Overview of Methanol Model We will start with Start.hsc and use it to do equipment design and cost estimation

Start.hsc This is a simplified model to represent the SynGas process The units you see are not intended to represent the actual pieces of equipment in the plant It’s purpose is to do the heat and mass balances necessary to create a feed stream for the methanol plant

Idea from Last Year Heat removal in methanol reactors was a big problem Both CO=>CO2 and methanol reactions are exothermic Reduce heat load in methanol section by converting as much of the CO as possible in the syngas section and then cooling the stream

Feed and Syngas Reactor

Water Gas Shift Reactors

Structure of Methanol Process Recycle Purge Water MeOH Reaction Section Recycle Section SeparationSection CO2* Syngas Lights Heavies * 126.667 kmol/hr

Reaction Section Reactor: Like a S&T heat exchanger Multi tubed Packed with catalyst Cooled with water in shell Uses HYSYS Plug Flow Reactor Unit Feed and coolant temperature are important

Defining Reactions

Check Rxn Phase & Rate Units

Kinetic Constants

Kinetic Constants Syngas, water gas, methanol values are in Start.hsc For the impurities use: Ethanol: 1E24, 2E5 Acetone: 1E28, 2E5 Fusel Oil: 1E25, 2E5

Plug Flow Reactor Design Read Process in Basic Data very carefully before you strat work on the reactor It contains much vital information on techniques and selection of parameters

HYSYS Plug Flow Reactor Unit

Develop Reactor Design Guess at T,P,Conc. of recycle stream Optimize four parameters T of feed and coolant (max MeOH) Flow of coolant (max MeOH) Number of tubes (95% to equilibrium) Compare actual recycle rate with assumed value If difference > 1%, start again

Close the Loop

Recycle Section Cool reactor product to condense methanol and water Collect liquid and send to Separation Purge some vapour to prevent buildup of light components Compress the rest of the vapour and send it back to the reactor

Questions to Think About At what temperature and pressure should the flasher operate? Why?

Distillation Train Purpose Purify product Recover light gases and heavy impurities for fuel Recover water for reuse See my feedback for the Initial Review for suggestions on the designs

Step 1: Water Column V Dry Organics to Lights Column L From Recycle Section Water for Reuse

Step 2: Lights Column Residual Gases and Acetone Dry Organics Alcohols

Step 3: Product Column Methanol Product Alcohols Ethanol & Fusel Oil

Report for Modeling Assignment In your group folder set up folder “Model” Put in it by 2:15 Wed Oct 15: HYSYS model - .hsc file Summary of our progress with the task Anything else you want me to consider

Summary of Progress An engineer from our client is coming to review our progress Our supervisor has asked us to prepare a summary of: What we have accomplished What we learned in working out the design Any issues of concern that have arisen

Summary continued Our visitor has 15 minutes to read and digest the report before discussing it with us Both the analysis assignment (mass balance and catalyst characterization) and the building of the model should be covered This probably means 3 to 6 pages