Process Integration Approach to the Methanol (MeOH) Production Variability from Syngas and Industrial Waste Gases

Methanol is expected to be a possible solution for reducing global greenhouse gas emissions and minimizing the dependency on fossil fuels. This paper presents a systematic approach of methanol (MeOH) production from industrial waste gases including flue gas (FG) and coke oven gas (COG) that are considered an important threat to the environment. The impact of process parameters, including dimensional parameters (length, diameter, and number of tubes) and operational parameters (reactor temperature, pressure, and thermal fluid temperature) over the MeOH synthesis, are investigated by Aspen Plus. Firstly, the synthesis process is designed and optimized using syngas (SG) as a feed material. Secondly, by replacing the feed material with FG and COG, methanol production variability is investigated and demonstrated for the same optimized process. Afterward, an efficient heat exchange network system is developed for all three different processes using Aspen Energy Analyzer. The optimized dimensional parameters of the MeOH synthesis reactor are determined to be a length of 12 m, a diameter of 0.06 m, and 5000 tubes for achieving a conversion rate of 75%. Meanwhile, the optimized operational parameters are identified as a reactor temperature of 209 degrees C, reactor pressure of 70 bar, and thermal fluid temperature of 196 degrees C. Furthermore, the influence of the stoichiometric number (SN) on the process was observed with higher SN values resulting in increased hydrogen (H2) concentration and an improved forward reaction of MeOH synthesis, leading to higher conversion rates. The findings and insights gained from this study can serve further improvements and advancements in MeOH synthesis processes.