Synthesis of E-Methanol

Livrable 4.1 : Final Report

Livrable 4.2 : Summary

Group 1-9: Tutor:

N’Namiansé Dan EBOUO Agathe HECHINGER
Ahmad Haziq BIN ANUAR Alice BAHA
Lara DIAZ MORA VELAZQUEZ Laura-Beatriz DELGADO-BORDA
Raissa COSTA CARVALHO Lilia BOUHIDEL
Xiaotong MAO Bruno DESTOUR
Diego GOMEZ-OCHOA
Diogo FELGUEIRA
Florian SKRZYPCZAK
Rafael FARIA GOMES

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 1. SUMMARY ..................................................................................................... 4
2. INTRODUCTION.............................................................................................. 6
2.1. GENERAL INTRODUCTION ................................................................................ 6
2.2. BIBLIOGRAPHIC ELEMENTS ............................................................................... 7
2.3. PROCESS PRINCIPLE ......................................................................................... 8

3. PROCESS CALCULATIONS ................................................................................ 9

3.1. PROCESS SIMULATION...................................................................................... 9
3.1.1. Simulation Design requirements : .................................................................................. 10
3.1.2. Considered Units for the Simulation: .............................................................................. 10
3.1.3. Thermodynamic Model : ................................................................................................. 10
3.1.4. Inlet Composition and Battery Limit Conditions : ........................................................... 11
3.1.5. Reactant heating and pressurisation .............................................................................. 12
3.1.6. Reactor............................................................................................................................ 13
3.1.7. Reactant Recycling and Purge ........................................................................................ 15
3.1.8. Vessels ............................................................................................................................ 16
3.1.9. Heat Exchange and Thermal Integration ........................................................................ 17
3.1.10. Water Tank .................................................................................................................... 19
3.1.11. Simulation results : ........................................................................................................ 21

3.2. EQUIPEMENTS SIZING .................................................................................... 21

3.2.1. VESSELS ........................................................................................................................... 22
3.2.2. PIPING ............................................................................................................................. 24
3.2.3. REACTOR ......................................................................................................................... 28
3.2.4. HEAT EXCHANGER ........................................................................................................... 29
3.2.5. COMPRESSOR ................................................................................................................. 30
3.2.6. PUMP .............................................................................................................................. 31
3.2.6.1. Calculation 1 ................................................................................................................. 32
3.2.6.2. Calculation 2 ................................................................................................................. 34

4. PROCESS ANALYSIS ....................................................................................... 36

4.1. HEALTH, SAFETY AND ENVIRONMENT ............................................................. 36
4.1.1. HEALTH ...................................................................................................... 36
4.1.2. SAFETY ...................................................................................................... 37
4.2. TECHNO-ECONOMIC ANALYSIS ....................................................................... 39
4.2.1. CAPEX ............................................................................................................................. 39
4.2.1.1. Pressure Vessel ............................................................................................................. 40
4.2.1.2. Reactor ......................................................................................................................... 41
4.2.1.3. Pump ............................................................................................................................ 41
4.2.1.4. Compressor .................................................................................................................. 41
4.2.1.5. Heat Exchangers ........................................................................................................... 42
4.2.1.6. CAPEX Summary ........................................................................................................... 42
4.2.2. OPEX ............................................................................................................................... 43
4.2.2.1. Variable cost ................................................................................................................. 43
4.2.2.2. Fixed cost ..................................................................................................................... 44
4.2.2.3. OPEX Summary ............................................................................................................ 45
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 4.2.3. Production cost ............................................................................................................... 46

4.3. CONTROL AND COMMAND UNIT .................................................................... 46

4.3.1. Process Flow Diagram (PFD) ........................................................................................... 46
4.3.2. Piping and Instrumentation Diagram (PID) ..................................................................... 47

5. FINAL DISCUSSION AND CONCLUSION .......................................................... 49

5.1. General Discussion ......................................................................................... 49
5.2. Conclusion ..................................................................................................... 50

6. BIBLIOGRAPHIC REFERENCES ........................................................................ 51

7. APPENDICES ................................................................................................. 53
7.1. Appendix 1 : ProII Simulation Diagramme ....................................................... 53
7.2. Appendix 2 : PDS Vertical Drum ...................................................................... 54
7.3. Appendix 3 : PDS Pump .................................................................................. 55
7.4. Appendix 4 : Process Flow Diagram (PFD) ....................................................... 56
7.5. Appendix 5 : Piping and Instrumentation Diagram (PID) .................................. 57

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 1. SUMMARY

Introduction
The objective of our industrial project is to establish a viable process for the
preparation of methanol, using green hydrogen obtained by electrolysis of water and
capturing collected carbon dioxide as feedstock, and producing methanol by a catalytic
reaction.
At the start of the project, we consulted a number of literature to determine
information including the appropriate conditions for the chemical reaction to produce
methanol, the appropriate choice of catalyst, and the amount of feedstock required.
Based on the results of this preliminary investigation, we carried out simulations using
PROII software to model the methanol preparation process in detail and to simulate
parameters such as flow rate, temperature, and pressure for each unit in the process.
From the simulation results, we then were required to carry out a preliminary estimate
of the equipment size. Using the equations and assumptions provided, we calculated the
dimensions of the reactor, pumps, compressors, and other equipment. However, we also
realized that these results were only to be used as a reference and that the actual design
would require further refinement and cooperation with the equipment supplier.
Finally, we carried out a CAPEX and OPEX economic analysis based on the previously
obtained simulation and sizing data to assess the economic viability of the project.

Methods
Preliminary research:
To carry out the project, we first carried out a literature search and had an initial insight
into the methanol preparation process. This revealed that favorable operating conditions for
the reaction are a temperature of 200-300°C and a pressure of 50-100 bar. A heterogeneous
catalyst of the Cu/ZnO/Al2O3 type is also required. To achieve the reaction conditions,
equipment such as heat exchangers, compressors and separation tanks had to be used.
Simulation:
We carried out simulations of the process to determine the data required to size our
equipment. We chose the SRK and Lee Kesler methods as the appropriate thermodynamic
models to bring the reactants to our desired temperature and pressure (200 degrees and
85barg respectively) in the early stages of the simulated process through multiple
pressurisation and cool-down of the filler.
In order to achieve energy savings and less waste of feedstock, we included a recycling
loop in the simulation and thermally integrated a suitable heat exchanger. Through several
simulations we ended up with a methanol product that met the product requirements.
PFD and PID:

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 After the simulation was completed, we studied and attempted to make separate PFD
and PID diagrams.
The process involved analyzing and plotting the process flow: the PFD provided an
overview of the entire process flow and helped us to organize and understand the process
design. While the PID was more detailed and helped us to understand the relationships
between the different piping, instrumentation and control systems that affect one another. It
not only includes parameters such as process flow, pressure and temperature, but also
describes the location, type and function of the instrumentation.
Equipment sizing:
Another step after determining the simulation is to design the size of the equipment.
Proper sizing helps to reduce the maintenance and failure rate of the equipment and
increases the reliability and durability of the system. We sized each piece of equipment in our
designed process based on the flow, temperature and pressure data obtained from the
simulations, in accordance with the design requirements for the different pieces of equipment
provided by the Process Design Criteria.
In addition, the subsequent economic analysis of the project will be directly influenced
by the dimensional design. Therefore, a reasonably correct design result is essential.
Economic and HSE analyses:
At the end of the project, we carried out an economic analysis of the process. Using
the economic data provided, we calculated the CAPEX and OPEX of our process separately and
extrapolated the corresponding production prices. By comparing this with the queried market
price of methanol, we were able to make a preliminary assessment of the process
performance.
Furthermore, an HSE analysis was undertaken. The safety analysis was conducted to
reduce the probability of accidents and injuries by identifying and assessing potential hazards
and to safeguard the lives of employees and the public. The health analysis is designed to
ensure that the project has no negative impact on human health. We also calculated the CO2
emissions of the process in order to assess the impact of the project on the natural
environment.

Results
Final Product
We obtained at the end of our analysis the final product is composed of 63 % methanol and
9.23.10^-7 ppmwt of. Therefore, the methanol produced respects the specification required.

Costs analysis
Fixed Capital
Equipements ISBL ($) Investment ($) Share (%)
Vessels 100.461,94 401.847,76 4,05%
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 Reactor and catalyst 329.661,90 329.661,90 3,32%
Pumps 7.153,80 21.461,40 0,22%
Compressors 2.860.843,08 8.582.529,24 86,53%
Heat Exchangers 194.430,36 583.291,07 5,88%
Total: $3.492.551,08 $9.918.791,37 100,00%

As we can see, compressors are the most expensive equipment. The number of compressors
must then be optimized.

