Catalytic removal of peroxide contaminants from a methanol-tertiary butyl alcohol recycle stream

Abstract: Methanol-tertiary butyl alcohol recycle stream contaminated with residual amounts of peroxide contaminants such as tertiary butyl hydroperoxide, ditertiary butyl peroxide, allyl tertiary butyl peroxide, etc., can be effectively catalytically treated with a catalyst consisting essentially of titania-supported transition metals to substantially completely decompose the peroxide contaminants to thereby provide a treated methanol-tertiary butyl alcohol product substantially free from contaminating quantities of such peroxides.

Description: This invention relates to a method for the purification of a MeOH/TBA recycle stream formed during the preparation of methyl tertiary butyl ether (MTBE) from methanol and from tertiary butyl alcohol prepared by the molybdenum-catalyzed reaction of propylene with tertiary butyl hydroperoxide. In accordance with the present invention, MeOH/TBA contaminated with peroxides is brought into contact with a titanium dioxide (titania) supported transition metal catalyst in order to substantially selectively decompose the peroxide contaminants. Methyl tertiary butyl ether (MTBE) can be prepared by the catalytic reaction of tertiary butyl alcohol (TBA) with methanol. Normally, an excess of methanol is used. Tertiary butyl alcohol can be prepared from isobutane. Isobutane can be reacted with oxygen to form oxygen-containing reaction products, principally tertiary butyl hydroperoxide. The tertiary butyl hydroperoxide can be decomposed (normally in the presence of a catalyst) to form tertiary butyl alcohol. However, the tertiary butyl alcohol will be contaminated with other oxygenated by-products, such as tertiary butyl hydroperoxide, ditertiary butyl peroxide, allyl tertiary butyl peroxide and isopropyl hydroperoxide, that are not easily removable by distillation. Tertiary butyl alcohol prepared in this manner can be used as a feedstock for the present invention. It is known to prepare tertiary butyl alcohol by the molybdenum-catalyzed reaction of propylene with tertiary butyl hydroperoxide. Thus, tertiary butyl hydroperoxide may be reacted with propylene by a process of the type disclosed in Kollar (US-A-3,351,635) to provide a reaction product comprising unreacted propylene, propylene oxide, tertiary butyl alcohol and residual quantities of oxygenated impurities, such as ditertiary butyl peroxide, tertiary butyl hydroperoxide and allyl tertiary butyl peroxide, that remain dissolved in tertiary butyl alcohol recovered from the reaction mixture. Tertiary butyl alcohol prepared in this manner can also be used as a feedstock for the process of the present invention. Thus peroxide contaminants will be present in the reaction medium that is formed when excess methanol is mixed with the contaminated tertiary butyl alcohol. The contaminants will remain in the MTBE reaction product formed by the catalytic reaction of the contaminated tertiary butyl alcohol with excess methanol to form methyl tertiary butyl ether. When MTBE is prepared in a continuous process by this method, the MTBE reaction product can be separated by distillation into a distillation fraction containing substantially all of the MTBE formed during the reaction and into a separate fraction comprising water, methanol and tertiary butyl alcohol. The separate fraction, after being dewatered, is suitable for use as a recycle fraction. It has been discovered in accordance with the present invention that when the MeOH/TBA is recovered from the MTBE reaction product for recycle, the peroxide contaminants introduced into the reaction medium with the contaminated tertiary butyl alcohol will be concentrated in the MeOH/TBA recycle stream. As a consequence, the recycle stream will be contaminated with minor quantities of peroxides such as ditertiary butyl peroxide, tertiary butyl hydroperoxide and allyl tertiary butyl peroxide. It is an object of the present invention for these peroxides to be removed in order to prevent their accumulation in the reaction medium. In US-A-4,822,921 there is disclosed a method for producing