WO2017121978A1 - Procédé de synthèse du méthanol - Google Patents
Procédé de synthèse du méthanol Download PDFInfo
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- WO2017121978A1 WO2017121978A1 PCT/GB2016/053827 GB2016053827W WO2017121978A1 WO 2017121978 A1 WO2017121978 A1 WO 2017121978A1 GB 2016053827 W GB2016053827 W GB 2016053827W WO 2017121978 A1 WO2017121978 A1 WO 2017121978A1
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- Prior art keywords
- gas
- methanol
- reactor
- synthesis
- process according
- Prior art date
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- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 title claims abstract description 297
- 238000000034 method Methods 0.000 title claims abstract description 30
- 230000008569 process Effects 0.000 title claims abstract description 28
- 238000003786 synthesis reaction Methods 0.000 claims abstract description 94
- 230000015572 biosynthetic process Effects 0.000 claims abstract description 91
- 239000003054 catalyst Substances 0.000 claims abstract description 54
- 238000010926 purge Methods 0.000 claims abstract description 28
- 239000000203 mixture Substances 0.000 claims abstract description 27
- 230000007423 decrease Effects 0.000 claims abstract description 12
- 238000001816 cooling Methods 0.000 claims abstract description 11
- 239000007789 gas Substances 0.000 claims description 160
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 claims description 32
- 229910052739 hydrogen Inorganic materials 0.000 claims description 32
- 239000001257 hydrogen Substances 0.000 claims description 32
- 238000010791 quenching Methods 0.000 claims description 5
- 230000004044 response Effects 0.000 claims description 4
- 238000012545 processing Methods 0.000 claims description 3
- 238000002453 autothermal reforming Methods 0.000 claims description 2
- 238000000746 purification Methods 0.000 claims description 2
- 238000011084 recovery Methods 0.000 claims description 2
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 36
- 229910002092 carbon dioxide Inorganic materials 0.000 description 24
- 239000001569 carbon dioxide Substances 0.000 description 18
- 238000004519 manufacturing process Methods 0.000 description 9
- 239000007788 liquid Substances 0.000 description 8
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 8
- 238000006243 chemical reaction Methods 0.000 description 6
- 239000002826 coolant Substances 0.000 description 6
- 239000000446 fuel Substances 0.000 description 6
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 5
- 238000003860 storage Methods 0.000 description 5
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical class [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 4
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 description 4
- 238000009835 boiling Methods 0.000 description 4
- 229910052799 carbon Inorganic materials 0.000 description 4
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 3
- 229910002090 carbon oxide Inorganic materials 0.000 description 3
- 230000008859 change Effects 0.000 description 3
- 229910052802 copper Inorganic materials 0.000 description 3
- 239000010949 copper Substances 0.000 description 3
- 238000005868 electrolysis reaction Methods 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- 239000011261 inert gas Substances 0.000 description 3
- 238000010248 power generation Methods 0.000 description 3
- 238000002407 reforming Methods 0.000 description 3
- 238000012546 transfer Methods 0.000 description 3
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 2
- 239000002028 Biomass Substances 0.000 description 2
- 239000005751 Copper oxide Substances 0.000 description 2
- LCGLNKUTAGEVQW-UHFFFAOYSA-N Dimethyl ether Chemical compound COC LCGLNKUTAGEVQW-UHFFFAOYSA-N 0.000 description 2
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 2
- 229910000431 copper oxide Inorganic materials 0.000 description 2
- 238000004821 distillation Methods 0.000 description 2
- 150000002431 hydrogen Chemical class 0.000 description 2
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 2
- 238000000629 steam reforming Methods 0.000 description 2
- 239000011787 zinc oxide Substances 0.000 description 2
- 238000010521 absorption reaction Methods 0.000 description 1
- 229910021529 ammonia Inorganic materials 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 229910002091 carbon monoxide Inorganic materials 0.000 description 1
- 238000003889 chemical engineering Methods 0.000 description 1
- 238000001311 chemical methods and process Methods 0.000 description 1
- 239000003245 coal Substances 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 230000001627 detrimental effect Effects 0.000 description 1
