Commodity Production Costs Report
MTBE Production from Isobutylene
MTBE Plant Capital & Operating Cost Analysis | United States | Q2 2025
This report presents the economics of Methyl tert-Butyl Ether (MTBE) production from an isobutylene stream from an isobutane dehydrogenation plant and methanol. The process examined is similar to UOP's Ethermax process for isobutylene etherification. In this process the etherification reaction is conducted in two steps, the first step being in a conventional reactor and the second in a reactive distillation column. Other established commercial etherification processes with similar configuration, like CBI's CDMTBE, Axens' MTBE Process and Evonik's MTBE Process may as well be represented by the economic analysis presented in this report.
The report provides a comprehensive study of MTBE production and related MTBE production cost, covering three key aspects: a complete description of the MTBE production process examined; an in-depth analysis of the related MTBE plant capital cost (Capex); and an evaluation of the respective MTBE plant operating costs (Opex).
The MTBE production process description includes a block flow diagram (BFD), an overview of the industrial site installations, detailing both the process unit and the necessary infrastructure, process consumption figures and comprehensive process flow diagrams (PFD). The MTBE plant capital cost analysis breaks down the Capex by plant cost (i.e., ISBL, OSBL and Contingency); owner's cost; working capital; and costs incurred during industrial plant commissioning and start-up. The MTBE plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
The process under analysis comprises two major sections: (1) Etherification reaction; and (2) Isobutane and Methanol Recovery.
Etherification reaction. Fresh and recycled methanol reacts with the isobutylene content in the isobutylene feedstream, in liquid phase, to form MTBE. This reaction is conducted in two stages. The first stage is carried out in an adiabatic reactor at 16 bar and relatively low temperature (55°C) in order to favor thermodynamic conversion, around 90% of the isobutylene is converted in this stage. The second stage is comprised of a reaction with distillation column, in which a section of a distillation column is replaced by a catalyst packing section. This section enables the continuous removal of MTBE product from the reaction medium, making it possible to overcome the equilibrium constraints to isobutylene conversion reaching figures as high as 99%. The top product of this column, mostly composed of isobutane and the excess methanol, is transferred to the Wash Column.
Isobutane and Methanol Recovery. Initially, in a extraction column excess methanol is extracted by contact with water resulting in a methanol-water mixture and a stream containing isobutane and light end contaminants. The methanol-water mixture is distilled to recover methanol, that is recycled to compose the feed stream of the first reactor. The hydrocarbons stream from the Wash Column is then introduced into a depropanizer column to eliminate light end impurities (C3- products). These light ends are consumed in the process as fuel, while the C4s by-products stream, composed mainly by isobutane, is directed to the integrated unit.
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Professional report based on Q2 2025 economic data, ensuring timely evaluations.
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the MTBE production plant examined.
Plant Capital Cost Details
Detailing of fixed capital (ISBL, OSBL & Owner’s Cost), working capital and additional capital requirements.
Plant Cost Breakdowns
Breakdown of MTBE process unit (ISBL) costs and infrastructure (OSBL) costs; plant cost breakdown per discipline.
Operating Costs Summary
Summary presenting the operating variable costs and the total operating cost of the MTBE production plant studied.
Operating Cost Details
Detailing of utilities costs, operating fixed costs and depreciation.
Plant Capacity Assessment
Comparative analysis of capital investment and operating costs for different MTBE plant capacities.
Production Process Information
Block Flow Diagram, descriptions of process unit (ISBL) and site infrastructure (OSBL).
Process Consumptions
Raw materials and utilities consumption figures, by-products credits, labor requirements
Process Diagrams
Process flow diagrams (PFD), equipment list and industrial site configuration
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Other MTBE Production Cost Reports
MTBE Production from Raffinate-1
This study provides an economical analysis of Methyl tert-Butyl Ether (MTBE) production from a raffinate-1 stream and methanol using a process similar to UOP's Ethermax process for isobutylene etherification in China. In this process, isobutylene from raffinate-1 is submitted to etherification with methanol in a conventional reactor and in a reactive distillation column.
Details: 700 kta China-based plant | Q2 2025 | 107 pages | Issue A | From $999 USD
MTBE Production from FCC C4 Raffinate
This process examined provides an economical analysis of Methyl tert-Butyl Ether (MTBE) production from FCC C4 raffinate and methanol using a process similar to UOP's Ethermax process for isobutylene etherification in China. In this process, isobutylene from FCC C4 raffinate is submitted to etherification with methanol in a conventional reactor and in a reactive distillation column.
Details: 700 kta China-based plant | Q2 2025 | 107 pages | Issue B | From $999 USD
MTBE Production from Butane
This report presents a feasibility analysis of an on-purpose Methyl tert-Butyl Ether (MTBE) production plant from butane and methanol in the United States. Initially, n-butane is isomerized to isobutane, which is then subjected to a dehydrogenation, yielding isobutylene. In the final step, generated isobutylene and methanol react leading to the formation of MTBE. These steps are similar to Butamer, Oleflex and Ethermax processes in sequence.
Details: 700 kta United States-based plant | Q2 2025 | 107 pages | Issue C | From $1,499 USD
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This study presents the economics of large-scale Methanol production from natural gas in the United States. In this process, natural gas is first converted into synthesis gas (syngas) by means of conventional steam reforming and secondary autothermal reforming. Then, the syngas is converted into Methanol.
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