Transcript Process Simulation and Integration of Methanol Production

Process Simulation and
Integration of Methanol
Production
3rd Year Chemical Engineering
Research Project
By: Aaron McClean
Introduction
Welcome to this Presentation on the
Simulation and Integration of a Methanol
Production Process
The Project in Brief
The Project Involves the Simulation of a
conventional methanol process using Aspen
simulation software. Using stream data
obtained from the simulation and Process
Integration techniques, a maximum energy
recovery system is then designed
Three Project Objectives
• Development of a Methanol Production
Process
• Simulation of the Methanol Production
Process using Aspen Plus
• Carryout Process Integration on the
Methanol Process to gain a Maximum
Energy Recovery system
Development of a Methanol
Production Process
• Research into various routes for the
production of methanol
• Process selection
• Producing a Flow Diagram of the Process
• Collecting information on the physical
properties and characteristics of the Process
Process Flow Diagram
Natural Gas
This
diagram
shows the
main
sections in
Methanol
Production
Oxygen
Combustion
Steam
Synthesis Gas
Reaction
Crude Methanol
Distillation
Methanol
Process Sections
• Partial Combustion of Natural Gas to
produce Synthesis Gas
• Conversion of Synthesis Gas to Methanol
• Purification of Crude Methanol by
Distillation
Partial Combustion of Natural
Gas to produce Synthesis Gas
• Natural Gas composed of 80% Methane,
15% Ethane and 5% Propane
• Partial Combustion Reaction
Natural Gas + O2
CO + H2
• Water Shift reaction
Natural Gas + H2O
CO + H2O
CO + 3H2
CO2 + H2
Conversion of Synthesis Gas to
Methanol
• Methanol Conversion Reactions
CO + 2H2
2CO + 4H2
CO2 + H2
CH3OH
CH3OCH3 + H2O
CO + H2O
Process Diagram
Simulation of the Methanol
Production Process using Aspen
Plus
• Aspen Plus is a Computer Simulation
Package for Chemical Processes
• It is Primarily used as a labour and time
saving tool
• It is still only a tool, and does not replace
the knowledge required by the Process
Engineer
Aspen Plus User Interface
Aspen Plus User Interface
Methanol Process Simulation
Process Integration
• What is Process Integration?
• What does Process Integration involve?
• Why carry out Process Integration?
What is Process Integration
• Process Integration is the optimisation of a
Chemical Process to produce a Maximum
energy recovery system
Cool FEED
RECYCLE
FEED
Cool
Reactor
Heat
PRODUCT
Heat
BYPRODUCT
What does Process Integration
involve?
•
•
•
•
Pinch Technology
What is a Pinch Analysis?
What is required for the analysis?
How is an analysis performed?
What is a Pinch Analysis?
• Linking streams that need heating to those
that need cooling
RECYCLE
HEATING
Heat
160
°
2500
210
°
270
REACTOR
210
50
°
°
°
REAC. OUT
COOLING
Cool
130
160
°
°
1980
FEED
HEATING
PRODUCT
COOLING
Heat
3200
220
°
Cool
60
3520
°
What is a Pinch Analysis?
• What is meant by the Pinch
220°
RECYCLE
STEAM
178°
1620
160°
880
CW
180°
160°
60°
2640
DIST
VAP130°
210°
REACTOR
REAC.
OUT
210°
270°
160°
Distillation
Column
149°
STEAM
FEED 50°
Above Pinch
Below Pinch
1220
1980
220°
PRODUCT
What is meant by the Pinch
• The Composite Curve
T
QHmin
Pinch
(Hot)
Pinch
(Cold)
QCmin
H
The Composite Curve
T
T
270 °
210°
220 °
160 °
160°
Reac.
Out
Recycle
Product
60 °
Feed
3520
50°
1980
2500
3200
H
H
No
Name
Tsupply
Ttarget
DH
No
Name
Tsupply
Ttarget
DH
1
Product
220
60
3520
3
Feed
50
210
3200
2
Reac. Out
270
160
1980
4
Recycle
160
210
2500
The Composite Curve
QHMIN = 1000
250 °
Hot Composite
Curve
200 °
D Tmin= 20
°
150 °
100 °
50 °
Hot Utility Target QHMIN = 1000
Cold Composite
Curve
0°
Qcmin= 800
Cold Utility Target QCMIN = 800
Creating a heat exchanger
network
Product
Reac. Out
180°
220°
270°
235.6°
80°
C
440
180°
60°
C
160°
360
210°
160°
50°
Feed
210°
H
1000
190°
177.6°
620
QHmin
= 1000
1000
160°
2200
Recycle
880
QCmin
= 800
Driving force plot
DT
a
b
DTmin
Driving Force Plot
Representation of driving forces
for vertical heat transfer
Tcold composite
Driving Force plot used to check
the use of exchangers
DT
CP
1
2
0.5
TC
Why carry out Process
Integration?
Process Costs Reduced
No Integration
40º
Steam
(100ºC)
40º
DH =
1000
H
40º
DH =
1000
H
Integration
DH =
1000
H
40º
DH = 1000
100º
DH = 1000
100º
DH = 1000
100º
20º
20º
20º
C
C
C
50º
100º
50º
100º
50º
Cooling water
(20º-40ºC)
Total Heat Transferred = 6000kW
Area = 112m²
40º
40º
DH =
1000
50º
DH =
1000
50º
DH =
1000
100º
20º
20º
50º
20º
Total Heat Transferred = 3000kW
Area = 69m²
Process Integration on Methanol
Process
Summary
•Aspen Plus is a great tool for the
development of chemical processes or
carrying out analysis on existing
processes
•Process Integration gives a reduction in
the amount of Energy required in the
process
•Pinch Technology can be used to reduce
the number of Heat Exchangers required
Thank You for your time and
patience
• Please feel free to ask questions or give feed
back on this presentation