- 230000029087 digestion Effects 0.000 description 1
- 230000005611 electricity Effects 0.000 description 1
- 230000008030 elimination Effects 0.000 description 1
- 238000003379 elimination reaction Methods 0.000 description 1
- 238000000855 fermentation Methods 0.000 description 1
- 230000004151 fermentation Effects 0.000 description 1
- 239000012528 membrane Substances 0.000 description 1
- WSFSSNUMVMOOMR-NJFSPNSNSA-N methanone Chemical compound O=[14CH2] WSFSSNUMVMOOMR-NJFSPNSNSA-N 0.000 description 1
- 238000013021 overheating Methods 0.000 description 1
- 238000004064 recycling Methods 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 239000002002 slurry Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
- B01J8/02—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J19/0006—Controlling or regulating processes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J35/00—Catalysts, in general, characterised by their form or physical properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J35/00—Catalysts, in general, characterised by their form or physical properties
- B01J35/30—Catalysts, in general, characterised by their form or physical properties characterised by their physical properties
-
- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C29/00—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring
- C07C29/15—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of oxides of carbon exclusively
- C07C29/151—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of oxides of carbon exclusively with hydrogen or hydrogen-containing gases
- C07C29/1512—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of oxides of carbon exclusively with hydrogen or hydrogen-containing gases characterised by reaction conditions
-
- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C29/00—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring
- C07C29/15—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of oxides of carbon exclusively
- C07C29/151—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of oxides of carbon exclusively with hydrogen or hydrogen-containing gases
- C07C29/152—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of oxides of carbon exclusively with hydrogen or hydrogen-containing gases characterised by the reactor used
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P20/00—Technologies relating to chemical industry
- Y02P20/10—Process efficiency
- Y02P20/129—Energy recovery, e.g. by cogeneration, H2recovery or pressure recovery turbines
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P20/00—Technologies relating to chemical industry
- Y02P20/50—Improvements relating to the production of bulk chemicals
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P20/00—Technologies relating to chemical industry
- Y02P20/50—Improvements relating to the production of bulk chemicals
- Y02P20/52—Improvements relating to the production of bulk chemicals using catalysts, e.g. selective catalysts
Definitions
- Methanol synthesis is generally performed by passing a synthesis gas comprising hydrogen, carbon oxides and any inert gases at an elevated temperature and pressure through one or more beds of a methanol synthesis catalyst, which is often a copper-containing composition.
- Methanol is generally recovered by cooling the product gas stream to below the dew point of the methanol and separating off the product as a liquid.
- the crude methanol is typically purified by distillation.
- the process is often operated in a loop: thus the remaining unreacted gas stream is usually recycled to the synthesis reactor as part of the synthesis gas via a circulator.
- Fresh synthesis gas termed make-up gas, is added to the recycled unreacted gas to form the synthesis gas stream.
- a purge stream is often taken from the circulating gas stream to avoid the build-up of inert gases.
- the process is typically operated at a target operating pressure and the purge valve is opened and closed to maintain this pressure.
- US2003039600 discloses a control scheme for conversion of variable composition synthesis gas to liquid fuels such as methanol in a three-phase or slurry bubble column reactor (SBCR).
- SBCR three-phase or slurry bubble column reactor
- the control scheme allows operation to achieve constant or optimum liquid fuel production and constant or limited purge gas flow with highly variable synthesis gas feed condition. This is accomplished by adjusting one or more of the recycle ratio, water addition, and bypass flow.
- SBCR's are complex and they are not generally used for methanol synthesis.
- the invention described herein overcomes the problems of the previous processes by utilizing the innate gas storage already in the methanol loop.
