Table of Contents

1 INTRODUCTION......................................................................................................................1
1.1 Physical and Thermodynamics Properties of Methanol.........................................................2
1.2 Reactions of Methanol...........................................................................................................3
1.3 Uses of Methanol...................................................................................................................3
1.4 Motivation..............................................................................................................................4
1.5 Feasibility...............................................................................................................................4
1.6 Market Assessment................................................................................................................4
1.6.1 Demand...........................................................................................................................4
1.6.2 Supply.............................................................................................................................6
1.7 Production and Consumption of Methanol............................................................................6
1.8 Handling and Storage.............................................................................................................7
1.9 Environmental Hazards..........................................................................................................8
2 Manufacturing Process................................................................................................................9
2.1 Synthesis of Methanol from natural gas...............................................................................10
2.2 Methanol synthesis from Biomass.......................................................................................11
2.3 Synthesis of Methanol from coal.........................................................................................12
2.4 Process Selection..................................................................................................................15
2.5 Process Description..............................................................................................................15
2.5.1 Raw Material.................................................................................................................15
2.5.2 Coal Preparation............................................................................................................16
2.5.3 Coal Drying...................................................................................................................16
2.5.4 Gasification...................................................................................................................17
2.5.5 Cyclone Separator.........................................................................................................17
2.5.6 Absorption Column.......................................................................................................17
2.5.7 Stripping Column..........................................................................................................17
2.5.8 Compressor...................................................................................................................18
2.5.9 Reactor and Condenser.................................................................................................18
2.5.10 Purified Methanol Section.........................................................................................18
2.6 Capacity Selection................................................................................................................18
3 Bibliography..............................................................................................................................20
 List of figure

Figure 1.1: Methanol use globally................................................................................................5

Figure 1.2: Global growth rate.....................................................................................................5
Figure 1.3: Methanol supply and demand....................................................................................6
Figure 1.4: Methanol demand in 2016..........................................................................................7
Figure 2.1: PFD of methanol from natural gas...........................................................................11
Figure 2.2: Block diagram of methanol from biomass...............................................................11
Figure 2.3: PFD for the manufacturing of methanol from synthesis gas...................................13
Figure 2.4: PFD for the manufacturing of methanol from synthesis gas...................................19
List of tables
Table 1.1: Physical properties......................................................................................................2
Table 1.2: Thermodynamic properties of methanol.....................................................................2
Table 2.1: Comparison of different available manufacturing process for methanol..................14
Table 2.2: Classification of Thar coal sample............................................................................16
Chapter 01 Introduction

CHAPTER 01
1 INTRODUCTION

1
 Chapter 01 Introduction
Methanol is an alcohol with a chemical formula of CH3OH. It is a clear, colorless liquid with a
mild odor, and dissolves readily in most common organic solvents. Methanol is among the most
widely produced bulk chemicals, with a worldwide annual production of about 30 million tons.

Methanol was first obtained commercially some 150 years ago by the destructive distillation of
wood. Today it is produced mainly from the reforming of natural gas via a synthesis gas intermediate.
Methanol is also being produced by gasification of coal and residue oil through syngas route.
Methanol has been traditionally used as a chemical intermediate for the production of formaldehyde,
solvents, methyl derivatives and increasingly acetic acid. [1]
Recently methanol has gained importance as a clean-burning fuel and fuel additive in such
diverse uses as a boiler fuel for NOx control, as an octane booster for gasoline by direct blending or as
a methyl tertiary butyl ether derivative and for fuel cell application.

