BAK-70U. The higher quality of the oligomerizate obtained on Ga-ZSM-5/Al₂O₃ is observed throughout the period of tests (191 h): MON is 2 points higher, and the concentration of gums is 50% lower. The results from these studies and tests are used for the development and industrial implementation of a technology for the production of the KOB-1 zeolite oligomerization catalyst: 2.5 t of industrial catalyst has been produced by September of 2016 at the industrial facilities of ZAO Redkino Catalyst Plant. The next important stage in the implementation of the Gazprom Netf innovative development strategy in oil refining is a pilot run of the new oligomerization catalyst in the combined industrial MTBE–oligomerizate production plant of Gazprom Neft Moscow Oil Refinery. The introduction of the KOB-1 catalyst at the Gazprom Neft Oil Refinery will be an important step in improving the efficiency of technologies for the production of high-margin products, especially compounds of commercial automobile gasoline.