Methanol ASPEN Plus

Methanol
ARAVIND BUDARAJU 2016A1PS0501G

UDAY PURAMSETTI 2017A1PS0036G
MOHAMED SHABBAR 2017A1PS0873G
VIVEK SOLOMON 2017A1PS0789
KOUNDINYA MANCHI 2017A1PS0890G
Existing Production processes
 Coal Gasification: Catalytic conversion of hydrogen (H2) and carbon

monoxide (CO) from coal-derived syngas
 Black liquor: Black liquor, a major waste product from pulp mills and paper
industries, can be converted into a bio fuel by the process of gasification.
 Bio-mass: Biosynthesis gas (bio-syngas) is a gas rich in CO and H2 obtained
by gasification of biomass.
Methanol production from Biomass
 Methanol production from bio mass has been chosen as the better
alternative
 The following reactions are occurring in the methanol processing
reactor:
𝐶𝑂 + 2𝐻2 ⇌ 𝐶𝐻3𝑂𝐻 Δ𝐻@(298 K,5 MPa) = −90.7 kJmol-1
𝐶𝑂2 + 3𝐻2 ⇌ 𝐶𝐻3𝑂𝐻 + 𝐻2 Δ𝐻@(298 K,5 MPa) = −40.9 kJmol-1
Methanol production from biomass
 Gasification: The process of producing syngas from coal water and

air.
 Drying: In the drying process the water in the moist fuel is
evaporated to produce dry fuel. The higher the moisture content
the higher the heat requirement of the gasification process.
 Pyrolysis: This step is the thermochemical decomposition of the dry
fuel at temperatures between 250 ∘C and 700 ∘C.
 Oxidation: This step is exothermic and provides the heat for the
other steps which are all endothermic.
 Reduction: The solid and gaseous products from the oxidation and
pyrolysis are mixed and react together to form more syngas.
Flow Sheet
Mole Flows
Methanol in Product Stream 2377.6 kmol/hr
Mass Flows
Methanol in Product Stream 76183.4 kg/hr
Mass Flows For Profit Calculation
Methanol in Product Stream 667 ktonne/oper-year
Energy Balance
Reactor
 RStoich module.
 Reactor Temperature 280 C and Duty 28.3 MW
 Energy Balance = 31431165.12 kcal/mol

Heat Exchanger
 It uses the hot effluents from the reactor to heat the inlet stream to
the reactor.
 Overall heat transfer coefficient U = 144 kcal/hr-sqm-K
 Area = 2157 sqm
 Hot inlet-Cold outlet Temperature Diff = 122 C
 Energy Balance = -536215963.9 kcal/mol
Separator
 The stream exiting the reactor contains a mixture of liquid and gas
containing inerts, which is separated in the Separator to remove
methane and nitrogen.
 The gas from the separator is compressed to 110 bar and recycled
to the reactor.
Flash Drum
 We used the flash tank to remove most of the lighter gaseous

components before feeding into the distillation column.
 If this stream were fed directly into the distillation column, these inert
components would build up in the condenser and blanket the
condenser.
 The flash tank is operated at 2 bar and -48.4 C
Mixers and Splitters
 Mixers are used at several places in the flow sheet to properly mix
one or more streams entering the reactor and separator.
 A splitter is used to separate the vent from the recycle stream, which
joins with the feed to enter the reactor.
 The recycle stream from the splitter is joined with the stream
containing the light components separated from the flash drum
which then is combined with the feed to be recycled back into the
reactor.
Distillation Column
 The liquid from the flash tank is pumped into a 42-stage distillation
column on stage 27.
 The column operates at 1 bar, Reflux ratio 0.407, Reboiler Duty 54.8
MW and Condensor Temperarure of 50 C
 Partial condenser is used.
 Energy Balance = 11349619.56 kcal/mol
Economic Analysis
Utility, Equipment Costs
Economic Potential
 883.5 Million USD/Year is around 17.5 Crore INR/Day
Economic Summary
 Total utilities cost (INR/Year) = 139.05 crores

 Total operating cost (INR/Year) = 159.13 crores
 Net Profit (first year of operation in INR) = 6230.81 crores
 Net Profit (after 1 year of operation in INR) = 6334.69 crores
 Net Profit (after 1 year of operation in INR) = 17.36 crore INR/Day
Key Shortcomings of Biomass
process
 Pyrolysis converts the biomass to liquid termed as bio-oil which is
used in engines and turbines. But the produced bio oil has a poor
thermal stability and is corrosive.
 Some of the long chain hydrocarbons are not easily broken down in
the pyrolysis process which decreases the conversion to bio-oil.
 To maximize the yield of liquid products resulting from biomass
pyrolysis, a low temperature, high heating rate, short gas residence
time process would be required.
 If the purpose were to maximize the yield of fuel gas resulting from
biomass pyrolysis, a high temperature, low heating rate, long gas
residence time process would be preferred
Environmental Impact
 Biofuels are a good alternative to petroleum fuels. They offer several
benefits to society and the environment.
 There are other challenges to using biomass such as pretreatment,
hydrolysis, microbial fermentation and fuel separation.
 The majority of biofuels are produced using syngas extruded from
agricultural feedstock or by converting starch into sugars primarily from
edible process.
 Soil contamination of biomass is considered as one of the biggest
challenges in biomass harvesting.
 Several other countries in the world have set their own targets to
replace petroleum fuels by biofuels due to the increasing pollution
caused by burning of crude oils.

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Methanol

ARAVIND BUDARAJU 2016A1PS0501G

 Coal Gasification: Catalytic conversion of hydrogen (H2) and carbon

 Gasification: The process of producing syngas from coal water and

 Energy Balance = 31431165.12 kcal/mol

 We used the flash tank to remove most of the lighter gaseous

 Total utilities cost (INR/Year) = 139.05 crores

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