KING FAHAD UNIVERSITY OF PETROLEUM AND MINERALS CHE 495: Senior Design Project MTBE

1. KING FAHAD UNIVERSITY OF PETROLEUM AND MINERALSCHE 495: Senior Design ProjectMTBE ABDALLAH ALHARABAH

2. INTRODUCTION

3. INTRODUCTION Problem Statement This term's problem is to design an MTBE plant that produces 2000 tons MTBE per day. MTBE is a gasoline additive used to increase octane number that is produced from methanol and isobutylene. MTBE is produced by a liquid-phase reaction over a catalyst. The reaction is between isobutene and methanol as follows: (CH3)2C=CH2 + CH3OH  (CH3)3C-O-CH3

4. INTRODUCTION Problem Statement MTBE 2000 ton/day Pure Methanol The reactor 30 bar and 90 °C , • Mixture : • 40% isobutylene • 55% isobutane • 5% propane The isobutene and propane are inert. The conversion is 95% and the selectivity is one.

5. Literature Review

6. Outlines • INTRODUCTION • MTBE SYNTHSIS • - Raw Material • - Properties and Thermodynamics • MTBE PROCESSES • - Process Description • - Process Flow Diagram (PFD) • - Uses and Alternatives • - Safety

7. INTRODUCTION MTBE known as methyl tertiary butyl ether • MTBE is a chemical compound with molecular formula C5H12O. • It has been used since 1979 when it was first added to gasoline to replace lead as an anti-knock agent and to boost octane. • MTBE oxygenate has achieved a great economic importance in recent years as a gasoline additive because of its ability to enhance the octane value of unleaded motor gasoline while increasing the oxygen content. • MTBE is produced by the reaction of isobutylene and methanol in the presence of a cation exchange resin catalyst Amberlyst 15.

8. INTRODUCTION MTBE known as methyl tertiary butyl ether • MTBE is also used in organic chemistry as a relatively inexpensive solvent with properties comparable to diethyl ether but with a higher boiling point and lower solubility in water. • It is also used medically to dissolve gallstones.

9. MTBE SYNTHsis Raw Material

10. RAW MATERIAL METHANOL known as methyl alcohol • its molecular formula is CH3OH. • Methanol was formerly produced by the destructive distillation of wood. • The modern method of preparing methanol is based on the direct combination of carbon monoxide gas and hydrogen in the presence of a catalyst. • Most methanol is produced from the methane which is found in natural gas.

11. RAW MATERIAL METHANOL known as methyl alcohol • Pure methanol is an important material in chemical synthesis. • Methanol is a colorless liquid, completely miscible with water and organic solvents and is very hydroscopic. It boils at 64.96° C (148.93° F) and solidifies at -93.9° C (-137° F). • It forms explosive mixtures with air and burns with a nonluminous flame. It is a violent poison; drinking mixtures containing methanol has caused many cases of blindness or death. Methanol has a settled odor.

12. RAW MATERIAL Isobutylene known as 2-methylpropene with a formula C4H8 • It is called olefin because it contains a four-carbon branched alkene. • It is colarless gas and on of the important hydrocarbon in industrial. • Isobutylene is used as an intermediate in the production of a variety of products. • It is reacted with methanol and ethanol in the manufacture of the gasoline oxygenates methyl tert-butyl ether (MTBE) and ethyl tert-butyl ether (ETBE), respectively. Alkylation with butane produces isooctane, another fuel additive.

13. RAW MATERIAL Propane It is molecular formula C3H8 • Propane is a colorless, flammable gas at atmospheric pressure and normal temperatures. • It has a natural gas odor and is soluble in ether, alcohol and slightly soluble in water. • Typical uses include vehicle fuel, home heating, and refrigerant gas.

14. MTBE SYNTHsis Properties and Thermodynamics

15. Properties and Thermodynamics MTBE known as methyl tertiary butyl ether

16. Properties and Thermodynamics METHANOL known as methyl alcohol with a formula CH3OH

17. Properties and Thermodynamics METHANOL known as methyl alcohol with a formula CH3OH

18. Properties and Thermodynamics Butenes

19. Properties and Thermodynamics Propane It is molecular formula C3H8

20. MTBE PROCES Process Description

21. Process Description • (MTBE) is a gasoline additive used to increase octane number that is produced from methanol and isobutylene. • Methanol is purchased but the isobutylene is obtained from the isomerization and dehydrogenation of butane . Butene waste stream Water Methanol Scrubber Methanol MTBE Reactor Methanol Recycle Column Butenes MTBE Column Waste stream BFD MTBE

22. Process Description • The Butenes stream contains 40% isobutylene, 55% isobutene and and 5% light gases mainly propane Butene waste stream Water Methanol Scrubber Methanol MTBE Reactor Methanol Recycle Column Butenes MTBE Column Waste stream BFD MTBE

23. Process Description • The MTBE produced is extracted from the reaction effluent via distillation, while the unreacted methanol is absorbed by water before it is separated from water via distillation. The recoverd methanol is recycled back to the reactor. Butene waste stream Water Methanol Scrubber Methanol MTBE Reactor Methanol Recycle Column Butenes MTBE Column Waste stream BFD MTBE

24. Process Description • MTBE is produced by a liquid-phase reaction over a catalyst. The reaction is between isobutylene and methanol as follows: • (CH3)2C=CH2 + CH3OH  (CH3)3C-O-CH3 Butene waste stream Water Methanol Scrubber Methanol MTBE Reactor Methanol Recycle Column Butenes MTBE Column Waste stream BFD MTBE

25. MTBE PROCES Process Flow Diagram (PFD)

26. Process Flow Diagram PFD

27. Process Flow Diagram

28. MTBE PROCES Kinetic Data and Uses

29. Process Flow Diagram • The catalyst used in this reaction is Amberlyst 15. • A kinetic model for the liquid phase reaction using Amberlyst 15 as a catalyst is

30. Uses • MTBE has many properties that make it a good gasoline component for technical and environmental reasons: • • MTBE can be used as fuel that can supplement the supply of gasoline components. • • Its high octane rating makes it an ideal substitute for other octane components, e.g. lead. • • It is an oxygenate, which can be used in the formulation of cleaner-burning gasoline.

31. MTBE PROCES Safety

32. Safety • Safety is very important in the plant because any small mistakes will cost money. For example: • in reactor we should have a jacket or coil to cool the reactor because the reaction is exothermic and isothermal. If we don't have cooler the reaction temperature with time will increase and that will lead to break the catalyst and explosion. • Also in the distillation column limit the maximum height to 53 m because of wind load and foundation considerations

33. Safety • Also we need to use spare pump because if the primary pump is not working we don't have problem. • Moreover we need to use PID tuning to control the process conditions like temperature and pressure. • Also some safety factors will required in the design's calculation to avoid problems.

34. ? ? ? Questions