- the invention provides a process for the synthesis of methanol comprising the steps of: (i) passing a synthesis gas mixture comprising a make-up gas through a reactor containing a bed of particulate methanol synthesis catalyst to form a product gas stream, (ii) cooling and recovering methanol from the product gas stream thereby forming a methanol- depleted gas mixture, (iii) dividing the methanol-depleted gas mixture into a purge gas stream and a loop gas stream by means of a purge valve and (iv) combining the loop gas stream with the make-up gas to form the synthesis gas mixture, wherein the purge valve is maintained at a fixed position so that the pressure of the loop gas increases or decreases in accordance to increases or decreases in the flow of the make-up gas.
- the volume of the methanol loop itself is being utilised to modulate the methanol reaction rate.
- the loop will continue to pressurise, until the methanol production rate balances out the rate of hydrogen and carbon dioxide addition and vice versa.
- the invention allows a methanol synthesis loop to operate down to a 5 % turndown of make-up gas and be responsive to rapid load changes.
- the make-up gas typically comprises hydrogen and carbon dioxide. Carbon monoxide may also be present.
- the make-up gas may be generated by the steam reforming of methane or naphtha using established steam reforming processes, including pre-reforming.
- the present invention is of particular effectiveness in utilising make-up gases generated by combining electrolytic hydrogen with a carbon dioxide containing gas stream.
- electrolytic hydrogen we mean a hydrogen-containing gas stream formed by the electrolysis of water/steam.
- the carbon dioxide-containing gas stream may be a captured carbon dioxide gas stream recovered from a power plant that combusts carbon-containing fuels, such as coal or biomass, or separated from a gas produced by anaerobic digestion of biomass.
- the carbon dioxide could be a pure carbon dioxide stream, such as that extracted from an ammonia plant, or that produced by a fermentation process, or from a geothermal source.
- off-gases from refineries or other chemical processes comprising principally hydrogen and carbon oxides may also be used.
- the make-up gas is compressed using conventional compression equipment, combined with the loop gas and passed to the methanol synthesis reactor.
- the hydrogen and carbon content of the synthesis gas mixture fed to the methanol synthesis catalyst in the reactor preferably should be adjusted so that the desired stoichiometry for the methanol synthesis reactions is achieved.
- the reactions may be depicted as follows;
- the composition of synthesis gas at the reactor inlet is preferably as follows; 15-45 mol% carbon dioxide, 55-85 mol% hydrogen and the balance one or more inert gases.
- the methanol-depleted gas may be divided into a loop gas stream, which is combined with make-up gas, and optionally other gas streams to form the synthesis gas mixture.
- a purge stream is recovered from the methanol-depleted gas mixture.
- the reactor may be an un-cooled adiabatic reactor.
- a cooled reactor may be used in which heat exchange with a coolant within the reactor may be used to minimise or control the temperature.
- a fixed bed of particulate catalyst is cooled by tubes or plates through which a coolant heat exchange medium passes.
- the catalyst is disposed in tubes around which the coolant heat exchange medium passes.
- the reactor may be a quench reactor, or a reactor selected from a tube-cooled converter or a gas-cooled converter, wherein the catalyst bed is cooled in heat exchange with the synthesis gas.
- the reactor may be cooled by boiling water under pressure, such as an axial flow steam-raising converter, or a radial flow steam-raising converter.
- the reactors contain fixed beds of methanol synthesis catalyst through which the synthesis gas is passed.
- the synthesis gas may pass axially, radially or axially and radially through a bed of particulate methanol synthesis catalyst.
- the exothermic methanol synthesis reactions occur resulting in an increase in the temperature of the reacting gases.
- the inlet temperature to the bed therefore is desirably cooler than in cooled reactor systems to avoid over-heating of the catalyst which can be detrimental to selectivity and catalyst life.
- a cooled reactor may be used in which heat exchange with a coolant within the reactor may be used to minimise or control the temperature rise.
- a coolant within the reactor may be used to minimise or control the temperature rise.
