(583b) Design and Intensification of Sorption-Enhanced Reaction Processes for Methanol Production
The objective of this work is to counter currently-existing process inefficiencies by enhancing single-pass reaction conversions and preventing catalyst deactivation. To this end, we apply the sorption enhanced reaction process (SERP) concept for designing a periodic sorption-enhanced methanol synthesis (SE-MeOH) process from syngas; in-situ removal of water byproduct favorably shifts the equilibrium towards enhanced methanol synthesis in accordance with the Le Chatelierâs principle. For capturing the dynamics of the SE-MeOH process, we use the generalized adsorption-reaction modeling and simulation (GRAMS) platform. GRAMS is based on a one-dimensional, pseudo-homogeneous, non-isothermal, non-adiabatic, and non-isobaric NAPDE-based model, and has been extensively validated with experimental data for several SERP case studies . GRAMS is coupled with an in-house simulation-based constrained grey-box optimizer for optimizing SE-MeOH process cycle configuration, design parameters and operating conditions . We obtain single-pass carbon conversions as high as 80% in the Lurgi-type Methanol reactor via SE-MeOH with production capacity exceeding 109500 tons/yr, which is the typical capacity of an industrial plant . The developed SE-MeOH process has smaller carbon footprint, enhanced product quality, and smaller reactor, condenser and recompressor size leading to significant savings in energy consumption and process economics. This presentation also covers the integration of the developed SE-MeOH process with a steam methane reforming reactor unit for converting natural gas to methanol via syngas route.
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