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System Approach Assignment

Methanol is an important chemical that can be used as a fuel or in fuel cells. It is synthesized from syngas in a three step process, with the main step being methanol synthesis using a catalyst. This document describes a cascade fluidized-bed membrane catalytic reactor for methanol synthesis that has two reactors in series - a water-cooled reactor followed by a gas-cooled reactor. The reactor aims to gradually reduce temperature along its length to increase conversion efficiency while selectively adding hydrogen through a membrane to shift equilibrium towards methanol production. Simulation results show this design enhances methanol yield over 1000 days compared to conventional reactors.

Uploaded by

Rohit Chauhan
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© © All Rights Reserved
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
59 views

System Approach Assignment

Methanol is an important chemical that can be used as a fuel or in fuel cells. It is synthesized from syngas in a three step process, with the main step being methanol synthesis using a catalyst. This document describes a cascade fluidized-bed membrane catalytic reactor for methanol synthesis that has two reactors in series - a water-cooled reactor followed by a gas-cooled reactor. The reactor aims to gradually reduce temperature along its length to increase conversion efficiency while selectively adding hydrogen through a membrane to shift equilibrium towards methanol production. Simulation results show this design enhances methanol yield over 1000 days compared to conventional reactors.

Uploaded by

Rohit Chauhan
Copyright
© © All Rights Reserved
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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METHANOL SYNTHESIS IN A CASCADE FLUIDISED BED MEMBRANE CATALYTIC

REACTOR
Methanol is a bulk chemical, a kind of transportation fuel and energy material for fuel cell. It is a clean-burning
fuel with versatile applications. As a combustion fuel, it provides extremely low emissions.

Methanol is basically synthesized in three steps: Synthesis gas generation, Methanol synthesis and Methanol
distillation. The main step of methanol process is Methanol synthesis. Methanol is largely produced by natural
gas and specifically by means of syngas (CO and H2 mixture) obtained via steam reforming operations.

CO+2H2CH3OH

Impact on process: Implementing a higher temperature at the entrance of the reactor for a higher reaction
rate, and then reducing the temperature gradually towards the exit from the reactor for increasing
thermodynamic equilibrium conversion is one of the significant issues in methanol synthesis reactor
configuration. The configuration of dual-type reactor system permits high temperature in the first reactor and
a low temperature in the second reactor. In this system, the first reactor, isothermal water-cooled reactor, is
combined in series with a gas-cooled reactor, which accomplishes partial conversion of synthesis gas to
methanol.

Specifications of reactor:

Parameter Water-cooled reactor Gas-cooled reactor

Di (mm) 40.3 21.2


Tube length (m) 8 10
Shell side Pressure (bar) - 71.2
Tube side Pressure (bar) 75 76.

A schematic diagram of cascade fluidized-bed membrane methanol reactor (CFBMMR).


Process description: This system is mainly based on the two-stage reactor system consisting of a water-cooled
and a gas-cooled reactor, where both the reactors are fluidized-bed. The cold feed synthesis gas is fed to the
tubes of the gas-cooled reactor(second reactor)from top of the reactor and flowing in counter-current mode
with reacting gas mixture in the shell of the reactor. Moreover, the walls of tubes in this reactor(gas-cooled
reactor) consist of a hydrogen perm- selective membrane. The pressure difference between the shell and tube
sides is the driving force for diffusion of hydrogen through the Pd–Ag membrane layer. On the other hand, in
the new system, the mass and heat transfer process simultaneously occurs between the shell and the tube.
Then the outlet synthesised gas from the second reactor is fed to the bottom of tubes in the first
reactor(water-cooled)and the chemical reaction is initiated by the catalyst. In the first stage, methanol is partly
produced. Reacting gas leaving the first reactor is routed to the bottom of the second reactor. Finally, the
product is removed from the upstream of the second reactor (gas-cooled reactor).

Model Equations:

Model assumptions:

(a) The dense catalyst bed is considered to be composed of bubble phase and emulsion phase.

(b) The operation is assumed to be isothermal, which means bubble and emulsion phases have same
temperature.

(c) Plug flow regime in bubble phase is assumed.

(d) The bubble rise velocity is constant and equal to average value.

(e) Ideal gas behavior is assumed.

Mass conservation equation:

(∂yi/∂t) = (-δ/A)( ∂Fi/∂z) + δ.Kb.ct.a(yie-yib) + δ.γ.a

Where Kb is mass transfer coefficient between bubble phase and emulsion phase.

The heat transfer equation between tubes and shell side:

ct.cpg (dT/ dt) =(∏Di/ Ac) UTube ( Tshell-T)+(1- δ) n.a + δ.γ.n.a

Operational Complexity: Complex operation due to the presence of sensitive membrane.

Manufacturing Complexity: Requires highly modified techniques to build a membrane reactor.

Capacity: 5000 ton/day

Catalyst productivity: 0.3 kg CH3OH /kg cat/hr

Catalyst life: This method uses catalyst deactivation technique. The catalyst can be used till 1000
days with decrease in the catalyst activity.

Conversion: 40.8% for CO and 25% for CO2


Critical Analysis:

Advantages:

 The simulation results represent good enhancement in the yield of methanol production during 1000
days of the operation in the cascade fluidized-bed membrane methanol reactor compared with
conventional dual type methanol reactor and even fluidized-bed membrane dual type methanol
reactor.
 Low pressure drop.
 Provides a uniform temperature along the reactor, which prolongs the service life of the catalyst.
 In addition, in the reaction system, the addition of hydrogen to the reacting gas selectively leads to a
shift of the chemical equilibrium towards the product side, resulting in a higher methanol production.

Disadvantages:

 Complex operation due to the presence of sensitive membrane.


 Manufacturing Complexity.
 Sensitivity of the membrane to heat.

Environmental Issues:

 Disposal of membrane.
 Emission of unconverted CO2 and CO to atmosphere must be checked.

References:

1. M.R. Rahimpour, M.Bayat, F.Rahmani; Dynamic simulation of a cascade fluidized-bed membrane


reactor in the presence of long-term catalyst deactivation for methanol synthesis.
2. M.R. Rahimpour, M. Bayat, F. Rahmani; Enhancement of methanol production in a novel cascading
fluidized-bed hydrogen perm-selective membrane methanol reactor.
3. Jean-Paul Lange; Methanol synthesis: a short review of technology improvements.
4. Francois Marechal, Georges Heyen, Boris Kalitventzeff; Energy savings in Methanol synthesis: Use of
heat integration techniques and Simulation tools.

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