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Propylene from Methanol via Lurgi MTP Process

Lurgi’s new MTP® process selectively converts methanol to propylene, with some byproduct
gasoline and LPG type fuels. Dimethyl ether (DME) is produced as an intermediate to the product
propylene in a dual step reaction system. The technology offers clients low cash costs, and its
propylene product can be used as feedstock for a variety of petrochemical processes.

Fig.2.3 MTP: Simplified Process Flow Diagram

Process Description of Lurgi’s Methanol to Propylene (MTP®) Technology

The first step of the Lurgi MTP™ process is the introduction of methanol to an adiabatic
DME pre-reactor where methanol is converted to dimethyl-ether (DME) and water. The high-
activity, high-selectivity catalyst used nearly achieves thermodynamic equilibrium. The first
reaction product is routed to the MTP® reactor together with steam and recycled olefins. Then, it
is converted over a tailored and optimized zeolite catalyst delivered by Clariant in the fixed-bed
MTP reactor. Methanol/DME are converted by more than 99%, with propylene as the predominant
hydrocarbon product. The process conditions in the five or six catalyst beds per reactor are chosen
to guarantee similar reaction conditions and maximum overall propylene yield. Conditions are
controlled by feeding small streams of fresh feed between the beds.
 From figure 2.4 ,two reactors are operating in parallel while the third one is in regeneration
or stand-by mode. Regeneration is necessary after about 500-600 hours of cycle time when the
active catalyst centres is blocked by coke formed in side reactions. By using diluted air at mildest
possible conditions, nearly at operating temperature, thus avoid thermal stress on the catalyst. The
product gas is compressed and traces of water, CO2 and DME are removed by standard techniques.
The cleaned gas is then further processed yielding chemical-grade propylene with a typical purity
of more than 97%. Several olefin-containing streams are recycled back as an additional source of
propylene. To avoid the accumulation of inert materials in the loop, a small purge is required for
light-ends and the C4/C5 cut.

Gasoline is produced as a byproduct and water is recycled to steam generation for the
process. The excess water resulting from the methanol conversion is purged. This process water
can be used for irrigation after appropriate and inexpensive treatment. It even can be processed to
potable water where needed.
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