- the reactor may be an axial steam raising converter, a radial-flow steam raising converter, a gas-cooled converter or a tube cooled converter.
- a bed of particulate catalyst is cooled by tubes or plates through which a coolant heat exchange medium passes.
- the synthesis reactor may be a quench reactor in which one or more beds of particulate catalyst are cooled by a synthesis gas mixture injected into the reactor within or between the beds.
- the synthesis gas typically passes axially through vertical, catalyst-containing tubes that are cooled in heat exchange with boiling water under pressure.
- the catalyst may be provided in pelleted form directly in the tubes or may be provided in one or more cylindrical containers that direct the flow of synthesis gas both radially and axially to enhance heat transfer.
- Such contained catalysts and their use in methanol synthesis are described in WO2012146904 (A1).
- Steam raising converters in which the catalyst is present in tubes cooled by boiling water under pressure offer a useful means to remove heat from the catalyst.
- the aSRC offers the highest cooling factor, it makes poorer use of the reactor volume so the reactor shell is relatively large for the quantity of catalyst that it holds.
- aSRCs can suffer from a high pressure drop.
- a radial-flow steam raising converter rSRC
- the synthesis gas typically passes radially (inwards or outwards) through a bed of particulate catalyst which is cooled by a plurality of tubes or plates through boiling water under pressure is fed as coolant.
- rSRC radial-flow steam raising converter
- Such reactors are known and are described for example in US4321234.
- a rSRC has poorer heat transfer than an aSRC but has very low pressure drop, hence it favours operation with high recycle ratio.
- a tube-cooled converter In a tube-cooled converter (TCC), the catalyst bed is cooled by feed synthesis gas passing through open ended tubes disposed within the bed that discharge the heated gas to the catalyst. TCC's therefore can provide sufficient cooling area for a range of synthesis gas compositions and is able to be used under a wide range of conditions.
- a gas cooled converter As an alternative to a TCC, a gas cooled converter (GCC), may be used to cool the catalyst bed by passing the synthesis gas though tubes in a heat exchanger-type arrangement.
- GCC is described for example in US 5827901 .
- the use of a TCC is preferred over the GCC in that it is simpler and cheaper to fabricate due to the use of open topped tubes and the elimination of the upper header and all of the differential expansion problems that the gas cooled converter raises.
- TCC therefore has the advantage of low equipment cost and lower outlet temperature, which favours the synthesis reaction equilibrium, but it has a lower heat transfer than aSRC and higher pressure drop than rSRC.
- a quench reactor the one or more beds of particulate catalyst are cooled by a synthesis gas mixture injected into the reactor within or between the beds.
- synthesis gas mixture injected into the reactor within or between the beds.
- the reactor is preferably a tube cooled converter (TCC) containing a bed of methanol synthesis catalyst in which a plurality of tubes are disposed, though which the synthesis gas passes before being fed to the methanol synthesis catalyst.
- TCC tube cooled converter
- the flow of the make-up gas may decrease or increase rapidly, for example, because of a fall or rise in the amount of power to produce electrolytic hydrogen.
- the flow of synthesis gas through the reactor and its operating pressure will therefore decrease or increase and it is necessary that the methanol synthesis catalyst is able to function through these and other fluctuations.
- One way of managing this is to control the temperature of the catalyst bed such that it is maintained within a desired range. This may be achieved by adjusting the temperature of the synthesis gas at the inlet of the reactor such that the weight average bed temperature of the methanol synthesis catalyst is maintained in response to a reduction in make-up gas flow, and vice versa, to sustain the methanol synthesis. Therefore, the catalyst bed does not need any substantial extra heat or cooling, when a rapid change of feed rate occurs.
- the synthesis gas mixture fed to the reactor is heated in a gas-gas heat exchanger using the product gas stream from the reactor, with the heating being supplemented by a small external heat supply, for example an electric heater, when the rate of methanol production is too low to provide enough heat to preheat the feed itself.