1.1 Physical and Thermodynamics Properties of Methanol

Table 1.1: Physical properties

Taste Mild Odor

Appearance Colorless liquid
Odor Faint odor
Formula CH3OH
Refractive index 1.3341

Table 1.2: Thermodynamic properties of methanol

Properties Values
Gibbs free energy -162.62 MJ/kmol
Freezing point -97.7 0C

Flash point 11 to 12°C

Vapor pressure 1302 kPa (at 20°C)
Explosive limit 36%
Heat of Formation -20130kJ/kmol

2
 Chapter 01 Introduction
1.2 Reactions of Methanol
Methanol is the 1st in a series of aliphatic, monohydric alcohols and undergoes many of the
reactions typical of this class of chemical compound. Methanol, for example, cannot undergo
elimination of the hydroxyl group and hydrogen to form the analogous olefins as do many of the
higher alcohols. The reactions of the aliphatic alcohols including methanol generally involve hydroxyl
group, either through the breaking of the C-O bond or O-H bond and substitution or displacement of
the H or OH group, the O-H and C-O bonds in alcohols are relatively strong, albeit polar and
kinetically labile. Hemolytic bond dissociation energies are in the order of 90 – 100 Kcal/mole.
Because of this bond strength in alcohols, some activation of these bonds is often necessary to achieve
acceptable reaction rates.
Combustion of Methanol
2CH3OH + 3O2 → 2CO2 + 4H2O
Oxidation of Methanol
CH3OH + [O] → CH2O + H2O
Esterification of Methanol
CH3OH + CH3CH2COOH → CH3CH2COOCH3 + H2O
Substitution of Methanol with Sodium
2Na(s) + 2CH3OH(l) → 2CH3ONa(l) + H2(g)
Substitution of Methanol with Hydrogen Chloride
CH3OH + HCl → CH3Cl + H2O

1.3 Uses of Methanol

The major portion of the methanol produced is used for making formaldehyde and a number of
chemical derivatives. Other applications include its use as solvent extractant and air automation
antifreeze. [4]
1. Methanol is miscible with most organic liquids and is a solvent for the variety of substance like
dyes, nitrocellulose, polyvinyl, butyl ethyl cellulose, Shellac, and modified resin. It is used in
the manufacturing of wood and metal polishes. Waterproofing formulation, coated fabrics,
aniline, and other inks, and duplicator fluids.
2. Methanol is used in many cleansing operations such as in washing steel surfaces before
coatings are applied, rinsing the interiors of electronic tubes before they are evacuated,
cleaning resin sheets before further processing.
3. Methanol offers the advantages of low molecular weights, low costs, and high efficiency when
used as automotive or industrial antifreeze. Methanol antifreeze solutions are considered less
result of internal leakage than the high boiling type.
4. Formaldehyde is made from methanol dehydrogenation. Worldwide, the largest amount of
formaldehyde is consumed in the production of urea-formaldehyde resins, the primary end use
of which is found in building products such as plywood and particle board.

3
 Chapter 01 Introduction
1.4 Motivation
The methanol industry is one of the world's most dynamic and vibrant - producing a basic
chemical molecule that touches our daily lives in a myriad of ways. From the basic chemical building
block of paints, solvents, and plastics, to innovative applications in energy, transportation fuel, and
fuel cells, methanol is a key commodity and an integral part of our global economy. Most of the
methanol is produced from biomass in worldwide. Due to its increasing demand, we get inspired to
explore the most economical and optimized method of production from coal.

1.5 Feasibility
The raw material required for this process is coal. The coal reserves in Pakistan are abundant
and can be tapped for versatile uses, our power sector is shifting to coal and in recent years many coal
fired plants are established in Pakistan. The production of methanol only from coal has an estimated
efficiency of 41-55%. Some harmful gases are also emitted in synthesis of methanol from coal which
includes carbon monoxide, nitrogen oxides and greenhouse gases etc.

