Syngas 2MeOH
Syngas 2MeOH
Syngas 2MeOH
1515/ijcre-2013-0061
got some good results using copper dispersed on zincbased catalysts (1960s). This development allowed the
use of milder conditions, strongly decreasing both costs
and process risks. This is still the base of the catalysts
employed today.
Methanol from syngas synthesis involves hydrogenation of CO (1) and CO2 (2) and reversed watergas shift
reactions (3):
CO 2H2 $ CH3 OH
H298 90:55kJ=mol
H298 49:43kJ=mol
2
CO2 H2 $ CO H2 O
H298 41:12kJ=mol
3
1 Introduction
Nowadays, methanol is one of the most consumed commodities around the world with an expected global
demand of 61.4 million metric tons [1]. Its main applications are as fuel, additive or reactant in the fine chemical
industry, but others are emerging such as hydrogen carrier for fuel cell technology applications or denitrification
agent for wastewater treatment. So its importance in the
chemical industry is clearly demonstrated.
Initially, methanol was produced by wood distillation
which was proved a very inefficient method [2]. The first
industrial methanol production process needed a highpressure (around 300 atm) syngas reaction, and it was
patented by BASF in 1923. Catalysts used in these early
processes were based on ZnO/Cr2O3. The ICIs company
470
2 Kinetic modelling
B Ct
dyi
Ft dyi
0
av Ct kgi yi ys
dt
Ac dz
i 1; 2; . . . ; N
6
dyis
0 kgi yi ys ri B a i 1; 2; . . . ; N
dt
N
X
dyis
ri Hfi
0 av hf T Ts B a
dt
i1
dT
Ft
dT
0 Cpg
av hf T Ts
dt
dz
Ac
Di
Ushell Tshell T
Ac
e) Erguns equation
dP
1 B 1 B u2g g
6
1:75 150
L 10
dz
Re
3B Dp
471
h
i
3=2
k3 KCO pCO pH2 pCH3 OH pH2 O = pH2 Kp2
h
i
r3
1=2
1=2
1 KCO pCO KCO2 pCO2 pH2 KH2 O =KH2 pH2 O
16
wi mass fractioni
Wt total mass flow
Mi molecular weighti
10
Wt dwi
Mi B a i 1; 2; . . . ; N
Ac dz
11
kgi 1:17Re0:42 Sci0:67 ug
17
0
Wt
dT Di
Cpg
Ushell Tshell T
dz
Ac
Ac
B a
N
X
12
ri Hfi
i1
13
1
1
1
Ushell hi ho
18
2.3 Kinetics
In this model, kinetic expressions were taken from the
work of Graaf et al. [8]. Heat of formation correlations for
the species were calculated from bibliographic correlations [9, 10] in order to predict the change of the heat of
reaction with temperature. Values of both kinetics and
equilibrium temperature-dependent parameters were
taken from Graaf et al. [8]. Eqs [1416] show the kinetic
expressions for the three existing reactions.
ho 7:96Tshell Tsat 3
Pshell 0:4
Patm
Values of Pshell and Tshell are 41.2 bar and 525 K, respectively, as reported in literature for these reactors [15].
Tube side heat-transfer coefficient can be calculated
by conventional correlations Nu f Re; Pr [16]. For
example,
hi
Cpg 2=3 0:458 uDp 0:407
k
B
Cpg
h
i
3=2
1=2
k1 KCO pCO pH2 pCH3 OH = pH2 Kp1
h
i
r1
1=2
1=2
1 KCO pCO KCO2 pCO2 pH2 KH2 O =KH2 pH2 O
14
h
i
3=2
1=2
k2 KCO pCO pH2 pCH3 OH pH2 O = pH2 Kp2
h
i
r2
1=2
1=2
1 KCO pCO KCO2 pCO2 pH2 KH2 O =KH2 pH2 O
15
19
20
472
Table 1
Parameter
Value
Pressure (bar)
Inlet temp. (K)
Total molar flowrate (mol/s)
Composition (mol%):
CH3OH/CO2/CO/H2O/H2/N2/CH4
s (kg/m3)
dp (m)
Cps (kJ/kgK)
c (W/mK)
av (m2/m3)
S/
Number of tubes
Tube length (m)
76.98
503
0.64
0.5/9.4/4.6/0.04/65.9/9.3/10.26
1,770
5.47 103
5
4 103
627
0.123
2,962
7.022
CH3OH
Mole fraction
0.075
H 2O
0.01
0.005
0
Temperature (K)
0.15
0.1
0.05
0
2
3
4
5
Reactor length (m)
H2
0.02
0.2
0.62
0.15
0.6
0.1
0.58
0.05
0
530
80
520
79.95
510
500
490
2
3
4
5
Reactor length (m)
N2
0.25
0.64
CH4
0.2
0.03
0.66
0.015
0.25
Mole fraction
Homogeneous
Heterogeneous
0.04
0.08
0.02
Homogeneous
Heterogeneous
0.09
0.085
CO
0.05
0.095
0.02
0
CO2
0.1
Homogeneous
Heterogeneous
0.04
Methanol synthesis process simulation has been previously studied in literature [1820]. Validated results
were presented in detail by Luyben [18] and are the
basis of this work.
