Co-production of MTBE and Alkylate via C4 Dehydrogenation
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Solution Overview
Problem
Current processes for converting paraffins to olefins and subsequent alkylation do not effectively leverage C4 feedstocks to their fullest potential, lacking flexibility in product slate adjustment and efficiency in co-producing tertiary-butyl ether compounds and alkylates.
Innovation Solution
Integration of a dehydrogenation unit with a tertiary-butyl ether unit and an alkylation unit, where a hydrocarbon feed stream comprising C4 hydrocarbons is dehydrogenated to produce C4 olefins, which are then processed to generate both tertiary-butyl ether compounds and alkylates, with a fractionator overhead stream recycled to optimize product yields and flexibility through control systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If C4 hydrocarbons are processed through conventional separate dehydrogenation and alkylation processes, then olefins are produced for alkylation, but the process lacks flexibility in product slate adjustment and does not fully leverage C4 feedstock potential
Solution Approach 1:
The patent combines dehydrogenation, etherification, and alkylation processes into an integrated system where C4 feedstock is simultaneously converted to both ether products and alkylate. The dehydrogenation unit feeds both the etherification unit and alkylation unit, creating a unified process that maximizes feedstock utilization and provides flexible product slate adjustment.
Solution Approach 2:
The integrated process design allows the same C4 feedstock to serve multiple product pathways - producing both ether compounds (like MTBE) and alkylate simultaneously. This multi-functional approach enables the process to adapt to different market demands and fully leverage the value of C4 feedstocks through diverse product outputs.
2Adaptability or versatility
If an integrated dehydrogenation-etherification-alkylation process is implemented, then co-production of MTBE and alkylate is achieved with enhanced flexibility, but process complexity increases
Solution Approach 1:
The integrated process is divided into distinct functional units - dehydrogenation unit, etherification unit, and alkylation unit - each performing a specific function. This segmentation allows for manageable complexity while achieving overall integration, as each unit can be independently optimized and controlled.
Solution Approach 2:
The dehydrogenation effluent serves as an intermediary stream that connects the dehydrogenation unit to both the etherification and alkylation units. This intermediary approach allows flexible distribution of olefin streams to different product pathways, enabling product slate adjustment without requiring complex direct coupling between all process units.
3Productivity
If fractionator overhead stream is recycled to the dehydrogenation unit, then MTBE and alkylate production is optimized, but hydrogen balance and process control become more challenging
Solution Approach 1:
The recycling of fractionator overhead stream to the dehydrogenation unit creates a feedback loop that allows optimization of hydrogen balance and product distribution. The recycled stream provides additional olefins for etherification while maintaining hydrogen balance through the dehydrogenation reaction, and the process control system can adjust recycle rates to optimize production efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This integrated process enhances the co-production of MTBE and alkylates, providing flexibility in product slate adjustment and increased efficiency by recycling streams to optimize MTBE and alkylate production without significant capital expenditure, resulting in higher octane products.
Implementation Method 1
passing a hydrocarbon feed stream comprising C4 hydrocarbons to a dehydrogenation unit to generate a dehydrogenation effluent comprising C4 olefins
Implementation Method 2
The mixed stream is separated to provide a tertiary-butyl ether product stream and a fractionator overhead stream comprising olefins
Implementation Method 3
The fractionator overhead stream is passed to an alkylation unit to produce an alkylation product stream comprising an alkylate
Data Source
AI summary
Processes for co-production of methyl tertiary-butyl ether (MTBE) and alkylate is disclosed. The process includes comprising passing a hydrocarbon feed stream comprising C4 hydrocarbons to a dehydrogenation unit to generate a dehydrogenation effluent comprising C4 olefins. The dehydrogenation effluent is passed to a MTBE unit to provide a mixed stream comprising C4 olefins and MTBE. The mixed stream is separated to provide an MTBE product stream and a fractionator overhead stream comprising olefins. The fractionator overhead stream is passed to an alkylation unit to produce an alkylation product stream comprising an alkylate.