1.6 Market Assessment

1.6.1 Demand
Methanol call for has been extended through the software of technology toward fee effective
substitution of subtle merchandise in strength utility, particularly in China. For the value unfold
between hydrocarbon particularly coal and natural gasoline and refine coal oil product expenses, the
continued growth in the use of technology which converts the hydrocarbon to update delicate
merchandise via methanol is expected in the forecast.
The most powerful increase of methanol demand will come from methanol to olefins utility,
driven through a number of industrial initiatives now undevout is expected that this use of methanol
simply crosses 19 million heaps by using the give up of 2018.
Major trade within the methanol call for panorama may also come from the opportunity gas
makes use of like gas blending, direct combustion biodiesel, dimethyl ether, and electricity era. By
way of 2018, these make use of could have grown to devour 21 million lots of methanol in line with
12 months.
The chart beneath indicates the distribution of worldwide methanol call for at the beginning
and quit of the forecast. It suggests that energy use of methanol will decrease the share of demand for
in the three biggest conventional uses (formaldehyde, acetic acid. Similar makes use of will claim
almost 21. Nine percent of the overall call for market by using the give up or take a look at the
forecast, even as Methyl to Olefins call for will include approximately 19. Nine percent of the global
market methanol market.
The increase of methanol demand will come from methanol to olefins utility, driven through a
number of industrial initiatives now undevout is expected that this use of methanol simply crosses 19
million heaps by using the give up of 2018.
Methanol is also a truly global commodity, and each day there is more than 80,000 metric tons
of methanol shipped from one continent to another. In 2013, global methanol demand is expected to
reach 65 million metric tons driven in large part by the resurgence of the global housing market and
increased demand for cleaner energy
4
Chapter 01 Introduction

Figure 1.1: Methanol use globally

Figure
Figure1.2:
1.2:Global
Globalgrowth
growthrate
rate

5
 Chapter 01 Introduction
Within Asia, China remains the most important methanol manufacturer. By itself, China is a
larger methanol purchaser than any region in the international. The graph display call for methanol by
using location and indicates China call for as an evaluation. Also, the opposite areas call for an
evaluation of methanol call for is shown below.

1.6.2 Supply
A graphical representation of global supply and demand for methanol.

Figure 1.3: Methanol supply and demand

1.7 Production and Consumption of Methanol

The methanol industry spans the entire globe, with production in Asia, North and South
America, Europe, Africa, and the Middle East. Worldwide, over 90 methanol plants have a combined
production capacity of about 100 million metric tons (almost 33 billion gallons or 90 billion liters),
and each day more than 100,000 tons of methanol is used as a chemical feedstock or as a
transportation fuel (60 million gallons or 225 million liters).
Methanol is also a truly global commodity, and each day there is more than 80,000 metric tons
of methanol shipped from one continent to another. In 2013, global methanol demand is expected to
reach 65 million metric tons driven in large part by the resurgence of the global housing market and
increased demand for cleaner energy.
But the methanol industry is not just those companies large and small throughout the globe that
produce methanol every day from a wide array of feedstocks - including natural gas, coal, biomass,
waste, and even CO2 pollution - the industry is also made up of thousands of distributors, technology
innovators, downstream manufacturers.
Until a few years ago, the size of a large-scale single-train methanol plant was considered to
be 2000 to 2500 metric tons per day. However, economies of scale and market conditions are driving
the trend toward building larger-sized plants with capacities in excess of 3,000 thousand tons per day.
The typical gas consumption for a world-scale methanol plant ranges from 28 to 31 million Btu per
metric ton of product based on LHV (Low heating value) of the feed; therefore, a 5000 metric tons per
day methanol plant will use approximately 157 Mscf/D (Million standard cubic feet) of gas. For a

6
 Chapter 01 Introduction
project lifetime of 20 years, a gas-field size of at least 1.15 Tcf (Trillion cubic feet) is required to
support a plant of this size. [5] The economics of methanol is very dependent on the cost of production
and the selling price of methanol. The market for methanol is volatile and competitive with large
swings in the price. The main components of the production cost of methanol are gas price and the
investment cost of the plant. A number of literature sources present the investment costs for steam-
reforming-based methanol plants. The investment costs for large-scale methanol plants based on
advanced syngas generation technologies are expected to be lower. A producer in a remote location
must also consider shipping costs for transporting the methanol product to the market.
Methyl tertiary butyl ether (MTBE) phase-out in the United States will have an effect on the
worldwide methanol demand; however, the phase-out is expected to be slow and prolonged. The
methanol market is currently saturated with adequate available capacity. The methanol market is
saturated; however, it is expected that new plants will be built. In the future, new low-cost production
will displace existing high-cost producers unless new applications for methanol are established.