CO2 emissions

Global carbon footprint

CW (t-CO2/an) 227,5195392
Electricity (t-CO2/an) 21851,7024
MP-stream (t-CO2/an) 25689,08
CO2 outlet from process 7537,28
From H2 process 160000
Total (t-CO2/an) 215305,5819
CO2 emission total

CO2 emissions due to the production of H2 by electrolysis represent 74% of the global
emissions. However, the total footprint is less than the classic methanol process (

2. INTRODUCTION

2.1. GENERAL INTRODUCTION

E-methanol is a renewable energy source that is considered to be the key to
sustainable energy development in the future. It can be used as a chemical, fuel, and energy
storage medium, and can replace traditional petroleum-based fuels in many industrial
applications.
There is currently an increasing global focus on the production and application of e-
methanol. Several countries and regions have started to build e-methanol production facilities
to reduce reliance on fossil fuels and lower carbon emissions. It has been also used and tested
in practical applications in transportation, chemicals, and energy storage.
The manufacture of e-methanol has important implications: firstly, compared to
traditional petroleum-based fuels, e-methanol produces lower carbon emissions during
production and use. It can reduce greenhouse gas emissions, helping to combat climate
change and improve air quality. In addition, the production of e-methanol relies heavily on
renewable energy sources such as solar, wind, and biomass. It can reduce dependence on
limited oil resources and achieve sustainable energy use.

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 E-methanol can be prepared by a variety of production methods, two of the main ones
being biomass gasification and electrolysis of water to produce hydrogen and synthesize it
with carbon dioxide. Biomass gasification uses renewable organic materials to produce syngas
consisting of hydrogen (H2) and carbon monoxide (CO), which are then converted into
methanol by a catalytic reaction. Hydrogen and carbon dioxide synthesis, on the other hand,
uses electricity to decompose water into hydrogen (H2) and oxygen (O2) and then reacts the
hydrogen with carbon dioxide (CO2) to produce methanol.
The latter is also the subject of our project: in this industrial project, we propose to
use electrolytic hydrogen and carbon dioxide collected by a carbon dioxide capture unit,
supported by a catalyst, to prepare e-methanol.
This project will be carried out through numerical simulations on PROII software, the
sizing of various equipment, the construction of PFD and PID, as well as economic analyses
and finished by the calculation of CO2 emissions.

2.2. BIBLIOGRAPHIC ELEMENTS

In the early stages of the project, we conducted some research into the concept and
preparation process of e-methanol to understand how the project would be undertaken. The
preliminary research consisted mainly of identifying the chemical reactions that would take
place in the production, favorable operating conditions, and the selection of a suitable
catalyst; furthermore, we learned about the way the preparation of carbon dioxide and
hydrogen as feedstock and the application of methanol.
We started with a preliminary design for the industrial production of methanol, which
consisted of compressing the raw material, methanol synthesis, recycling, and collecting the
methanol product. The following is an initial process design flowchart:

Figure 1. Process Design Flowchart

Based on bibliographic research, for the synthesis reaction of methanol, the ratio of
reactants hydrogen to carbon dioxide is approximately 3:1 and that the production is
accompanied by the production of carbon monoxide as a by-product. The following equation
shows the main reaction equation (1) and the side reaction equation (2):
CO2 + 3H2 = CH3OH + H2O ΔrH = -49,51 kJ/mol (1)
CO2 + H2 = CO + H2O ΔrH = 41,17 kJ/mol (2)

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 Equations 1 and 2. Reaction of synthesis.

Moreover, we also understand from the literature consulted that favorable operating
conditions include reaction temperatures in the range of 200-300°C and reaction pressures in
the range of 50-100 bar. Since the primary reaction is an exothermic reaction, low
temperatures are favorable for the reaction equilibrium to advance. This is because the lower
ambient temperature allows the system to dissipate heat more efficiently and avoid
overheating; the sum of the gaseous reactant coefficients of the main reaction is greater than
the sum of the gaseous product coefficients, and according to Le Chatelier's Principle, high
pressure drives the reaction equilibrium in the direction of the products. A relatively low
temperature and high-pressure reaction environment is therefore our first choice.
To make the reaction progress more easily, copper/zinc oxide compounds are often
added as catalysts, and sometimes additives such as Al, Zr, Cr, and Ga are also added to
improve the reaction performance.
For the collection of reaction materials, hydrogen is obtained by electrolysis of water
molecules in an electrolytic cell using renewable energy sources such as solar photovoltaic or
wind energy, which decomposes the water molecules and forms hydrogen and oxygen. For
carbon dioxide, we use captured carbon dioxide. The most common technologies for
capturing carbon dioxide are chemical absorption, physical separation, membrane separation,
etc.
Methanol also has a great variety of industrial applications: as a versatile compound,
methanol can be used to produce chemical derivatives such as formaldehyde, acetic acid,
methyl tertiary butyl ether (MTBE), and dimethyl ether (DME). In addition, methanol also
serves as a fuel substitute, for example by blending with gasoline to produce DME and/or
biodiesel.
2.3. PROCESS PRINCIPLE
First of all, it is essential to select the production process as the basis of the project, as
this will be related to the selection of the type and amount of raw materials, the
determination of the reaction conditions, and a number of other subsequent processes.
According to the documentation provided, the process chosen is a carbon dioxide
hydrogenation process, which is depicted in the following simplified diagram:

Figure 2. Simplified Concept diagram

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 As shown in the document Process Design Basis, we know that the temperature and
pressure of the hydrogen and carbon dioxide as reactants are below what is required for the
reaction conditions. The two reactants have to be pressurized separately, and when the
pressure reaches the reaction pressure both of them will be mixed and then heated up
together to the reaction temperature and enter the reactor.
The methanol product obtained after the reaction is in the gaseous state and needs to
be cooled down and then fed into the drum. As the production rate is low compared to the
amount of reactant input, the unreacted reactant needs to be recovered, pressurized and
recycled in order not to waste the reactant. At the same time, the side reactions produce
carbon monoxide which, when accumulated in excess, will inhibit the production of methanol,
for this reason, a purger is added alongside the recycle to reduce the accumulation of carbon
monoxide by dosing it out. The cooled crude liquid methanol passes underneath the drum
and is fed into a separate drum for storage.
It should be noticed that the pre-pressurization of the reactants is not done all at once,
but in a step-wise manner; also the temperature of the reactants rises along with the different
pressurization, but in order to meet the prerequisite that the compressor outlet temperature
should not be higher than 140 degrees, we need also cool it down before each compression.
In the second place, in order to save energy, we implement the integration of the heat
exchangers before and after the reactor on the basis of thermal integration in order to transfer
and reuse energy. The simplified diagram shown above only represents the rough process
flow, for details of the process please refer to the PFD diagram shown later.

3. PROCESS CALCULATIONS
3.1. PROCESS SIMULATION
For the simulation of processes, we used PROII, a simulation software that allows us
to simulate and analyze various process operations and process parameters. PROII's
simulation data also allows us to build up mass and material balances and design equipment
sizes using.
The main objective of the simulation is to optimize the process to improve the
efficiency and performance of the equipment by varying the simulation parameters so that
the methanol product meets the specifications. In addition to this, we are required to design
all process equipment based on the simulation data obtained (e.g., temperature, pressure,
flow rate) and to estimate the energy consumption generated and the overall cost of building
the process.

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 3.1.1. Simulation Design requirements :
The design of the methanol installation will be associated with a 250 MW electrolyzer,
which will produce 50 000 Nm3/h of pure hydrogen. The carbon dioxide feedstock is provided
by a carbon dioxide capture unit.
From this determined oxygen feed, we need to calculate the corresponding required
CO2 feed, as well as the content of the other gas components.
The aim of the simulation is to maximize methanol production. The methanol
produced after completion of the simulation needs to meet the condition below :
◼ H2 content (ppmwt) < 10
This is because our product, methanol, is an important chemical raw material and its
purity is highly demanded in many applications. High levels of hydrogen can affect the purity
and quality of methanol. In addition, hydrogen is a flammable and explosive gas, which poses
certain safety risks during handling and transport. For safety reasons, reducing the hydrogen
content in methanol decreases the potential risk of fire and explosion and increases the safety
of the production process.

3.1.2. Considered Units for the Simulation:

The units used in the simulations are defined by the Process Design Basis and are
summarised in the following table:

Figure 3. Defined Units

Standardised, uniform units can ensure the accuracy of calculations, improve the
efficiency of simulations, facilitate comparison of results and exchange of data, as well as
ensuring consistency and reproducibility of modelling.

