The main object of this research is dynamic modeling and optimization of the methanol synthesis section in the dual type configuration considering catalyst deactivation to improve methanol production capacity. In the methanol unit, deactivation of CuO/ZnO/Al 2 O 3 catalyst by sintering and low equilibrium conversion of reactions limit the production capacity, and changing operating temperature is a practical solution to overcome the production decay. In the first step, the considered process is modeled based on the mass and energy balance equations at dynamic condition. To prove the accuracy of developed model, the simulation results are compared with the plant data at the same operating conditions. In the second step, a dynamic optimization problem is formulated, and the optimal trajectories of manipulated variables are determined considering methanol production rate as the objective function. Finally, the performance of optimized process is compared with the conventional system at the same design conditions. The results show that operating at the optimal conditions increases methanol production capacity about 6.45%.
Nomenclature aActivity of catalyst (-) A C Cross section area of each tube (m 2 ) CtTotal concentration (mol m À3 ) C p Specific heat of the gas at constant pressure (J mol À1 K À1 ) DDiameter (m) E d Activation energy used in the deactivation model (J mol À1 ) F t Total molar flow rate (mol s À1 ) f i Partial fugacity of component i (bar) K i Adsorption equilibrium constant for component i (bar À1 ) K p Equilibrium constant based on partial pressure for component i (-) k 1 Reaction rate constant for the first rate equation (mol kg À1 s À1 bar À1/2 ) k 2 Reaction rate constant for the second rate equation (mol kg À1 s À1 bar À1/2 ) k 3 Reaction rate constant for the third rate equation (mol kg À1 s À1 bar À1/2 ) K d Deactivation constant (h À1 ) P Total pressure (bar) r 1Rate of reaction for hydrogenation of CO (mol kg À1 s À1 ) r 2 Rate of reaction for hydrogenation of CO 2 (mol kg À1 s À1 ) r 3Reversed water-gas shift reaction (mol kg À1 s À1