Vapour phase tert-butylation of toluene with tert-butylalcohol was studied over ultra-stable Y zeolite (USY) catalyst. The effects of reaction temperature, toluene/TBA molar ratio and liquid space velocity on conversion of toluene and selectivity for 4-tert-butyltoluene were studied. The deactivation and regeneration of the catalyst was also investigated. The results showed that the USY zeolite catalyst offered better toluene conversion of about 30% and 4-tert-butyltoluene selectivity of about

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... 9% at the suitable reaction condition as follows: reaction temperature of 120 o C, toluene/TBA ratio of 2:1 and liquid space velocity of 2 ml/g•h. The clogging of micropores by the formed carbon or oligomers was the main reason for the deactivation of the catalyst. By combustion at 550 o C, the catalyst just lost about 5% in toluene conversion and about 2% in para-tert-butyltoluene (PTBT) selectivity.