Ici Methanol

MANUFACTURE OF METHANOL
A Project Report submitted in the partial fulfilment of the

Requirements for the award of degree of
BACHELOR OF TECHNOLOGY
IN
CHEMICAL ENGINEERING
By
P. SAI PRANAV P. ANIL KUMAR P. RAJESH
(Regd. No 314106202028) (Regd. No 314106202029) (Regd.No314106202030)
P. RAVI KIRAN P.S. KEDARNATH

(Regd. No 314106202032) (Regd. No 314106202033)
Under the guidance of
Prof. K.V. RAMESH
DEPARTMENT OF CHEMICAL ENGINEERING,
ANDHRA UNIVERSITY COLLEGE OF ENGINEERING (A)
ANDHRA UNIVERSITY
VISAKHAPATNAM
2018
CERTIFICATE
This is to certify that the project report entitled “MANUFACTURE OF

METHANOL” has been prepared by P. SAI PRANAV, P. RAJESH
KUMAR, P. ANIL KUMAR, P. RAVI KIRAN, P.S. KEDARNATH under
my guidance in partial fulfilment of the requirements for the award of
Bachelor of Technology in Chemical Engineering, Andhra University,
Visakhapatnam.
(K.V. RAMESH)
Project Guide
ACKNOWLEDGEMENT
We wish to express our thanks to Prof. K. V. RAMESH,

Department of chemical Engineering, Andhra University for his guidance
and encouragement for the completion of this project report.
We express our sincere thanks to PROF. S. V.

NAIDU, Head of the department and support given in bringing out this
project successfully.
Our thanks to all the staff members of the department of

Chemical Engineering for the assistance offered in bringing out this
project report successfully.
P SAI PRANAV
P RAJESH
P ANIL KUMAR
P RAVI KIRAN
P S KEDARNATH
PROBLEM STATEMENT
To Prepare a preliminary project report for the Manufacture of

Methanol from Natural gas using ICI LCM project with a
capacity of 30,000 tonnes per annum.
CONTENTS
S.NO TOPIC PG.NO
1. Introduction 1
2. Properties 5
3. Applications and Uses 9
4. Various commercial Processes
and Process selection 15&31
5. Material Balance 32
6. Energy Balance 38
7. Design of the reactor 48
8. Cost Estimation 62
9. Plant Location 66
10. Plant Layout 70
11. Bibliography 76
CHAPTER – I
INTRODUCTION
INTRODUCTION
Chemicals are a part of every aspect of human life, right from the food
we eat to the clothes we wear to the cars we drive. Chemical industry
contributes significantly to improving the quality of life through
breakthrough innovations enabling pure drinking water, faster medical
treatment, stronger homes and greener fuels. The chemical industry is
critical for the economic development of any country, providing products
and enabling technical solutions in virtually all sectors of the economy.
Methanol, also known as methyl alcohol among others, is a chemical

with a formula CH3OH (often abbreviated as MeOH). Methanol acquired
the name wood alcohol because it was once produced chiefly by
destructive distillation of wood. Today Methanol is mainly industrially
produced by hydrogenation of carbon monoxide.
Methanol is the simplest alcohol consisting of methyl group linked to

hydroxyl group. It is a light, volatile, colourless, flammable liquid with a
distinctive odour similar to that of ethanol. Methanol is however far more
toxic than ethanol. At room temperature, it is a polar liquid. With more
than 20 million tons produced annually, it is used as a precursor to other
commodity chemical, including formaldehyde, acetic acid as well as a
host of more specialized chemicals.
Methanol is a very versatile chemical primarily produced in India from

natural gas and naptha. Alternative routes for production of methanol are
coal and pet coke. Coal and Pet coke route is however not yet
commercialized. Current Methanol consumption is 1.5 million tonnes.
The demand is growing at 10% and is expected to continue to be met
through imports. The two major end use segments for methanol are
chemical and energy. In the chemical segment, methanol is used for
production of formaldehyde, acetic acid, di-methyl terephthalate (DMT)
and a range of solvents. The consumption of methanol in the energy
segment is substantial as blending component for petrol and methyl
tertiary ether (MTBE), tertiary amyl methyl ether (TAME) and di-methyl
ether (DME). In the India, the usage pattern for methanol has remained
unchanged over a period of time formaldehyde sector, the industry
1
estimates that current demand growth of 10% would be sustained with
relatively higher growth in the energy segment. It is estimated that by the
end of XIIth five-year plan period, demand of methanol would reach 2.5
million tonnes thus providing substantial opportunities for domestic
industry in this sector. The current production capacity in the country is
0.385 million tonnes thereby creating gap of 2.115 million tonnes which
would primarily met through imports from Middle East and China.
Investment opportunity exists for a world scale capacity of over 2 million
tonnes.
Sectoral usage of methanol(%)
Formaldhehyde
MTBE
Pharma
DMT
Acetic acid
Others
India is a large importer of Methanol. Due to insufficient domestic

production, in FY09 the net import of methanol was 1.06 million tonnes
i.e. more than 4 times the domestic production of 0.24 million tonnes.
Imports have grown from 0.5 million tonnes in FY07 to 0.8 million tonnes
in FY10.
2
HISTORY
The ancient Egyptians used a mixture of substances including methanol
which they obtained from pyrolysis of wood. Pure methanol, however
was first isolated in 1661 by Robert Boyle, when he produced via
distillation of boxwood. In 1834, the French chemists Jean-Baptiste
Dumas and Eugene Peligot determined its elemental composition.
In 1923, the German chemists Alwin Mittasch and Mathias Pier, working
for Badische-Anilin & Soda–Fabrik(BASF) developed a means to convert
synthesis gas into Methanol, the process used a chromium and
manganese oxide catalyst with extremely vigorous conditions, pressures
ranging from 50 – 220 atm and temperatures up to 450 centigrade.
Modern Methanol has been made more efficient through use of catalysts
capable of operating at lower pressures. The modern low-pressure
Methanol (MLP) was developed by ICI in the late 1960s with the
technology now owned by Johnson Matthey, which is a leading sponsor
of methanol technology. During world war II, Methanol was used as a
fuel in several German military rocket designs, under the name M- Stoff,
and in a roughly 50/50 mixture with Hydrazine, known as C - Stoff.
They also introduced the word “methylene” to organic chemistry, forming

it from Greek methyl =” alcoholic liquid “+hyle= “woodland, forest”, with a
Greek language error xylon =” wood as a material” would have been
more suitable. “Methylene” designated a radical that was about 14% of
hydrogen, so they gave a formula as CH. The term “methyl” was derived
in about 1840 by back-formation from “methylene” and was then applied
to describe “methyl alcohol”. This was shortened to “methanol” in 1892
by the International Conference on Chemical Nomenclature. The suffix –
yl used in organic chemistry to form names of carbon groups, was
extracted from the word “methyl”.
The use of Methanol as a motor fuel received attention during the oil
crises of the 1970s. By the mid -1990s over 20,000 methanol flexible
fuel vehicles capable of operating on methanol or gasoline were
introduced in the U.S. I n addition, low levels of methanol were blended
in gasoline fuels sold in Europe during much of the 1980s and early -
1990s. Automakers stopped building Methanol FFVs by the late-1990s,
switching their attention to ethanol-fuelled vehicles. While the methanol
3
FFV program was a technical success, rising methanol pricing in the
mid-to late-1990s during period of slumping gasoline pump prices
diminished the interest in methanol fuels.
In the 1960s-1980s methanol emerged as the precursor to acetic acid

and acetic anhydride. The process included the Monsanto acetic acid
synthesis, Cativa. In the early 1970s, a process was developed by Mobil
for producing gasoline fuel for vehicles.
4
CHAPTER- II
PROPERTIES
5
PROPERTIES
PHYSICAL PROPERTIES:
1. Molecular Formula = CH4O