MTBE by reacting tertiary butyl alcohol and methanol in the presence of a catalyst comprising an inert support, such as titania, having a phosphoric acid impregnated thereon. US-A-4,827,048 discloses a method for producing MTBE by reacting tertiary butyl alcohol and methanol in the presence of a catalyst comprising a heteropoly acid such as 12-tungstophosphoric acid or 12-molybdophosphoric acid on an inert support, such as titania. Sanderson et al US-A-4,547,598 discloses the use of unsupported cobalt borate and cobalt borate supported on titanium dioxide to decompose organic hydroperoxides to alcohols. It has also been proposed to remove the residual hydroperoxide contaminants from tertiary butyl alcohol through the use of a heterogeneous cobalt oxide catalyst containing a copper oxide promoter as shown, for example, by Coile US-A-4,059,598. Allison et al in US-A-3,505,360 have more generically taught that alkenyl hydroperoxides can be decomposed catalytically through the use of a catalyst based on a metal or compound of a metal of group IV-A, V-A or VI-A. In DE-A-3248465 a two-step process is disclosed wherein isobutane is oxidized noncatalytically with air to a conversion of about 48-90% to form the corresponding hydroperoxide, which is then catalytically decomposed under hydrogenation conditions in the presence of a supported catalyst such as palladium, platinum, copper, rhenium, ruthenium or nickel to form tertiary butyl alcohol. The decomposition product obtained using 1.3% palladium on lithium spinel as a catalyst contained significant quantities of acetone, water and methanol. A process for the decomposition of peroxides, such as a mixture of tertiary butyl hydroperoxide and tertiary butyl alcohol formed by the noncatalyzed oxidation of isobutane is disclosed in Taylor et al US-A-4,551,553 wherein the decomposition is catalyzed with a catalytic system composed of chromium and ruthenium which is soluble in the hydroperoxide. Sanderson et al also disclose catalytic methods for the purification of t-butyl alcohol contaminated with residual quantities of tertiary butyl hydroperoxide and ditertiary butyl peroxide using catalysts composed of mixtures of nickel, copper, chromia and iron (US-A-4,704,482), catalysts composed of mixtures of iron, copper, chromia and cobalt (US-A-4,705,903), catalysts composed of mixtures of nickel, copper, chromium and barium (US-A-4,873,380), or catalysts composed of metals selected from group VIB or VIIIB of the Periodic Table (US-A-4,742,179). This invention relates to a process for continuously treating a peroxides-contaminated MeOH/TBA stream prior to use of the stream as a recycle stream in the continuous reaction of methanol with tertiary butyl alcohol (TBA) to form methyl tertiary butyl ether wherein MeOH/TBA contaminated with peroxides is brought into contact with a titanium dioxide (titania) supported transition metal catalyst in order to substantially completely decompose the peroxide contaminants. Still more particularly, this invention relates to a continuous process (a) wherein peroxides-contaminated tertiary butyl alcohol is continuously mixed with excess methanol to form a reaction medium (b) wherein the reaction medium is continuously charged to a reaction zone containing an etherification catalyst to continuously convert a portion of the methanol and tertiary butyl alcohol in the reaction medium into MTBE and water and to form an MTBE reaction product, (c) wherein the MTBE reaction product is continuously separated into an MTBE distillation fraction and a second fraction comprising water, unreacted methanol, unreacted tertiary butyl alcohol and peroxide contaminants, (d) wherein the second fraction is continuously dewatered to form a MeOH/TBA recycle fraction, (e) wherein the MeOH/TBA recycle fraction (which is contaminated with peroxides) is continuously brought into contact with a titanium dioxide (titania) supported transition metal catalyst in order to substantially selectively decompose the peroxide contaminants and (f) wherein the thus-treated MeOH/TBA recycle fraction is continuously mixed with fresh methanol and fresh tertiary butyl