MTBE Reactor Recycle After C4 Separation to Cut Reactor Volume
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Solution Overview
Problem
Conventional MTBE production methods require large reactor volumes and high utility consumption due to the recycling of non-reactive C4 hydrocarbons, leading to increased capital and operational costs, as well as reduced reaction efficiency and catalyst sintering.
Innovation Solution
Recycle a portion of the MTBE product stream to the MTBE synthesis reactor after separating non-reactive C4 hydrocarbons, using a resin-based catalyst to enhance the affinity and diffusivity of isobutylene and methanol, thereby reducing reactor volume and utility consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If non-reactive C4 hydrocarbons are recycled back to the fixed bed reactor, then reaction efficiency is improved by maintaining reactant concentration, but reactor volume must be increased to handle the large recycle stream
Solution Approach 1:
The patent extracts and removes non-reactive C4 hydrocarbons from the recycle stream through a separation unit before recycling to the reactor. This allows the recycle stream to contain only reactive components (MTBE and reactants), maintaining reaction efficiency while reducing the volume required to handle the recycle stream.
Solution Approach 2:
The patent changes the composition parameter of the recycle stream by separating out non-reactive C4 hydrocarbons. This parameter change enables the recycle stream to have higher concentration of reactive species, improving reaction efficiency without requiring proportionally large reactor volume.
2Productivity
If large reactor volume is used to handle large recycle stream, then reaction efficiency is maintained, but utility consumption increases due to consistent cooling requirements
Solution Approach 1:
By extracting non-reactive C4 hydrocarbons from the recycle stream, the patent reduces the total volume of material requiring cooling in the reactor. This leads to reduced utility consumption for cooling while maintaining reaction efficiency through the recycled reactive components.
Solution Approach 2:
The patent changes the flow rate and composition parameters of the recycle stream by removing non-reactive components. This results in lower cooling requirements and reduced utility consumption while preserving the reactive species needed for efficient reaction.
3Productivity
If conventional etherification method is used, then MTBE production is achieved, but catalyst sintering occurs reducing long-term reliability
Solution Approach 1:
The patent extracts and removes non-reactive C4 hydrocarbons that contribute to catalyst sintering. By recycling only the reactive components (MTBE and reactants), the patent protects the catalyst from sintering damage, improving long-term reliability while maintaining MTBE production.
Solution Approach 2:
The patent changes the composition parameter of the recycle stream to exclude non-reactive C4 hydrocarbons. This parameter change reduces catalyst exposure to sintering conditions, improving catalyst stability and long-term reliability while preserving production capability.
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 approach allows for smaller reactor sizes, lower utility costs, and increased MTBE production efficiency by improving catalyst performance and reaction kinetics.
Implementation Method 1
reacting isobutylene and methanol in a reactor unit to form a reactor unit effluent comprising MTBE
Implementation Method 2
distilling the dried reactor unit effluent in a distillation column to produce a first bottom stream comprising MTBE
Data Source
AI summary
Systems and methods for producing MTBE are disclosed. A C4 feed stream containing isobutylene and other C4 hydrocarbons is fed into a reactor unit for producing MTBE. The effluent of the reactor unit comprising MTBE is further processed to produce a MTBE product stream that comprises at least 90 wt. % MTBE. At least a portion of the MTBE product stream is then recycled back to the reactor unit.