Process for converting methanol to alkyl ethers, gasoline, disti

Chemistry of hydrocarbon compounds – Plural serial diverse syntheses – Including alkylation to produce branched-chain paraffin

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585314, 585315, 585316, 585469, 585640, 585731, C07C 120, C07C 200

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046847570

ABSTRACT:
A multistage process for producing ethers from lower aliphatic oxygenate feedstock, such as methanol. Feedstock is catalytically converted in a primary catalyst stage at elevated temperature in contact with zeolite catalyst to predominantly C.sub.2 -C.sub.5 lower olefins comprising isobutylene and isoamylene, by-product water and a minor amount of C.sub.6.sup.+ hydrocarbons, followed by fractionation of the C.sub.2 -C.sub.5 olefins to recover a C.sub.2 -C.sub.3 -rich recycle stream for further catalytic conversion in the primary stage. C.sub.4 -C.sub.5 olefins are passed to a second catalytic etherification stage for reaction of isoalkenes with methanol to produce methyl tertiary-butyl ether and methyl isoamylether. The second stage effluent may be fractionated to recover an ether product, C.sub.5.sup.+ hydrocarbon liquid product, and unreacted butenes. Advantageously, the unreacted butenes are further reacted wtih isoparaffin in a third catalytic stage under acid catalysis alkylation conditions, and fractionated to recover C.sub.6.sup.+ alkylate liquid, liquid hydrocarbon product. The ethers may be blended with at least one C.sub.6.sup.+ hydrocarbon to produce high octane gasoline.

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