Mal-distribution of temperature in an industrial dual-bed reactor for conversion of CO 2 to methanol

Mirvakili, A.; Rahimpour, Mohammad Reza

doi:10.1016/j.applthermaleng.2015.08.067

Cited by 24 publications

(22 citation statements)

References 8 publications

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“…Thermal conductivity Table 3 [22]. It appears that there is a good agreement between plant data and simulation results at the same process condition.…”

Section: Parameter Equationmentioning

confidence: 69%

“…In this part, the process description, considered kinetic and process models, formulated optimization algorithm and considered method to solve the optimization problem and obtained equations are presented. Figure 1 shows the process flow diagram of syngas conversion section in the considered methanol unit [22]. The methanol unit consists of three main steps including syngas production from natural gas, methanol synthesis from syngas and downstream purification sections.…”

Section: Methodsmentioning

confidence: 99%

“…The outlet product from gas cooled reactor enters to the separation section to produce pure methanol. Table 1 shows the reactor design data, catalyst characteristics and feed specifications of the dual type configuration [22].…”

Section: Methodsmentioning

confidence: 99%

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Dynamic optimization of methanol synthesis section in the dual type configuration to increase methanol production

Masoudi

Farsi

Rahimpour

2019

Oil Gas Sci. Technol. – Rev. IFP Energies nouvelles

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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

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“…Thermal conductivity Table 3 [22]. It appears that there is a good agreement between plant data and simulation results at the same process condition.…”

Section: Parameter Equationmentioning

confidence: 69%

Section: Methodsmentioning

confidence: 99%

See 1 more Smart Citation

Dynamic optimization of methanol synthesis section in the dual type configuration to increase methanol production

Masoudi

Farsi

Rahimpour

2019

Oil Gas Sci. Technol. – Rev. IFP Energies nouvelles

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“…In the second section, syngas is converted to methanol which can be achieved by different method. One of these methods is conventional dual type which consists of two reactors including gas-cooled and water-cooled reactors which are shell and tube heat exchangers [8,9]. The water-cooled reactor tube and gas-cooled reactor shell are loaded with Cu/ZnO/Al 2 O 3 catalyst which is the catalyst of methanol synthesis reactions.…”

Section: Introductionmentioning

confidence: 99%

“…In this reactor, the reacting gas and syngas go counter-currently through shell and tubes, respectively. Therefore, the reactant gas temperature flowing inside gas-cooled reactor shell side decreases continuously to provide the driving force for methanol production reaction [9]. However, it is observed that by the course of time, the shell side temperature of the gas-cooled reactor decreases so that it reaches the dew point temperature of methanol and water vapors.…”

Section: Introductionmentioning

confidence: 99%

Development of Two Novel Processes for Hydrogenation of CO2 to Methanol over Cu/ZnO/Al2O3 Catalyst to Improve the Performance of Conventional Dual Type Methanol Synthesis Reactor

2018

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Conventional methanol synthesis process (CR configuration) consists of water-cooled and gas-cooled reactors in which methanol and water are condensed inside the gas-cooled reactor which deactivates the catalyst. In this study, two novel configurations (AW and ACW configurations) are represented to address this problem in which the gas-cooled reactor is replaced with adiabatic reactor. Moreover, a condenser is applied between adiabatic and water-cooled reactors in ACW configuration. Results show that temperature increases somewhat along the adiabatic reactor that prevents gas condensate formation. Besides, the adiabatic reactor maximum temperature is less than that of first reactor in CR configuration which prevents copper based catalyst thermal sintering. Moreover, a high cross section-to-length ratio of the adiabatic reactor leads to negligible pressure drop along the reactor and improvement in CO 2 conversion to methanol that has positive environmental effects. Also, water mole fraction decreases along the reactors of AW and ACW configurations to prevent the deactivation of catalyst active sites. Eventually, methanol production rates by AW and ACW configurations are improved around 25.5% and 43.1% in comparison with CR configuration. So, novel AW and ACW configurations provide many benefits including improvement in catalyst activity and durability, CO 2 conversion, and the methanol production rate.

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Nonlinear Behavior of Methanol Synthesis Compared to CO₂ Methanation

Leipold,

Jung,

Keßler

et al. 2023

Chem Eng & Technol

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The nonlinear behavior of CO2 methanation over a Ni‐catalyst is compared to methanol synthesis over a standard Cu/ZnO‐catalyst in a continuous stirred tank reactor (CSTR). Both reactions have received a lot of attention these days for chemical energy storage. Both reactions are exothermic but behave in a different way. CO2 methanation is known to be strongly exothermic, giving rise to multiple steady states. This behavior is induced by the self‐acceleration of the methanation reaction because the heat production of the chemical reaction increases with rising temperature. It is shown that methanol synthesis behaves fundamentally different under the operating conditions usually employed in practice. It is less exothermic but, even more important, the overall heat production of the methanol reaction system decreases with increasing temperature, giving rise to a unique and stable steady state. This insight is obtained with an extension of the classical graphical analysis with heat production and heat removal curves.

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Mal-distribution of temperature in an industrial dual-bed reactor for conversion of CO 2 to methanol

Cited by 24 publications

References 8 publications

Dynamic optimization of methanol synthesis section in the dual type configuration to increase methanol production

Dynamic optimization of methanol synthesis section in the dual type configuration to increase methanol production

Development of Two Novel Processes for Hydrogenation of CO2 to Methanol over Cu/ZnO/Al2O3 Catalyst to Improve the Performance of Conventional Dual Type Methanol Synthesis Reactor

Nonlinear Behavior of Methanol Synthesis Compared to CO₂ Methanation

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Mal-distribution of temperature in an industrial dual-bed reactor for conversion of CO 2 to methanol

Cited by 24 publications

References 8 publications

Dynamic optimization of methanol synthesis section in the dual type configuration to increase methanol production

Dynamic optimization of methanol synthesis section in the dual type configuration to increase methanol production

Development of Two Novel Processes for Hydrogenation of CO2 to Methanol over Cu/ZnO/Al2O3 Catalyst to Improve the Performance of Conventional Dual Type Methanol Synthesis Reactor

Nonlinear Behavior of Methanol Synthesis Compared to CO2 Methanation

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Nonlinear Behavior of Methanol Synthesis Compared to CO₂ Methanation