3.1.3. Thermodynamic Model :

According to the process design basis, the SRK and Lee Kesler methods are chosen for
the enthalpy calculation of thermodynamic models.

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 As one of the most commonly used models in thermodynamic calculations, the SRK
and Lee Kesler methods are widely used in thermodynamic simulations and calculations of
industrial processes. The SRK method is an equation of state which is highly accurate in
describing the behaviour of non-ideal gases and gas-liquid phase equilibria. The Lee Kesler
method is applicable to a wide range of gas and liquid systems.
The SRK and Lee Kesler methods provide more accurate results in industrial methanol
production processes involving the behaviour of liquid phases at high pressures and
temperatures, such as enthalpy calculations and phase equilibrium calculations for liquid-
phase mixtures.

3.1.4. Inlet Composition and Battery Limit Conditions :

The following is the feedstock composition of the raw materials H2 and CO2 and Battery
Limit Condition provided by Process Design Basis.

Figure 4. O2 Feedstock

Figure 5. CO2 Feedstock

Figure 6. Battery Limit Condition

By setting a battery limit condition, the boundaries of the system design can be
clarified, helping to ensure that important components are not overlooked or missed by our
group during the project. Additionally, the battery limit condition ensures consistency and
control throughout the engineering design process. Once it has been set, each group must
design the system within this condition, ensuring coordination and consistency between the
various components.

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 3.1.5. Reactant heating and pressurisation
Based on the hydrogen and carbon dioxide conditions provided by the Battery Limit
Condition, we found that the basic conditions for methanol production were not met
compared to the temperature range of 200～300 degrees and the pressure range of 50～100
barg indicated by the preliminary research. Therefore, at the beginning of the process, we set
up a series of compressors and heat exchangers to gradually pressurise and raise the
temperature. The PROII simulation is illustrated below.

Figure 7. Compressors and Heat Exchangers in simulation

To begin with, as hydrogen and carbon dioxide have different feedstock pressures, we
need to first pressurise the carbon dioxide once to bring it to roughly the same pressure range
as the hydrogen feed. This is because when there is a large difference in concentration and
pressure between the one and the other, the efficiency of the following pressurisation may be
limited by the lower concentration of the substance, thus affecting the efficiency of the
compressor, and causing unnecessary losses.
Another reason is that a one-step increase in pressure may lead to instability and
operational difficulties in the reaction system, which adds to the load and safety risks of the
equipment. We therefore need to gradually increase the pressure in order to better control
and regulate the reaction system and provide better flow and operational safety.
Below are the operating pressures of the compressors we use. For the choice of a final
pressure of 85barg we will explain in the reactor section.

Figure 8. Compressor Pressure Settings

The calculation of the polytropic efficiency is essential to determine the actual shaft
power. Based on the equations provided by Process Design Criteria, we have also calculated
the polytropic efficiency for each of the three compressors and the results are as follows:

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 Figure 9. Compressor Efficiency

According to the requirements for the design of the simulated compressor, we needed
to comply with the basic condition that the compressor outlet temperature should not exceed
140 degrees Celsius. In order to meet this limit, we have placed separate heat exchangers
before the compressors to cool down the heat in time. In addition to this, as all our fluids are
gaseous in the pre-process stage, each heat exchanger has to be set at a pressure drop of 0.3
bar according to the Process Design Criteria.

3.1.6. Reactor
To focus on the process simulation, design and optimization, reactors will be
considered as a Gibbs reactor. According to our research, this should be because the Gibbs
reactor allows the use of different reaction kinetic models to describe the rate of chemical
reactions. Furthermore, it can consider the transfer of substances and energy between the
different phases (assuming that some of our products are liquid) to better describe and
optimise the reaction process in terms of transfer phenomena. The following table shows the
basic conditions of the reactor:

Figure 10. Defined Reactor Conditions

With the information provided, we found that the reaction temperature and pressure
needed to be defined by ourselves. To this end we have implemented a series of simulations
to find the relatively optimum reaction conditions.

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 For the reaction temperature, it is known that a range of suitable reaction
temperatures is between 200 and 300 degrees and that the main reaction is exothermic, so a
relatively low temperature is favourable for the reaction equilibrium to move in the direction
of methanol production.
For this reason, ten sets of temperature conditions were simulated from 200 to 300
degrees Celsius, using 10 degrees Celsius as an interval. By comparing the hydrogen content
(i.e. the hydrogen conversion rate) at the outlet of the reactor with that at the inlet, we
concluded that 200 degrees was the most favourable temperature for methanol preparation.
Later on, on the advice of our Technip tutor, we set the reaction temperature to 207 degrees.
This is because the PROII simulation always gives a theoretical result, and a small deviation of
temperature is necessary to ensure that our reaction can reach 200 degrees.
For the determination of the pressure, we then simulated six sets of data from 50 to
100 barg by varying the working pressure of the last compressor in intervals of 10 barg
respectively. The final methanol production was compared to select the appropriate working
pressure.

Figure 11. Relation between Methanol Product Mass and Recycle Rate

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 Figure 12. Relation between Power and Pressure
As can be seen from Figure 11, a higher pressure results in a better final yield of
methanol. However, when taking into account the effect of the recycle rate, we found that
with a high recycle rate, it is possible to achieve a high methanol yield at a medium pressure.
At the same time the Shaft Work of the compressor is also an aspect to be considered: high
energy consumption is not desired. Finally, according to Figure 12, we chose to use 85barg
(98% of the cycle rate) as our reaction pressure after a compromise.

3.1.7. Reactant Recycling and Purge

Figure 13. Recycling Loop and Purge

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 After exiting the reactor, the product cooled by the heat exchanger is separated in a
vertical vessel and we have set up a recycling circuit to ensure process performance. The
circulation has the following implications.
The first thing we found, based on the first few simulations without recycling, was that
the effective conversion rate of the reaction was extremely low due to the very large amount
of reactants we had.
If unreacted reactants were to be discharged directly, this would result in significant
waste and pollution. By recycling the unreacted reactants, we can maximise the use of raw
materials and reduce the amount of waste generated.
Secondly, recycling can increase the effective concentration of reactants and promote
further reactions, thus increasing the conversion and yield of the reaction.
At the same time, we considered that a simple recycle would result in the
accumulation of carbon monoxide as a by-product, which could potentially reduce product
purity, inhibit catalyst activity or cause undesirable reactions. We have therefore included a
purge at the same level as the recycle in order to periodically remove the accumulated by-
products from the reaction system and to maintain the stability and efficiency of the system.
In addition, this reduces the contact time and concentration of by-products to the
catalyst, thereby extending the life of the catalyst and protecting its activity.

3.1.8. Vessels
In our simulations, we have used the vessel for separating liquids and gases several
times. They are shown in the following diagrams:

Figure 14. Vessels for Separation of Liquids

The two vessels in this diagram are located before the compressor, this is because the
liquid can cause damage to the compressor. The vessel separation device makes it possible to
separate the liquid from the gas, thus reducing the load on the compressor and ensuring it
works efficiently.

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 Figure 15. Vessels for Separation of Gas
In this diagram the first vessel is used to collect the crude methanol product after
liquefaction and to transport the methanol out of the lower outlet. The upper outlet is then
used and delivers the unreacted gaseous reactants into the recycle.
The second vessel separates the further transformed methanol product again to avoid
the possible presence of gas or air bubbles in the liquid entering the pump. Since this can
cause a cavitation effect, which can adversely affect the performance and efficiency of the
pump. Prompt separation of excess gas allows for reduced pump wear and failure and
increases the efficiency of the overall system.
In order to simulate vessel, the following assumptions were considered:
i) The vessel is isenthalpic :
𝐷𝑢𝑡𝑦 = 0
ii) No pressure drop in the vessel :
∆𝑃 = 0

3.1.9. Heat Exchange and Thermal Integration

In our initial version of the simulation, we used separate heat exchangers for heating
and cooling in order to meet the temperature requirements. To improve the performance of
the process, we carried out a thermal integration of the different functional heat exchangers
to realise the recovery and reuse of thermal energy. This contributes to increased energy
efficiency, reduced dependence on external energy sources and lower energy costs.

