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Executive Summary
In September of 2004, the ALPHA Consultancy entered into a bidding agreement t design a Methanol Production plant with special requirements to produce methanol from Syngas, using natural gas. The following outlines the major factors being considered an the investment cost necessary for the plant to be manufactured.
With the availability of 99% purity natural gas the Syngas is to be produced using gas v steam reforming process. Under a required production of 1000 tonne per year this metho of Syngas was deemed most suitable as alternative methods involves air purifiers, whic are more suited for methanol production capacities above 2500 tonnes per year.
The table shows a Financial Summary of the major results from the design of the process Natural Gas Cost Yearly Operation
300 days
Daily Cost
1604500/7200
37483 x 50 7200 hrs
Total Variable cost
£ 1836630 h-1 £230 £ 15454965
Fixed Cost
Insurance Total Fixed cost
1% fixed capital
Direct Direct production production cost
£17640983 £17640983 + £ 6,132,567 6,132,567
Pric Pricee of Meth Methan anol ol
£158 £158.3 .34/ 4/to tonn nnee
Sales revenue
£158.34 x 1000 x 300
Profit Profit
Sales revenue revenue – direct production production cost =
£ 372035 £ 6132567 £231,773, £231,773,550 550
£47,502,000 £23,728,540 £23,728,540
Profit = 47 502 000 – 15 454 965 = £ 23, 728,450
The basis of producing methanol from Syngas is to be using a multi tubular isotherm reactor. This reactor would operate at low temperatures and pressure with the use o Master your semester with Scribd proces Cu/Zn/AL production isDays atitle modern 2O3/CrO as catalyst. This method of methanol Read Free Foron 30this Sign up to vote would give up to a conversion of 85% CO, which determines the actual amount o & The Newwhich York Times Useful Not useful Cancel anytime. the reactions ar Methanol produced. Shell and tube reactors were chosen because Special offer for students: Only $4.99/month. exothermic. exothermic. Therefore Therefore heat needs to be removed removed from the reaction reaction system. system. Shell an tube reactors not only allow heat to be removed from the process by circulating a coolin
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Table of Contents
Page
1.
Introduction
3
2.
HY HYSIS – Process Simulation
4 -6
3.
Energy Recovery
7 -9
4
Methanol Reactor Design
10
5.
Chemical Engineering Design
10-19
6.
Mechanical Design
20-23
7.
Process Control and Instrumentation
24-26
8.
HAZOP
27-29
9.
Cost Estimation and Economic Appraisal
30-32
1 0.
Critical Review
33-34
11.
Reference
35
12.
Appendix
36
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Methanol Energy Balance
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Water Gas - Shi� Reaction
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Table of Contents
Page
1.
Introduction
3
2.
HY HYSIS – Process Simulation
4 -6
3.
Energy Recovery
7 -9
4
Methanol Reactor Design
10
5.
Chemical Engineering Design
10-19
6.
Mechanical Design
20-23
7.
Process Control and Instrumentation
24-26
8.
HAZOP
27-29
9.
Cost Estimation and Economic Appraisal
30-32
1 0.
Critical Review
33-34
11.
Reference
35
12.
Appendix
36
Phase1 Report Phase 2 Report Master your semester Phase 3Reportwith Scribd HYSIS material and Energy Balance
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Introduction
Phase 4 of the design report represents the last in a series of 4 reports on the design of th Alpha Consultancy Methanol Plant. The previous covered aspects of design routine, the methanol market, environmental issues and sustainability. Phase 4 is a summary of the entire report as well as detail reports on the methanol reacto design, simulation of process using HYSIS and a final cost estimation appraisal.
The major part of the entire process is the reactors, this is where initially Syngas is produced in the process, and secondly where methanol is produced. This report will cove all the aspects considered when designing a methanol reactor, with special interest in the multi-tubular isothermal methanol reactor. Issues of both chemical and mechanical design are covered as well as cooling medium fo the reactor.
Also covered in this report is a detailed Hazard Analysis Syngas reformer. It is necessary fro a standard as well as management point of view to understand the steps taken in analyzing a process for risks and hazards to estimate any unforeseeable accident. This detailed study gives more depth to process control, which is also considered in this repor fort the Methanol Synthesis reactor.
