The first commercially viable solid-acid catalyst for isoparaffin alkylation is developed by simultaneously applying basic engineering concepts at many scales during process development. The pore structure, the acid site density, and the active site distribution are optimized to achieve the desired isomeric products, while resisting coking. Concurrent reactor design further enhances product quality, while reducing capital cost. The result is a "green" process that eliminates the hazards of liquid-acid catalysts, while also reducing cost.The phase-out of methyl tertiary-butyl ether (MTBE) has important consequences on the US reformulated gasoline (RFG) market both in terms of octane value and volume loss. MTBE has an octane rating of 110 and it commands approximately 10% of the RFG and California Air Resources Board (CARB) gasoline pool. Although MTBE will likely continue to be used in the rest of the world, eliminating it from domestic gasoline will require compensation in the form of alternative high-octane additives. The shortfall in gasoline volume and octane rating can be met by substituting alkylate for MTBE.Alkylate is an ideal clean fuel component because it has a high octane rating, low vapor pressure, low toxicity, and costs less than MTBE. Table 1 compares some relevant properties of alkylate and MTBE. Alkylate has been blended into gasoline for decades to improve octane. EIA (Energy Information
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