2016 Methanol by DEMAND END USE

DMT Solvents
5% 4% MTO
22%

Formaldyde Chlromethane
25% Methylamines
1%
3%

Dimethyl Rther
8%

Acetic Acid
8% Gasoline Fuel
MTBE Methacylate 16%
7% 1%

Figure 1.4: Methanol demand in 2016

1.8 Handling and Storage

Because methanol is corrosive to some metals and damaging to rubber and some plastics, fuel
storage tanks and dispensing equipment must be corrosion and damage resistant. California requires
that underground storage tanks for methanol be double walled. Because methanol is water soluble, it
could be quickly diluted in large bodies of water to levels that are safe for organisms. Environmental
recovery rates for methanol spills are often faster than for petroleum spills. As with gasoline, methanol
can be fatal when ingested. Inhalation of fumes and direct contact with skin can also be harmful.
Because pure methanol flames are nearly invisible in daylight, gasoline is added as a safety precaution
to provide color to a flame. Added gasoline also serves to add a smell to this otherwise odorless liquid.
Because of its high flash point, methanol is less volatile than gasoline. It burns more slowly and at a
lower temperature. Methanol is transported by barge, truck, or rail. [10]

7
 Chapter 01 Introduction
1.9 Environmental Hazards
The methanol molecule has a simple chemical structure, which leads to clean combustion;
reports from emissions studies, however, vary more widely for methanol than for other fuels probably
because of differences among fuel blends used across the country and because vehicles may not be
optimized for using methanol. Comparisons of M100 with gasoline and diesel have shown these
results:
Carbon Monoxide: Emissions vary — sometimes lower, but are usually equal or slightly higher.
Ground-Level-Ozone-Forming Potential: 30 to 60 percent less. (In order to take advantage of this
characteristic, vehicles must be properly adjusted.)
No methane Evaporative Hydrocarbons: Usually less.
Toxics: M100 contains none of the carcinogenic ingredients such as benzene, 1,3butadiene, and
acetaldehyde. M85 (with 15 percent gasoline) has 50 percent fewer toxic air pollutants than
gasoline.
Formaldehyde Levels: Much higher, although still low. The toxicity of formaldehyde is lower
than that of other toxics, and formaldehyde emissions can be reduced dramatically with new
technology, such as improved catalytic converters.
Nitrogen Oxides: Usually comparable or less.
Greenhouse Gases: Comparable to gasoline. [11]

8
Chapter 01 Introduction

CHAPTER 02

2 Manufacturing Process

9
 Chapter 01 Introduction

Three manufacturing processes are available for commercial production of methanol viz:
1. Production from natural gas
2. Production from coal
3. Production from biomass

