MTBE Production from Fischer-Tropsch C4 Hydrocarbons

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Solution Overview

Problem

There is a need for new and improved methods to produce useful compounds from low molecular weight C1-C5 hydrocarbons, such as C4 hydrocarbons, from non-petroleum feedstocks, as existing methods like the Fischer-Tropsch process primarily produce gasoline-range hydrocarbons and heavier products.

Innovation Solution

A system comprising a Fischer-Tropsch reactor, olefin separator, deisobutanizer, iso-butane to isobutylene reactor, and MTBE reactor, where C4 hydrocarbons are processed to produce isobutylene, which is then converted into methyl tert-butyl ether (MTBE) through a series of separation, isomerization, and reaction steps.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If the Fischer-Tropsch process is used to produce hydrocarbons from syngas, then gasoline-range hydrocarbons and heavier products are obtained, but lower molecular weight C1-C5 hydrocarbons are not sufficiently produced

Engineering Contradiction:

Improveproduction of C1-C5 hydrocarbonsVSAvoidselectivity to desired product range

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The patent modifies the Fischer-Tropsch process parameters including catalyst composition (using iron or cobalt with promoters like rhenium, zirconium, or manganese), reaction temperature (20-300°C), and pressure conditions to shift product distribution toward lower molecular weight C1-C5 hydrocarbons while maintaining acceptable selectivity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs dynamic control of process conditions including staged addition of reactants, variable temperature zones within the reactor, and adjustable catalyst bed configurations to optimize the balance between producing C1-C5 hydrocarbons and preventing over-cracking or polymerization

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If multiple separation and reaction units are added to convert C4 hydrocarbons to MTBE, then product value and utility are improved, but device complexity increases

Engineering Contradiction:

Improveproduct utility and market valueVSAvoidnumber of process units

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines multiple functions into integrated process units where the olefin separator and deisobutanizer are operatively connected in sequence, and the iso-butane to isobutylene reactor is integrated with the MTBE reactor system, allowing continuous processing through a unified flow path that reduces intermediate storage and handling complexity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent divides the complex conversion process into distinct functional segments: C4 hydrocarbon separation, olefin isolation, isobutylene production, and MTBE synthesis, where each segment can be independently optimized and maintained while contributing to the overall value-added transformation

Inventive Principle:

Principle #1Segmentation

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 method effectively converts C4 hydrocarbons into MTBE, a valuable gasoline additive, enhancing octane quality and providing a sustainable production pathway from non-petroleum sources.

Implementation Method 1

The Fischer-Tropsch catalytic process for catalytically producing hydrocarbons from syngas

Methodology Applied

Scientific EffectFischer-Tropsch catalytic process: Catalysis

Implementation Method 2

separating at least a portion of the C4 olefin hydrocarbon product comprising isobutylene from the first C4 hydrocarbon product

Methodology Applied

Scientific EffectPhysical separation:

Implementation Method 3

separating at least a portion of the n-butane from the second C4 hydrocarbon product

Methodology Applied

Scientific EffectDistillation/Fractionation: Distillation

Implementation Method 4

producing isobutylene from at least a portion of the fourth C4 hydrocarbon product

Methodology Applied

Scientific EffectDehydrogenation/Cracking:

Implementation Method 5

producing methyl tert-butyl ether (MTBE) from at least a portion of the fifth C4 hydrocarbon product

Methodology Applied

Scientific EffectChemical reaction:

Data Source

PatentUS9969667B2Systems and methods related to the production of methyl tert-butyl ether

Publication Date: 2018.05.15 SABIC GLOBAL TECHNOLOGIES BV

AI summary

Disclosed herein is a system comprising: a) a Fischer-Tropsch reactor comprising a first inlet and a first outlet; b) an olefin separator comprising a second inlet and a second outlet; c) a deisobutanizer comprising a third inlet and a third outlet; d) an iso-butane to isobutylene reactor comprising a fourth inlet and a fourth outlet; and e) a MTBE reactor comprising a fifth inlet, the recited structures are in fluid communication.