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 .
Figure 16. Heat Exchanger for Thermal Integration
First of all, we describe the available heat in the process stream using the PINCH
method and from this we derive the range of possible areas where thermal integration can
take place. This is an indispensable first step in heat integration.
Overall, since we have only one heat exchanger for heating, while the rest of the heat
exchangers are used for cooling. We have therefore constructed the following graph:

Figure 17. Pre-PINCH Representation

As can be seen from the graphs, the heat exchangers in the initial version of the
simulation in front of the reactor (E3) and behind the reactor (E4) are the most suitable for
thermal integration, as they have a pinch point. We then used this as a basis and manually
calculated the possible cooling junctions, as shown in the following figure：

Figure 18. Pre-PINCH Calculation

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 However, this is an inaccurate extrapolation because theoretically after the gaseous
methanol product has been cooled down by the heat exchanger at the reactor outlet, a part
of the phase will condense, so this will not be a linear line.
With the help of PROII, we therefore simulated an integrated heat exchanger E-003
and set the fluid in which it performs heat exchange to the corresponding stream in the main
process. Using the heat exchange analysis tool in PROII, a temperature variation curve was
drawn, as shown in the following figure:

Figure 19. Heat Exchanger Analysis

This diagram clearly illustrates the condensation phenomenon of the phase, while we
found that this thermal integration could not simultaneously meet the temperature rise and
fall requirements before and after the reactor. This is why in the simulation we added a heat
exchanger after the hot and cold products respectively: to ensure that the temperature was
raised or lowered to the temperature we had designed.

3.1.10. Water Tank

Although it is not directly represented in the PROII simulation, we have used a
simulated heat exchanger to represent a water tank that could be set next to the reactor. This
is illustrated in the PFD below:

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 Figure 20. Water Tank in PFD
In this tank we pass into the Boiling Feed Water with the following conditions :

Figure 21. Defined Boiling Feed Water Condition

Its main function is to control the temperature, as exothermic reactions generate large
amounts of heat. The water cycle is used to effectively dissipate heat from the reactor to keep
it at the reaction temperature we set, preventing high temperatures from inhibiting the
reaction. In addition to this, high temperatures can also lead to an increase in pressure inside
the reactor, so this water circulation also indirectly helps to control the pressure in the reactor
and keep it within safe limits.
Furthermore, the water circulation tank can be used to recover the heat released by
the reaction. The heated Boiling Feed Water is then exported as water vapour, which can be
utilised for heating other processes, thus increasing energy efficiency.

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 3.1.11. Simulation results :

Figure 22. Methanol Product Result

The complete simulation data results are in the Heat & Mass Balance. The above graph
shows the methanol product information obtained from the simulation. Based on our
designed process simulation, we can obtain 22,790kg/hour of methanol production, which is
a good yield. We also have observed that the hydrogen content meets the Process Design
Basis requirement of less than 10ppwt, so our final methanol yield is in line with the project
criteria.

3.2. EQUIPEMENTS SIZING

The equipment sizing is divided into six parts, each one of which corresponds to a
different equipment category: vessels, piping, reactor, heat exchanger, compressor, and pump.
Each equipment category has its own characteristic dimensions that are interesting for the
calculation of the final price but also for the proper functioning of the process. Together with
the equations that were given, the process simulation and the PFD the sizing process is
described below.
In each equipment category, a design temperature and pressure were used. They are
obtained by different relations. Regarding the design temperature, the following relation is
used.
𝑇𝐷 = 𝑇𝑀𝐶𝑂 + 15℃ (3)
Equation 3. Design Temperature

Regarding the design pressure there are two different relations: one for the equipment
(vessels, piping, reactor, heat exchanger and compressor) and the other one for the discharge
of pumps.

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 3.2.1. VESSELS

In this process, there are six vessels in total represented in the simulation, one of them
(V01 as its PROII name) is only a simulation tool, so there is no need to represent it neither in
the PFD nor in the sizing since it will not be used in the real process plant. Therefore, five
vessels were sized, four of them are vertical vessels and one of them is horizontal, the last one
is not represented in the PRO II Simulation, since it is only a real-life tool for the process
functioning.
The vessel sizing starts with the specification of the design temperature and pressure,
then followed by the identification of the inlets flows in each vessel. One of the vertical vessels
(C-002) had two inlets, so the parameters were considered as the ratio of the parameters of
each inlet. Other simulation parameters such as liquid fraction, volumetric flow, liquid and
vapor density were also identified to its future utilization in the calculations. In the following
tables, these parameters are presented for each equipment. Also, it was identified the vessels
that needed to have Mash Pad or not, since this is a key information for some sizing
calculations.

Table 1. Vessels sizing parameters.

Subsequently, it is important to establish a critical vapor velocity for each vessel which
will guide all the other size parameters. This critical vapor velocity is calculated by the
following equation. But, depending on the presence or absence of Mash Pad this velocity will
be multiplied for a security factor of 2.2, if there is Mash Pad, or 0.8, if there is not. Except for
the horizontal vessel, it is necessary to multiply its critical vapor velocity by a factor of 170%.
Moreover, another difference between the horizontal vessel that differs from the vertical
vessel is that its final diameter must be increased by a factor of security that corresponds to a
HHLL and LLL marge.

𝜌𝐿 −𝜌𝐺
𝑣𝑐 = 0,048√ (4)
𝜌𝐺

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 Equation 4. Critical vapor velocity.

The volumetric flow is multiplied also by a security factor of 1.1 and after that it is used
for calculating the cross-sectional area of the Vessel with the following equation to obtain an
initial value of the area and consequently an initial value of the diameter.

𝑚3
𝑚 𝑄( )
𝑠
𝑣𝑐 ( 𝑠 ) = 2
(5)
𝐴 (𝑚 )

Equation 5. Critical vapor velocity related to the vessel flow and area.

𝜋𝐷 2
𝐴= (6)
4

Equation 6. Vessel Area.

Once we obtain the initial diameter, it is possible to obtain the first estimation of the
equipment height, knowing that the maximum height is equal to four times the diameter of
the equipment and the minimum height is equal to two times the diameter of the equipment.
Other parameters calculated in this part are the corrosion allowance, the maximum
allowable stress value and the equipment thickness, since they are parameters that depend
on the type of flowing process, the design temperature and the diameter of the vessels. The
following table gathers these parameters.

Table 2. Corrosion allowance, the maximum allowable stress value and equipment thickness.

To calculate the final diameter of each vessel, it is crucial to consider the pressure drop
in the lines connected with them but also the requested liquid level control. Therefore, it is
important to find a new diameter using the initial diameter and incorporating those other
pressure and liquid level constraints. An interactive process is done to find the adequate
diameter that can respect the conditions of maximum and minimum height (between two and
four times the diameter of the equipment).
This interactive process consists of choosing an initial diameter (for most vessels we
choose 1m of diameter), which will be used together with the found value of nozzle diameter
(calculated in the piping section) to calculate the small heights level control (h1, to h7) that

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depend on the value relation between the equipment diameter and the nozzle diameter, this
relations were found in the Process Design Criteria. The nozzle diameter is equal to the pipe
diameter associated to the vessel of interest. After calculating all the small heights with the
initial equipment diameter, they are summed to find the initial height. This height is compared
to the initial equipment diameter to verify if the height is in between the maximum and
minimum height rule. If this condition is not met, then a new equipment diameter must be
set, and the calculation takes place again. This process is repeated until a coherent equipment
diameter, height, cross-sectional area and volume are found.
In the case of the horizontal vessel, the initial diameter was already coherent with the
other dimensions of the vertical vessels. Then, it was just adjusted by adding the correction
factor of 20% of its diameter for the HHLL and a height of 300 mm for the LLL. The final values
for the Vessels are reunited as follows.

3.2.2. PIPING

The Piping Sizing is important for the Vessel Sizing as well as the PID representation.
All the Piping appearing in the PID and those that were considered as the inlets of the vessels
were sized, therefore, fifteen lines should be sized but since some of them were referred to
the same flows in the simulation, only 9 lines were sized. The lines were divided into liquid,
mixed and vapor lines, each line type has its own categories of classification that also changes
the calculation that needed to be done. In the following table, the lines names together with
its classifications are resumed.

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 Table 3. Classification of lines.

For the liquid lines, the sizing starts with the choice of the velocity, with which the
cross-sectional area is found and subsequently the line diameter can be obtained. For this
reason, the liquid density and volumetric flow in each line is needed and they can be obtained
from the PROII Simulation. The velocity and the diameter are associated with each other.

Thus, it is possible to relate the value of the velocity and the diameter until they meet
the conditions of maximum velocity and corresponding diameter present in " Process Design
Criteria". Once the velocities are chosen, the pressure drop calculation takes place and the
diameter chosen will be readjusted until an acceptable value of pressure drop is reached. For
the pressure drop in liquid lines the equations used were those indicated for single phase
lines. The following equations were used and a value of 0,0018" was used for the absolute
roughness of the carbon steel pipe.