2. Physical state = Colourless liquid
3. Molecular mass = 32.04 g mol-1
4. Melting point = -97.80 C
5. Boiling point = 64.70C at 760 mm Hg
6. Water solubility = Miscible
7. Density = 0.7915 g/cc
8. Vapour density at 1 atm, 1000C = 1.4
9. Vapour pressure = 126 mm Hg at 250C
10. Flash point = 120C
11. Henry’s law of constant = 4.55×106 atm m3 /mol
12. Magnetic susceptibility = -21.40×10-6cm3 /mol
13. Viscosity at 250C = 0.545 mPa.s
14. Dipole moment = 1.69D
6
CHEMICAL PROPERTIES:
1. Combustion of Methanol:
Methanol burns with a pale blue, non-luminous

flame to form carbon dioxide and steam.
2CH3OH+3O2 ---------> 2CO2 + 4H2O
2. Oxidation of Methanol:
Methanol is oxidised with acidified

Potassium Dichromate, K2Cr2O7, or with acidified Potassium
permanganate, KMnO4 to form formaldehyde.
CH3OH -------------> HCHO + H2
2H2 + O2 -----------> 2H2O
3. Catalyst Oxidation of Methanol:
The catalytic oxidation of methanol

using platinum wire is of interest as it is used in model air craft
engines to replace the sparking plug arrangement of conventional
petrol engine. The heat of reaction is sufficient to spark the engine.
4. Dehydration of methanol:
Methanol can also be oxidized to

formaldehyde by passing its vapour over copper heated to 300 C.
Two atoms of are eliminated from each molecule to form hydrogen
gas and hence this process is termed as dehydration.
Cu, 3000C
CH3OH ---------------> HCHO + H2
(Methanol) (Formaldehyde)
7
5. Esterification of Methanol:
Methanol reacts with organic acids to form esters.
CH3OH + HCOOH -------> HCOOH3 + H2O
6. Substitution of Methanol with sodium:
Methanol reacts with sodium at room

temperature to liberate hydrogen. This reaction is similar to the reaction
of sodium with ethanol.
2 CH3OH + 2 Na --------> 2 CH3ONa + H2
(Methanol) (Sodium) (Sodium Methoxide)
7. Substitution of Methanol with Phosphorus Pentoxide:
Methanol reacts with Phosphorus pentoxide

at room temperature to form hydrogen chloride, methyl chloride
and phophorylchloride.
CH3OH + PCL 5 -----------> HCL + CH3Cl + POCl3
8. Substitution of Methanol with Hydrogen Chloride:
Methanol reacts with hydrogen

chloride to form methyl chloride (i.e. Chloromethane) and water. A
dehydrating agent (e.g. Zinc Chloride) is used.
CH3OH + HCL ----------> CH3Cl + H2O
8
CHAPTER- III
APPLICATIONS AND USES
9
USES AND APPLICATIONS
APPLICATION
Methanol is primarily converted to formaldehyde, which is widely used in

many areas, especially polymers. The conversion entitles oxidation:
2CH3OH +O2  2 CH2O +2H20
Acetic acid is produced from methanol. Methanol and isobutene

combine to give methyl tert-butyl ether (MTBE). MTBE is major octane
booster in gasoline.
Condensation of methanol to produce hydrocarbons and even aromatic

systems is the basis of several technologies related to gas to liquids.
These include methanol-to-hydrocarbons (MTH), methanol to gasoline
(MTG) and methanol to olefins (MTO) and methanol to propylene (MTP).
These conversations are catalysed by Zeolites as heterogeneous
catalysts. The MTG process was once commercialized at Motunui in
New Zealand.
The European Fuel Quality Directive allows up to 3% methanol with an

equivalent amount of co solvent to be blended with gasoline sold in
Europe. China uses more than one billion gallons per year as
transportation fuel in low level blends for conventional vehicles and high-
level blends in vehicles designed for methanol fuels.
Methanol is the precursor to most simple methylamines, methyl halides,

methyl ethers. Methyl esters are produced from methanol, including the
transesterification of fats and production of biodiesel via
transesterification.
Methanol is a promising energy carrier because as a liquid, it is easier to

store than hydrogen and natural gas. Its energy density is however low
reflecting the fact that it represents partially combusted methane. Its
energy density is 15.6MJ/L whereas ethanol’s is 24 and of gasoline’s is
33 MJ/L. Further advantages of methanol are its ready biodegradability
and toxicity. It does not persist either in aerobic and anaerobic
environments. The half-life of methanol in groundwater is just one to
10
seven days, while many common gasoline components have half-lives in
hundreds of days. Since methanol is miscible with water and
biodegradable, it is unlikely to accumulate in groundwater, surface
water, air or soil.
Methanol is occasionally used to fuel internal combustion engines. It

burns forming carbon di-oxide and water.
2CH3OH + 3O2  2CO2 + 4H2O
One problem with high concentrations of methanol in fuel is that alcohol

corrodes some metals, particularly aluminium. Methanol fuel has been
proposed for ground transportation. The chief advantage of methanol
economy is that it could be adapted to gasoline internal combustion
engines with minimum modification to the engines and to the
infrastructure that delivers and stores liquid fuel. Its energy density is
however half that of gasoline, meaning that twice the volume of
methanol would be required.
Other Applications
Methanol is a traditional denaturant for ethanol, the product being known
as “denatured alcohol” or “methylated spirit”. This was commonly used
during the prohibition to discourage consumption of bootlegged liquor
and ended up causing several deaths. Methanol is used as a solvent
and antifreeze in pipelines and windshield washer fluid. Methanol was
used as an automobile coolant antifreeze in the early 1990s.
In some waste water treatments plants, a small amount of methanol is

added to wastewater to provide carbon food source for the denitrifying of
bacteria, which converts nitrates to nitrogen gas and reduce the
nitrification of sensitive aquifers. Methanol is used as a destaining agent
in polyacrylamide gel electrophoresis.
Methanol is also a widely used fuel in camping and boating stoves.

Methanol burns well in unpressurized burner, so alcohol stoves are often
very simple, sometimes little more than the cup to hold fuel. This lack of
complexity makes them a favourite of hikers who extended time in the
wilderness. Similarly, the alcohol can be gelled to reduce the risk leaking
or spilling, as with the brand “Sterno”. Methanol is mixed with water and
11
injected into high performance diesel and gasoline engines for an
increase of power and a decrease of intake air temperature in a process
known as water methanol injection.
USES
Methanol is primarily used as an industrial solvent for inks, resins,
adhesives and dyes. It is also used as a solvent in the manufacturing of
cholesterol, streptomycin, vitamins, hormones and other
pharmaceuticals. Methanol is also used as an antifreeze for automotive
radiators, an ingredient of gasoline (as an antifreezing agent and octane
booster) and as fuel for picnic stoves. Methanol is also an ingredient in
paint and varnish removers. It is also used as an alternative motor fuel.
Methanol is a toxic alcohol that is used industrially as a solvent,

pesticide, and alternative fuel source. It also occurs naturally in humans,
animals and plants. Foods such as fresh fruits and vegetables, fruit
juices, fermented beverages, and diet soft drinks containing aspartame
are the primary sources of methanol in the human body. Most methanol
poisonings occur as a result of drinking beverages contaminated with
methanol or from drinking methanol containing products. In the industrial
setting, inhalation of high concentrations of methanol vapour and
absorption of methanol through the skin are as effective as the oral route
in producing toxic effects.
Industry uses
A1. Adhesives and sealant chemicals
2. Adsorbents and absorbents

