ABSTRACT
A one-step integrated process for the generation of the high-octane fuel ether, diisopropyl ether (DIPE), from acetone-rich feedstocks has been demonstrated. Three continuous, downflow, reactor configurations have been considered, including: a) A two-bed reactor design containing one multi-functional catalyst, but with each bed separated by inerts, b) a gradient, multi-catalyst, two-reactor design, containing three distinct transition-metal/solid acid catalyst combinations, and c) an integrated, two-zone layout, incorporating two, multicomponent, transition-metal catalyst combinations on zeolite, or oxide supports. Typically, the bifunctional catalysts have both hydrogenation and etherification/dehydration capabilities and may comprise Group IB, VIB, and VIII metals incorporated into acidic, large and medium-pore zeolites, Group III or IV metal oxides, as well as heteropoly acid structures. DIPE syntheses are typically conducted at 100 to 165°C, under hydrogen pressure. The gradient reactor design, with prudent choice of hydrogenation and etherification catalyst compositions, allows DIPE to be generated in exit concentrations approaching 40%, with quantitative acetone conversions and little or no C3/C6/C9 formation.
INTRODUCTION