𝐿 𝐺2
∆𝑃 = 𝐹𝐷 . 𝐷 . 2𝜌 (7)

1
8 12
12
1
𝐹𝐷 = 8. [(𝑅𝑒) + 3 ] (8)
(𝐴+𝐵)2

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 16
1
𝐴 = [2.457. ln ( 7 0,9 0,27.𝜀
)] (9)
( ) +
𝑅𝑒 𝐷

37530 16
𝐵=( ) (10)
𝑅𝑒

Equation 7 to 10. Liquid phase lines pressure drop calculation process.

Although the pressure drop does not correspond exactly to the provided normal and
maximum pressure drop, the results were considered acceptable since they are in the same
order of magnitude as the ones requested. This could also be due to the diameter chosen
having to be standardized into integers and the inlet flows being relatively small. The results
found for the liquid lines were gathered in the following table.

Table 4. Liquid lines results.

For the mixed lines, the vapor fraction was obtained from the PROII Simulation to
calculate the pressure drop mixed. Besides the condition of the pressure drop for mixed lines
also must respect a condition between the value of the density and velocity of the fluid, as
shown by the following relations:

2
5000 𝑃𝑎 < 𝜌𝑚 𝑣𝑚 < 15000 𝑃𝑎 (11)

Equation 11. Condition of density and velocity.

As for the classifications of the liquid lines, the classification Partial Condenser Outlet
(General liquid) was chosen for the outlet lines of heat exchangers and the category of Mixed
Phase Condensates was chosen for the rest of the lines. The calculations of the pressure drop
for the mixed line were based on the given model of pressure drop for two phase flow. This
model is based on the following equations.

∆𝑃 ∆𝑃𝐿 ∆𝑃 ∆𝑃𝑉 ∆𝑃𝑉

= + 𝐶. √ ∆𝐿𝐿 . + (12)
∆𝐿 ∆𝐿 ∆𝐿 ∆𝐿

𝜌 𝜌
𝐶2 = √𝜌 𝐿 + √ 𝜌𝐺 (13)
𝐺 𝐿

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 𝜌 𝜌 0,125
𝐶3 = √ 𝜌𝐻 . (𝜌 𝐿 ) (14)
𝑉 𝑉

𝜌𝐿 .𝜌𝐺
𝜌𝐻 = 𝑥.𝜌 (15)
𝐿 +(1−𝑥).𝜌𝐺

32.𝑌
𝐶1 = 2 + (16)
1+1,005664.𝐶𝐹0,8

3
𝑌 = [1 − [0,16. (2,5 + log(𝑋))2 ]] (17)

𝜌𝑉 𝜇 0,2
𝑋 = max [0,00316; . ( 𝐿) ] (18)
𝜌𝐿 𝜇𝑉

(300−𝐺)2
𝐶𝐹 = 𝐺 , if 𝐶𝐹 < 300, then 𝐶𝐹 = 300 + (19)
40

Equation 12 to 19. Mixed phase lines pressure drop calculation process.

The priority established was to obey the maximum velocity in the line and then with
the resulting diameter calculate the pressure drop until a reasonable value was found. Lastly,
the velocity was adapted to follow the condition of integer value to the diameter size. The
final pressure drops were considered high in comparison to the references, but this can be
justified by the fact that the flow rating was very low in these lines, so it was necessary to
establish a low velocity to a minimum pressure drop and a coherent piping diameter. The
following table resumes the final values for the chosen velocities and pressures drops.

Table 5. Mixed lines results.

For the vapor lines, the lines were categorized as normal gas lines since they were not
related to any compressor, columns, reboilers or steam lines. The vapor lines were classified
as pump suction bubble point, because the line presents gases dissolved in it, and pump
discharge (with a pressure smaller than 50 bar), because of the location and the pressure of
the line. Once the gas lines do not have pressure drop restrictions, the only calculation made

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in this part was to respect the condition between the density and the velocity chosen, as
shown by the equation below.

6000 𝑃𝑎 < 𝜌𝑣 2 < 15000 𝑃𝑎 (20)

Equation 20. Condition of density and velocity.

The adequate velocity was chosen to obey the condition above and to obtain an
integer value of diameter. In the table below, the chosen velocities and diameters are
represented.

Table 6. Vapor lines results.

3.2.3. REACTOR

Above all, it is necessary to obtain the volumetric feed of the reactor PROII Simulation
since it is the only parameter needed for the calculation. This value was equal to the
volumetric inlet flow of the line INLET_FIN. With this inlet flow, it is possible to calculate all
the parameters of interest, such as the diameter, length, and reactor volume. The equations
used are described below.

𝑄
𝑉 = 𝐺𝐻𝑆𝑉 (21)

Equation 21. Reactor volume and GSHV as being Gas Hourly Space Velocity (1/h).

The final values are resumed in the following table. We used 3 as the factor between
the length and the diameter, which could be chosen between 2 and 4. Although the final value
of 2 m³ for the whole reactor is not acceptable and relatively small for the parameters of an
industry, it is possible to justify this value with the small volumetric inlet in comparison to the
required GHSV given.

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 Table 7. Reactor results.

3.2.4. HEAT EXCHANGER

There are six heat exchangers in the PROII Simulation but only five of them are really
concerned with industrial installation, in the PFD and PID, thus only five heat exchangers were
sized.
Firstly, each heat exchanger is identified with its utility fluid, which was chosen
whether the heat exchanger was a condenser or a reboiler and whether the working
temperature was close to those of the utility’s fluids. For the equipments E-001, E-002, E-003,
and E-005 cold water (CW) was used as the cold fluid and for the E-004 medium pressure
steam (MP Steam) was used as the hot fluid.
The minimum approach temperatures were given, and they were inserted into the
PROII Simulation to obtain more information about the heat exchanger parameters, and they
were also used to obtain the outlet temperature of the cold side utility. With this information,
it was possible to obtain the correction factor, Ft, the logarithmic temperature difference,
LMTD, and the energy flow of each heat exchanger.
Next, the heat exchangers were classified according to their service and utilities fluids
to obtain the heat transfer coefficient, U. The E-001 and E-002 were classified as Inert Vent
Gas Chiller, the E-003 was classified as Feed Reactor/Effluent reactor, the E-004 was classified
as Effluent Reactor / Saturated steam and the E-005 was classified as Effluent reactor/CW.
Once we obtain all the parameters, we can calculate the area of heat transfer by the following
equation.

𝑄 = 𝑈. 𝐴. 𝑀𝐷𝑇 (22)

Equation 22. Area of heat transfer.

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 The final parameters for each heat exchanger are represented in the following table.

Table 8. Heat exchanger results.

3.2.5. COMPRESSOR

There are three compressors in total in the present process and all of them are used
in the real-life industrial plant. The first information needed is the presence or absence of
recycling flow in the compressor inlet. Afterward, the compressor inlet line must be identified,
and its temperature, shaft work, pressure, and volumetric flow are obtained from the PROII
Simulation and noted. If there is a recycling flow in the current equipment, then the
volumetric flow will be multiplied by a factor of 5%.
With all the updated values of the volumetric flow and the following equation, the
efficiency of each compressor is obtained.

𝑄 𝑄 2
𝑉 𝑉
𝜂 = 0,751 + 0,01985. ln (8500) − 0,02. (ln (8500)) (23)

Equation 23. Compressor Efficacity.

The final parameters for each compressor are represented in the following table.

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 Table 9. Compressor results.

3.2.6. PUMP

In the current process, only two pumps were needed in the final line of the methanol
product but only one pump was sized since the two of them have the same characteristics.
For the sizing of the pump, some parameters of the PROII Simulation are needed, such as:
volumetric flow, inlet line vapor pressure, pump pressure drop, efficiency, differential head,
and density of the inlet flow. Other parameters were obtained from the vessels and piping
sizing, namely the design temperature and pressure, the LLL of the vessel C-005, the pressure
drop in the suction and the difference of pressure in the suction and discharge lines. Still, the
water density was obtained from the literature as equal to 997 kg/m³ [XX]. The parameters of
control equipment, pressure drop, pump suction and discharge height were given. All the
values used for the calculations are resumed in the following table:

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 Table 10. Pump parameters.

