Two-step system and method for the production of methyl isobutyl ketone

A system for producing methyl isobutyl ketone (MIBK) from acetone and hydrogen, comprising:

• a first reactor, said first reactor configured to receive acetone and does not perform simultaneous separation of the acetone such as by distillation, where a portion of the acetone undergoes a condensation reaction to form diacetone alcohol (DAA), followed by a dehydration reaction that converts at least a portion of the DAA to mesityl oxide (MO), in the presence of a suitable catalyst;
• a first separator, said first separator configured to control the composition of the outlet of the first reactor by removing acetone and adding an appropriate amount of MIBK such that a favorable liquid-liquid phase split occurs, producing two liquid phases that can be subsequently separated in a decanter, without reacting acetone substantially completely and without first removing DAA by separation;
• a second reactor, said second reactor configured to contact the organic phase containing MO with hydrogen , where MO is converted to MIBK in the presence of a suitable hydrogenation catalyst;
• and
• a second separator, said second separator configured to purify the MIBK-rich stream from the second reactor to produce high purity MIBK.