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

2. 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

3. 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

4. Feed and Syngas Reactor

5. Water Gas Shift Reactors

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

7. 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

8. Defining Reactions

9. Check Rxn Phase & Rate Units

10. Kinetic Constants

11. 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

12. 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

13. HYSYS Plug Flow Reactor Unit

14. 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

15. Close the Loop

16. 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

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

18. 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

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

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

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

22. 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

23. 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

24. 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