The main difference is in how the reactor is modelled.
Luyben modelled this reactor by changing the original
Pressure (bar)
Mole fraction
0.06
3 Process simulation
2
3
4
5
Reactor length (m)
79.9
79.85
79.8
79.75
Figure 1 Comparison between heterogeneous and homogeneous kinetic models for methanol synthesis.
473
CH3OH
0.04
0.02
0
Molar homogeneous
Massic homogeneous
0
Mole fraction
0.02
0.08
0.03
0.66
4
H2
0.02
4
N2
2
4
Reactor length (m)
0.105
0.64
0.1
0.62
0.01
0.6
0.005
0.095
0.58
0
CH4
0.112
Temperature (K)
0.108
0.106
0.104
0
2
4
Reactor length (m)
0.09
530
0.11
0.102
0.04
CO
0.05
0.09
0.015
Mole fraction
4
H2O
CO2
0.1
80
520
Pressure (bar)
Mole fraction
0.06
510
500
490
79.9
79.8
79.7
Figure 2 Comparison between mass and molar homogeneous kinetic models for methanol synthesis.
474
475
CH3OH
Mole fraction
0.1
0.08
0.08
0
10
12
0.075
10
0.06
12
0.6
0.032
0.01
0.55
0.03
0.005
0.5
0.028
10
CH4
0.22
0.21
0
10
12
0.026
550
Temperature (K)
0.23
0.2
0.45
12
4
6
8
Lenght of reactor (m)
10
12
500
450
400
10
12
10
12
10
12
N2
110
Pressure (bar)
H2
H2O
0.015
Mole fraction
CO
0.12
0.1
0.05
Mole fraction
CO2
0.085
4
6
8
Lenght of reactor (m)
10
12
109
108
107
4
6
8
Lenght of reactor (m)
Table 2
Stream ID
Ref. 13
This work
Vent
Methanol
Water
F1
872
3,311
707
4,019
1,034
3,203
738
4,098
4 Conclusions
A conventional methanol synthesis reactor was modelled
by using three different approaches: molar homogeneous,
molar heterogeneous and mass homogeneous models. It
was shown that both heterogeneous and homogeneous
models resulted in similar compositions for the tested
reactor. Significant differences were obtained when applying the proposed mass approach for the reactor, allowing
changes for the total mole flowrate along the reactor. The
model is rigorously implemented in commercial process
simulation software showing small differences in terms of
the final amount of methanol obtained.
Acknowledgements: The authors gratefully acknowledge
Jasper van Baten comments and support when dealing
with the implementation of Matlab model into process
simulation software.
74.0
Pressure
248.5
CH4
0.069
0.23
0.002
0.675
0.003
0.022
CO2
CO
H2O
H2
N2
CH4
CH3OH
34.4
Mole frac
7,724.9
26.3
H2O
N2
2,630.3
CO
H2
785.5
CO2
CH3OH
(kmol/h)
Mole Flow
0.0
371.4
Temp. (K)
(atm)
0.022
0.003
0.675
0.002
0.23
0.069
248.5
34.4
7,724.9
26.3
2,630.3
785.5
0.0
74.0
311.1
Stream results.
