17th September, 2019

Department of Chemical Engineering

Rijksuniversiteit, Groningen
Assignment #1
General Process Equipment 2019-2020
METHANOL PRODUCTION AND MANUFACTURING
Due date: 24th September

Dear Sir/Madam:

Methanol is widely used in the industry for the production of chemicals such as formaldehyde, acetic acid etc.
1000 tons/year of methanol is planned to be produced using hydrogen and carbon dioxide (Eqn.1) as raw materials.
Based on the proposed process diagram (Scheme 1), you are asked to design a Packed Bed Reactor (PBR) by using
given reaction kinetics (Table 1). Table 1 includes different kind of kinetics based on the type of the catalysts. You are
asked to use kinetics and design the PBR reactor for each given catalyst type. Reaction rate is power law (Eqn 2). Thus,
it can be directly integrated to the ASPEN without further adjustment. The properties of the catalyst are given at Table 2.
The purpose is to compare the effect of type of catalyst on the production of methanol. The comparison can be done
based on the amount of the catalyst required for the asked production rate of methanol. (Hint; As the activity of catalysts
changes it will affect reactor dimensions leading to higher cost etc. So, you can roughly make comparison based on the
reactor dimensions and amount of the catalyst required.)

𝐶𝑂2 + 3𝐻2 ↔ 𝐶𝐻3 𝑂𝐻 + 𝐻2 𝑂 𝐸𝑞𝑛. 1

We would like to design methanol synthesis reactor based on the following information:
1. The flow rates of the raw materials are based on the stoichiometry of the reaction.
Inlet conditions: Pressure 50 bar, Temperature: 170 C.
2. Assume there is no pressure drop in the reactor and pipes.
3. Assume the reactor operates isothermal.
4. As the reaction is reversible, specify the reversibility at reaction configuration of ASPEN and select the option
of Equilibrium Compute Keq from Gibbs Energies.
5. Reactor Dimensions: consider (|Length/Diameter) L/D is between 5-8.

𝐸
𝑟𝑀 = 𝐴𝑒𝑥𝑝 (− ) 𝑝𝑚 𝑝𝑛 𝐸𝑞𝑛(2)
𝑅𝑇 𝐶𝑂2 𝐻2
Table 1. Kinetic data for methanol production
Catalyst A E m n
Mol/(gcat.h.barm+n) kJ/mol
TMC-3/1 1.11*102 43 0.31 1.17
Cu/Zn/Al/Mg/1 4.91*101 43.4 0.52 1.34

Recycle

Methanol

H2 Plug Methanol/Water Sep.

Reactor Sep.
CO2

Scheme 1. Block diagram of methanol production

Water
 Page 2 November 11, 2019

Table 2. Properties of catalysts

The following information should be available in your report:

1. Format (Cover Page, Abstract, List of Table/Figure, Outline etc) 5 points
2. Abstract (write a coincide abstract indicating objective, dramatic result of your simulation) 5 points
3. Introduction (substance properties, MeOH, CO2, H2 etc), give information regarding to the property package
that you select, market of methanol, production technologies of methanol, 10 points
SRK used because methods assi
tant said that this would be ideal for given conditions (high pressure, temperature chemical system)
4. Methodology and sample calculation (Which features of ASPEN did you use, show your steps, show in details
which parameters you used in the simulation, make sample mass balance calculation. 15 points

5. Results and Discussion parts (60 points)

 Show your design specifications, dimensions of the reactor, the amount of the catalyst
loaded, graphical representation of results is highly appreciated.
 What is the achieved conversion and yield values? (Introduce Stream Table)
 Compare the results obtained for each catalyst and select the best catalyst for
methanol production. Clearly explain which output is the selection criteria for catalyst.
 Introduce sensitivity analysis to your system. Clearly state why do you need sensitivity
analysis and in which section in your design you introduce.
How the pressure will effect the composition of ethanol and CO2 in the

6. Conclusion (5 points)

7. Bonus (10 points)

Investigate the pressure drop effect on the design of the reactor for one type of catalyst, compare the
results without pressure drop simulation.

If there is missing information required in the simulation environment (ASPEN), you should clearly state the chosen
input data by supplying relevant references.
We expect a report (maximum 15 pages; including figures, data, a list of references and appendices). If you have
questions, please feel free to contact with TAs. The contact information of TAs is available at Nestor.

Hand in your report as Hard Copy to TAs in the computer practice of 24th September. As an alternative you can hand
to mail box (O. Akin, building 18 second floor, 5118). Delayed reports (5 points/day of delay)

The possibility of uploading reports to NESTOR will be announced.

Best regards,

Dr. Okan Akin