Mtbe preparation from isobutylene/tba and methanol in presence of an acid resin catalyst

Abstract: Methyl tertiary butyl ether (MTBE) can be produced by reacting methanol with isobutylene, tertiary butyl alcohol (TBA), or preferably a mixture of isobutylene and TBA, in a distillation column packed with a sulfonic acid resin catalyst. The reaction proceeds substantially to completion and MTBE is distilled from the column with good purity.

Description: The present invention relates to a process for the preparation of tertiary-alkyl ethers and, more particularly, to the preparation of ethers such as methyl-t-butyl ether (MTBE) and t-amyl methyl ether (TAME). Recent concern with environmental pollution by lead from the exhaust gases of internal combustion engines has forced a transition away from the use of lead antiknock compounds in gasoline. In order to produce unleaded gasoline having an acceptable octane value without varying the compounding ratio of gasoline, it has become necessary to use organic blending compounds with high octane ratings. A variety of organic compounds are known as fuel extenders and octane value improving agents. Particularly, the well known organic compounds include methyl t-butyl ether (MTBE), ethyl t-butyl ether, isopropyl t-butyl ether, t-amyl methyl ether (TAME) and t-butyl alcohol (TBA). The preparation of these ethers and alcohols by the catalytic addition of an alcohol or water to an olefin having a double bond on a tertiary carbon atom has been extensively studied. In the past and presently, there have been, and are, many processes developed, and being developed, to produce methyl t-butyl ether (MTBE). For the most part, these processes have involved several steps and have been comprehensive as well as being costly. The problem being that only a substantially pure product of MTBE is useful in fuels. Contaminated fuels are not effective and require further treatment to be useful in fuels. Thus, it is an object of the present invention to provide a one-step process for producing a product of a substantially pure t-alkyl ether such as MTBE or TAME. EP-A-0008860 describes a method for the production of methyl tertiary butyl ether by reaction of methanol with isobutylene in a distillation column packed with a sulfonic acid resin catalyst. The document does not describe the use of tertiary butyl alcohol or a mixture of acid butylene and a tertiary butyl alcohol as starting materials. Chemical Abstracts, Vol. 92, No. 58165y, describes a method for the production of MTBE by reaction of methanol with a mixture of isobutylene and TBA in the presence of a sulfonic acid resin. A continuous reaction is used. The feeding of reactants into different levels of a reactor is not described. US-A-2,480,940 discloses catalysts employed for the etherification or alcoholification of olefins which have been acids such as H₂SO₄, Lewis acids, platinum metal salts, and various heterogenous catalysts, and discloses solid sulfonated organic resins that may be used for ion exchange applications. US-A-4,071,567 discloses a two-step process for preparing methyl t-butyl ether with methanol and isobutylene in the presence of an acid ion exchange resin. US-A-4,198,530 discloses a two-step process for preparing tertiary butyl methyl ether from isobutene and methanol in the presence of an acidic ion exchange catalyst. Accordingly to the present invention, there is provided a method of producing methyl tertiary butyl ether (MTBE) by reacting methanol (MeOH) with isobutylene and acid resin catalyst, the reaction being carried out in a distillation column packed with the catalyst, methanol being fed into the column with a mixture of isobutylene and TBA at a molar ratio of MeOH/(TBA + isobutylene) being between 1:1 and 10:1 and MTBE being distilled from the column, characterized in that the column contains either one catalyst bed where isobutylene is fed near the top of the bed, TBA at the middle of the bed, and MeOH in the bottom of the bed, or the column contains upper and lower catalyst beds, where isobutylene is fed into the upper bed, TBA is fed near the top of the lower bed, and MeOH is fed near the bottom of the lower bed. The process is carried out at a temperature of 65°C (150°F) to 121°C (250°F) and under a pressure of between 0.34 and 1.38 MPa (50 and 200 psi). The basis of the present invention is the fact that both the TBA-MeOH and isobutylene-MeOH reactions to yield MTBE are equilibrium controlled. Therefore, in the TBA-MeOH reaction, for example, if the MTBE is continuously removed from the reaction zone by distillation, the reaction theoretically can go to completion. For example, The process is also arranged so that the product water continuously drops out of the reaction zone since it is heavier than the other components of the equilibrium, mixture, and thus too, drives the equilibrium-controlled reaction towards completion. Therefore, the combination of (a) a reaction zone containing active catalysts and (b) distillation capability in a single unit uniquely adapts itself to the TBA-MeOH and isobutylene-MeOH reactions to yield high purity. Although the invention will be described with specific reference to the preparation of methyl t-butyl