Stream ID
Table 3
0.022
0.003
0.675
0.002
0.23
0.069
248.5
34.4
7,724.9
26.3
2,630.3
785.5
0.0
108.6
358.2
0.089
0.002
0.003
0.006
0.372
0.528
14.1
0.3
0.0
0.4
0.9
58.6
83.1
108.6
800
0.023
0.003
0.666
0.002
0.227
0.073
0.007
262.6
34.6
7,724.9
26.8
2,631.3
844.2
83.1
108.6
369.1
0.244
0.033
0.54
0.001
0.063
0.112
0.008
11,375.6
1,528.2
25,203.7
23.4
2,923.6
5,247.5
369.9
108.6
334.9
0.2
0.027
0.565
0.001
0.095
0.105
0.008
11,638.1
1,562.8
32,928.6
50.1
5,554.9
6,091.6
453.0
108.6
341
10
0.2
0.027
0.565
0.001
0.095
0.105
0.008
11,638.1
1,562.8
32,928.6
50.1
5,554.9
6,091.6
453.0
108.6
414.7
11
0.225
0.03
0.498
0.014
0.058
0.105
0.071
11,638.1
1,562.8
25,780.1
723.0
2,990.0
5,418.7
3,690.8
105.9
545.4
13
0.225
0.03
0.498
0.014
0.058
0.105
0.071
11,638.1
1,562.8
25,780.1
723.0
2,990.0
5,418.7
3,690.8
105.9
471.8
14
0.225
0.03
0.498
0.014
0.058
0.105
0.071
11,638.1
1,562.8
25,780.1
723.0
2,990.0
5,418.7
3,690.8
105.1
311.1
15
0.24
0.033
0.557
0.063
0.102
0.004
11,104.3
1,536.6
25,780.1
11.2
2,924.0
4,715.4
178.2
105.1
311.1
16
0.096
0.005
0.128
0.012
0.127
0.632
533.8
26.3
0.0
711.8
66.0
703.3
3,512.6
105.1
311.1
17
0.24
0.033
0.557
0.063
0.102
0.004
10,856.0
1,502.2
25,203.7
11.0
2,858.6
4,610.0
174.2
105.1
311.1
19
0.24
0.033
0.557
0.063
0.102
0.004
10,856.0
1,502.2
25,203.7
11.0
2,858.6
4,610.0
174.2
108.6
314.7
20
0.357
0.018
0.009
0.045
0.438
0.134
519.6
26.0
0.0
12.4
65.0
637.5
195.7
2.0
311.1
21
0.003
0.171
0.016
0.809
14.3
0.3
0.0
699.4
0.9
65.8
3,316.9
2.0
311.1
22
0.357
0.018
0.009
0.045
0.438
0.134
519.6
26.0
0.0
12.4
65.0
637.5
195.7
108.6
759.1
23
0.2
0.027
0.565
0.001
0.095
0.105
0.008
11,638.1
1,562.8
32,928.6
50.1
5,554.9
6,091.6
453.0
108.6
423.1
24
0.089
0.002
0.003
0.006
0.372
0.528
14.1
0.3
0.0
0.4
0.9
58.6
83.1
1.0
323.1
26
0.016
0.002
0.981
0.2
0.0
0.0
52.5
0.0
7.2
3,142.8
1.0
323.1
Methanol
0.022
0.003
0.675
0.002
0.23
0.069
248.5
34.4
7,724.9
26.3
2,630.3
785.5
0.0
50.5
323
Syngas
0.24
0.033
0.557
0.063
0.102
0.004
248.3
34.4
576.4
0.3
65.4
105.4
4.0
105.1
311.1
Vent
0.877
0.123
0.0
0.0
0.0
646.5
0.0
0.0
91.0
1.0
358.7
Water
476
R. De Mara et al.: Industrial Methanol from Syngas
477
Nomenclature
B
Ct
yis
kgi
yi
ri
B
a
Cps
av
hf
Ts
T
Hfi
Ft
Ac
Di
Bed porosity
Total mole concentration
Molar fraction of i component in the solid phase
Mass-transfer component of i component
Molar fraction of i component in the gas phase
Effectiveness factor
Reaction rate of i component
Bed density
Catalytic activity
Heat capacity of solid phase
Catalyst surface area
Heat-transfer coefficient
Temperature of the solid phase
Temperature of the gas phase
Enthalpy of formation of component i
Total mole flowrate
Cross-section area of each tube
Tube diameter
Ushell
Tshell
L
Re
Dp
ug
g
Wt
wi
Mi
ki
Ki
Kpi
N
P
Sci
hi
ho
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