alcohol to form a portion of the reaction medium. As a result of this invention, when a peroxides-contaminated MeOH/TBA recycle stream is brought into contact with a titania-supported transition metal catalyst of the present invention, the peroxides are decomposed and form tertiary butyl alcohol (main product) and also minor amounts of acetone and methanol. Since the recycle stream already contains tertiary butyl alcohol and methanol, some additional methyl tertiary butyl ether is also formed. A minor amount of isobutylene is also formed by dehydration of the tertiary butyl alcohol present in the recycle stream. Although the reaction can be conducted batchwise in an autoclave using powdered catalyst, it is preferably conducted on a continuous basis by continuously passing the peroxides-contaminated MeOH/TBA recycle fraction through a reactor containing a fixed bed of a pelleted catalyst of the present invention. The reaction may suitably be conducted at a temperature of 50°C to 250°C. and a pressure of 0.1 to 13.9 MPa (0 to 2000 psig). The reaction is preferably conducted at a temperature within the range of 80°C to 200°C and a pressure of 0.8 to 5.6 MPa (100 to 800 psig). When the reaction is conducted batchwise, contact time may suitably be from 0.5 to 4 hours. When the reaction is conducted on a continuous basis, the peroxides-contaminated MeOH/TBA recycle fraction should be passed over the bed of catalyst at a liquid hourly space velocity of 0.5 to 5 volumes of recycle per volume of catalyst per hour. The specific correlation of conditions to be utilized with any specific catalyst can be determined by one of ordinary skill in the art with comparative ease. Thus, for example, the peroxides-contaminated MeOH/TBA recycle fraction should be analyzed prior to catalytic treatment to determine the level of peroxides contamination. The reaction product can then be analyzed for peroxides content after catalytic treatment. If there is an insufficient reduction of the peroxides, the reaction conditions are not sufficiently severe and should be increased by, for example, increasing reaction temperature or contact time or both. If, on the other hand, there is a significant increase in the level of contamination of by-products such as acetone or methyl formate, the reaction conditions should be ameliorated (e.g., by reducing contact time or reaction temperature or both). Quite unexpected and surprising is our discovery that one of the more significant reaction products that is formed by the treatment of the peroxides-contaminated MeOH/TBA stream is methyl tertiary butyl ether. Thus, both the quality and quantity of the MeOH/TBA reaction stream are enhanced through the provision of the process of the present invention. Isobutylene is also formed, but this is not detrimental because when the isobutylene is recycled it will tend to react with methanol to form methyl tertiary butyl ether. Thus, the process of the present invention is one wherein a MeOH/TBA stream containing contaminating quantities of peroxides is catalytically treated for the decomposition of the peroxides so that they are substantially completely removed and at least partially converted to methyl tertiary butyl ether. This is accomplished without significantly increasing the contamination levels of other undesirable contaminants. The net effect, therefore, is an improvement in the quality of the treated MeOH/TBA recycle stream by the substantially complete removal of peroxide contaminants and by the formation of methyl tertiary butyl ether. This improvement is obtained, in part, because the MeOH/TBA recycle stream contains tertiary butyl alcohol that can react with the methanol to form an additional quantity of methyl tertiary butyl ether. The process of the present invention is preferably conducted in a continuous manner. The preferred continuous method for the practice of the process of the present invention comprises the steps of: a. continuously mixing peroxides-contaminated tertiary butyl alcohol with excess methanol, including substantially peroxides-free recycle MeOH/TBA to form a reaction medium; b. continuously charging the reaction