Development studies on conversion of methanol and related oxygenates to gasoline. Final report

Abstract

A novel process for the conversion of methanol to high octane gasoline has been successfully demonstrated in process development units (PDU). Both fixed and fluid bed process concepts have been pursued. Two reactors are used in the fixed bed process. Methanol is partially dehydrated to an equilibrium mixture of methanol, dimethylether, and water over a dehydration catalyst in the first reactor, and both methanol and dimethylether are converted to high octane gasoline by a Mobil catalyst in the second reactor. Over 200 days of successful operation were achieved during nine cycles (including regenerations of the Mobil conversion catalyst) in a fixed bed pilot plant. About 8000 lb methanol/lb conversion catalyst were processed, and catalyst performance was still satisfactory when the aging test was terminated. The dehydration catalyst did not require any regeneration during the entire aging test. A single reactor is used in the fluid bed process. The feasibility of converting methanol to gasoline in a fluid bed was demonstrated during an aging test of two months duration. The gasoline from this process has exceptional product qualities (i.e., high octane). Gasoline stability (i.e., potential gum formation) is acceptable at reasonable additive levels. Durene concentrations are higher than in petroleum-derived fuels.more » However, car tests with gasolines containing added durene have shown that concentrations up to 4 wt percent durene have no significant effects on vehicle performance. The engineering design of a 100 BPD fixed bed pilot plant for the conversion of methanol to gasoline was completed. « less

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