3. Agricultural chemicals
4. Anti – adhesive agents
5. Bleaching agents
6. Corrosion inhibitors and anti-scaling agents
12
7. Dyes
8. Fuels and fuel additives
9. Functional fluids (open systems)
10. Intermediates
11. Ion exchange agents
12. Laboratory chemicals
13. Odour agents
14. Oxidising agents and reducing agents
15. Paint additives and coating additives not described any
another category
16. Viscosity adjustors
17. Solvents (for cleaning or degreasing)
18. Process regulators
19. Processing aids, specific to Petroleum production
20. Solvents (which become art of product formulation or
mixture)
1. CONSUMER USES
 Automotive care products
 Agricultural products (non-pesticidal)
 Anti- freeze and De-icing products
 Building /Construction Materials

13
 Fabric, textile and leather products not covered elsewhere
 Fuels and related products
 Ink, Toner and colorant products
 Paints and Coatings
 Paper Products
 Plastic and rubber products
 Water treatment products
14
CHAPTER-IV
VARIOUS COMMERCIAL
PROCESSES
15
VARIOUS COMMERCIAL PROCESSES
1. CPL –VULCAN PROCESS:
Gaseous hydrocarbon feed stock is initially

processed by catalytic or adsorptive means to remove sulphur
impurities. The cleansed feed stock, along with steam and
carbon dioxide, are brought to reformer pressure and
catalytically reacted at elevated temperature to produce
synthesis gas containing hydrogen and varying proportions of
carbon dioxide. Carbon- hydrogen ratios are adjusted to
optimum levels prior to reforming. Fuel gas and process purge
gas are used for reformer thermal requirements. Thermal
energy in the resulting flue gas is effectively recovered in a
series of exchangers for the production of high pressure super-
heated steam and boiler feed water heating. Cooled flue gas is
discharged to atmosphere. Synthesis gas is likewise used in
boiler feed water heating and the production of steam. Plant
turbine drive requirements of synthesis gas compression use
high pressure and recycle gases boosts gas pressure to loop
design levels prior to entering multistage methanol convertor. A
unique converter control concepts permits optimum thermal
sensing and temperature control over narrow spans of
individual catalytic beds that effectively promote reaction
resulting high methanol yields and minimum by product
formation. Development of a high activity methanol catalyst
permits operation at significantly low pressures than ordinarily
encountered in comparable units.
Gas leaving the converter gives up its

exothermic heat of reaction to pre heating incoming synthesis
gas. Additional cooling promotes condensation non-
condensable and crude methanol enters separators at loop
pressures, where the unreacted gases stripped off and return to
compression. Crude methanol is then let down in pressure prior
to entering the purification section. Crude methanol is refined by
distillation, A “heads” fractioner and rectifying column are
16
employed in producing high purity methanol. Light ends stripped
off in the process are returned to reformer furnace for fuel.
Methanol products flows through a cooler exchanger and is
then sent to storage.
17
––
18
2. UKW HIGH PRESSURE PROCESS:
In this process, synthesis gas, after compression and removal

of any iron Penta carbonyl in activated carbon absorber, is
charged together with recycled gas at about 300 atm to reactor,
which contains several catalyst beds. Quench gas at is
introduced between the catalyst beds to maintain a temperature
of about 350 centigrade. The Methanol-bearing gas leaving the
reactor is cooled with recycle gas exchanger and finally with air
or water. The condensed crude Methanol is separated from the
gas, being recycled to the reactor. Inerts are removed by
continuous purge of the recycle upstream of the recycle
compressor.
The crude Methanol from the separator, after degassing, is

sent to the Distillation unit for processing to pure methanol.
Dimethyl ether, methyl formate and low boiling impurities are
removed in the low boiler column. While water and higher
alcohols are removed in the high boiler column.
19
20
3. HALDOR-TORPOSE HIGH PRESSURE PROCESS:
In the manufacture of methanol by this

process the loop pressure is around 275-300Kg/cm2 and a catalyst
temperature of 4000C with a space velocity of 30000. The gas is
compressed to operating pressure and is mixed with unconverted
recycled synthesis gas, filtered and is then passed through Zinc-
Chromite catalyst. The effluents from the converter are cooled.
Crude methanol from the separator enters the let-down tank

where methanol pressure is released.
Crude methanol is further processed by extractive distillation

with water followed by concentration and refining. The crude
methanol is fed to an extraction column with water where low
boiling impurities are separated out from the top. Dilute methanol
is introduced to methanol finishing column where impure methanol
is separated out as overhead product from the column and tails
containing higher alcohols and water are drawn as side streams
which are further processed in a tail column to separate high
boiling components from methanol. Methanol extracted from tail
column is recycled to extraction column, where it is re processed
with the main stream.
21
HALDOR TORPOSE PROCESS
22
4. ICI LOW PRESSURE PROCESS
(Steam Reforming Application) The hydrogen

feedstock is desulfurized by catalytic or absorptive process, mixed
with process steam and passed forward to a tubular reformer. The
reformed gas leaves the tubes at 80 to 850C before passing to the
heat recovery section. After cooling to ambient temperature, it is
compressed by a turbine driven centrifugal compressor to a
pressure between 50 to 10 atm. The synthesis gas is added to the
synthesis loop, which comprises the following items: circulator,
convertor, heat exchanger, heat recovery exchanger, cooler, and
separator. The crude product is distilled in two or three columns.
Main features of the process are a high stable copper-based

methanol synthesis catalyst, simple converter design and heat
recovery and an optimised distillation system catalyst operates in
the pressure range 50 to 100 atm at 200 to 300C and has age of
up to four/five years. The convertor is a pressure vessel containing
a single bed of catalyst. The reaction is quenched at several levels
by cold gas injected through specially designed spargers. Catalyst
can be loaded through top of the convertor and discharged at the
base in a matter of hours. Reaction heat is recovered from the
convertor effluent to preheat the high-pressure boiler feed water.
(Partial Oxidation Application) Heavy fuel oil or coal is partially

oxidised by oxygen and steam. The product gas containing largely
hydrogen and CO. together with some CO2 and trace impurities is
treated to remove sulphur compounds and adjusted to the
optimum ratio of hydrogen to carbon monoxides. Partial oxidation
processes can operate at intermediate pressures such that no
further compression is required before the synthesis gas passes
forward to the synthesis loop.
23
24
5. FOSTER WHEELER PROCESS:
To prevent poisoning of the reformer catalyst,

all sulphur must be removed from the natural gas feed by
adsorption by activated carbon or by any other means. The heat of
reaction is supplied by combustion of natural gas or other fuels.
The waste heat is used to generate process steam. When
supplemental steam is not available for start-up, this steam can be
supplied by burning additional fuel in the reformer furnace. The
quantities of natural gas, steam, carbon dioxide in the feed to the
reformer are carefully controlled to assure the correct proportion of
hydrogen, carbon monoxide and carbon dioxide in the methanol
synthesis gas. The reformer product gas, consisting of hydrogen,
carbon monoxide, carbon dioxide, and steam is cooled in a waste
heat boiler, it passes to a boiler feed-water heater, and then into
heat exchanger where it is cooled to 1050F the steam condensed
and separated. The cooled gas is now delivered to the synthesis
gas compressor ready for conversion.
The synthesis gas is compressed to 4300 psi, cooled and