medium to a reaction zone containing a bed of an etherification catalyst to convert a portion of the methanol and tertiary butyl alcohol in the reaction medium into MTBE and water and to form an MTBE etherification reaction product comprising methanol, isobutylene unreacted tertiary butyl alcohol, water, methyl tertiary butyl ether and peroxide contaminants; c. continuously charging the MTBE etherification reaction product to a first methyl tertiary butyl ether recovery distillation zone and separating it therein into a first lighter distillation fraction comprising isobutylene, methanol and methyl tertiary butyl ether and a second heavier distillation fraction comprising methanol, tertiary butyl alcohol, water and peroxide contaminants; d. continuously dewatered the second heavier distillation fraction to form a MeOH/TBA recycle fraction (which is contaminated with peroxides); e. continuously charging the second heavier MeOH/TBA recycle fraction to a peroxides decomposition zone containing a bed of a titania-supported transition metal catalyst under peroxide-decomposition reaction conditions in order to substantially selectively decompose the peroxide contaminants; and f. continuously mixing the thus-treated MeOH/TBA recycle fraction with fresh methanol and fresh tertiary butyl alcohol to form a portion of the reaction medium. The tertiary butyl alcohol feedstock that is used in the practice of the present invention is a peroxides-contaminated tertiary butyl alcohol feedstock, or feed stream, such as a distillation fraction obtained by distillation of a reaction product prepared by the molybdenum catalyzed reaction of propylene with tertiary butyl hydroperoxide to form propylene oxide and tertiary butyl alcohol. Typically, the tertiary butyl alcohol will be contaminated with residual quantities of peroxide contaminants including 0.1 to 5 wt.% of ditertiary butyl peroxide, 0.0 to 1 wt.% of tertiary butyl hydroperoxide and 0.05 to 2.5 wt.% of allyl tertiary butyl peroxide. The fresh methanol feedstock may suitably comprise a technical grade of methanol. The tertiary butyl alcohol feedstock and the fresh methanol feedstock are mixed with a substantially peroxides-free MeOH/TBA recycle stream of the type described herein. The catalyst compositions of the present invention comprise titania supported transition metal catalysts, such as one or more of the metals of Group III-B, Group IV-B, Group V-B, Group VI-B, Group VII-B, Group VIII-B and Group I-B. More preferably, the catalyst will consist essentially of 85 to 99.9 wt.% of titania or zirconia and 15 to 0.1 wt.% of transition metal catalyst. A preferred group of titania-supported catalysts are catalysts of the type disclosed in Moss US-A-3,151,112 which consists essentially of one or more of the metals from the group consisting of copper, nickel, cobalt, chromium, aluminum, iron, calcium, magnesium, and manganese. The catalyst will preferably consist essentially of a mixture of a hydrogen-reducible transition metal with a normally non-reducible transition metal oxide such as chromium oxide, molybdenum oxide or manganese oxide. An example of a preferred catalyst is a nickel, copper, chromia catalyst of the type disclosed in Moss US-A-3,151,112 consisting essentially of a mixture of 60 to 85 wt.% of nickel and 14 to 37 wt.% of copper with 1 to 5 wt.% of chromia supported on titania. Another example of a suitable catalyst is a catalyst of the type disclosed in Sanderson et al US-A-4,705,903 consisting essentially, on an oxygen-free basis, of 20 to 80 wt.% of iron, 5 to 40 wt.% of copper, 0.1 to 10 wt.% of chromium and 0.01 to 5 wt.