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Process Simulation and Integration of Methanol Production

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.

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Process Simulation and Integration of Methanol Production

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  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. Natural Gas Oxygen Combustion Steam Synthesis Gas Reaction Crude Methanol Distillation Methanol Process Flow Diagram 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. Natural Gas + H2OCO + 3H2 CO + H2OCO2 + H2 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 + O2CO + H2

  9. CO + 2H2CH3OH • 2CO + 4H2CH3OCH3 + H2O • CO2 + H2CO + H2O Conversion of Synthesis Gas to Methanol • Methanol Conversion Reactions

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

  19. ° 220 RECYCLE ° STEAM 178 1620 880 CW ° 160 ° ° 60 180 ° 160 2640 DIST ° VAP 130 ° 210 REAC. OUT REACTOR Distillation ° ° 160 270 ° 210 Column ° 149 STEAM 1220 1980 ° FEED 50 PRODUCT ° 220 Above Pinch Below Pinch What is a Pinch Analysis? • What is meant by the Pinch

  20. What is meant by the Pinch • The Composite Curve

  21. T T ° 270 8 1 ° 220 = P C ° 210 2 ° 2 160 Reac. 0 = 5 = P Out P ° C C 160 0 2 Recycle Product = P C ° 60 Feed 3520 1980 ° T T T T 50 2500 D D 3200 No Name H No Name H s u p p l y t a r g e t s u p p l y t a r g e t H 1 220 60 3520 3 50 210 3200 Product Feed H Reac. Out Recycle 2 270 160 1980 4 160 210 2500 The Composite Curve

  22. QHMIN = 1000 ° 250 Hot Composite Curve ° 200 ° D Tmin= 20 ° 150 ° 100 ° 50 Hot Utility Target QHMIN = 1000 Cold Composite Cold Utility Target QCMIN = 800 Curve ° 0 Qcmin= 800 The Composite Curve

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

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

  25. CP D T 1 2 0.5 T C Driving Force plot used to check the use of exchangers

  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

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