combined with unconverted recycle gas from methanol recycle
compressor and all compressed water and entrained oil removed
before it enters the Casale Converter.
The synthesis gas is preheated to reaction temperature by heat

exchange with product gas of Casale Converter. The preheated
gas flows down through the catalyst bed where the exothermic
methanol synthesis reaction takes place quench gas produced at
several points between catalyst bed to optimise the reaction
temperature profile.
After synthesis, the crude methanol is condensed and separated

from the unreacted gas stream. The unreacted gas (composed of
25
hydrogen, carbon dioxide, carbon monoxide, methane, nitrogen) is
recycled by continuous proportion of recycle stream.
When the crude liquid methanol pressure is reduced to 65 psi,

dissolved gases are released and combined with high pressure
purge. These are scrubbed with water and any flashed methanol is
removed. The scrubbed gas is directed into the plant fuel system.
Crude methanol may be purified by extractive distillation or
fractional distillation to the purity desired.
26
27
6. LURGI LOW PRESSURE PROCESS:
Hydrocarbons methane to naphtha is desulfurized,

mixed with steam and reformed at 830-850 C to synthesis gas
containing hydrogen and carbon dioxides. If feedstock with low
molecular weight is used, it may be economic to add CO2 to avoid
loop hydrogen build up. High pressure steam is generated by the
waste heat of flue gas and synthesis gas. Together with the steam
raised in the synthesis reactor, it is used to power gas
compression, at intermediate pressure for reforming and at low
pressure for methanol distillation.
The synthesis gas containing

approximately 8-9%CO2, 20-21%CO, 69%H2 AND 1.5-2.0% CH4
and N2 (molar basis) is compressed to 50-60 atm, together with the
recycle gas in a centrifugal compressor, preheated, and charge to
the reactor. After cooling to 250 C the gas is supplied without
further treatment to the methanol synthesis section.
In the shell and tube reactor, the tubes are

filled with copper-based catalyst and shell side filled with boiling
water. Reaction temperature (between 230-250 C) is controlled by
the boiling water steam pressure.
The reactions occurring to appreciable extent are:
CO + 2H2 ------------> CH3OH +21684 Cal
CO2 + 3 H2----------> CH3OH + H2O + 11830 Cal
2CO + 4H2 ----------> CH3OCH3 + H2O
2CO +4H2------------> C2H5OH + H2O
2CO +2H2------------> HCOOCH3
28
Good reaction heat transfer to the boiling water gives the
conversion per pass around 10-25% and protects the catalyst even
at abnormal operation conditions. The product gases are cooled
and methanol is condensed and removed in a separator while the
gas is recycled to compressor. A small portion of gas is purged
and used as hydrogenation gas for desulfurization or as fuel.
Crude Methanol from the separator containing about 70% of

methanol in water and higher alcohols is processed further by
stripping with steam followed by preheating and refining in the
distillation column. In the stripping section the low boiling impurities
such as Di-methyl ether, Methyl- Formate are removed from the
top. The bottoms of the finishing column where in pure Methanol is
distilled bottoms. Pure Methanol (99.95%) from the finishing
column is cooled, condensed and pumped to storage for
distribution.
29
30
SELECTION OF PROCESS
A conventional high-pressure process has always been used in the

production of methanol. Inspite of the high conversion obtained in this
process the low-pressure synthesis of methanol is gaining importance in
the record times. This is mainly due to the fact that the total cost of low-
pressure methanol production process is reduced by appreciable
amounts as compared to high-pressure process. The main advantages
of this process can be summarized as follows
 The substantial decrease in power requirement for synthesis gas

compression associated with compressor synthesis is probably
the most important factor in comparing utilization of this concept
with previous economics dictates.
 The by-product formation over the catalyst is minimized as a
result of lower operating temperatures and pressures and a very
high purity methanol is obtained. This leads to an overall increase
in process material efficiencies.
 Reduced reformer and compression installation costs and use of
low-pressure equipment in synthesis loop giving lower capital
costs.
 Reduced compressor maintenance requirements and a simple
converter design which allows rapid catalyst replacement
increasing on stream line.
 The process parameters available allow relatively low
temperatures and pressures which facilitates the usage of
standard equipment and standard materials of construction.
Hence, the ICI LCM (Leading Concept Methanol) low pressure

process is selected for further calculations and design.
31
CHAPTER-V
MATERIAL BALANCE
32
MATERIAL BALANCE
Composition of Natural Gas:
Component Mole fraction
Methane 0.90
Ethane 0.01
Propane 0.01
Hydrogen Sulphide 0.08
BASIS: 3290 Kmoles/Day of Natural Gas
Component Weight
Methane 47368 Kg
Ethane 988 Kg
Propane 1447 Kg
Hydrogen Sulphide 8947 Kg
TOTAL 58750 KG
This 58750 Kg of Natural Gas yields us 100Ton of Methanol per day

which is our target.
33
The Material Balance is applied to the following equipments :
1) Purifier (H2S Recovery)

2) Gas Heated Reformer (Primary Reformer)
3) Secondary Reformer
4) Steam and Hydrogen Recovery Unit
5) Methanol Converter
6) Loop Catchpot
Balance around Purifier:
Compound Entering Leaving

Methane 47368 47368
Ethane 988 988
Propane 1447 1447
Hydrogen Sulphide 8947 -
Total 58750 49803
It is assumed that 100% purification of H2S is taking place in the Purifier

and hence the total amount of H2S is retained in the Purifier.
34
Balance around Gas Heated Reformer (Primary Reformer):

Methane 47368 11842
Ethane 988 -
Propane 1447 -
Steam 163421 120493
Carbon Monoxide - 66776
Hydrogen - 14112
Total 213224 213223
It is assumed that the Primary Reformer converts the input Methane by

75% and input Ethane and Propane by 100%. Also, we send an excess
amount of steam (for 1mole of Methane we inject 3 moles of steam) to
Primary Reformer so as to avoid any side reactions and therefore
excess steam should be recovered.
Balance around Secondary Reformer:

Methane 11842 -
Oxygen 11842 -
Steam 120493 120493
Carbon Monoxide 66776 87500
Hydrogen 14112 17072
Total 225065 225065
35
It is assumed that in the Secondary Reformer, the remaining Methane
gas is further converted to 100% Carbon Monoxide and Hydrogen. So,
this Reformer is assumed to be 100% efficient.
Balance around Steam and H2 Recovery Unit:

Steam 120493 -
Total 225065 100000
In this Unit, the excess Steam and Hydrogen are recovered so that the
inlet to Methanol Converter is in perfect Stoichiometric Ratio.
Balance around Methanol Converter:

Methanol - 100000
Total 200000 200000
The Methanol converter is assumed to have 50% efficiency. It is also to

be noted that this converter is employed with a recycle stream. So, the
inputs are doubled so as to meet the daily production requirement.
36
Balance around Loop Catchpot:

Methanol 100000 100000
Total 200000 200000
The Loop Catchpot is merely a separator where Carbon monoxide+

Hydrogen and Methanol are separated. Separated methanol is extracted
as crude methanol. Here this unit is assumed to separate 100% of the
mixture.
37
CHAPTER – VI
ENERGY BALANCE
38
ENERGY BALANCE
Calculation of Heat of Reactions:
1) CO+ 2H2–––––––––––––––> CH3OH
ΔHR= (ΔHF) prds– (ΔHF) react
= -20060-(-110525)
= -90135 J/mol
= -90.135 KJ/mol.
2) CH4 + H2O ––––––––––––––> CO + 3H2
= 205.813 KJ/mol.
3) C2H6 + 2H2O ––––––––––––––> 2CO + 5H2
= 346.406 KJ/mol.
4) C3H8 + 3H2O ––––––––––––––> 3CO + 7H2

ΔHR = (ΔHF) prds – (ΔHF) react
= 498.559 KJ/mol.
5) CH4 + ½ O2 –––––––––––––––> CO + 2H2
= -36.005 KJ/mol.
39
Model calculation:
Heat released or absorbed = mCpmΔT
m = Mass of the compound

Cpm =Average specific heat calculated at Entering/Leaving and
250C.
ΔT = Corresponding Temperature Difference.
THE GENERAL ENERGY BALANCE EQUATION IS:
ΔHINPUT + ΔHGEN = ΔHOUTPUT + ΔHREMOVED
1) For Heat Exchangers the heat generation term is Zero.