% of cobalt. The invention will be described in further detail with regard to the accompanying drawing. The drawing is a schematic flow sheet with conventional parts omitted showing the general sequence that is used in accordance with the present invention in purifying the methanol recycle stream. In the drawing, for convenience, conventional parts such as heat exchangers, reflux condensers, reboilers, valves, pumps, sensors and flow control regulation apparatus have been omitted. In accordance with the preferred embodiment of the present invention, peroxides-contaminated tertiary butyl alcohol from a suitable source (not shown) is charged by a charge line 100 to a junction 104 where it is mixed with a molar excess of substantially peroxides-free methanol (e.g., from 2 to 5 moles of methanol per mole of tertiary butyl alcohol) charged by a feed line 102 leading from a junction 144 and composed of fresh methanol charged to junction 144 by a line 150 and recycle MeOH/TBA obtained in a manner to be described which is charged to the junction 144 by a line 142. The reaction medium formed in the junction 104 by the mixing of the peroxides-contaminated tertiary butyl alcohol 100 with the excess methanol 102 is routed by a charge line 106 to an MTBE reaction zone containing a bed of suitable catalyst (not shown). The reaction medium 106 may be charged to the reaction zone 110 at a suitable charge rate, for example being charged at a liquid hourly space velocity of 0.5 to 5 volumes of reaction medium per volume of catalyst per hour. The reaction may be conducted at a temperature of 50°C to 250°C. and a pressure of 0.1 to 13.9 MPa (0 to 2000 psig) and more preferably at a temperature within the range of 80°C to 200°C. and a pressure of 0.8 to 5.6 MPa (100 to 800 psig). As a consequence, a significant portion (e.g. 0.5 to 3 wt.%) of the tertiary butyl alcohol will react with the methanol to form MTBE. The resultant MTBE reaction product is discharged from the MTBE reaction zone 120 by a line 112 leading to a distillation zone of any suitable construction. In accordance with the illustrated embodiment the distillation zone comprises distillation columns 120 and 130 operating in series. Thus, the MTBE reaction product 112 is charged to the first distillation column 110 where it is separated into a lighter fraction comprising substantially all of the MTBE formed in the reaction zone 110 and lesser amounts of other components such as methanol and tertiary butyl alcohol. A heavier distillation fraction is discharged from the distillation column 120 by a feed line 124 leading to a second distillation column 130 wherein the heavier distillation fraction 124 is separated into a lighter MeOH/TBA recycle fraction 134 and a heavier water fraction 132 whereby water of reaction is discharged from the system. The peroxide impurities, such as tertiary butyl hydroperoxide, ditertiary butyl peroxide, allyl tertiary butyl peroxide and isopropyl hydroperoxide, introduced into the system with the contaminated tertiary butyl alcohol feedstock 100 will pass without significant change through the MTBE reaction zone 110, the first distillation column 120 and the second distillation column 130 and will be concentrated in the MeOH/TBA recycle fraction 134. Thus, typically, the MeOH/TBA recycle stream 134 will contain from 45 to 55 wt.% of methanol, from 30 to 40 wt.% of tertiary butyl alcohol, 5 to 15 wt.% of water, from 0 to 5 wt.% of methyl tertiary butyl ether and from 0.1 to 5 wt.% of peroxide impurities, such as, for example, 0.1 to 5 wt.% of ditertiary butyl peroxide, 0.0 to 1 wt.% of tertiary butyl hydroperoxide, and 0.05 to 2.5 wt.% of allyl tertiary butyl peroxide, including small amounts of other peroxides and other oxygen-containing impurities such as methyl formate and acetone. In accordance with the present invention, the peroxides-contaminated MeOH/TBA stream 134 is charged to a peroxide decomposition zone 140 containing a fixed bed of a pelleted titania-supported transition metal catalyst, such as, for example, a titania-supported iron, copper, chromia catalyst having the following composition: iron = 0.25%, chromium = 0.06%, copper = 0.01%. The peroxides-contaminated MeOH/TBA recycle fraction 134 is brought into contact with the pelleted titania-supported catalyst in the peroxides decomposition zone 140 under appropriate reaction conditions, for example being charged at a liquid hourly space velocity of 0.5 to 5 volumes of methanol recycle fraction per volume of catalyst per hour. The reaction may be conducted at a temperature of 50°C to 250°C and a pressure of 0.1 to 13.9 MPa (0 to 2000 psig) and more preferably at a temperature