Optimization Of Synthetic Process For Methanol Production Unit 600,000 Tons/year

Methanol known as a basic organic chemical raw material plays an important role in the modern chemical industry.Although 101.535 Million tons of China’s methanol production capacity until 2021 reached the number one in the world,some problems still need to be solved,such as slow technology update,small production and so on.Especially,a methanol manufacturer in Xinjiang also has a common problem that the rapid deactivation of the catalyst in the synthesis of methanol seriously influenced the service life of equipment.This dissertation mainly focused on the solution of catalyst deactivation problem by th e analysis of operation data and the process transformation design.It consists of four parts.Part one:Analysis of the operation of the original process.On the basis of the original methanol synthesis process and the mechanism of synthetic reaction,through studying various influencing factors of reaction,comparing with the operation parameters of the original equipment and the original design indexes,checking the catalyst operation parameters of the original synthesis tower,carbon monoxide conversion,methanol production data,and researching the over-temperature of the synthesis outlet tower,it was demonstrated that the catalyst deactivation was caused by insufficient catalyst loading.Part two:Design the transformation plan of the synthetic process.On the basis of the principles of synthetic reaction and the analysis of process operation,combining the reality of enterprises and the experience of domestic and foreign relevant technical remolding,referencing the technical guidance of designer,it is considered to increase catalyst loading quantity.Therefore,a new synthetic tower would be combined with the former tower to increase the catalyst loading quantity.At the same time,a new heater and a cold shock on the top of the gas cooled tower will be added to improve the reaction temperature.Part three:Analysis of the operation after the process transformation.Collecting the data of the fresh air volume,the temperature of inlet and outlet tower,instantaneous production of the equipment after the reforming technique,after process analysis,the outlet temperature of the synthetic Tower 1 was stabilized at 220℃,the hot-spot temperature of the synthetic Tower 2 was lower than 230℃,and the temperature of recycling gas was controlled below 45℃.These results meet the design requirements.The catalyst has been operating for 2 years under normal condition.The expected service life can exceed more than 2.5 years.Part four:Evaluation and summary of the process improvement.After reforming the new equipment,the unit load and annual output in 2021 increased by 15%and 27.1%,respectively.At the same time,the transformation goal has been successfully achieved to reduce 367,200 tons of total carbon dioxide emissions and lower nearly 21%of the ton methanol production costs,which provides a good example to solve the practical problems in the chemical production process.