2) For any chemical reaction, the heat generated term
corresponds to heat of reaction at 298K.
Units Involved in Energy Balance:
1) Compressor
2) Heat Exchanger
3) G.H.R Preheater
4) Primary Reformer
5) Secondary Reformer
6) G.H.R Preheater
7) Heat Exchanger
8) Interchanger
9) Methanol Converter
10) Heat Exchanger
11) Interchanger
12) Loop Cooler
Here ΔHREMOVED is taken as simply ΔH.
40
1) Energy Balance for Compressor:
Inlet Temperature : 298K

Outlet Temperature : 881K
Compound Inlet Enthalpy(GJ) Outlet Enthalpy(GJ)
Methane 0 89
Ethane 0 2
Propane 0 2
Hydrogen Sulphide 0 6
Total 0 99
ΔH= -99 GJ
2) Energy Balance for Heat Exchanger

Methane 89 21
Ethane 2 0.4
Propane 2 0.5
Hydrogen Sulphide 6 1.6
Total 99 23.5
ΔH= 75.5 GJ
3) Energy Balance for G.H.R Preheater:

41
Methane 21 69.5
Ethane 0.4 1.2
Propane 0.5 1.8
Total 21.9 72.5
ΔH = -50.6 GJ
4) Energy Balance for Primary Reformer

Methane 69.5 35.8
Ethane 1.2 -
Propane 1.8 -
Steam 153.8 207.7
Carbon Monoxide - 61.6
Hydrogen - 172.5
Total 226.3 477
ΔHGEN = 2.506 GJ
42
ΔH = -251.3 GJ
5) Energy Balance for Secondary Reformer:

Methane 36 -
Steam 207.7 251.2
Carbon Monoxide 61.5 96.5
Hydrogen 172.5 247.5
Oxygen 10 -
Total 488 595.2
ΔHGEN = -0.0266 GJ
ΔH = -107.8 GJ
6) Energy Balance for G.H.R Preheater:

43
Steam 251.2 118.5
Hydrogen 247.8 122.3
Total 595.6 288.1
ΔH = 307.5 GJ
7) Energy Balance for Heat Exchanger:

Steam 118.5 40
Hydrogen 122.2 42.4
Total 288 98.7
ΔH = 189.3 GJ
44
8) Energy Balance for Interchanger:

Carbon Monoxide 16.3 18
Hydrogen 31 34
Total 47.3 52
ΔH = -4.7 GJ
9) Energy Balance for Methanol Converter:

Hydrogen 68 40
Methanol - 38
Total 104 99
ΔHGEN = -0.3 GJ
ΔH = -5 GJ
45
10) Energy Balance for Heat Exchanger:

Hydrogen 40 36
Methanol 38 35
Total 99 90
ΔH = 9 GJ
11) Energy Balance for Interchanger:
Carbon Monoxide 19 11.7
Hydrogen 36.5 22
Methanol 35 20
Total 90.5 53.7
ΔH = 36.8 GJ
46
12) Energy Balance for Loop Cooler:
Hydrogen 22 2.6
Methanol 20 4.3
Total 53.7 8.3
ΔH = 45.4 GJ
47
CHAPTER – VII
RAEACTOR DESIGN
48
REACTOR DESIGN
The reactor designed in this project is an Adiabatic Continuous Plug

Flow Reactor.
To design this, we need the kinetics of the reaction.
DATA:
For the systems where synthesis gas is composed of only CO and H2,
the following rate equation was proposed for the hydrogenation of CO
over a Cu/ZnO on alumina catalyst for a temperature range of 450-650K
and pressures 50-100 bar.
CO + 2H2 ––––––––––––> CH3OH
𝑃𝐶𝐻3𝑂𝐻
r = k (PCOP2H2 – ) (mol/kg-cat min)
𝑘𝑒
k = 743.198 exp (-80000/RT) mol (kgcat)-1min-1atm-3
ke = 3.567X10-12 exp (90.13KJ mol-1/ RT) atm-2
The catalytic packed bed bulk density was given as 1120 Kg m-3.
OPERATING CONDITIONS:
1) The methanol converter has an efficiency of 50% and is operated

at 100 atm pressure.
2) The operating temperature is in between 490K and 521K
49
Preliminary Calculations:
Let the component CO be designated as A, H2 as B and CH3OH as C.
The feed composition is 33.33% CO and 66.67 H2.
In the rate equation, we have partial pressure terms for each

component. We can convert this in terms of total pressure of the reactor
by Dalton’s Law.
So,
PCO = yCO × PT
The mole fraction can be linked to flow rates of the input components.
yCO = FCO/FT
FT = FCO+FH2 = FA0+FB0.
For gas phase reactions,
𝐶𝐴0 (1–𝑋𝐴 )𝑉0

FA =
1+∈𝑋𝐴
𝐶𝐵0 (1–𝑋𝐴 )𝑉0

FB =
1+∈𝑋𝐴
𝐶𝐴0 (𝑋𝐴 )𝑉0

FC =
1+∈𝑋𝐴
We have,
𝐹𝐴 𝑃𝑇
PA =
𝐹𝑇
𝐹𝐵 𝑃𝑇
PB =
𝐹𝑇
𝐹C 𝑃𝑇
PC =
𝐹𝑇
50
So,
CA0 = 33.33% and CB0 = 66.67%
𝐶𝐴0 (1–𝑋𝐴 )𝑃𝑇 (1–𝑋𝐴 )𝑃𝑇 (1–𝑋𝐴 )𝑃𝑇

PA = = 𝐶 =
𝐶𝐴0 +𝐶𝐵0 –2𝐶𝐴0 𝑋𝐴 1+( 𝐵0 )−2𝑋𝐴 3−2𝑋𝐴
𝐶𝐴0
Similarly,
(2−2𝑋𝐴 )𝑃𝑇
PB =
(3−2𝑋𝐴 )
𝑋𝐴 ×𝑃𝑇
PC =
(3–2𝑋𝐴 )
Substituting these partial pressure terms in rate expression we get:
(1–𝑋𝐴 )(2−𝑋𝐴)3 𝑃𝑇 3 𝑋𝐴 𝑃𝑇
r=k[ – ]
(3−2𝑋𝐴 )3 𝐾𝑒 (3−2𝑋𝐴)
The performance equation for Plug Flow Reactor is:
𝑉 𝑋
= ∫0 𝐴 𝑑 𝑋𝐴 /(−𝑟𝑎 )
𝐹𝐴0
For the methanol synthesis, adiabatic conditions favour the product

formation. So, an Adiabatic reactor is used. Here we incorporate a series
of 5 PFRs in order to achieve 50% conversion.
We have FA0 = 6250Kmol/day = 4.34027778 Kmol/min. (Based on

material balance)
51
Energy Balance:
Inlet stream : FCO, FH2

Outlet stream: F CH3OH, FCO, FH2
General energy balance equation

𝑇𝑟𝑒𝑓 𝑇𝑜𝑢𝑡
∫𝑇𝑒𝑛𝑡 ∑ Fi Cpi dT +∫𝑇𝑟𝑒𝑓 ∑ Fi Cpi dT – QRemoved = (–ΔHRFA0XA)
In an adiabatic process the term QRemoved = Zero.
Reactor volume calculations:

