US Pat. No. 10,364,204

PROCESS FOR MANUFACTURING METHYL TERTIARY-BUTYL ETHER (MTBE) AND OTHER HYDROCARBONS

Lyondell Chemical Techno...

1. A process for manufacturing methyl t-butyl ether (MTBE) comprising:a first step comprising cracking raw material comprising ethane or propane to form ethylene; and recovering residual uncracked raw material;
a second step comprising dimerizing ethylene to form a n-butylene feed stream, wherein the n-butylene feed stream comprises:
(i) about 30 to 50 wt. % of 2-butene, based on the total weight of the feed stream,
(ii) about 25 to 45 wt. % of 1-butene, based on the total weight of the feed stream, and
(iii) a higher molecular weight ethylene oligomer
wherein the dimerizing step is performed at a temperature of about 10-100° C., wherein the dimerizing step takes place in the presence of a dimerization catalyst, wherein the dimerization catalyst comprises a nickel compound and an aluminum compound, and wherein the catalyst has a Ni:Al ratio from 0.9:10 to 1:2.5;
a third step comprising isomerizing the n-butylene feed stream to form an isobutylene stream using a isomerization catalyst at a weight hourly space velocity (WHSV) of 0.2-4 kg feedstock per kg catalyst per hour at a pressure of about 345-3450 kPa and a temperature of about 40-200° C., wherein the isomerization catalyst is an acidic isomerization catalyst;
recovering unconverted n-butylene;
alkylating isobutylene with isobutane at a pressure of at least 600 kPa to form gasoline alkylate;
recovering gasoline alkylate;
isomerizing the higher molecular weight ethylene oligomer; and
recovering the isomerized higher molecular weight ethylene oligomer;
a fourth step comprising oxidizing methane to form methanol;
a fifth step comprising etherifying the isobutylene stream with methanol to form methyl t-butyl ether;
etherifying the higher molecular weight ethylene oligomer contained in the isobutylene stream with methanol to form a higher-molecular-weight-ethylene-oligomer-based methyl ether;
recovering the higher-molecular-weight-ethylene-oligomer-based methyl ether;
etherifying an isomerized higher molecular weight ethylene oligomer contained in the isobutylene stream with methanol to form an isomerized-higher-molecular-weight-ethylene-oligomer-based methyl ether; and
recovering the isomerized-higher-molecular-weight-ethylene-oligomer-based methyl ether; and
a sixth step comprising collecting the methyl t-butyl ether.