within the range of 80°C to 200°C and a pressure of 0.8 to 5.6 MPa (100 to 800 psig). As a consequence, the peroxides charged to the peroxide decomposition zone 140 will be substantially completely decomposed into decomposition products such as tertiary butyl alcohol and water. Minor amounts of other contaminants, such as acetone, methyl formate and isobutylene, will also be formed. At least a portion of the tertiary butyl alcohol and the isobutylene formed in the peroxides decomposition zone 140 will react with methanol present in the methanol recycle stream to form MTBE. As a consequence, the MeOH/TBA recycle fraction discharged from the peroxides decomposition zone 140 by a line 142 will comprise 45 to 55 wt.% of methanol, from 30 to 40 wt.% of tertiary butyl alcohol, 5 to 15 wt.% of water, from 0 to 5 wt.% of methyl tertiary butyl ether and other oxygen-containing impurities such as methyl formate and acetone. The MeOH/TBA recycle fraction 142 is charged to the junction 144 where it is mixed with fresh methanol 150 to form a methanol mixture that is discharged from the junction 144 by a methanol feed line 102 leading to the junction 104. The invention will be described in further detail having regard to the following non-limiting Examples. EXAMPLES A. REACTOR The reactor was a stainless steel tube 13mm x 740mm (0.51" x 29") which was electrically heated. Liquid feed was pumped into the bottom of the reactor. Pressure was regulated with a Skinner Uni-Flow valve and a Foxboro controller. The liquid feed was pumped with a Ruska dual drive pump. Skinner, Uni-Flow, Foxboro and Ruska are Trade Marks which may or may not be registered. B. FEED The feed was a blend of 10 wt.% of water, 51 wt.% of methanol, 35 wt.% of tertiary butyl alcohol, 1.0 wt.% of methyl tertiary butyl ether and 2.5 wt.% of ditertiary butyl peroxide. C. CATALYST PREPARATION (1) Iron (III) acetylacetonate (5g), chromium (III) acetylacetonate (5g), and copper (II) acetylacetonate were dissolved in 500 ml acetone and added to 500g 3mm titania pellets (1/8"). This was let stand for 1.0 hour with occasional stirring and then the acetone was removed on a rotary evaporator. The pellets were then calcined in air at 400°C overnight, followed by reduction with hydrogen at 200°C for 3 hours. % Fe = 0.25, % Cr = 0.06, % Cu = 0.01 D. CATALYST PREPARATION (2) Cobalt (III) acetylacetonate (5g), manganese (III) acetylacetonate (5g) were dissolved in 500 ml acetone and added to 500g 3mm titania pellets (1/8"). The pellets were let stand for 1 hour with occasional stirring and then the acetone removed on a rotary evaporator. The pellets were then calcined in air at 400°C overnight, followed by reduction with hydrogen at 200°C for 3 hours. % cobalt = 0.16, % Mn = 0.05 E. DECOMPOSITION Data on the catalytic decomposition of the ditertiary butyl peroxide was generated in a plurality of runs conducted in the reactor under reaction conditions including a pressure of 3.5MPa (500 psig) feed rates of from 100 to 400 cc/hr, temperatures ranging from 120 to 180°C., run lengths of 4 hours and space velocities of from 1 to 4 cc of feed per hour per cc of catalyst. The data are shown in the following tables. Examples 24-35 are provided for comparative purposes. Catalytic Decomposition of DTBP in a Continuous Reactor Run No. 1 2 3 4 5 Catalyst Fe,Cu,Cr on TiO2 Fe,Cu,Cr on TiO2 Fe,Cu,Cr on TiO2 Fe,Cu,Cr on TiO2 Reactor (cc) 100 100 100 100 Pressure (psig) 500 500 500 500 Feed Rate (cc/hr) 100 100 100 100 Temperature (°C.) 120 140 160 180 Time on Stream (hr) 4 4 4 4 Space Vel. (cc/cc) 1.0 1.0 1.0 1.0 DTBP Conversion (%) 12.3 37.9 88.3 100.0 TBA Conversion (%) 0.3 0.0 0.0 0.0 Remarks H2O Free Basis H2O Free Basis H2O Free Basis H2O Free Basis H2O Free Basis Composition: IC4 0.004 0.011 0.007 0.013 0.223 MEOH/MF 55.398 55.922 55.760 55.725 55.772 Acetone 0.009 0.053 0.260 0.759 0.993 MTBE 1.248 1.236 1.197 1.273 1.951 TBA 39.997 39.889 40.706 41.533 40.576 DTBP 2.960 2.597 1.839 0.347 0.000 TBHP 0.000 0.000 0.000 0.001 0.021 Catalytic Decomposition of DTBP in a Continuous Reactor Run No. 1 6 7 8 9 Catalyst Fe,Cu,Cr on TiO2 Fe,Cu,Cr on TiO2 Fe,Cu,Cr on TiO2 