The volumetric flow must be multiplied for a correction factor of 1.1. Other parameters
such as the liquid minimum heigh (∆𝐻𝑠 ) are obtained from the C-005 vessel sizing and
corresponds to the LLL plus 1 m as suggested. Also, in some calculations it is considered the
relative density, that is equal to the liquid density divided by the water density.
Two different methods were considered in the pump sizing, one method using only
the equations and relations given (Calculation 1) and the other using also the notions of
Bernoulli pressure drop (Calculation 2). Each method will be explained in the sequence.

3.2.6.1. Calculation 1

In "Calculation 1", all the parameters available – such as difference of pressure in the
pump, volumetric flow and pump efficacity - in the PRO II Simulation were used. With them,
it is possible to calculate the power with the equation 24. This value is only a basis value to
find the nominal power, that is found by following the instructions in "Process Design Criteria".
Since it is smaller than 22 kW, a factor of 1,25 is multiplied to it to find the nominal power.
With the nominal power it is possible to find the performance, by the values on the table X.

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 (24)

Equation 24. Pump power consumption in kW.

Figure 23. Pump nominal power.

Primary to the NPSH calculation, it is necessary to calculate the ℎ𝑠𝑚𝑖𝑛 and the ∆𝐻𝑠
with the following equations.

(25)

Equation 25. Minimum height suction.

(26)
Equation 26. Height suction variation.

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 For the pressure drop at the suction, the value of the suction pressure drop was found
by the Equation X. With ∆𝑃𝑠𝑢𝑐𝑡𝑖𝑜𝑛 𝑙𝑖𝑛𝑒 as the pressure drop HC 006/008 line for the 30 m
suction line.

(27)
Equation 27. Pressure drop suction.

Then the ℎ𝑠𝑚𝑖𝑛 is calculated. Finally, the NPSH can be obtained with the equation
below. For the 𝑃𝑠𝑣𝑚𝑖𝑛 , is ℎ𝑠𝑣𝑚𝑖𝑛 used.

(28)
Equation 28. Pump NPSH.

In this calculation procedure, the pump performance was very low, smaller than 70%,
since the nominal power was also very low. Although, the NPSH obtained had a value bigger
than 3 m, that means It presented no cavitation. These results are coherent with the PROII
Simulation values, from where the parameters were obtained. It is important to notice that
the pump sized was not crucially important to the process in terms of power availability
because of the great pressure that the vessel C-005 and the lines in the suction were already
submitted.

3.2.6.2. Calculation 2

In "Calculation 2", the pressure drop of every control equipment was considered, as
well as the efficiency obtained from the correlation shown in figure above and the pressure
drop at the pump discharge. The pressure calculation was based in Bernoulli's model, as the
following equation 29 shows, although the velocity term was neglected.

1 1
𝑃1 + 2 . 𝜌. 𝑉12 + 𝜌. 𝑔. ℎ1 = 𝑃2 + 2 . 𝜌. 𝑉22 + 𝜌. 𝑔. ℎ2 (29)

Equation 29. Bernoulli's principle.

For the power calculation the same equation was used, but the pressure drop, and the
efficiency was calculated in a different manner. Starting with the pressure drop calculation,
first, it was obtained separately, the values of the suction and the discharge pressure. The
equations 30 to 31 were used.

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 𝑃𝑑𝑖𝑠𝑐ℎ𝑎𝑟 = 𝑃𝑓𝑖𝑛𝑎𝑙 + ∆𝑃𝑣𝑎𝑙𝑣𝑒 + ∆𝑃𝑐𝑜𝑛𝑡𝑟𝑜𝑙 𝑓𝑙𝑜𝑤 + ∆𝑃𝑑𝑖𝑠𝑐ℎ𝑎𝑟 𝑙𝑖𝑛𝑒 (30)

𝑃𝑠𝑢𝑐𝑡𝑖𝑜𝑛 = 𝑃𝑣𝑒𝑠𝑠𝑒𝑙 + 𝜌. 𝑔. (ℎ𝑠𝑣𝑚𝑖𝑛 − ℎ𝑝𝑠) − ∆𝑃𝑓𝑖𝑙𝑡𝑒𝑟 − ∆𝑃𝑠𝑢𝑐𝑡𝑖𝑜𝑛 𝑙𝑖𝑛𝑒 (31)

Equations 30 and 31. Discharge and suction pressure.

The efficiency was found by the values of volumetric flow and the pump head, using
figure above, the value found was 51.7 %. Afterwards, the ∆𝐻𝑠 is calculated with the same
equation as in "Calculation 1" as well as ℎ𝑠𝑚𝑖𝑛 . Lastly, the NPSH is calculated by the same
equation.

Figure 24. Correlation between volumetric flow and pump head

The nominal power obtained in this calculation method is significantly greater than
that found in the first calculation method which results in higher performance as well (85%).
However, in this case the results are not coherent with the PRO II Simulation results.
Moreover, the NPSH obtained was a negative number, which has no physical meaning. That
problem was due to the value of vapor pressure being greater than the pressure in the C-005
Vessel.

The final parameters for the pump are represented in the following table.

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 Table 11. Pump results.

4. PROCESS ANALYSIS
4.1. HEALTH, SAFETY AND ENVIRONMENT
4.1.1. HEALTH

Figure 25. Danger methanol

Methanol is a colorless, volatile liquid that can be toxic when ingested, inhaled or in
contact with the skin. It is therefore essential to implement personal protection measures,
such as appropriate protective equipment (gloves, masks, safety glasses), as well as safe
handling procedures to avoid direct contact. The actions that can be taken for the health are:
Workers training: Workers must be informed of the health risks associated with methanol,
including exposure by inhalation, skin contact, or accidental ingestion. They must also be
trained in good methanol handling practices, including the use of personal protective
equipment (PPE) such as gloves, safety glasses and protective suits.
Exposure control measures: Procedures should be in place to minimize worker exposure to
methanol, such as adequate ventilation of work areas, and proper storage and handling of the
product. implementation of containment and vapor capture systems, as well as air quality
monitoring.
Personal hygiene: Adequate sanitary facilities must be available for workers, including hand-
washing facilities and showers.

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 4.1.2. SAFETY

The table below shows the causes, consequences and actions that can be taken for the safety
of the personnel.

Causes Consequences Actions to be taken

Fire and - Leak detection

Methanol leaks explosion hazards systems and prevention of leaks
quick response.

- Regular inspection of
equipment, piping and valves to
identify and repair leaks.
- Use of chemical-
resistant materials and seals
quality seals.
Exposure to Health problems - Use of adequate
methanol vapors ventilation to remove vapors of
methanol.
- Use of personal
protective equipment (PPE)
such as breathing masks, safety
glasses and overalls.

- Training workers on
the health risks associated with
methanol exposure and
preventive measures.
Fires and Injuries, loss of - Implementation of
explosions life fire detection and suppression.

- Worker training on
evacuation procedures and
measures to combat fires.

- Regular maintenance
of fire protection equipment.
Chemical Spills, toxic -In-depth assessment
unwanted reactions discharges of potential chemical reactions
and product incompatibilities
chemicals used.
- Proper storage and
handling of chemicals to avoid
spills.
- Training workers in
reaction management
procedures chemicals.

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 Failure to comply Accidents, - Regular training of
with safety procedures. injuries workers in safety procedures
and procedures best working
practices.
- Regular monitoring
and auditing of safety practices
to ensure compliance.
- Investigate incidents
and accidents to identify root
causes and implement
corrective measures corrective
measures.

Isolation valves were also placed to isolate each device of the process. This ensures safety for
the employee in case of maintenance. Furthermore, we connected another pump in parallel
to the main one in case of maintenance needs.

6.1.3 ENVIRONMENT

Causes Consequences Actions to be taken

Waste management Soil and water - Setting up appropriate waste management systems
pollution
- Sorting, recycling and reusing waste whenever
possible
- Safe and proper disposal of hazardous waste

- Reducing waste generation at source

- Raising awareness and training staff on waste

management practices

CO2 emissions Contributing to - Adoption of carbon capture and storage (CCS)

change and the technologies
greenhouse effect - Encouraging research and development of low-energy
processes carbon emission

Air and water pollution Deterioration of air - Use of emission control systems to reduce
and water quality atmospheric emissions of pollutants

- Use of wastewater treatment systems to remove

contaminants before discharge

- Regular monitoring of air and water quality to ensure

compliance with standards environmental

- Implementation of waste management to minimize

discharges and impacts environmental

- Conservation and restoration of affected natural

habitats

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 - Promoting biodiversity and offset initiatives

- Integration of management principles in the

production unit's activities

Comparison between CO2 emissions from normal methanol synthesis and e-methanol
synthesis of our process:

CO2 emissions from other processes (source : Carbon footprint evaluation of coal-to-methanol chain
with the hierarchical attribution management and life cycle assessment Zhen Qin a,b , Guofu Zhai c , Xiaomei
Wu a,b , Yunsong Yu a , Zaoxiao Zhang)

Global carbon footprint

CW (t-CO2/an) 227,5195392
Electricity (t-CO2/an) 21851,7024
MP-stream (t-CO2/an) 25689,08
CO2 outlet from process 7537,28
From H2 process 160000
Total (t-CO2/an) 215305,5819
CO2 emissions from our process

It can be noticed that the CO2 produced from our process is less than the basic coal-
to-coal chain process. Furthermore, one solution is to install a secure CO2 capture and storage
system, then reinject it into the process. This reduces the impact on the environment.