2.1 Synthesis of Methanol from natural gas

1. In this process, steam reforming and partial oxidation are combined to enhance the whole
process to manage the composition of the produced gas.
2. This process also requires that the steam reforming operates with high methane slip, usually 35-
45 %, to provide a high enough methane content for the partial oxidation step.
3. The original high-pressure process was operated at 250-350 bar and 320-450°C employing a
relative poison (Sulphur and chlorine contamination) resistant catalyst, ZnO/Cr2O3.
4. This process operates at pressures between 50 and 100 bar and temperature range of 200-300°C.
5. The equilibrium limited methanol synthesis reactions are favored at low temperature but have an
adverse effect on catalyst activity.
6. To ensure the activity of the catalyst and effective use of reaction heat, methanol converters are
operated at a temperature in the range of 200-300°C.
7. Depending upon the process technology employed, SG may be washed, compressed and heated
before entering the methanol synthesis loop.
8. This fresh feed is mixed with recycled unreacted SG and sent to methanol converter where
following reactions take place:
CO + 2H2 ↔ CH3OH ∆H298K = -21.7kcal/mole
CO2 + 3H2 ↔ CH3OH + H2O ∆H298K = -11.9kcal/mole
CO2 + H2 ↔ CO + H2O ∆H298K = 9.8kcal/mole
9. The reaction is carried out on copper oxide, zinc oxide, and alumina (CuO/ZnO/Al2O3) catalyst.
10. The produced methanol contains water, dissolved gases and the small amount of H2.
11. Under normal operating conditions, only a small amount of by-products exist in the outlet
stream.
12. These impurities are to be removed in the methanol purification section. This section normally
consists of 2-3 distillation columns.
13. The physically dissolved gases are flashed off in a flash vessel while low boiling impurities are
removed in a pre-run column.

10
 Chapter 01 Introduction
14. The stabilized methanol is distilled in a two-stage system first under pressure and second at
atmospheric pressure to obtain a specific product. The higher boiling point components are
removed in the two-stage distillation columns. [12] [13]

Figure 2.5: PFD of methanol from natural gas

2.2 Methanol synthesis from Biomass

The gasification technique of biomass is much like the synthesis gas procedure from coal. For
gasification of biomass, the feedstock is first dried and pulverized. The moist content material needs to
usually be no higher than 15-20 wt.%. The first step in a two-step gasification manner is called
pyrolysis, or adverse distillation. The dried biomass is heated to four hundred-six hundred °C in an
oxygen deficient environment to prevent entire combustion. Carbon monoxide, carbon dioxide,
hydrogen, methane as well as water and risky tars are released. The last biomass (≈10– 25 wt.%),
called charcoal. Is further reacted with oxygen at an excessive temperature (1300-1500 °C) to supply
particularly carbon monoxide. The synthesis fuel made from the pyrolysis and charcoal conversion is
purified earlier than the methanol synthesis. Compared to coal-biomass consists of lots much less
Sulphur but the tar content offers operational challenges because it condenses effortlessly in pipes,
filters, and boilers. This can to a volume be managed by choosing the right operational pattern and
approach in step with the composition of the available biomass. A one-step partial oxidation method is
an attractive opportunity but the technical demanding situations have up to now averted massive

11
 Chapter 01 Introduction

Figure 2.6: Block diagram of methanol from biomass

2.3 Synthesis of Methanol from coal

The process used to convert coal to synthesis gas is a combination of partial oxidation and
steam treatment called gasification.

C + 0.5*O2 ⇌ CO ΔH298K = -29.4 kcal/mole

C + H2O ⇌ CO + H2 ΔH298K = 31.3 kcal/mole
CO + H2O ⇌ CO2 + H2 ΔH298K = -9.8 kcal/mole
CO2 + C ⇌ 2CO ΔH298K = 40.8 kcal/mole

1. The design and processing conditions vary greatly depending on the composition of the coal
used as feedstock.
2. The synthesis gas produced have a deficit of hydrogen and must be subjected to the water gas
shift reaction in improve the H2/CO ratio.
3. The synthesis gas produced from coal is usually in higher need of purification.
4. H2 and CO adjusted to molar ratio of 2.25.
5. The mixture is compressed to 200 – 350 atms.
6. Recycle gas (Unreacted feed) is also mixed and sent to the compressor.
7. Then eventually the mixture is fed to a reactor. Steam is circulated in the heating tubes to
maintain a temperature of 300 – 375°C.
8. After reaction, the exit gases are cooled.
9. After cooling, phase separation is allowed. In this phase separation operation methanol and
other high molecular weight compounds enter the liquid phase and unreacted feed is produced
as the gas phase.
10. The gas phase stream is purged to remove inert components and most of the gas stream is sent
as a recycle to the reactor.

