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Development of a Catalyst for Conversion of Syngas-Derived Materials to Isobutylene - 1996

Gajda, G. J.
Barger, P. T.
Spehlmann, B. C.

UOP

Table of Contents 253kb

Section 1
824kb		 Table of Contents i
List of Tables iv
List of Figures vii
Executive Summary viii
1 Objectives 1
2 Introduction 3
 

2.1

 Utilization of Higher Branched Alcohols (Isobutanol) 3
  2.1.1 Current Production and Utilization of Isobutanol 4
2.1.2 Isobutanol Dehydration to Isobutylene 4
2.1.3 Isobutyraldehyde Hydrogenation to Isobutanol 5

2.2

 Formation of Higher Branched Alcohols from Synthesis Gas 5
  2.2.1 Alkali Modified Methanol Synthesis Catalysts 6
2.2.2 Noble Metal on Zn/Mn/Zr Oxide Catalysts 7
2.2.3 Proposed Reaction Mechanisms 8

2.3

 Formation of Higher Branched Alcohols from Light Alcohols 9
  2.3.1 Condensation of Mixtures of Methanol, Ethanol and Propanol 9
2.3.2 Condensation of Methanol Only 10
2.4 Basic Metal Oxides 10
2.5 Direct Conversion of Synthesis Gas to Isobutylene (Isosynthesis) 11
Section 2
1574kb

3

 Experimental Summary 13
 

3.1

 Catalyst Identification and Reaction Mechanism (Task 1) 14
 

3.1.1

 Pilot Plant Descriptions 15
  3.1.1.1 Pilot Plant for CO/H2 Conversion to Higher Alcohols 15
3.1.1.2 Blank Runs with CO/H2 Feed 16
3.1.1.3 Pilot Plant for Conversion of Methanol and Methanol/Ethanol to Higher Alcohols 16
3.1.1.4 Blank Runs with Methanol and Methanol/Ethanol Feeds 17

3.3.4

 H2, CO and CO2 Co-Feeds 35
Section 3
1005kb

3.4

 Pilot Plant Demonstrations (Task 3) 36
  3.4.1 Methanol-Only Conversion over Pt on Zn/Mn/Zr Oxide Catalysts 36
3.4.2 Demonstration of Optimum Conditions for Methanol/Ethanol Conversion to Higher Alcohols with 2% Pt on Zn/Mn/Zr Oxide Catalyst 38
3.4.3 Methanol/Ethanol Conversion with High H2 Co-Feed 39

3.5

 Economic Evaluation (Task 5) 40
  3.5.1 Summary of Process Variable Studies/Optimum Conditions Obtained Experimentally 40
3.5.2 Modeling of a Commercial Isobutanol Synthesis Plant 40
3.5.3 Basis for Capital Cost Estimate 41
3.5.4 Process Simulation Results 42
3.5.5 Vent Loss Study 43
3.5.6 Economic Analysis 44
  3.5.6.1 Overview of Methodology 44
3.5.6.2 Utility and Other Operating Costs 44
3.5.6.3 Base Case Economic Study and Other Cases Considered 45
3.5.6.4 Conclusions of the Economic Analysis 46

3.6

 Direct Conversion of Synthesis Gas to Isobutylene (Isosynthesis) 46
4 Conclusions and Recommendations 49
  5 Tables 53
6 Figures 1028kb 113
7 Appendix 133kb 139
8 References 127kb 143