4.2. TECHNO-ECONOMIC ANALYSIS

In addition to the technical feasibility of a process, the economic feasibility must also
be considered. The economic analysis in the following project is calculated from CAPEX
(Capital Expenditure) and OPEX (Operating Expenses). This results in the total price that has
to be spent for the realization of the process and thus the necessary information for the
decision-making.
4.2.1. CAPEX

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 First, the CAPEX (Capital Expenditure) of the project was estimated. This step consists
in quantifying the investment necessary for the acquisition of fixed assets or equipment
required to build and install a plant.
The calculation involves estimating the acquisition costs of the equipment and its
installation cost. Thus, the costs involved in each piece of equipment were calculated
according to the ratios provided in the Process Design Criteria. The following is a summary of
the equipment cost calculations.

4.2.1.1. Pressure Vessel

The calculation of the cost of the flashes was estimated based on the thickness. To
calculate it, we use the following relation:
∅
𝑃×( +𝑐)
2
𝑒 = 𝑆×𝐸 −0,6×𝑃 + 𝑐 (32)
Equation 32. Thickness

With: P [MPa]: Design pressure for vessel; E [-]: E=1; ∅ [mm]: diameter of each vessel;
c [mm]: corrosion allowance; S [MPa]: Maximum constraint.

Maximum allowable stress values, S, exist for several typical materials as a function of
design temperature. As the vessels were at a design temperature between 55 and 222 °C,
according to Process Design Criteria (figure 1 - Working limits for steels in hydrogen service to
avoid high temperature hydrogen attack), the appropriate material for the vessels is Carbon
steel. The choice of Carbon steel as a material has a positive impact on the economic analysis,
since between Cr-Mo steel and Stainless steel it presents the most advantageous cost-benefit.
Next, the thickness was used to find a relationship that would provide the volume
value of each vessel. Knowing the density of the carbon steel and the volume of the
equipment it was then possible to calculate the mass. Finally, the carbon steel price ratio given
in the PDC was used to calculate the price of the equipment and the installation price.

Fixed Capital
Equipment Name ISBL ($) Investment ($)
Vessel C-001 2.421,00 9.683,99
Vessel C-002 34.775,61 139.102,44
Vessel C-003 42.264,52 169.058,09

Vessel C-004 19.159,53 76.638,11

Vessel C-005 1.841,28 7.365,13
Total: $100.461,94 $401.847,76
Table 12. Vessels costs

Groupe 1.9 - Academic Year 2022/2023 40

 The investment price for purchasing the equipment is about $100M, so the fixed
capital investment is about $402M, which represents 4,05% of the total project investment.

4.2.1.2. Reactor

The reactor cost is estimated considering the reference cost of 150€/m3. The volume
of the reactor was estimated at 2.06 m3 during sizing, which results in a cost of about €
308,5M. Considering the currency conversion of July 1th 2023, €1 = $1.07, the cost of the
reactor is $329M, which represents 2.52% of the total project investment.

Equipment Name ISBL (€) ISBL ($)

Reactor R-001 308.455,58 329.661,90

Table 13. Reactor cost

4.2.1.3. Pump

To estimate the value of the pumps, the following relation was used:

𝑃 0,7
𝐶 = 800 × (1000) (33)
Equation 33. Pump cost
With: C: Equipment cost in k$; P: Shaft Power in kW

From a technical point of view, it is necessary to have a second pump in case of

maintenance or technical problems. For this reason, it was considered in the estimate the
presence of two pumps. Each pump has a fixed capital value of $10,7M, which is a small fee
of 0.22% of the total investment, as it is possible to analyze in the following table in the
following table:
Fixed Capital
Equipment Name Shaft-Power(kW) ISBL ($) Investment ($)
Pump P-001 A 0,44 3.576,9 10.730,70
Pump P-001 B 0,44 3.576,90 10.730,70
Total: $7.153,80 $21.461,40
Table 14. Pumps costs

4.2.1.4. Compressor

To estimate the value of the compressor, the reference cost of €0.5 million/ MW and
the Power (MW) is used. Currency conversion from euros to dollars resulted in a total
equipment cost of $2,9M, resulting in a fixed capital investment of $8,6M. The total
expenditure for compressors represents the highest expenditure for the project at 86.5%.

Groupe 1.9 - Academic Year 2022/2023 41

 Fixed Capital
Equipment Name ISBL (€) ISBL ($) Investment ($)
Compressor K-001 383.850,00 410.218,58 1.230.655,74
Compressor K-002 1.426.750,00 1.524.760,59 4.574.281,77
Compressor K-003 866.350,00 925.863,91 2.777.591,73
Total: €2.676.950,00 $2.860.843,08 $8.582.529,24
Table 15. Compressors costs.

4.2.1.5. Heat Exchangers

To estimate the cost of the heat exchangers the area previously calculated in the sizing phase
was used in the following relation for moderate design conditions (50 barg / 270°C):

𝐴 0,8
𝐶 = 150 (1000) (34)
Equation 34. Heat exchangers costs
With: C: Heat exchanger cost in k$; A: Area in m2;

When the design pressure is higher than 50 barg, the following factors were considered:

Figure 26. Factors for heat exchangers costs

Thus, for the 5 heat exchangers, the total cost is $194M, resulting in a final cost of
$538,3M, which is 5.9% of the total project cost.

Fixed Capital
Equipment Name ISBL ($) Investment ($)
Heat Exchanger E-001 9.588,53 28.765,59
Heat Exchanger E-002 25.864,02 77.592,07
Heat Exchanger E-003 12.981,63 38.944,90
Heat Exchanger E-004 27.262,65 81.787,94
Heat Exchanger E-005 118.733,52 356.200,56
Total: $ 194.430,36 $ 583.291,07
Table 16. Heat exchangers costs

4.2.1.6. CAPEX Summary

Finally, the total cost of the e-methanol production plant was estimated at $9,9M. The
description of the values of each equipment was made in the following table:
Groupe 1.9 - Academic Year 2022/2023 42
 Fixed Capital Share
Equipements ISBL ($) Investment ($) (%)
Vessels 100.461,94 401.847,76 4,05%
Reactor and catalyst 329.661,90 329.661,90 3,32%
Pumps 7.153,80 21.461,40 0,22%
Compressors 2.860.843,08 8.582.529,24 86,53%
Heat Exchangers 194.430,36 583.291,07 5,88%
Total: $3.492.551,08 $9.918.791,37 100,00%
Table 17. CAPEX results

To better illustrate the data below, we have also created a graph illustrating the
distribution of costs:

Graphic 1. CAPEX expenditures repartition

Thus, it can be concluded that the compressor is the equipment that most impacts
CAPEX.

4.2.2. OPEX

OPEX (Operating Expenses) refers to the operating costs required to produce a

product. In calculating OPEX, variable costs, such as utilities and raw materials, and fixed costs,
such as labor costs were considered. To determine the operating time of the industry, we
considered the maintenance of the plant, so it was assumed 24 hours per day and 8000 hours
per year, which results in approximately 340 operating days.