Fe,Cu,Cr on TiO2 Reactor (cc) 100 100 100 100 Pressure (psig) 500 500 500 500 Feed Rate (cc/hr) 200 200 200 200 Temperature (°C.) 120 140 160 180 Time on Stream (hr) 4 4 4 4 Space Vel. (cc/cc) 2.0 2.0 2.0 2.0 DTBP Conversion (%) 10.6 29.4 73.3 98.1 TBA Conversion (%) 0.0 0.0 0.0 0.0 Remarks H2O Free Basis H2O Free Basis H2O Free Basis H2O Free Basis H2O Free Basis Composition: IC4 0.004 0.004 0.009 0.012 0.045 MEOH/MF 55.398 55.855 55.875 55.683 55.728 Acetone 0.009 0.037 0.204 0.705 1.098 MTBE 1.248 1.183 1.224 1.221 1.372 TBA 39.997 40.046 40.334 41.274 41.315 DTBP 2.960 2.646 2.091 0.789 0.057 TBHP 0.000 0.000 0.000 0.000 0.015 Catalytic Decomposition of DTBP in a Continuous Reactor Run No. 10 11 12 13 14 Catalyst Fe,Cu,Cr on TiO2 Fe,Cu,Cr on TiO2 Fe,Cu,Cr on TiO2 Fe,Cu,Cr on TiO2 Reactor (cc) 100 100 100 100 Pressure (psig) 500 500 500 500 Feed Rate (cc/hr) 400 400 400 400 Temperature (°C.) 120 140 160 180 Time on Stream (hr) 4 4 4 4 Space Vel. (cc/cc) 4.0 4.0 4.0 4.0 DTBP Conversion (%) 1.2 10.8 43.2 88.7 TBA Conversion (%) 2.3 1.4 0.3 0.0 Remarks H2O Free Basis H2O Free Basis H2O Free Basis H2O Free Basis H2O Free Basis Composition: IC4 0.003 0.001 0.003 0.005 0.011 MEOH/MF 54.786 55.917 55.829 55.813 55.719 Acetone 0.009 0.015 0.087 0.434 1.028 MTBE 1.225 1.185 1.156 1.207 1.242 TBA 40.795 39.876 40.215 40.664 41.273 DTBP 2.789 2.756 2.488 1.584 0.315 TBHP 0.000 0.000 0.000 0.000 0.000 Catalytic Decomposition of DTBP in a Continuous Reactor Run No. 15 16 17 18 19 Catalyst Co, Mn on TiO2 Co, Mn on TiO2 Co, Mn on TiO2 Co, Mn on TiO2 Reactor (cc) 100 100 100 100 Pressure (psig) 500 500 500 500 Feed Rate (cc/hr) 200 200 200 200 Temperature (°C.) 120 140 160 180 Time on Stream (hr) 4 4 4 4 Space Vel. (cc/cc) 2.0 2.0 2.0 2.0 DTBP Conversion (%) 0.0 35.5 87.5 99.8 TBA Conversion (%) 2.9 0.0 0.0 0.0 Remarks H2O Free Basis H2O Free Basis H2O Free Basis H2O Free Basis H2O Free Basis Composition: IC4 0.004 0.002 0.003 0.005 0.021 MEOH/MF 56.015 56.538 55.610 55.231 55.273 Acetone 0.008 0.053 0.397 1.356 1.524 MTBE 1.194 1.397 1.208 1.204 1.239 TBA 39.912 38.745 40.478 41.140 41.149 DTBP 2.792 2.862 1.800 0.348 0.005 TBHP 0.000 0.000 0.000 0.000 0.000 Catalytic Decomposition of DTBP in a Continuous Reactor Run No. 15 20 21 22 23 Catalyst Co, Mn on TiO2 Co, Mn on TiO2 Co, Mn on TiO2 Co, Mn on TiO2 Reactor (cc) 100 100 100 100 Pressure (psig) 500 500 500 500 Feed Rate (cc/hr) 400 400 400 400 Temperature (°C.) 120 140 160 180 Time on Stream (hr) 4 4 4 4 Space Vel. (cc/cc) 4.0 4.0 4.0 4.0 DTBP Conversion (%) 3.8 10.4 58.5 97.9 TBA Conversion (%) 0.1 0.0 0.0 0.0 Remarks H2O Free Basis H2O Free Basis H2O Free Basis H2O Free Basis H2O Free Basis Composition: IC4 0.004 0.002 0.005 0.005 0.008 MEOH/MF 56.015 55.747 55.870 55.770 55.582 Acetone 0.008 0.037 0.133 0.687 1.337 MTBE 1.194 1.221 1.217 1.180 1.205 TBA 39.912 39.890 40.087 41.019 41.459 DTBP 2.792 2.687 2.502 1.158 0.058 TBHP 0.000 0.000 0.000 0.000 0.004 Catalytic Decomposition of DTBP in a Continuous Reactor Run No. 15 24 25 26 27 Catalyst Glass Beads Glass Beads Glass Beads Glass Beads Reactor (cc) 100 100 100 100 Pressure (psig) 500 500 500 500 Feed Rate (cc/hr) 100 100 100 100 Temperature (°C.) 130 140 150 160 Time on Stream (hr) 4 4 4 4 Space Vel. (cc/cc) 1.0 1.0 1.0 1.0 DTBP Conversion (%) 0.0 6.2 65.4 97.5 TBA Conversion (%) 3.7 4.6 2.2 0.0 Remarks H2O Free Basis H2O Free Basis H2O Free Basis H2O Free Basis H2O Free Basis Composition: IC4 0.004 0.001 0.001 0.002 0.004 MEOH/MF 56.015 56.892 57.297 57.033 56.040 Acetone 0.008 0.000 0.112 0.863 1.113 MTBE 1.194 1.447 1.493 1.509 1.288 TBA 39.912 38.431 38.094 39.029 40.763 DTBP 2.792 2.805 2.619 0.965 0.069 TBHP 0.000 0.000 0.000 0.000 0.001 Catalytic Decomposition of DTBP in a Continuous Reactor Run No. 15 28 29 30 31 Catalyst Glass Beads Glass Beads Glass Beads Glass Beads Reactor (cc) 100 100 100 100 Pressure (psig) 500 500 500 500 Feed Rate (cc/hr) 200 200 200 200 Temperature (°C.) 130 140 150 160 Time on Stream (hr) 4 4 4 4 Space Vel. (cc/cc) 2.0 2.0 2.0 2.0 DTBP Conversion (%) 8.0 19.7 29.9 56.0 TBA Conversion (%) 0.0 0.0 0.0 0.0 Remarks H2O Free Basis H2O Free Basis H2O Free Basis H2O Free