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HYSIS
In the modern methanol and other chemical industries, the initially process flow of plant is usually defined by simulation packages, and other control software packages. Th use of simulation packages in chemical plants over the past 3 decades has grown rapid and more companies buy into the idea each day. Simulation packages do as the term suggests, simulates and put an actual process into theoretical operation. With thes packages getting more user friendly and capable to do more than normal, simulatio packages can set up an entire production with a few user specified variable. Use knowledge is always the key however as all simulation package can only give an outpu based on an input. HYSIS, a user-friendly computer software package developed by Hyprotech is one these packages; The goal of programs like HYSYS is to provide users with the capability to design a entire process as completely and accurately as possible. In the ALPHA Consultancy, HYSIS was used to do a simulation and design wit reference to hand calculations that were done in phase 2 of these reports. PFD
The two main areas of methanol production are the Syngas production and methano synthesis. These were the only two areas in the process where reaction actually occurre Unlike the hand calculation, only some basisa Preview had to be specified for HYSIS, thes You're Reading including components, reaction equations with appropriate stoichiometry, reaction typ Unlock full access with a free trial. and where necessary process conditions. The first obvious difference was the principle b which HYSIS does the calculations. Gibbs free is the basis of its calculations, an Download With Free Trial because of this showed a difference in calculated conditions. The Peng-Robinson basis of fluid package was chosen since the PRSV is a two-fold modification of the P equation of state that extends the application of the original PR method for highly non ideal systems, even though ideality was assumed for much part of the phase 2 repo calculations.
Master your semester with Scribd Read Free Foron 30this Sign up to vote title Syngas was produced with the use of an equilibrium reactor, asDays the basis for th & The Newproduction York Times useful the CO an Useful Notbetween was, (Fro phase2) defined by an equilibrium relationship Special offer for students: $4.99/month. steamOnly reaction, with the
water gas shift reaction.
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Fig 7 – Process Flow Diagram ‘ALPHA Methanol Process’ HYSIS METHANOL PRODUCTION PROCESS.
You're Reading a Preview Unlock full access with a free trial.
Download With Free Trial
Fig 7 shows the final PFD of the methanol production process simulated through the HYSIS TM, simulation package. From P reports, the inlet ratio of CO to steam was found to be 3:1, and a SET block was use to set this ratio. The SET operation se one stream variable (the independent variable) to meet a required ratio (the dependent variable) in another stream or oper gives a short description to some the major units and streams in the PFD.
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Table 8 – HYSIS equipment unit and streams explained.
Unit/ Streams MIX-1
Mixer used to mix the process flow water with the treated and recycled water from the process
HTR-1
Heater used to raise the temperature of the process water to form steam
SET-1
Used to set the inlet flow of steam to 3 times the molar flow rate of natural gas
n.gas
Raw methane feed, of 99% purity at ambient temperature and pressure at a flow rate of at 2000kgmol/hr
p.water
Pure uncontaminated water at 2O˚C and ambient pressure
MIX-2
Mixer used to mix steam and natural gas before entry into the steam reformer.
HX-1
Heat Exchanger, which exchanges heat between the cold, feed mixture of natural gas and steam with hot outlet syngas. Beyo You'reforReading a Preview an array of heat exchangers, which are responsible adequately exchanging heat while making HP, MP and LP steam from the the reactor. st Steam Reformer, in the form of an equilibrium reactor, where 1with set of reaction occurs in the process. Produces syngas at very h Unlock full access a free trial. low pressure. Reaction highly endothermic so a considerable amount of energy is needed to drive reaction. Representing a series of heat exchangers and cooling system, the purpose of the cooler is to bring the temperature of stream temperature (60˚C), suitable for water separation. Download With Trialfrom the process as possible. Water is very corro Separator used to condense the gas mixture; so as much water can Free be removed etc. Stream x27 is the recycled stream, of gases rich in CO concentration, used to improve the efficiency of the process, by recombi before entering the synthesis reactor. In the form of a converter reactor, this is where methanol is produced from high pressure (70bars), low temperature (260˚C) and H2. Reaction highly exothermic. The mixing of the fresh feed and recycled feed to the synthesis reactor.
