Process Simulation and Integration of Methanol Production 3rd Year Chemical Engineering Research Project By: Aaron McClean

Introduction Welcome to this Presentation on the Simulation and Integration of a Methanol Production Process

The Project in Brief The Project Involves the Simulation of a conventional methanol process using Aspen simulation software. Using stream data obtained from the simulation and Process Integration techniques, a maximum energy recovery system is then designed

Three Project Objectives Development of a Methanol Production Process Simulation of the Methanol Production Process using Aspen Plus Carryout Process Integration on the Methanol Process to gain a Maximum Energy Recovery system

Development of a Methanol Production Process Research into various routes for the production of methanol Process selection Producing a Flow Diagram of the Process Collecting information on the physical properties and characteristics of the Process

Process Flow Diagram Combustion Natural Gas Synthesis Gas Reaction Crude Methanol Distillation Oxygen Steam Methanol This diagram shows the main sections in Methanol Production

Process Sections Partial Combustion of Natural Gas to produce Synthesis Gas Conversion of Synthesis Gas to Methanol Purification of Crude Methanol by Distillation

Partial Combustion of Natural Gas to produce Synthesis Gas Natural Gas composed of 80% Methane, 15% Ethane and 5% Propane Partial Combustion Reaction Water Shift reaction Natural Gas + O2 CO + H2 Natural Gas + H2O CO + 3H2 CO + H2O CO2 + H2

Conversion of Synthesis Gas to Methanol Methanol Conversion Reactions CO + 2H2 CH3OH 2CO + 4H2 CH3OCH3 + H2O CO2 + H2 CO + H2O

Process Diagram

Simulation of the Methanol Production Process using Aspen Plus Aspen Plus is a Computer Simulation Package for Chemical Processes It is Primarily used as a labour and time saving tool It is still only a tool, and does not replace the knowledge required by the Process Engineer

Aspen Plus User Interface

Aspen Plus User Interface

Methanol Process Simulation

Process Integration What is Process Integration? What does Process Integration involve? Why carry out Process Integration?

What is Process Integration Process Integration is the optimisation of a Chemical Process to produce a Maximum energy recovery system

What does Process Integration involve? Pinch Technology What is a Pinch Analysis? What is required for the analysis? How is an analysis performed?

What is a Pinch Analysis? Linking streams that need heating to those that need cooling REACTOR PRODUCT COOLING REAC. OUT FEED HEATING RECYCLE 220 ° 210 50 270 60 160 2500 3200 3520 1980 130 Cool Heat

What is a Pinch Analysis? What is meant by the Pinch REACTOR FEED STEAM RECYCLE PRODUCT Distillation Column DIST VAP CW REAC. OUT 880 1980 1220 1620 2640 160 ° 130 220 210 270 149 178 50 60 180 Above Pinch Below Pinch

What is meant by the Pinch The Composite Curve

The Composite Curve ° ° 210 160 50 270 220 160 60 3200 2500 C P = 5 2 Feed Recycle C P = 5 2 T H 160 ° 60 220 270 Product 3520 1980 Reac. Out T H C P = 2 1 8 No Name T s u p l y t a r g e D H 1 2 Product Reac. Out 220 270 60 160 3520 1980 3 4 Feed Recycle 50 210 3200 2500

The Composite Curve ° D Tmin= 20 Hot Utility Target QHMIN = 1000 200 ° 250 150 50 100 Qcmin= 800 Hot Composite Curve Cold Composite D Tmin= 20 Hot Utility Target QHMIN = 1000 Cold Utility Target QCMIN = 800 QHMIN = 1000

Creating a heat exchanger network 220 ° 180 ° ° 60 ° 80 Product C ° 440 270 ° 160 ° 235.6 180 ° Reac. Out C 360 210 ° 160 ° 50 ° Feed 2200 ° 177.6 ° 1000 210 190 ° 160 ° H Recycle 1000 620 880 Q = 1000 Q = 800 H m i n C m i n

Driving force plot D T a b Driving Force Plot m p s i t e Driving Force Plot Representation of driving forces for vertical heat transfer a b n

Driving Force plot used to check the use of exchangers CP 1 2 0.5

Why carry out Process Integration? Process Costs Reduced

Process Integration on Methanol Process

Summary Aspen Plus is a great tool for the development of chemical processes or carrying out analysis on existing processes Process Integration gives a reduction in the amount of Energy required in the process Pinch Technology can be used to reduce the number of Heat Exchangers required

Thank You for your time and patience Please feel free to ask questions or give feed back on this presentation