Energy balance for Reactor 1:
Tent = 490K (T0) and Tout= 650K (TF); Tref= 298K (TR)
𝑇𝑟𝑒𝑓 𝑇
∫𝑇 (𝐹𝐴0𝐶𝑃𝐴 + 𝐹𝐵0 𝐶𝑃𝐵 )𝑑𝑇 + ∫𝑇 𝑜𝑢𝑡(𝐹𝐴 𝐶𝑃𝐴 + 𝐹𝐵 𝐶𝑃𝐵 + 𝐹𝐶 𝐶𝑃𝐶 )𝑑𝑇
𝑒𝑛𝑡 𝑟𝑒𝑓
= (−𝛥𝐻𝑅 𝐹𝐴0 𝑋𝐴 )
(−𝛥𝐻𝑅 𝐹𝐴0 𝑋𝐴 )
𝑇𝑟𝑒𝑓
=∫ (𝐹𝐴0 𝐶𝑃𝐴 + 𝐹𝐵0 𝐶𝑃𝐵 )𝑑𝑇
𝑇𝑒𝑛𝑡
𝑇𝑜𝑢𝑡
+∫ (F𝐴0 C𝑃𝐴 − F𝐴0C𝑃𝐴 X𝐴1 ) + (F𝐵0 C𝑃𝐵 − 2F𝐴0 C𝑃𝐵 X𝐴1)dT
𝑇𝑟𝑒𝑓
𝑇𝑜𝑢𝑡
+ ∫𝑇𝑟𝑒𝑓 (F𝐴0 X𝐴1C𝑃𝐶 )𝑑𝑇
Heat of Reaction ΔHR = -90680J/mol
52
CP= R (A+BT+CT2+DT-2)
Taking thermodynamics data, and subjecting conversion factor we get
82.092(𝑇𝐹 –𝑇0 )+0.005824(𝑇𝐹 2 –𝑇0 2 )−13500(1⁄𝑇 –1⁄𝑇 )

𝐹 0
XA1=
90680+63.71(𝑇𝐹 –𝑇𝑅 )–0.4495(𝑇𝐹 2 –𝑇𝑅 2 )+9.56×106 (𝑇𝐹 3 –𝑇𝑅 3 )–13500(1⁄𝑇 –1⁄𝑇 )
𝐹 𝑅
TF XA KX106 Ke -ra 1/(-ra)

490 0 2.204 0.014456 0.32398 3.0866
500 0.009 3.264 0.009287 0.478 2.091
520 0.027 6.84 0.004034 0.984 1.016
540 0.0452 13.57 0.001864 1.90 0.5244
560 0.0625 25.63 0.000911 3.493 0.28627
580 0.08 46.35 0.00046739 6.148 0.16265
600 0.097 80.58 0.0002506 9.611 0.1040
620 0.1152 135.178 0.00014 13.610 0.0734
640 0.133 219.55 0.0000813 14.87 0.06725
650 0.14135 277 0.0000624 111.88 0.08415
Conversion achieved in 1st Reactor is 0.14135

Plotting a graph between XA and 1/ (-ra) we get the value of V1/FA0
So,
V1/FA0= 0.078
V1 = 0.078×4.34027778×103 Kg-cat = 338.541667 Kg-cat.
Let the void fraction be 0.5
Also given catalytic packed bed bulk density as 1120 Kg m-3.
53
Therefore, V1 = 338.541667/ (1-0.5) ×1120
= 0.604454 m3
= 604.454 lit.

𝑇 𝑇
∫𝑇 𝑟𝑒𝑓 (𝐹𝐴0𝐶𝑃𝐴 + 𝐹𝐵0 𝐶𝑃𝐵 )𝑑𝑇 + ∫𝑇 𝑜𝑢𝑡(𝐹𝐴 𝐶𝑃𝐴 + 𝐹𝐵 𝐶𝑃𝐵 + 𝐹𝐶 𝐶𝑃𝐶 )𝑑𝑇
Inlet : FA1, FB1, FC1

Outlet : FA2= FA0 (1–XA2)
FB2= FB0– 2FA0XA2
FC2= FA0XA2.
Substituting these values in the Energy Balance Equation and solving
XA2=
82.092(𝑇𝐹 –𝑇0 )+0.005824(𝑇𝐹 2 –𝑇0 2 )–112239(1⁄𝑇 –1⁄𝑇 )–[63.71(𝑇𝐹–𝑇0 )–0.4495(𝑇𝐹 2 –𝑇0 2 )+9.56×106 (𝑇𝐹 3 –𝑇0 3 )
𝐹 0
−112239(1⁄𝑇 –1⁄𝑇 )]𝑋𝐴1
𝐹 0
90680+63.71(𝑇𝐹 –𝑇𝑅 )–0.4495(𝑇𝐹 2 –𝑇𝑅 2 )+9.56×106 (𝑇𝐹 3 –𝑇𝑅 3 )–112239(1⁄𝑇 –1⁄𝑇 )
𝐹 𝑅
54
495 0.14135 2.684 0.011576 0.3375 2.963
515 0.1695 5.71 0.0049454 0.687 1.455
525 0.175 8.15 0.003311 0.966 1.035
545 0.1963 16 0.00155 1.797 0.5565
565 0.215 29.83 0.000767 3.075 0.3252
585 0.231 53.41 0.000398 4.713 0.2121
605 0.249 92 0.000216 5.715 0.175
625 0.26657 153 0.0001268 2.5 0.4
Conversion achieved in 2nd Reactor is 0.26657

FA20= FA0 (1–XA1)
V2/FA20= 0.105
V2= 0.105×4.34 × (1–0.14135) × 1000
= 391.31185 Kg-catalyst
Let void fraction be 0.5
V2= 391.31185×1000/ (1-0.5) ×1120

= 698.77 lit
55

Outlet : FA3 = FA0 (1–XA3)
FB3 = FB0– 2FA0XA3
FC3 = FA0XA3
Substituting these values in the Energy Balance Equation, we get
XA3 =
𝐹 0
−112239(1⁄𝑇 –1⁄𝑇 )]𝑋𝐴2
𝐹 0
90680+63.71(𝑇𝐹 –𝑇𝑅 )–0.4495(𝑇 2 2
)+9.56×106 (𝑇 3 3
)–112239(1⁄𝑇 –1⁄𝑇 )
𝐹 –𝑇𝑅 𝐹 –𝑇𝑅 𝐹 𝑅
56
500 0.26657 3.26 0.0093 0.339 2.95
520 0.303 6.843 0.00404 0.653 1.53
540 0.32077 13.56 0.001866 1.198 0.8432
560 0.3385 25.63 0.0009111 1.957 0.51
580 0.356 46.35 0.00046739 2.59 0.386
600 0.37363 80.58 0.00025 1.6 0.626
Conversion achieved in 3rd Reactor is 0.37363
Plotting a graph between XA and 1/ (-ra) we get the value of V3/FA30.

