1. ABDALLAH ALHARABAH

2. INTRODUCTION The purpose MTBE PLANT, PRODUCTION MASS AND ENARGY BALANCE EQUIPMENT DESIGN, SIZING ECONOMICS ANALYSIS

3. Problem Statement This term's problem is to design an MTBE plant that produces 2000 tons MTBE per day. INTRODUCTION 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: (CH 3 ) 2 C=CH 2 + CH 3 OH  (CH 3 ) 3 C-O-CH 3

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

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

7. INTRODUCTION  MTBE is a chemical compound with molecular formula C 5 H 12 O.  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. MTBE known as methyl tertiary butyl ether

8.  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. INTRODUCTION MTBE known as methyl tertiary butyl ether

9. Raw Material

10. RAW MATERIAL METHANOL known as methyl alcohol  its molecular formula is CH 3 OH.  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 C 4 H 8  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 C 3 H 8  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. Properties and Thermodynamics

15. MTBE known as methyl tertiary butyl ether MTBE properties 88.15Molecular weight (g/mole) 54Boiling Temperature ( °C) 0.74Specific gravity 50000Water solubility (mg/L) 251Vapor pressure (mm Hg) 1.5E-3Henry's Law 81.7Latent heat of vaporization (Cal/g) 0.51Specific heat (Cal/g.°C)

16. Properties and Thermodynamics METHANOL known as methyl alcohol with a formula CH 3 OH Liquid Properties: Viscosity: a = 555.3 b = 260.6 where log(viscosity) = a * ( 1/T - 1/b ) viscosity: mNs/m² T: °K Vapor Properties: Heat capacity: a = 21.152 b = 0.07092 c = 2.59E-05 d = -2.85E-08 where Cp = a + b*T + c*T² + d*T³ Cp: kJ/kmol.K T: °K Vapour pressure: a = 18.5875 b = 3626.55 c = -34.29 where ln(P) = a - b/(T+c) P: mmHg6 to 91°C

17. Methanol properties 32.04Molecular weight (g/mole) 65Boiling Temperature (°C ) -97.7Melting pint (°C ) 0.79Relative Density 0.8Specific gravity infinityWater solubility (mg/L) 122Vapor pressure (mm Hg) 201.3-Heat of Formation (MJ/kmol) -162.62Gibbs Free Energy 512.6Tc (K) 81Pc (bar) 0.118Vc ( m³/kmol) 791Density ( kg/m³) 35278Heat of Vaporization (kJ/kmol) 1.1E-4Henry's Law Properties and Thermodynamics METHANOL known as methyl alcohol with a formula CH 3 OH

18. 1-buteneisobutyleneButenes properties 56.10756.11Molecular weight (g/mole) -6.3-6.9Boiling Temperature (°C ) -185.4-140.3Melting pint (°C ) 1.9980.59Specific gravity 0.085insolubleWater solubility (mg/ml) 268268.8Vapor pressure ( kPa) -79-76Flash point (°c) 146.4-144.7Tc (°c) 40.239.48Pc (atm) -239Vc ( cm³/mol) 2.72(kg/m³)0.5879Density ( g/cm³) gas 390 (kj/kg)94.3Latent Heat of Vaporization (cal/g) 0.083 (kj/mol.k)1.487Specific heat (kj/kg.k) Properties and Thermodynamics Butenes

19. Propane It is molecular formula C 3 H 8 Properties and Thermodynamics Propane properties 44.1Molecular weight (g/mole) -42.09Boiling Temperature (°C ) -187.6Melting pint (°C ) 1.5503Specific gravity 0.07Water solubility (mg/ml) 109Vapor pressure (psig) 0.008029Viscosity (centipoise) -162.62Gibbs Free Energy 206.2Tc (°F) 617.4Pc (psia) 1.83Density ( kg/m³) gas 507.7Density ( kg/m³) liquid 101.76Heat of Vaporization (cal/g) 0.3885Specific heat (cal/g.°c)

20. Process Description

21.  (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. Methanol Butenes Water MTBE Methanol Recycle Column MTBE Column MTBE Reactor Methanol Scrubber Waste stream Butene waste stream

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

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. Methanol Butenes Water MTBE Methanol Recycle Column MTBE Column MTBE Reactor Methanol Scrubber Waste stream Butene waste stream

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

25. Process Flow Diagram (PFD)

26. Process Flow Diagram

28. 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. 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. Uses

31. Safety

32. 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 Safety

33.  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. Safety

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