Isobutylene separation

The reaction between isobutylene (separated from C4 fractions from cracking units or from cracking isobutane to isobutene) and formaldehyde produces a cyclic ether (dimethyl dioxane). Pyrolysis of dioxane gives isoprene and formaldehyde. The formaldehyde is recovered and recycled to the reactor. 

Isobutyl alcohol [78-83-1] forms a substantial fraction of the butanols produced by higher alcohol synthesis over modified copper—zinc oxide-based catalysts. Conceivably, separation of this alcohol and dehydration affords an alternative route to isobutjiene [115-11 -7] for methyl /-butyl ether [1624-04-4] (MTBE) production. MTBE is a rapidly growing constituent of reformulated gasoline, but its growth is likely to be limited by available suppHes of isobutylene. Thus higher alcohol synthesis provides a process capable of supplying all of the raw materials required for manufacture of this key fuel oxygenate (24) (see Ethers). 

Methylphenol. y -Cresol is produced synthetically from toluene. Toluene is chlorinated and the resulting chlorotoluene is hydrolyzed to a mixture of methylphenols. Purification by distillation gives a mixture of 3-methylphenol and 4-methylphenol since they have nearly identical boiling points. Reaction of this mixture with isobutylene under acid catalysis forms 2,6-di-/ f2 -butyl-4-methylphenol and 2,4-di-/ f2 -butyl-5-methylphenol, which can then be separated by fractional distillation and debutylated to give the corresponding 3- and 4-methylphenols. A mixture of 3- and 4-methylphenols is also derived from petroleum cmde and coal tars. 

In commercial extraction operations, the fractions that contain butadiene, isobutene, and 1- and 2-butenes usually first go through a butadiene extraction unit in which the butadiene is removed. This may be followed by isobutylene removal via reaction between isobutylene and methanol to form methyl /-butyl ether [1634-04-4] (MTBE). The butenes are then distilled from the MTBE. 1-Butene may then be separated from 2-butene by distillation. 

Sulfuric acid is about one thousand times more reactive with isobutylene than with the 1- and 2-butenes, and is thereby very useful in separating isobutylene as tert-huty alcohol from the other butenes. The reaction is simply carried out by bubbling or stirring the butylenes into 45—60% H2SO4. This results in the formation of tert-huty hydrogen sulfate. Dilution with water followed by heat hydrolyzes the sulfate to form tert-huty alcohol and sulfuric acid. The Markovnikov addition implies that isobutyl alcohol is not formed. The hydration of butylenes is most important for isobutylene, either directiy or via the butyl hydrogen sulfate. 

Isomerization. Isomerization of any of the butylene isomers to increase supply of another isomer is not practiced commercially. However, their isomerization has been studied extensively because formation and isomerization accompany many refinery processes maximization of 2-butene content maximizes octane number when isobutane is alkylated with butene streams using HF as catalyst and isomerization of high concentrations of 1-butene to 2-butene in mixtures with isobutylene could simplify subsequent separations (22). One plant (Phillips) is now being operated for this latter purpose (23,24). The general topic of isomerization has been covered in detail (25—27). Isomer distribution at thermodynamic equiUbrium in the range 300—1000 Kis summarized in Table 4 (25). 

The Coastal process uses steam pyrolysis of isobutane to produce propylene and isobutylene (as weH as other cracked products). It has been suggested that the reaction be carried out at high pressure, >1480 kPa ( 15 atm), to facHitate product separation. This process was commercialized in the late 1960s at Coastal s Corpus Christi refinery. 

These processes are aH characterized by low isobutane conversion to achieve high isobutylene selectivity. The catalytic processes operate at conversions of 45—55% for isobutane. The Coastal process also operates at 45—55% isobutane conversion to minimize the production of light ends. This results in significant raw material recycle rates and imposing product separation sections. 

Dehydrogenation of isobutane to isobutylene is highly endothermic and the reactions are conducted at high temperatures (535—650°C) so the fuel consumption is sizeable. Eor the catalytic processes, the product separation section requires a compressor to facHitate the separation of hydrogen, methane, and other light hydrocarbons from-the paraffinic raw material and the olefinic product. An exceHent overview of butylenes is avaHable (81). 

Separation and Purification of Isomers. 1-Butene and isobutylene caimot be economically separated into pure components by conventional distHlation because they are close boiling isomers (see Table 1 and Eig. 1). 2-Butene can be separated from the other two isomers by simple distHlation. There are four types of separation methods avaHable (/) selective removal of isobutylene by polymeriza tion and separation of 1-butene (2) use of addition reactions with alcohol, acids, or water to selectively produce pure isobutylene and 1-butene (3) selective extraction of isobutylene with a Hquid solvent, usuaHy an acid and (4) physical separation of isobutylene from 1-butene by absorbents. The first two methods take advantage of the reactivity of isobutylene. Eor example, isobutylene reacts about 1000 times faster than 1-butene. Some 1-butene also reacts and gets separated with isobutylene, but recovery of high purity is possible. The choice of a particular method depends on the product slate requirements of the manufacturer. In any case, 2-butene is first separated from the other two isomers by simple distHlation. 

There are currentiy three important processes for the production of isobutylene (/) the extraction process using an acid to separate isobutylene (2) the dehydration of tert-huty alcohol, formed in the Arco s Oxirane process and (3) the cracking of MTBE. The expected demand for MTBE wHl preclude the third route for isobutylene production. Since MTBE is likely to replace tert-huty alcohol as a gasoline additive, the second route could become an important source for isobutylene. Nevertheless, its avaHabHity wHl be limited by the demand for propylene oxide, since it is only a coproduct. An alternative process is emerging that consists of catalyticaHy hydroisomerizing 1-butene to 2-butenes (82). In this process, trace quantities of butadienes are also hydrogenated to yield feedstocks rich in isobutylene which can then be easHy separated from 2-butenes by simple distHlation. 