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 Chapter 01 Introduction
11. The liquid stream is further depressurized to about 14 atms to enter a second phase separator
that produces fuel gas as the gaseous product and the liquid stream bereft of the fuel gas
components is rich of the methanol component.
12. The liquid stream then enters a mixer fed with KMNO4 so as to remove traces of impurities
such as ketones, aldehydes etc.
13. Eventually, the liquid stream enters a distillation column that separates dimethyl ether as a top
product.
14. The bottom product from the first distillation column enters a fractionator that produces
methanol, other high molecular weight alcohols and water as three different products. [16] [17]

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 Chapter 2 Manufacturing Process

R-101, CS-101 A-101 D-101, E-101, E- P-101, RB-101, CD-101, V-101 -101, D-102 M-101
R-102 D-102, 102 C-101 RB-102, CD-102
D-103 RB-103
Reactor Cyclone Absorber Distillation Heat Pump, Reboiler Condenser Valve Surge drum, Mixer
Separator tower exchanger Compressor Flash drum

Figure 2.7: PFD for the manufacturing of methanol from synthesis gas

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 Chapter 2 Manufacturing Process

Table 2.3: Comparison of different available manufacturing process for methanol

Process [ Temperature Pressure Advantages Disadvantages Efficiency

(o C) (bar) (%)
Methanol In future natural
synthesis process gas is about to
From was operated at finish.
natural gas 200-300 50-100 high temperature 50-60
and pressure. Expensive
method.
Preferable for
medium to large
scale processes.

A large amount of
carbon is present
in the produced
synthesis gas.

From Above 400 300-1000 This method is Temperature and 37-40

biomass economical. pressure ranges
are high enough.

Economical Cost to setup and

process due to maintain the
From 300-375 200-350 inexpensive raw necessary facilities 41.55
coal material. is high.

Efficiency is high
as compared to
other processes.
Abundant reserve
of coal in
Pakistan.

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 Chapter 2 Manufacturing Process

2.4 Process Selection

We have selected the manufacturing of Methanol from synthesis gas (coal gasification)
due to following reasons:
Abundant reserve of coal in Pakistan.
Highly efficient process compared to other processes.
Temperature and Pressure ranges are moderate.
Economical process due to inexpensive raw material.

2.5 Process Description

The major steps involved in the synthesis of methanol from coal are:
1. Coal Preparation
2. Coal drying
3. Gasification
4. Gas Purification
5. Methanol Production
6. Methanol purification

2.5.1 Raw Material

The Thar coal is suitable as a solid fuel in its natural form, needs less amount of energy to
start ignition for burning process and its combustion is also safe for environment as it produces
less ash and poisonous gases, a recently published study says.
The most important finding of the study is the ranking of coal as lignite to sub-
bituminous (a type of coal primarily used as fuel for steam-electric power generation) using
standard classification of coal by American Standard and Testing Materials (ASTM).
“The samples were characterized as high moisture, high volatile matter and low ash. High
moisture (i.e. between 21 and 44 per cent) lowers the flame temperature and increases
transportation cost. High volatile is good for the stability of flame and it suggests that the coal is
suitable for combustion and gasification purposes. Hence, it may be used as a solid fuel for
combustion in boiler or it may be converted easily into gaseous products,” the study says.
Therefore, the combustion of coal is considered safe for environmental concern as it
produces little ash and low amount of SOx (oxides of sulfur) gases.
“Ignition temperature (the temperature required to start ignition) of the coal varied from
315°C to 450°C. The activation energy (Ea) for pyrolysis and combustion reactions was
calculated as 35.50 and 34.27 kJ/mol, respectively.

