How does the alkylation process work and what products does it make?

Alkylation combines isobutane with light olefins (propylene, butylene) to produce high-octane branched paraffins (alkylate) for gasoline blending. Acid catalysts: HF (hydrofluoric acid) or H2SO4 (sulfuric acid). Reaction: isobutane + butene = isooctane (2,2,4-trimethylpentane, 100 RON). Conditions: 5-40C (low temperature favors product quality), high isobutane/olefin ratio (5-15:1 external), intimate mixing. Products: alkylate (94-98 RON), n-butane, propane. HF process: liquid HF catalyst, continuous, compact, but HF hazard concern. H2SO4 process: requires continuous acid refresh, larger equipment. Newer solid acid catalysts being developed. Alkylate is premium gasoline component - no sulfur, no aromatics, no olefins, high octane.