Isothermal Methanol Converter (IMC) UA Distribution Analysis - Case Study: #0630416GB/H; ACME Co. 9,000 MTD MeOH
This converter uses plates instead of tubes to remove the heat from the reaction gas. The use of the plates and the orientation allow the heat transfer within the converter to be more accurately controlled to follow the maximum rate line.
This case study examines the Radial Flow – Isothermal Methanol Converter (IMC) for ACME Co. 9,000 MTD, based on the Casale Isothermal Methanol Converter (IMC) design.
Apidays Singapore 2024 - Building Digital Trust in a Digital Economy by Veron...
Isothermal Methanol Converter (IMC) UA Distribution Analysis
1. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
GBH Enterprises, Ltd.
Isothermal Methanol
Converter (IMC)
UA Distribution Analysis
Case Study: #0630416GB/H
ACME Co. 9,000 MTD MeOH
Process Information Disclaimer
Information contained in this publication or as otherwise supplied to Users is
believed to be accurate and correct at time of going to press, and is given in
good faith, but it is for the User to satisfy itself of the suitability of the Product for
its own particular purpose. GBHE gives no warranty as to the fitness of the
Product for any particular purpose and any implied warranty or condition
(statutory or otherwise) is excluded except to the extent that exclusion is
prevented by law. GBHE accepts no liability for loss, damage or personnel injury
caused or resulting from reliance on this information. Freedom under Patent,
Copyright and Designs cannot be assumed.
2. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
Methanol Synthesis
The synthesis loop comprises a circulator, converter, feed/effluent exchanger,
separator, and in some cases a heat recovery exchanger. The optimum
operating pressure is typically about 80 bar for large plants, but for smaller plants
(less than 600 te/day) a pressure of 50 bar may be economic due to the reduced
material requirements.
Synthesis gas is mixed with the recycle gas and preheated in a feed/effluent
interchanger. The exact arrangement of interchanger is dependent on the type
of converter used.
The converter effluent is cooled by passing through the feed/effluent interchanger
and dependent on the reactor type, a heat recovery exchanger. Prior to the
catchpot, the gas is cooled to about 40oC to condense the product methanol. A
purge is taken from the recycle gas to remove inerts (N2, CH4, Argon, and
surplus hydrogen or carbon oxides) from the loop. This is used as fuel in the
reformer. A purge gas expander may be used to recover power from the purge
gas as it is let down to the fuel system pressure.
There are a number of different types of converters offered by technology
licensors;
Two key types:
• Multiple beds with intercooling
• Single bed with continuous cooling
However, this case study examines the Radial Flow – Isothermal Methanol
Converter (IMC) for ACME Co. 9,000 MTD, based on the Casale Isothermal
Methanol Converter (IMC) design, detailed below;
3. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
The Casale Isothermal Methanol Converter (IMC)
Design
This converter uses plates instead of tubes to remove the heat from the reaction
gas. The use of the plates and the orientation allow the heat transfer within the
converter to be more accurately controlled to follow the maximum rate line.
It can be used in either feed heating or steam raising.
This converter is a new design which uses less volume than previous designs.
Casale Isothermal Methanol Converter (IMC)
5. Spreadsheet to calculate optimum UA distribution through a cooled methanol synthesis reactor or calculate
performance given a matrix of UA values.
Version 1.13.20
2 July 2014 – G B HAWKINS
Routines imported from VULCAN Dbase_01 for thermodynamics.
Data imported from VULCAN Dbase_01 (see "Data" page in spreadsheet).
Routines imported from VULCAN Dbase_02 for kinetics and numerical integration, etc.
Fugacity calculations can be incorporated into equilibrium and rate of reaction routines to be consistent with original
Cresswell work, but activity data was not evaluated on this basis. To be consistent with what we do in MeOH Bed in
VULCANFlow Equilibrium calculations include component fugacities so this has also been implemented in the rate
calculations.
In design mode, UA values selected such that the temperature at the outlet of each segment is equal to the temperature at
which the maximum rate of reaction is achieved for that gas composition.
Enthalpies are calculated using ExAPI with no RKS correction for non-ideality. The RKS correction can easily be incorporated
(maybe a selection option for a future version), but it makes no obvious difference to the results and slows the calculations
down by an order of magnitude.
The maximum rate temperature calculation routine is new and is based on a golden section search method.
8. Spreadsheet to calculate optimum UA distribution through a cooled methanol synthesis reactor or
calculate performance given a matrix of UA values.
Version 1.13.20
2 July 2014 – G B HAWKINS
Routines imported from VULCAN Dbase_01 for thermodynamics.
Data imported from VULCAN Dbase_01 (see "Data" page in spreadsheet).
Routines imported from VULCAN Dbase_02 for kinetics and numerical integration, etc.
Fugacity calculations can be incorporated into equilibrium and rate of reaction routines to be consistent with
original Cresswell work, but activity data was not evaluated on this basis. To be consistent with what we do in
MeOH Bed in VULCANFlow, the equilibrium calculations include component fugacities so this has also been
implemented in the rate calculations.
In design mode, UA values selected such that the temperature at the outlet of each segment is equal to the
temperature at which the maximum rate of reaction is achieved for that gas composition.
Enthalpies are calculated using ExAPI with no RKS correction for non-ideality. The RKS correction can easily be
incorporated (maybe a selection option for a future version), but it makes no obvious difference to the results and
slows the calculations down by an order of magnitude.
The maximum rate temperature calculation routine is new and is based on a golden section search method.
11. "ACME" Methanol Company
Case Study: UA Distribution Through a
Methanol Synthesis Converter of a
9000 MTD MeOH Plant
Radial Flow ACME Reactor Set-Up
Gas Cooled vs. Water-Cooled Performance
Analysis