16
 Chapter 2 Manufacturing Process

“It is significantly less than the Ea of other foreign coals. Low activation energy values of
Thar coal categorize it as a reactive coal and can undergo pyrolysis and combustion reactions
easily,” the paper says.
He adds that low sulfur content and ash in Thar coal ranks it at a better position from
other coals as it will help reduce repair and maintenance cost significantly.
“Reduction in repair and maintenance cost of the coal-based power generation plant is an
attractive economical aspect of Thar coal. The study also showed that the coal has the potential
to convert into gaseous products and liquid fuel easily with a good yield of products which may
act as a substitute for oil or natural gas,” he explains.
Table 2.4: Classification of Thar coal sample

ASTM RANK Lignite

Parameters Samples
Moisture 41.19 37.62 42.09
Volatile Matter 16.47 14.38 13.45
Ash Yield 5.06 19.17 0.63
Fixed Carbon 37.28 28.83 43.83
Ultimate Composition
Hydrogen 6.06 7.49 5.01
Nitrogen 2.22 2.95 1.91
Oxygen 1.42 0.19 0.22
Sulfur 58.17 48.27 74.39
GCV (kcal/kg) 4289.46 3194.16 2541.36

2.5.2 Coal Preparation

Coal from crusher and breaker is fed to the screening system. Here the 1/8 in (3mm)
particle size material is separated and fed to the gasifier.

2.5.3 Coal Drying

Since the coal consists of 11.12% moisture content material. And this percent of moisture
can lead to decrease the efficiency of the gasifier. So, it's miles necessary to reduce the moisture
content material of coal earlier than feeding it to the gasifier. The device decided on for this
motive is Rotary Dryer. This Dryer is appropriate to free of charge flowing granular substances.
It consists of a cylindrical shell into which the wet cloth is charged at one give up and dry fabric
leaves at the other give up. Drying is done by contact with warm air getting into at 328K and
leaving the dryer at 317K. Coal is entering the dryer at 298K and leaving at 303K. In the dryer,
the moisture content material of coal is decreased to 2.44%. From here, the beaten coal is
subsequently dispatched to the gasifier.

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 Chapter 2 Manufacturing Process

2.5.4 Gasification
The gasifier selected is a fixed bed kind gasifier commercially named as Lurgi Gasifier. It
consists of some of the sections such as a coal bunker, coal lock, gasifier, cooling jacket, and ash
elimination device. Crushed coal enters the gasifier at the pinnacle. A coal distributor keeps a
uniform waft of coal from coal lock to the gasifier. An ash grate constantly movements ash from
the gasifier into the ash lock. Both coal and ash locks are depressurized within the cycle to
charge coal and to remove ash from the gadget. As the coal actions via the gasifier from pinnacle
to bottom, it passes thru several awesome zones. The first zone preheats and dries the coal
through contact with warm fuel leaving the response n quarter. In the reaction sector, the coal is
devolatilized and the gasification response takes area. Combustion takes area at the bottom of the
reaction zone, wherein the char is reacted with oxygen (generating principally carbon dioxide) to
offer the warmth required inside the zones above. The backside of the gasifier is the ash zone.
The gasifier operates at about 350 psi (2.7 MPa). Oxygen required for the gasification of coal is
produced in an air separation plant and then compressed to coal gasifier strain. Oxygen is fed at a
floating rate of 129.8 kmol/hr. at 545psia. Superheated steam for the method is furnished at
approximately 673 K temperature and 565psia pressure. In the present operation, steam is
brought at a fee of about 137.21kmol/hr.

2.5.5 Cyclone Separator

A cyclone separator gets rid of most of the entrained fly ash and dirt. The percentage of
solids in the crude gas is two.94%. Raw gasoline enters the separator at 350 K and leaves at 448
K. About eighty-five percent of solids are removed in this unit. It is an opposite flow cyclone. In
an opposite go with the flow cyclone the gasoline enters the top chamber tangentially and spirals
right down to the apex of the conical segment; it then actions upward in a 2nd smaller diameter
spiral and exits at the top through a critical vertical pipe. The solids flow radially to the walls,
slide down the partitions, and are accrued at the lowest.