- a small external heat supply for example an electric heater
- the synthesis gas may also be heated by passing it through tubes or plates disposed within the methanol synthesis catalyst in a tube-cooled converter (TCC) or gas cooled converter (GCC).
- TCC tube-cooled converter
- GCC gas cooled converter
- the synthesis gas is passed through at least a gas-gas heat exchanger where it is heated by the product gas and then passed through tubes or plates within the reactor where it is heated by the reacting gases passing through the methanol synthesis catalyst.
- Other temperature adjustment of the feed gas may be performed using conventional heat exchange apparatus.
- the methanol synthesis catalysts are preferably copper-containing methanol synthesis catalysts, in particular the methanol synthesis catalyst in the synthesis reactor is a particulate copper/zinc oxide/alumina catalyst.
- Particularly suitable catalysts are Mg-doped copper/zinc oxide/alumina catalysts as described in US4788175.
- Methanol synthesis may be effected in the reactor at pressures in the range 10 to 120 bar abs, and temperatures in the range 130°C to 350°C.
- the pressure of the synthesis gas at the reactor inlet is preferably 50-100 bar abs, more preferably 70-90 bar abs at maximum operating rate, but may fall to 10-20 bar abs.
- the temperature of the synthesis gas at the synthesis reactor inlet is preferably 200-250°C and at the outlet preferably 230-280°C.
- a purge gas stream is recovered from the loop.
- the purge stream is controlled by means of a purge valve.
- a purge valve Such purge valves are known but are conventionally opened or closed in response to the build-up of gaseous inventory in the loop and to maintain an optimum fixed operating pressure.
- the purge valve is maintained at a fixed position so that the pressure of the loop gas increases or decreases in accordance to increases or decreases in the flow of the make-up gas.
- the operating strategy in the present invention is to maintain a fixed loop purge valve position and allow the loop to pressurise/depressurise as the make-up gas rate changes.
- recycle ratio we mean the molar flow ratio of the recycled loop gas to the make-up gas that form the synthesis gas mixture fed to the reactor.
- the recycle ratio to form the synthesis gas mixture may be in the range 0.01 :1 to 25:1 .
- the purge gas typically comprises hydrogen and carbon oxides and may be used for hydrogen recovery, for example by pressure-swing absorption or by using suitable membranes, or may be subjected to one or more further processing stages including autothermal reforming, water- gas shift and methanol synthesis.
- the product gas comprising unreacted hydrogen and carbon dioxide, along with methanol vapour is cooled to below the dew point to condense liquid methanol.
- the cooling may be performed using conventional heat exchange apparatus.
- the product gas stream from the reactor may be cooled in one or more stages of heat exchange, e.g. with water or air cooling, to condense methanol therefrom, which may suitably be recovered using gas-liquid separators.
- the cooling may be performed to fully or partially condense the methanol.
- Preferably substantially all the methanol is condensed from the product gas stream.
- the recovered liquid methanol stream may be further processed, for example by one or more, preferably two or three, stages of distillation to produce a purified methanol product. Alternatively, the crude methanol may be fed recovered and stored.
- the methanol product may be subjected to further processing, for example to produce dimethyl ether or formaldehyde, but in one embodiment is stored for use in future electrical power generation.
- the methanol may be fed to a direct methanol fuel cell to generate electrical power, or may be subjected to reforming in a methanol reformer containing a methanol reforming catalyst to generate a hydrogen gas stream, which may be fed to a conventional fuel cell for electrical power generation.
- the methanol may be used as a fuel.
- Figure 1 depicts a process according to one embodiment of the present invention
- Figure 2 is a graph of inlet and turn temperatures in a tube-cooled converter in a process according to Figure 1 for constant weight average bed temperature at varying hydrogen availability.
- a carbon dioxide stream 10 is compressed in a compressor 12 and combined with a stream of pressurised electrolytic hydrogen 14.