RX-100 CLR-1 SEP -1 x27 RX-200 MIX-100 CMPR-1 HX-2 Sep 2
The compressor increases the pressure of the reactor inlet feed to the reactor operating pressure 70bars. Also a representation as one compressor would need too much of an unrealistic volume to yield correct pressure increase. Also used to decrease the temperature of the exit stream from the reactor, this set of heat exchangers also produces LP steam from the reactor. To obtain gas for recycling, the separator maintained at a pressure and temperature below BP of methanol, so the gases recycled, while the stream rich methanol concentration is distilled for purification.
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HYSIS
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HYSIS
Selected HYSIS simulated data comparison with results from PHASE 1, Hand Calculate results. Units Inlet Natural Gas Molar Flow Inlet Steam Molar Flow CH4: Steam Ratio CH4 conversion Reformer Temperature Reformer Pressure CO: H2 ratio in Synthesis Reactor Inlet Reactor Temperature Reactor Pressure CO conversion in synthesis reactor CO2 conversion Methanol Production Overall Energy usage
(kgmol/hr) (kgmol/hr) % K bar K bar % % Kgmol/hr KJ/hr
Phase-1 Report 1803 5410 3:1 85 1273 16 15 : 1 533 100 74 5 995 5.74E+09
HYSIS Simulated 2000 6000 3:1 94 1273 16 3.6 : 1 533 70 77 0 1340 2.29E+09
From the above data comparison it can be seen that the HYSIS package, throug optimization produced on average more methanol than using hand calculations. Th principles and basis for the HYSIS calculations has to be taken into account as well as th nature by which optimizations You're are done. For e.g., the inlet pressure of the reactor wa Reading a Preview varied, and by hand calculations this would take a very long time to examine the effect o full access with a free trial. methanol production and otherUnlock downstream processes. With added units also, the he flow throughout the process was almost halved comparing with that of the phase Download With Free Trial calculation. Energy Recovery
The area of Syngas production produced a considerable amount of heat, and this was see Master your semester with Scribd as major source of energy recovery for the Alpha Consultancy. The heat from the exiting Read Free Foron 30this Days Sign up to vote title stream from the reformer is cooled through a series of heat exchangers. These & The Newfeed York Useful IPNot exchangers Times use the useful heat from in the stream to produce HP,anytime. anduseful LP steam. Cancel Special offer for students: Only $4.99/month.
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Methanol Reactor Design
Methanol synthesis is believed a combination of two exothermic reactions, namel conversion of CO via the water gas shift reaction to CO2 followed by hydrogenation o CO2 to methanol. CO + H 2O ↔ H 2 + CO2 CO2 + 3H 2 ↔CH 3OH + H 2O
∆H 298 = -41.2 KJmol -1 ∆H 298 = -49.5 KJmol -1
-1-2-
These two reactions will be considered for the major unit design of an Isothermal Mult tubular Methanol Synthesis Reactor. Design Approach Kinetics
Various personnel have studied the complex chain reaction of the methanol synthes process over the years and many theories have been made for the actual rate kinet equations that correctly define the mechanism.
Bussche and Froment (Journal of Coal and Petroleum, 1996) have reported a propose model of the kinetic relationshipYou're basedReading on production of methanol in the presence of hig a Preview selective Cu/ZnO/Al2O3 catalyst, which permits operation at lower pressure than classi pressure process. Unlock full access with a free trial.
The proposed model takes intoDownload consideration onlyTrial reaction from carbon dioxide an With Free inverse water-gas shift reaction, the two also been considered for ALPHA methan synthesis reactor design. CO + H 2O ↔ H 2 + CO2 CO2 + 3H 2 ↔CH 3OH + H 2O
-1-2-
Master your semester with Scribd Read Free Foron 30this Days Sign up to vote title and Froment showed that for the rate of methanol synthesis and the invers & The NewBussche York Times Useful Not useful water gas shift reaction the following expressions are accepted: Special offer for students: Only $4.99/month.
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