FA30 = FA0 (1–XA2)
V3/FA30= 0.135
V3 = 0.135×4.34 × (1–0.26657) ×1000
= 429.744 Kg-catalyst.
V3 = 429.744×1000/ (1–0.5) ×1120
= 767.4 lit
57

FC4 = FA0XA4
XA4 =
𝐹 0
−112239(1⁄𝑇 –1⁄𝑇 )]𝑋𝐴3
𝐹 0
90680+63.71(𝑇𝐹 –𝑇𝑅 )–0.4495(𝑇𝐹 2 –𝑇𝑅 2 )+9.56×106 (𝑇𝐹 3 –𝑇𝑅 3 )–112239(1⁄𝑇 –1⁄𝑇 )
𝐹 𝑅
58
510 0.37363 4.755 0.006079 0.395 2.526
525 0.413 8.151 0.00331185 0.5938 1.684
545 0.431 15.97 0.00155 0.9947 1
565 0.45 29.83 0.000767 1.310 0.762
585 0.46688 53.41 0.00039838 0.6402 1.561
Conversion achieved in 4th Reactor is 0.46688

.
FA40 = FA0 (1–XA3)
V4/FA40= 0.1425
V4 = 0.1425×4.34 × (1–0.37363) ×1000

V4= 387.44×1000/ (1–0.5) ×1120
= 691.8 lit
59

FC5 = FA0XA5
XA5 =
𝐹 0
−112239(1⁄𝑇 –1⁄𝑇 )]𝑋𝐴4
𝐹 0
90680+63.71(𝑇𝐹 –𝑇𝑅 )–0.4495(𝑇𝐹 2 –𝑇𝑅 2 )+9.56×106 (𝑇𝐹 3 –𝑇𝑅 3 )–112239(1⁄𝑇 –1⁄𝑇 )
𝐹 𝑅
60
520 0.46688 6.834 0.00404 0.434 2.304
521 0.502 7.08 0.00388 0.393 2.54
Conversion achieved in 5th Reactor is 0.502

.
FA50 = FA0 (1–XA4)
V5/FA50= 0.085
V5 = 0.085×4.34 × (1–0.46688) ×1000

V5= 196.68×1000/ (1–0.5) ×1120
= 351.215 lit
Total Volume of Reactors = 604.454+698.77+767.4+691.8+351.215

= 3113.64 lit.
61
CHAPTER –VIII
COST ESTIMATION
62
COST ESTIMATION
PURCHASED COST OF EQUIPMENT:
1. Natural gas compressor and circulator = 24000$
2. Purifier = 50000$
3. Columns (5) = 150000$
4. Heat Exchangers (6) = 360000$
5. Methanol Converter = 750000$
TOTAL PURCHASED COST OF EQUIPMENT = 1334000$
Direct Costs:
1. Purchased equipment cost = 626980$
2. Instrumentation and Control = 240120$
3. Piping = 880440$
4. Electrical installation = 146740$
5. Building and Auxiliaries = 240120$

63
6. Yard improvement = 133400$
7. Service facilities = 933800$
8. Land = 80040$
Total Direct Cost = 4615640$
Indirect costs:
1. Engineering and supervision = 440220$
2. Construction expenses = 546940$
3. Total direct and indirect plant cost = 280140$
Contractor’s fee about 5%
4. Contingencies = 5602804
5. Fixed capital investment = 6443220$
6. Working capital = 1147240$
Total Capital Investment = 7590460$
64
The above cost data correspond to year 2002 in which the Marshall
and Swift all indirect cost index was 1102. The cost index in 2017 was
1594. Therefore, the present costs are given below by taking (1US = Rs
65).
Fixed Capital Investment = [(6443220×1594×65)]/(1102) = Rs

60.6crores
Turnover Ratio = Fixed Capital Investment / Gross Annual Sales = 1
Gross Annual Sales = 60.6 crores
Assuming 20% profit,
Average Profit = 60.6×0.2= Rs 12 crores
Profit After Tax = 12 (1-0.34) = Rs 8 crores
Pay-out Period = Fixed Capital Investment / (average profit per year +

depreciation per year)
Let life of equipment = 5 years without any salvage value.
Depreciation by straight line method = 60.6/ 5= 12.1 crores
Pay-out Period = 60.6/ (8+12.1) = 3 years
65
CHAPTER-IX
PLANT LOCATION
66
PLANT LOCATION
The geographical location of a chemical plant

manufacturing concern can have strong influence on the success of the
industrial venture. With the main aim of selecting the appropriate place
which enables the necessary materials to be assembled, the manufacturing
process to be carried out and the product to be delivered.
To customers all at the lowest possible cost, the following

factors have been taken into account and examined.
1. RAW MATERIAL:
This is the key factor in locating a chemical plant because near

the raw material source permits considerable reduction in the
transportation and storage charges. This is especially true for a
methanol plant where in large quantities of Natural gas or heavier
hydrocarbons are required as raw materials.
2. MARKETS:
The location of market or intermediate distribution centres

effect costs of the product distribution and time required for shipping.
A buyer usually finds advantageous to purchase from nearby sources.
Hence the methanol plant can be located near a formaldehyde or
MTBE producing unit so as to have an intermediate market.
3. ENERGY AVAILABILITY:
Power and steam requirement for a methanol plant are

sufficiently high. Hence the plant must be located near cheap sources
of electricity. In this case local cost of power should be considered to
determine whether power should be purchased or self-generated.
67
4. CLIMATE:
The plant should be located a region of equable climate rather

than extreme climate so as to avoid excess costs occurring due to these
extremities such as special cooling towers in high temperature regions,
protective shelters in cold regions and additional de - humidification
and dryers in coastal regions.
5. TRANSPORTATION FACILITIES:
The plant must be located where all the types of

transport are effective. In case of Methanol pipelines also provides
effective means of transport.
6. WATER SUPPLY:
Large amount of water is required for cooling and steam

generation. Hence it is advisable to locate the plant near a river or
artesian well. The seasonal fluctuations in the river and its components
analysis must be taken into consideration.
7. WASTE DISPOSAL:
Efficient methods of treatment should be employed to

treat Di-methyl ether, Methyl formate and higher alcohols, which are
produced during production methanol. The permissible tolerance level
in air and water must be considered with reference to Environmental
pollution protection regulations. Hence the plant should be located
away from the residential areas.
8. LABOUR SUPPLY:
The plant should be located where the labour supply

is abundant and pay rates are low. The number of working hours per
68
week, the skill and intelligence of workers and workers problems must
also be considered.
9. TAXATION AND LEGAL RESTRICITON:
Tax rates, zoning difficulties number of required

permits and time delays associated with them vary from place to
place. An optimal location reduces the expenditure incurred and time
lag of supply to a considerable extent.
10. SITE CHARACTERISTICS:
The topography of land and soil structure has pronounced

effect on construction costs. A future expansion should be accounted
for in terms of site characteristics.
11. FLOOD AND FIRE PROTECTION:
Plant located along large water

bodies must be protected from floods. The regional history must be
taken into account in locating a plant at such a place. There should be
efficient fire protection departments within the plant to avoid fire
hazards, which are most common in chemical industry. Rajahmundry
(Andhra Pradesh, India) satisfying almost all the required criteria
mentioned above to an appreciable extent, is an ideal place for
location of a methanol plant.
69
CHAPTER-X
PLANT LAYOUT
70
PLANT LAYOUT
Planning of a chemical factory layout is however difficult task and a good deal
of experience. Some of the plans which appear quite alright on the drawing
often fail when put into actual practice. Industry is for production and in the
modern production is to be well organized based on scientific principles. The
layout of factory building be such that the building time is minimized to a great
extent.
The best layout will show that it saves the floor space, shortens the travel of
materials, increases production and reduces cost by utilizing labour more
efficiently. If the layout is haphazard the products will not be economical and
the cost may be every high resulting in losses.
Apart from technical considerations, the factory building should have good
appearance, look neat and clean. Such a plant will have a good effect on the
moral of workers and the people in its surroundings will also proud of it.
Following are the major consideration, it should be followed while making
layout of any kind of factory.
Organisation of Departments:
It means, when the several production departments such as medicine shop,

welding shop, assembly shop etc. should be located in the building. What
should be their size etc.
For this purpose, product analysis should be made as follows:
1. What is to be produced?
2. How much is to be produced?
3. What will be the sequence of operation?
4. How much time each operation will take?