- the combined make-up gas stream is fed by line 16 to a compressor 18 which further raises its pressure.
- the pressurised make up gas 20 is combined with a loop gas stream 22 and the resulting synthesis gas fed via line 24 to a gas- gas heat exchanger 26 were it is heated in exchange with a product gas stream.
- the temperature of the heated synthesis gas in line 28 is adjusted if necessary by means of a heat exchanger 30 and the temperature-adjusted synthesis gas fed to a plurality of tubes 32 disposed within a tube-cooled converter 34 containing a bed 36 of a particulate copper-based methanol synthesis catalyst.
- the synthesis gas is heated as it passes through the tubes and is discharged into a space above the catalyst bed 36.
- the synthesis gas then passes through the bed 36 where the methanol synthesis takes place to form a product gas comprising unreacted hydrogen and carbon dioxide, steam and methanol vapour.
- the product gas is fed from the reactor 34 to the gas-gas heat exchanger 26 where it is partially cooled in heat exchange with the synthesis gas.
- the partially cooled gas 40 is fed to one or more further heat exchanges 42 where it is cooled to below the dew point to condense methanol and steam.
- the cooled stream is fed by line 44 to a gas-liquid separator 46 where a crude liquid methanol stream is separated from the gases.
- the crude methanol stream is recovered from the separator 46 via line 48.
- the methanol-depleted gas stream recovered from the separator 46 is fed via line 50 to a compressor 52 where the pressure is increased to form the loop gas 22, which is combined with the pressurised make-up gas 20.
- the methanol-depleted gas stream 50 is divided before the compressor and a portion 54 removed as a purge gas stream.
- a purge valve 56 is set at a fixed position in the purge gas stream 54.
- Example 1 The Invention is further illustrated by reference to the following Example.
- Example 1 The Invention is further illustrated by reference to the following Example.
- a flow sheet was modelled according to the process shown in Figure 1 .
- the base case for 100 % electrolytic hydrogen availability, is taken as a 20 MTPD methanol plant, using hydrogen and carbon dioxide feeds. Carbon dioxide was compressed to the pressure of the hydrogen from electrolysis. This make up feed of carbon dioxide and hydrogen was compressed to the loop pressure and introduced to the synthesis loop.
- the synthesis loop used a tube cooled converter.
- the inlet streams were as follows: Table 1
- the maximum hydrogen flow rate was set to achieve 20 MTPD of methanol.
- the model shows that the energy requirements for steady state operation ranged from 10.7 MW producing 20 MTPD to 0.54 MW producing 0.86 MTPD.
- the varying make-up rate was compensated for by varying the loop pressure, and this varied between 80 barg at the 20 MTPD case and 13 barg at the 0.86 MTPD case.
- the carbon efficiency of the process was less at lower rates; 93 % for the 20 MTPD case, and 80 % at the 0.86 MTPD case.
- a methanol loop running with a fixed pressure of 80 barg would only be capable of operating at energy requirements between 10.7 and 7.5 MW.
- the time to pressurise the loop to 80 barg (100 % availability) can be as short as 2 minutes if there is an instantaneous change in make-up rate. Additional heating was provided to ensure that the reactor did not lose temperature and stop methanol production. This was achieved by maintaining the weight average bed temperature across the range of pressures by raising the converter inlet temperature at lower make up rates. This required additional power for heating at lower make up rates.
- the model outputs for the extremes of operation were as follows;
- Figure 2 shows how the converter inlet temperature and tube turn temperature in the TCC vary with hydrogen availability if the weight average bed temperature is maintained. This shows how the temperature rises are reasonable. The additional power requirement is also shown for each case. Also shown in Figure 2 is the required input power to maintain bed temperature at low synthesis gas flowrates. Above 40 % availability it is assumed that the interchanger will have sufficient capacity to provide the extra heat to the feed gas.
- a by-pass around the gas-gas interchanger 26 may be provided to improve temperature control, so that for > 40 % hydrogen availability there is no need for external heat to provide the temperature rise as more heat can be recovered from the exit gas by closing the bypass valve.
