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

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

3. 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

4. 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

5. 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

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

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

8. 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

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

10. Process Diagram

11. 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

12. Aspen Plus User Interface

13. Aspen Plus User Interface

14. Methanol Process Simulation

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

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

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

18. 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

19. 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

20. What is meant by the Pinch
The Composite Curve

21. 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

22. 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

23. 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

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

25. Driving Force plot used to check the use of exchangersCP 1 2
0.5

26. Why carry out Process Integration?
Process Costs Reduced

27. Process Integration on Methanol Process

28. 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

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