ether (MTBE) for the purpose of clarity, it should be understood that other ethers and alcohols prepared by the catalytic addition of alcohols or water to olefins having a double bond at the tertiary carbon are within the scope of the present invention. Such olefins include isobutylene, 2-methyl butene-1, 2 methyl butene-2, 2-methyl pentene-1 and 2-methyl pentene-2. The process that may be used for preparing MTBE according to the present invention is illustrated by the following equation: The basis for the present reaction is that the combined streams of isobutylene and TBA can be reacted with MeOH over a sulfonic acid resin catalyst, in one-step, to yield MTBE. Tertiary alkyl ethers, such as methyl t-butyl ether (MTBE) and t-amyl methyl ether (TAME) are useful as fuel extenders and, in particular, as gasoline octane enhancers. Generally, processes for producing these materials all rely on a primary alcohol and an olefin which contains a double-bond on a tertiary carbon as raw materials. The reactions are carried out in the liquid phase in which ion exchange resins in their acid form are particularly suitable for the present reaction. The optimum results are obtained when macroreticular resins are used such as the Amberlyst® 15 catalysts. The catalyst, i.e., a solid-acid catalyst may be Amberlyst® 15 or Nafion-H® resin catalysts. The preferred catalysts are the Amberlyst® 15 catalysts. The catalyst is packed in a distillation tower and is substantially insoluble to the liquid components therein. The catalyst can be present in the column either undiluted or with an inert diluent in weight ratios of as little as 200/1 of inert to catalyst. The process of the present invention and a condensation phase of the components (i.e., MTBE, MeOH, TBA, isobutylene and H₂O) are illustrated in the attached drawings which is FIG.1 is a flow diagram of the present reaction process showing the equipment used therefor and the material flow thereof. In the present process, isobutylene and TBA is used to produce MTBE. TBA is conventionally produced in large quantities from processes for producing propylene oxide from propylene. The subject of the present invention is a one-step process which makes it possible to achieve high conversions of isobutylene/TBA and MeOH to MTBE using a distillation column as the reactor and primary separator. An object of the present invention is to obtain a product stream which is substantially MTBE and substantially free of water, isobutylene, TBA and MeOH. This can be accomplished by catalytic distillation in a combination reactor and distillation column that has been packed with acidic resin catalysts. Under these conditions, as it is formed in the reaction, low-boiling MTBE is removed at the top of the reactor distillation column and by-product water is removed at the bottom of the column. Adding isobutylene and TBA at the middle catalyst bed of the catalyst bed, and methanol near the bottom of the column, results in a dual mass action effect. The tert-butyl alcohol (TBA) being relatively more dense material, continuously drops down the column while isobutylene, being a gas under reaction conditions, continuously rises up the column. Near the bottom of the column, where methanol is in excess, the conversion of TBA to MTBE is nearly complete and unreacted TBA is present in the bottoms. Near the top of the column where isobutylene and TBA is in excess, the conversion of unreacted MeOH to MTBE is complete and very little methanol is present in the overhead. The advantage of minimizing the presence of unreacted methanol is that it minimizes the need for auxiliary separation towers to purify MTBE by separating it from unreacted methanol. Above the point at which isobutylene and TBA enters the column at the top of the catalyst beds, the distillation trays contain only unreacted isobutylene, MTBE and small amounts of MeOH which can be easily separated in ascending trays. Below the point at which methanol is added, the distillation trays contain only water and tert-butanol which can be easily separated in descending trays. The distillation tower or column may have one or two packed catalyst beds depending on the choice and preference of design. The reaction can be carried out at a temperature of 65° to 121°C (150° to 250°F), preferably from 74° to 77°C (165° to 170°F) and under a pressure of 0.34 to 1.38 MPa (50 psi to 200 psi), preferably 0.69 MPa (100 psi). The liquid flow rate of the materials in the reaction ranges from 1.0 to 10.0 LHSV. The preferred liquid flow rate is 2.0 LHSV. The charge of the present process is fed in a molar ratio of MeOH/(TBA + isobutylene) of between 1:1 and 10:1; and the molar ratio of MeOH/TBA/isobutylene is about 2.0/1.5/0.5. In contrast to known processes where either TBA or isobutylene is used with MeOH to prepare MTBE, the present process uses both TBA and isobutylene to prepare MTBE. The advantages for using the combination of C₄ components are: 1. The combination gives the operation of the process increased flexibility since there are times when both components (isobutylene and TBA) are available and could be used in combination. The run conditions described (Example I) below are equally suitable for either TBA + MEOH or isobutylene + MEOH or combinations of TBA + isobutylene. 