In the physical separation process, a molecular sieve adsorbent is used as in the Union Carbide Olefins Siv process (88—90). Linear butenes are selectively adsorbed, and the isobutylene effluent is distilled to obtain a polymer-grade product. The adsorbent is a synthetic 2eohte, Type 5A in the calcium cation exchanged form (91). UOP also offers an adsorption process, the Sorbutene process (92). The UOP process utilizes ahquid B—B stream, and uses a proprietary rotary valve containing multiple ports, which direct the flow of Hquid to various sections of the adsorber (93,94). The cis- and trans-isomers are alkylated and used in the gasoline blending pool. 

Di- and Triisobutylcncs. Diisobutylene [18923-87-0] and tnisobutylenes are prepared by heating the sulfuric acid extract of isobutylene from a separation process to about 90°C. A 90% yield containing 80% dimers and 20% trimers results. Use centers on the dimer, CgH, a mixture of 2,4,4-trimethylpentene-1 and -2. Most of the dimer-trimer mixture is added to the gasoline pool as an octane improver. The balance is used for alkylation of phenols to yield octylphenol, which in turn is ethoxylated or condensed with formaldehyde. The water-soluble ethoxylated phenols are used as surface-active agents in textiles, paints, caulks, and sealants (see Alkylphenols). 

Commercially, sulfonic acid ion-exchange resins are used in fixed-bed reactors to make these tertiary alkyl ethers (14). Since the reaction is very selective to tertiary olefins and also reversible, a two-step procedure is also used to recover commercially pure tertiary olefins from mixed olefin process streams. The corresponding tertiary alkyl ether is produced in the olefin mixture and then easily separated from the unreacted olefins by simple fractionation. The reaction is then reversed in a second step to make a commercially pure tertiary olefin, usually isobutylene or isoamylene. 

Because of limitations on the ready availability of HCN, particularly in Japan, processes involving the oxidation of C4 intermediates have been developed and are now replacing the older route developed by Crawford. One important process is based on the two-stage oxidation of isobutylene or -butyl alcohol to methacrylic acid, which is then separated and esterified Figure 15.5a). 

Normal butenes and isobutylene are separated by a selective reaction-extraction... 

The acid extract phase is separated, diluted with water, and heated to regenerate isobutylene. The isobutylene is then caustic and water washed to remove traces of acid, distillation dried, and rerun. The unreacted C4 stream, containing normal butenes, is also caustic washed before further processing. 

The principal components of the cut are butene-1, butene-2, isobutylene and butadiene-1,3. Methyl, ethyl, and vinyl acetylenes, butane and butadiene-1,2 are present in small quantities. Butadiene is recovered from the C4 fraction by extraction with cuprous ammonium acetate (CAA) solution, or by extractive distillation with aqueous acetonitrile (ACN). The former process is a liquid-liquid separation, and the latter a vapor-liquid separation. Both take advantage of differences in structure and reactivity of the various C4 components to bring about the desired separation. 

Such a mechanism is open to serious objections both on theoretical and experimental grounds. Cationic polymerizations usually are conducted in media of low dielectric constant in which the indicated separation of charge, and its subsequent increase as monomer adds to the chain, would require a considerable energy. Moreover, termination of chains growing in this manner would be a second-order process involving two independent centers such as occurs in free radical polymerizations. Experimental evidence indicates a termination process of lower order (see below). Finally, it appears doubtful that a halide catalyst is effective without a co-catalyst such as water, alcohol, or acetic acid. This is quite definitely true for isobutylene, and it may hold also for other monomers as well. 

UOP in a joint venture with ChevronTexaco developed an additive technology named Alkad . The additive is based on HF salts of amines, which form liquid onium polyhydrogen fluoride complexes with HF, reducing the vapor pressure of the catalyst 65% to more than 80% aerosol reduction is claimed with this additive. As in the ReVap technology, additional separation columns have to be installed. Both additives are claimed to increase the product octane number, especially when propene, isobutylene, and pentenes are employed in the feedstock. 

MTBE is a well known enhancer of the number of octanes in gasoline and as excellent oxygentated fuel additives that decrease carbon monoxide emissions. Therefore, MTBE has been one of the fastest growing chemicals of the past decade. MTBE is produced by reacting methanol with isobutylene from mixed-C4 stream liquid phase over a strong acid ion-exchange resin as catalyst. An excess of methanol is used in order to improve the reaction conversion. This excess has to be separated from the final product. The pervaporation technique, more energy efficient and with lower cost process, has been proposed as alternative to distillation [74],... 

The source of these compounds is varied. The butanes are found naturally in crude oils and natural gas. They, plus the olefins, are products of various refinery processes and of olefins plants. They are separated by fractionation, except for butadiene and isobutylene, which are sometimes recovered by extractive distillation. They all vaporize at room temperature, so they are handled in closed, pressurized systems.. 

Extractive distillation is used to remove butadiene from a C4 stream fractionation can be used to separate out butene-1 adsorption is also sometimes used to separate out butene-1 polymerization is sometimes used to pull out the isobutylene dehydrogenation can be used to convert some of the butylenes and normal butane to butadiene and alkylation is used to convert the butylenes to alkylate. 

---