2.5.6 Absorption Column

Gas from coal gasification consists of a large amount of C02 and H2S, natural sulfur, and
different impurities. The MDEA procedure is based on the potential of coal methanol to absorb
all fuel impurities, consequently achieving the complete purification of the gas in a single
procedure unit. The extremely high purity of the fuel from MDEA purification makes the fuel
appropriate for use in any form of synthesis, together with those synthesis employing a very
sensitive catalyst. The raw syngas enters the absorption column at 313K. The absorber operates
at approximately 63 bars.

2.5.7 Stripping Column

Stripping is a physical separation method wherein one or extra additives are removed
from a liquid circulate by means of a vapor circulation. In commercial applications, the liquid
and vapor streams will have co-modern-day or countercurrent flows. Stripping is usually

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 Chapter 2 Manufacturing Process

accomplished in either a packed or tray column. In this section, MDEA is recovered from a
wealthy solvent and is dispatched returned to the absorption column.

2.5.8 Compressor
Hydrogen and Carbon monoxide in a mole ratio of 2.25(12% greater than theoretical) is
compressed to 3000-5000 psi, mixed with recycle gas, and fed to a high-pressure converter.
Internal preheat is usually employed.

2.5.9 Reactor and Condenser

The reactor is copper coated and incorporates a blended catalyst of Zinc, Chromium,
Manganese or Aluminum oxides. The temperature is maintained at 300-375℃ by right area
velocity and heat change design. The reaction is particularly exothermic and takes an area with a
lower in volume. The go out gases are cooled by way of heat change with reactants, then with
water to 0-20C after which condensed in excessive-strain condensers, wherein methanol is
condensed at 3000-4000 psi. The liquid methanol is drawn off and the residual gases are
recycled. The methanol condenses under complete working stress to maximize yields
(50%conversion in line with pass). The reactions happening in the reactor are the following:

CO + 2H2 ⇌ CH3OH ΔH298K= -21.7 kcal/mole

CO2 + 3H2 ⇌ CH3OH + H2O ΔH298K=-11.9 kcal/mole
CO2 + H2 ⇌ CO+H2O ΔH298K= 9.8 kcal/mole.

2.5.10 Purified Methanol Section

The liquid methanol is depressurized, purified by means of permanganate to take away
lines of ketones, aldehydes, and different such impurities, sent to a stripper to cast off mild ends
consisting of dimethyl ether, and to fractionators to separate methanol from better molecular
weight compounds. The methanol from a stripper on distillation offers ninety-nine percent
natural methanol. The yield is around ninety-eight percent with recycling. Dimethyl-ether (1-2%)
and higher alcohols, together with n-propanol and isopropanol (0.3-0.5%) are acquired as by
means of products.

2.6 Capacity Selection

Consumption of Methanol in Pakistan for year 2017-2018= 2480 MTY.
Average percent increase for Methanol demand in Pakistan per year = 12%
Increase in Demand of Methanol for Pakistan per year = 300 MTY.

Capacity of plant = 5480 MTY

= 20 MTD.

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 Chapter 2 Manufacturing Process

R-101, CS-101 A-101 D-101, E-101, E- P-101, RB-101, CD-101, V-101 -101, D-102 M-101
R-102 D-102, 102 C-101 RB-102, CD-102
D-103 RB-103
Reactor Cyclone Absorber Distillation Heat Pump, Reboiler Condenser Valve Surge drum, Mixer
Separator tower exchanger Compressor Flash drum

Figure 2.8: PFD for the manufacturing of methanol from synthesis gas

20
Chapter 2 Manufacturing Process

21
 16. Thermochemical
3 Bibliography production of methanol from
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