Basis H2O Free Basis Composition: IC4 0.004 0.003 0.003 0.004 0.002 MEOH/MF 56.015 55.721 54.801 55.050 55.409 Acetone 0.008 0.076 0.150 1.050 0.734 MTBE 1.194 1.260 1.167 1.217 1.228 TBA 39.912 39.977 41.212 40.266 40.825 DTBP 2.792 2.570 2.243 1.956 1.229 TBHP 0.000 0.000 0.000 0.000 0.000 Catalytic Decomposition of DTBP in a Continuous Reactor Run No. 15 32 33 34 35 Catalyst Glass Beads Glass Beads Glass Beads Glass Beads Reactor (cc) 100 100 100 100 Pressure (psig) 500 500 500 500 Feed Rate (cc/hr) 400 400 400 400 Temperature (°C.) 130 140 150 160 Time on Stream (hr) 4 4 4 4 Space Vel. (cc/cc) 4.0 4.0 4.0 4.0 DTBP Conversion (%) 6.6 5.8 15.3 34.2 TBA Conversion (%) 0.0 0.0 0.0 0.0 Remarks H2O Free Basis H2O Free Basis H2O Free Basis H2O Free Basis H2O Free Basis Composition: IC4 0.004 0.002 0.003 0.002 0.002 MEOH/MF 56.015 55.476 55.726 55.703 55.661 Acetone 0.008 0.025 0.058 0.131 0.371 MTBE 1.194 1.209 1.260 1.211 1.221 TBA 39.912 40.295 39.939 40.278 40.548 DTBP 2.792 2.608 2.631 2.365 1.837 TBHP 0.000 0.000 0.000 0.000 0.000

Claims: A method for the production of MTBE which comprises the steps of: a. mixing a peroxides-contaminated tertiary butyl alcohol feedstock with a peroxides-free methanol feedstock to form a reaction medium, b. charging said reaction medium to an etherification reaction zone containing a bed of an etherification catalyst to convert a portion of said tertiary butyl alcohol and said methanol to methyl tertiary butyl ether and to form a methyl tertiary butyl ether reaction product, c. charging said methyl tertiary butyl ether reaction product to a distillation zone and separating it therein into a methyl tertiary butyl ether distillation fraction, a peroxides-contaminated MeOH/TBA recycle fraction and a water fraction, d. charging said peroxides-contaminated MeOH/TBA recycle fraction to a peroxides-decomposition zone containing a bed of a peroxides-decomposition catalyst under reaction conditions correlated for the substantially complete decomposition of said peroxides to thereby form a substantially peroxides-free MeOH/TBA recycle fraction, and e. recycling said substantially peroxides-free MeOH/TBA recycle fraction to said etherification reaction zone, characterized in that said catalyst consists essentially of a titania supported transition metal. A method as claimed in Claim 1, wherein the catalyst consists essentially of a mixture of iron, copper and chromia supported on titania. A method as claimed in Claim 2, wherein the catalyst consists essentially of a mixture of 0.1 to 15 wt.% of iron, 0.01 to 2.5 wt.% of copper and 0.01 to 5.0 wt.% of chromia supported on titania. A method as claimed in Claim 1, wherein the catalyst consists essentially of a mixture of cobalt and manganese supported on titania. A method as claimed in any one of Claims 1 to 4, wherein the catalyst is calcined in air at 200-600°C and subsequently partially reduced in a stream of hydrogen at 100-500°C. A method as claimed in any one of Claims 1 to 5, wherein the MeOH/TBA recycle fraction is contaminated with peroxides including 0.1 to 5 wt.% of ditertiary butyl peroxide, 0.0 to 1 wt.% of tertiary butyl hydroperoxide and 0.05 to 2.5 wt.% of allyl tertiary butyl peroxide, which comprises: a. continuously contacting the MeOH/TBA recycle fraction in a peroxide decomposition reaction zone with said peroxide decomposition catalyst at a temperature within the range of 50° to 250°C, a pressure of 20 to 170 MPa (100 to 800 psig) and a space velocity of 0.5 to 5 volumes of contaminated MeOH/TBA feedstock per hour per volume of catalyst to substantially decompose said peroxide contaminants, and b. recovering from the products of said reaction a MeOH/TBA product contaminated with not more than about 300 ppm of peroxide contaminants. A method as claimed in Claim 6, wherein the temperature in the peroxide decomposition reaction zone is 80°C to 200°C.

Inventors: KNIFTON JOHN FREDERICK, SANDERSON JOHN RONALD, KNIFTON, JOHN FREDERICK, SANDERSON, JOHN RONALD
Applicants: TEXACO CHEM INC, TEXACO CHEMICAL INC.
Application year: 1993
Main classification: C07C29
IPC codes: C07C29, C07C41, C07B61, B01J23, C07C43