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- Chemical & Material Sciences (AREA)
- Organic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Organic Low-Molecular-Weight Compounds And Preparation Thereof (AREA)
Abstract
L'invention concerne un procédé de synthèse du méthanol comprenant les étapes consistant à : (i) faire passer un mélange de gaz de synthèse comprenant un gaz d'appoint dans un réacteur contenant un lit de particules de catalyseur de synthèse de méthanol pour former un courant de gaz produit, (ii) refroidir et récupérer le méthanol à partir du courant de gaz produit, formant ainsi un mélange gazeux appauvri en méthanol, (iii) diviser le mélange gazeux appauvri en méthanol en un courant de gaz de purge et un courant de gaz de boucle au moyen d'une soupape de purge et (iv) combiner le courant de gaz de boucle avec le gaz d'appoint pour former le mélange de gaz de synthèse, la soupape de purge étant maintenue à une position fixe de sorte que la pression du gaz de boucle augmente ou diminue selon la hausse ou la réduction de la pression du gaz d'appoint.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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GB1600475.6 | 2016-01-11 | ||
GBGB1600475.6A GB201600475D0 (en) | 2016-01-11 | 2016-01-11 | Methanol process |
Publications (1)
Publication Number | Publication Date |
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WO2017121978A1 true WO2017121978A1 (fr) | 2017-07-20 |
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Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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PCT/GB2016/053827 WO2017121978A1 (fr) | 2016-01-11 | 2016-12-05 | Procédé de synthèse du méthanol |
Country Status (2)
Country | Link |
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GB (2) | GB201600475D0 (fr) |
WO (1) | WO2017121978A1 (fr) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2023194178A1 (fr) * | 2022-04-06 | 2023-10-12 | Casale Sa | Procédé de contrôle d'une boucle de synthèse |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO1990006297A1 (fr) * | 1988-11-30 | 1990-06-14 | Davy Mckee Corporation | Production de methanol a partir d'une charge d'hydrocarbures |
US7786180B2 (en) * | 2005-05-27 | 2010-08-31 | Johnson Matthey Plc | Methanol synthesis |
EP2228357A1 (fr) * | 2009-03-12 | 2010-09-15 | Methanol Casale S.A. | Processus de synthèse de méthanol |
Family Cites Families (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6642280B2 (en) * | 2001-08-09 | 2003-11-04 | Air Products And Chemicals, Inc. | Control scheme for conversion of variable composition synthesis gas to liquid fuels in a slurry bubble column reactor |
CA2357527C (fr) * | 2001-10-01 | 2009-12-01 | Technology Convergence Inc. | Procede de production de methanol |
-
2016
- 2016-01-11 GB GBGB1600475.6A patent/GB201600475D0/en not_active Ceased
- 2016-12-05 WO PCT/GB2016/053827 patent/WO2017121978A1/fr active Application Filing
- 2016-12-05 GB GB1620655.9A patent/GB2546867B/en active Active
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO1990006297A1 (fr) * | 1988-11-30 | 1990-06-14 | Davy Mckee Corporation | Production de methanol a partir d'une charge d'hydrocarbures |
US7786180B2 (en) * | 2005-05-27 | 2010-08-31 | Johnson Matthey Plc | Methanol synthesis |
EP2228357A1 (fr) * | 2009-03-12 | 2010-09-15 | Methanol Casale S.A. | Processus de synthèse de méthanol |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2023194178A1 (fr) * | 2022-04-06 | 2023-10-12 | Casale Sa | Procédé de contrôle d'une boucle de synthèse |
Also Published As
Publication number | Publication date |
---|---|
GB2546867B (en) | 2018-07-18 |
GB201620655D0 (en) | 2017-01-18 |
GB201600475D0 (en) | 2016-02-24 |
GB2546867A (en) | 2017-08-02 |
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