2. The reaction of isobutylene + MeOH is very exothermic while the reaction of TBA + MeOH is slightly endothermic. The exothermic reaction will supply heat to the distillation of the MTBE product and, therefore, the combination (isobutylene + TBA) would be the most efficient use of heat energy. Otherwise, this energy would be wasted. 3. The presence of isobutylene in the reaction zone drives the reaction to completion since it reacts (a) with water which is formed and prevents the reverse reaction, i.e., splitting of MTBE as shown in the equations: TBA + MeOH→MTBE + H₂O Isobutylene + H₂O→TBA (to reaction) (b) with unreacted methanol to drive the reaction to completion. Therefore, the substantially pure MTBE results as illustrated by the following equation: Unreacted MeOH + Isobutylene→MTBE Thus, as indicated above, the introduction of isobutylene at the mid-point or top of the reactor will drive the reactions to completion. Referring to FIG.1, a typical reaction process according to the present invention is illustrated with the flow of the feed (charge) components, the products and unreacted charge components. The flow rates of the feed components, products, etc. are provided below in Table I. The advantages of present invention will be more apparent when considering the following example which described the present process illustrated in FIG.1 for producing MTBE. EXAMPLE I In this example, crude tert-butyl alcohol is initially purified of acids and hydroperoxides by running it through a guard case containing an absorbent consisting of sodium oxide-cobalt oxide on activated alumina. Then, the purified TBA is used in the process as illustrated in FIG.1. A combination reactor-distillation column is used in the process. The bottom portion of the reactor contains a single or double beds of resin catalyst and distillation trays, while the top part of the reactor contains distillation trays and a take-off line for separation of products. Below the catalyst beds are lines for the introduction of methanol and the take-off of unreacted tert-butyl alcohol and water which is a reaction product. The preferred reaction conditions of the process are a temperature of 74°-77° (165-170°F) and a pressure of about 0.69 MPa 100 psi. Methanol is continuously pumped at the rate of 14.5 kg/hr (32 lb/hr) in the upflow made up catalyst bed No.1 packed with an Amberlyst® 15 resin catalyst. Meanwhile, TBA is continuously pumped at the rate of 49 kg/hr (108 lb/hr) into the top of catalyst bed No. 1. As the TBA descends the column it contacts and reacts with the MeOH to yield MTBE and water. The dense water phase continuously drops down the reactor along with some unreacted TBA, while the lighter MTBE product plus unreacted methanol rise up the column where at the entrance to catalyst bed No.2 TBA contacts isobutylene which is being continuously introduced at the rate of 12.7 kg/hr (28 lb/hr). The isobutylene reacts with unreacted methanol in the MTBE-methanol product stream. The reaction product which is almost pure MTBE is continuously distilled out of the reaction zone at the top of catalyst bed No.2 (packed with Amberlyst® 15 catalyst) along with small amounts of unreacted isobutylene and methanol. The compositions of the proposed charge materials, estimated product of the example above and process shown in FIG.1, are provided below in Table I. PROCESS FOR MTBE OVERALL STOICHIOMETRY Charge Materials Products/Unreacted Materials MeOH (64 lb/hr) 29 kg/hr MTBE (146 lb/hr) 66 kg/hr TBA (108 lb/hr) 49 kg/hr MeOH (9.6 lb/hr) 4.3 kg/hr Isobutylene (28 lb/hr) 12.7 kg/hr Isobutylene (11.2 lb/hr) 5.1 kg/hr H₂O (25 lb/hr, 11.3 kg/hr The estimate average yield of MTBE is calculated as follows: In review of the present process, it can be assumed that the yield of MTBE is at least about 85.0 percent.

Claims: A method of producing methyl tertiary butyl ether (MTBE) by reacting methanol (MeOH) with isobutylene and tertiary butyl alcohol (TBA) in the presence of a sulfonic acid resin catalyst, the reaction being carried out in a distillation column packed with the catalyst, methanol being fed into the column with a mixture of isobutylene and TBA at a molar ratio of MeOH/(TBA + isobutylene) being between 1:1 and 10:1 and MTBE being distilled from the column, characterized in that the column contains either one catalyst bed where isobutylene is fed near the top of the bed, TBA at the middle of the bed, and MeOH in the bottom of the bed, or the column contains upper and lower catalyst beds, where isobutylene is fed into the upper bed, TBA is fed near the top of the lower bed, and MeOH is fed near the bottom of the lower bed. A method according to Claim 1, characterized in that the temperature is 150°F to 250°F (65°C to 121°C) and the pressure is 50 to 200 psi (0.34 to 1.38 MPa). A method according to Claim 1 or Claim 2, characterized in that the flow rate of the materials is from 1.0 to 10.0 LHSV.

Inventors: HAGAN JOHN JOSEPH, HERBSTMAN SHELDON, HAGAN, JOHN JOSEPH, HERBSTMAN, SHELDON
Applicants: TEXACO DEVELOPMENT CORP, TEXACO DEVELOPMENT CORPORATION
Application year: 1990
Main classification: C07C43
IPC codes: B01D3, C07C41, C07C43