71
5. How the machines can be best grouped?
6. What will be the capacity of the machines and their quantities etc.
7. The amount of space needed and necessity of special provisions, if

any
1. Location of Production Department in the Building:
The various production departments should be located in such a way that the
traffic or movement workers should be easy. The flow of materials within
the department and also between one department and another department
should be economically and neatly managed.
2. Position of Service Departments:
Service departments such as canteen, stores, toilet rooms, first aid, water
and schooling and conveyance etc. These properly positioned after making
the plant layout.
3. Premises:
The various sections of the departments of the factory can be arranged into
three main groups i.e., administrative, service and production departments.
4. Size and Location Conditions of Site:
If the size is of small size in the manufacturing methods involve the

gravity flow of products e.g. Chemicals and paints, a multi-story building
must be designed. In this case the flow material will be much easier.
72
5. Types of Construction:
The chief points concerning structural materials are as below:
(a) Strength
(b) Durability
(c) Safety
(d) Speed of construction
(e) Cost
The building may be made of timber, bricks, steel frames or concrete.
6. Ventilation and Air Conditioning:
This factor is of extreme importance. As heat, dust moisture, fumes and

smoke etc, greatly appear in manufacturing process. Proper ventilation and
air conditioning is very essential. These are concerning to health and
efficiency. It may create healthy atmosphere in the factory and provide good
motivation for working staff.
7. Lighting:
Good lighting provides safe working place and helps in increasing the
visibility. This efficiency of workers and also reduces the accidents.
73
8. Appearance:
The appearance of factory places an important role in rising productive

efficiency and reduces labour turnover. Therefore, this factor should not be
neglected.
10. Plant Protection:

The factory should be surrounded by boundary walls all around and
boundary walls must be covered with fencing wire, provision for
inflammable materials should be made far away from the main building.
11. Provisions for Future Expansion:
Enough space in each shop must be allowed for future expansion. The usual
practice to layout building corresponding to shapes of such letters as U, H, E,
T, L and F shown in figure attached depending upon departmental problem
and flow of materials to the plant is adopted.
12. Transportation:
Transportation plays an important role in moving the raw material and

finished products. So, the layout should be in such a way that proper
provisions are made for transportation. All shipping container (tank cars,
tank trucks and drums) should be of Carbon-Steel and in a clean and dry
condition prior to loading. Air pressure should never be used to load or
unload methanol. Pumping is preferred but inert gas should be used when
loading or unloading is done under pressure. Caution labels should be
attached whenever and wherever necessary.
74
13. Storage:
Methanol can be stored in Carbon-Steel equipment. Storage tanks should be

constructed with an internal floating roof with an inert gas pad to minimize
vapour emissions, because of the flammability of the product. Tanks are
usually enclosed by alike and protected by a foam type (either CO2 or dry
chemical) fire extinguishing system. All applicable federal state and local
agencies should be contacted for guidance on emission control and fire
safety regulations.
All the above factors must be taken into account while planning a general
factory layout
75
BIBLIOGRAPHY
1. Encyclopaedia of Chemical Technology, Vol 16 by Kirk &

Othmer.
2. Chemical Engineering Handbook, 7th edition by J.A. Perry.
3. Industrial Chemicals by Faith, Keys and Clerk.
4. Plant Design and Economics for Chemical Engineering by
Max. S. Peters & Thimmerhaus.
5. Process Heat Transfer by Donald. Q. Kern
6. Chemical Process Industries by Shreve’s
7. Ullmann’s Encyclopaedia of Industrial Chemistry, 7th
edition
8. Outlines of Chemical Technology by Charles. E. Dryden
9. Introduction to Chemical Engineering Thermodynamics by
Smith, Abbott & H.C. Van.
Internet Sources:
 Wikipedia
 www.researchgate.net
 www.sciencedirect.com
 http://jultika.oulu.fi
76

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MANUFACTURE OF METHANOL

A Project Report submitted in the partial fulfilment of the

P. RAVI KIRAN P.S. KEDARNATH

Under the guidance of

Prof. K.V. RAMESH

DEPARTMENT OF CHEMICAL ENGINEERING,

ANDHRA UNIVERSITY COLLEGE OF ENGINEERING (A)

This is to certify that the project report entitled “MANUFACTURE OF

We wish to express our thanks to Prof. K. V. RAMESH,

We express our sincere thanks to PROF. S. V.

Our thanks to all the staff members of the department of

To Prepare a preliminary project report for the Manufacture of

S.NO TOPIC PG.NO

3. Applications and Uses 9

4. Various commercial Processes

and Process selection 15&31

7. Design of the reactor 48

10. Plant Layout 70

Methanol, also known as methyl alcohol among others, is a chemical

Methanol is the simplest alcohol consisting of methyl group linked to

Methanol is a very versatile chemical primarily produced in India from

Sectoral usage of methanol(%)

India is a large importer of Methanol. Due to insufficient domestic

They also introduced the word “methylene” to organic chemistry, forming

In the 1960s-1980s methanol emerged as the precursor to acetic acid

1. Molecular Formula = CH4O

Methanol burns with a pale blue, non-luminous

2CH3OH+3O2 ---------> 2CO2 + 4H2O

Methanol is oxidised with acidified

CH3OH -------------> HCHO + H2

2H2 + O2 -----------> 2H2O

3. Catalyst Oxidation of Methanol:

The catalytic oxidation of methanol

Methanol can also be oxidized to

Methanol reacts with organic acids to form esters.

CH3OH + HCOOH -------> HCOOH3 + H2O

6. Substitution of Methanol with sodium:

Methanol reacts with sodium at room

2 CH3OH + 2 Na --------> 2 CH3ONa + H2

(Methanol) (Sodium) (Sodium Methoxide)

7. Substitution of Methanol with Phosphorus Pentoxide:

Methanol reacts with Phosphorus pentoxide

CH3OH + PCL 5 -----------> HCL + CH3Cl + POCl3

8. Substitution of Methanol with Hydrogen Chloride:

Methanol reacts with hydrogen

CH3OH + HCL ----------> CH3Cl + H2O

Methanol is primarily converted to formaldehyde, which is widely used in

2CH3OH +O2  2 CH2O +2H20

Acetic acid is produced from methanol. Methanol and isobutene

Condensation of methanol to produce hydrocarbons and even aromatic

The European Fuel Quality Directive allows up to 3% methanol with an

Methanol is the precursor to most simple methylamines, methyl halides,

Methanol is a promising energy carrier because as a liquid, it is easier to

Methanol is occasionally used to fuel internal combustion engines. It

2CH3OH + 3O2  2CO2 + 4H2O

One problem with high concentrations of methanol in fuel is that alcohol

In some waste water treatments plants, a small amount of methanol is

Methanol is also a widely used fuel in camping and boating stoves.

Methanol is a toxic alcohol that is used industrially as a solvent,

2. Adsorbents and absorbents

 Automotive care products

 Agricultural products (non-pesticidal)