Optimal Integrated Facility for Oxymethylene Ethers Production from Methanol

Abstract

In this work, we use a mathematical optimization approach for the evaluation of the production of oxymethylene ethers (OMEs) from methanol. OME1, methylal, and the mixture of OME3–5 are the targeted products. The process consists of formaldehyde production, OMEs synthesis from formaldehyde and methanol, and separation. The processes are modeled based on chemical equilibrium for the reactors and surrogate models for the rest of the units to determine the optimal operating conditions for producing the two products. The negative effect of water in the OMEs synthesis presents the alternative of partially removing water from the formaldehyde. However, no yield improvement is found. The production of OME1 results in 0.93 €/kg and an investment of 46 M€ while the production of OME3–5 mixture shows a production cost of 0.61 €/kg and an investment of 51 M€ for a production capacity of 247 and 264 kt/yr, respectively, from the same methanol feedstock. The effect of the methanol source in the cost from different renewable resources is also evaluated with biomass showing the most attractive OMEs prices and competitive ones for biomass price below 100 €/ton.

Process modelling and life cycle assessment coupled with experimental work to shape the future sustainable production of chemicals and fuels

“…62,63 Specifically, two different routes involving intermediate production of formaldehyde are particularly promising. 64,65 New synthesis pathways for OMEs have been welcome with enthusiasm by industry as well, with Chinese and German companies already testing some of these routes in pilot plants. 66 An alternative pathway relies on the production of syngas via either the reverse water gas shift (RWGS) reaction in tandem with water splitting or the co-electrolysis of water and CO 2 .…”

“…Furthermore, relying on a process model is more convenient because it allows analysing more indepth the process variables' economic and environmental role, generating valuable insight into how to improve technologies. The scale-up is considered next to elucidate whether higher production capacities can improve, mainly economically, 65,78,121 the performance at an industrial scale. Moreover, certain technologies may prove more appropriate than others at different scales, which needs to be investigated before their eventual deployment.…”

“…For example, methanol from switchgrass via gasification, and its use as intermediate feedstock towards OMEs, was shown to outperform its biogasand renewable-based CO 2 hydrogenation production counterparts. 65 Notably, different biomass types exhibit various performance trade-offs, e.g., ethylene via bioethanol from corn stover shows lower GHG emissions but is more expensive than ethylene from corn grain. 121 Hybrid plants were also investigated that use renewable electrolytic hydrogen (i) to utilise the CO 2 captured during the production of syngas or to improve its quality, 30,150 (ii) for biogas upgrading via CO 2 hydrogenation towards methane 116 and methanol, 115 or (iii) to minimise the fossil feedstocks.…”

“…The scale-up is considered next to elucidate whether higher production capacities can improve, mainly economically, 65,78,121 the performance at an industrial scale. Moreover, certain technologies may prove more appropriate than others at different scales, which needs to be investigated before their eventual deployment.…”

“…For example, methanol from switchgrass via gasification, and its use as intermediate feedstock towards OMEs, was shown to outperform its biogas- and renewable-based CO 2 hydrogenation production counterparts. 65 Notably, different biomass types exhibit various performance trade-offs, e.g. , ethylene via bioethanol from corn stover shows lower GHG emissions but is more expensive than ethylene from corn grain.…”