4.2.2.1. Variable cost

For the variable cost, the electricity consumed by the equipment, expenses with
utilities, and raw materials were considered.
• Electricity:
To calculate the amount spent on electricity per equipment, the following relation was
used, the shaft power values were taken from the simulation.
Groupe 1.9 - Academic Year 2022/2023 43
 𝐸𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡𝐶𝑜𝑠𝑡 = 𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐𝑖𝑡𝑦𝐹𝑟𝑜𝑚𝐺𝑟𝑖𝑑 × 𝑆ℎ𝑎𝑓𝑡𝑃𝑜𝑤𝑒𝑟 × 8000ℎ (35)
Equation 35. Electricity costs

This made it possible to calculate the annual electricity expenditure for

compressors and for one pump which resulted in an expenditure of $5M responsible for
1.2% of the total OPEX costs.
• Utilities:
For the utilities calculation three streams were mapped using cooling water, one stream
with BFW and one stream with steam. The value of the utility expenses was done as
follows:
𝑈𝑡𝑖𝑙𝑖𝑡𝑦𝐶𝑜𝑠𝑡 = 𝐶𝑜𝑠𝑡 × 𝑀𝑎𝑠𝑠𝐹𝑙𝑜𝑤 (36)
Equation 36. Utilities costs

Thus, a value of $159M was obtained for the utilities, which represents 38,6% of
the overall OPEX value.
• Raw materials (feed):
To calculate the amount spent on feed, the following expression was used:

𝐹𝑒𝑒𝑑𝐶𝑜𝑠𝑡 = 𝐶𝑜𝑠𝑡 × 𝑀𝑎𝑠𝑠𝐹𝑙𝑜𝑤 (37)

Equation 37. Feed costs

With this, we had a value of $247M which represents the largest portion of the OPEX
expenses, 60%.
4.2.2.2. Fixed cost

For the fixed cost, expenses with labor, supervision, quality control, maintenance
labor, maintenance material, and operating supplies were considered.
• Operating labor:
To determine the labor expenses, it is necessary to determine the amount of salary and
the amount of employees needed to operate in the plant for this the following equation
was used:
0,5
𝑁𝑂𝐿 = (6,29 + 31,7𝑃2 + 0,23 × 𝑁𝑛𝑝 ) (38)
Equation 38. Number of operators

With: NOL: number of operators per team; P: number of process steps (unit operation);
Nnp: number of steps of type: compression, heating/cooling, mixing, separation, and
reaction.

In the synthesis of e-methanol, there is one unit operation and three compression stages,
five heating stages, two mixing stages, four separation stages, and two reaction stages, for

Groupe 1.9 - Academic Year 2022/2023 44

 a total of 16 stages. With a total number of 7 workers per team and a daily working time
of 8 hours per day, 3 teams are needed, which results in 21 workers.
According to data from the National Institute for Statistics and Economic Studies (INSEE),
the average salary in France in 2023 is about 2,439 euros. Considering this average salary,
it is possible to calculate the total annual salary cost according to the following formula:

𝑇𝑜𝑡𝑎𝑙𝐿𝑎𝑏𝑜𝑟𝐴𝑛𝑛𝑢𝑒𝑙𝑆𝑎𝑙𝑎𝑟𝑦 = 𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑆𝑎𝑙𝑎𝑟𝑦 × 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑜𝑝𝑒𝑟𝑎𝑡𝑜𝑟𝑠 × 12𝑚𝑜𝑛𝑡ℎ𝑠 (39)

Equation 39. Labor salary

Thus, the total salary cost for the project is $659M, which represents 0,16% of the OPEX
expenses.
• Other expenses:
The following formulas were used to determine the other expenses included in the fixed
costs of OPEX:
𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝑆𝑢𝑝𝑒𝑟𝑣𝑖𝑠𝑖𝑜𝑛 = 0,20 × 𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝐿𝑎𝑏𝑜𝑟 𝐶𝑜𝑠𝑡 (40)
𝑄𝑢𝑎𝑙𝑖𝑡𝑦 𝐶𝑜𝑛𝑡𝑟𝑜𝑙 = 0,20 × 𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝐿𝑎𝑏𝑜𝑟 𝐶𝑜𝑠𝑡 (41)
𝑀𝑎𝑖𝑛𝑡𝑒𝑛𝑎𝑛𝑐𝑒 𝐿𝑎𝑏𝑜𝑟 = 0,027 × 𝐹𝑖𝑥𝑒𝑑 𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐶𝑜𝑠𝑡 (42)
𝑀𝑎𝑖𝑛𝑡𝑒𝑛𝑎𝑛𝑐𝑒 𝑀𝑎𝑡𝑒𝑟𝑖𝑎𝑙 = 0,018 × 𝐹𝑖𝑥𝑒𝑑 𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐶𝑜𝑠𝑡 (43)
𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝑆𝑢𝑝𝑝𝑙𝑖𝑒𝑠 = 0,0075 × 𝐹𝑖𝑥𝑒𝑑 𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐶𝑜𝑠𝑡 (44)

4.2.2.3. OPEX Summary

To summarize the results of the expenditures that make up OPEX, the following table
shows the total manufacturing costs and their impact on total OPEX expenditures:
Type of cost Description Cost ($) Share (%)
Fixed costs Operating Labour 659.007,21 0,16%
Fixed costs Operating Supervision 131.801,44 0,03%
Fixed costs Quality control 131.801,44 0,03%
Fixed costs Maintenance Labor 267.807,37 0,06%
Fixed costs Maintenance Material 178.538,24 0,04%
Fixed costs Operating Supplies 74.390,94 0,02%
Variable costs Electricity 5.007.762,94 1,21%
Variable costs Utilities 159.267.063,83 38,56%
Variable costs Raw materials (Feed) 247.286.149,20 59,87%
Total costs Annuel costs $413.004.322,60
Table 18. OPEX results

Through the analysis it is possible to verify that the highest operating costs are
associated with the purchase of materials, which reflect in a share of 60% of total costs.
Finally, it was possible to establish that the plant has annual operating costs of $413M.

Groupe 1.9 - Academic Year 2022/2023 45

 4.2.3. Production cost
With the CAPEX and OPEX values calculated, it is now possible to determine the total
production cost of maintaining the process. For any future investment, it is necessary to work
with the updated capital value, since in this way inflation can be considered. For this reason,
the updated CAPEX value was calculated at a rate of 10% per year for an estimated 20 years.
Then it was possible to calculate the production cost with the formula (X).
𝑖(1+𝑖)𝑁
𝐶𝐴𝑃𝐸𝑋𝑛𝑒𝑤 = 𝐶𝐴𝑃𝐸𝑋 × [𝑖(1+𝑖)𝑁 −1](45)
Equation 45. CAPEX with actualization factor
With: i: actualization factor; N: number of years;

𝐶𝐴𝑃𝐸𝑋𝑁𝐸𝑊 +𝑂𝑃𝐸𝑋
𝑃𝐶 = (46)
𝑃𝑅𝑂𝐷𝑈𝐶𝑇𝐼𝑂𝑁
Equation 46. Production cost

Production Cost
CAPEX ($) 9.918.791,37
fa (10%/year, 20 years) 0,12
CAPEXnew ($) 1.165.057,51
OPEX ($) 413.004.322,60
Methanol Product (t/h) 22,80
Annual Product (t/year) 182.360,00
Production cost ($/tMeOH) $2.271,16
Table 19. Production cost

Thus, the total expenditure for production is $2,273 per ton of e-methanol. This value
means that the product must be sold at this price to ensure that the factory does not make
losses or profits after 20 years.

4.3. CONTROL AND COMMAND UNIT

4.3.1. Process Flow Diagram (PFD)

A Process Flow Diagram (PFD) is a diagram used in chemical engineering to describe
equipment flows and the main equipment of a process. For this project, we will only consider
the equipment being used to synthesize E-Methanol. Appendix 4 shows the integrality of the
process.
• Vessels
The vessels can be differentiated into two different forms: a vertical vessel (to separate
vapor from liquid) and a horizontal vessel (to separate liquid from liquid). The level of the
vessel will be monitored to prevent it from overflowing. This will be ensured by a valve that is
connected to a level controller. The level of liquid inside the vessel is very important for it to
operate correctly. If the level falls below the warning line or surpasses the warning line, an
alarm will be triggered.

Groupe 1.9 - Academic Year 2022/2023 46

 For each vessel connected to a compressor, a mesh pad is installed to prevent droplets
from getting into the compressor because it can damage the equipment.
• Heat Exchangers
There are 5 heat exchangers in total that are being used in the process. 3 of them are
used to lower the temperature and create a two-phase mixture so that it can be separated in
the flash immediately afterward while the other two increase the temperature so the reaction
can initiate which takes place in the reactor. For the heat exchanger E-004 in PFD (Appendix
4), medium-pressure steam (MPS) will be used. The type of steam has been studied to choose
the right type that can achieve the objective while retaining a reasonable cost.
For heat exchanger E-003 in PFD (Appendix 4), thermal integration is applied thus
minimizing the use of cooling water and overall, the cost of utilities. Moreover, a bypass circuit
is also being applied here to control the temperature. To control the desired temperature of
the product, each of them will be installed with a temperature controller.
• Compressors
For compressors K-001 and K-002, the pressure outlet will be controlled by a pressure
controller. This is to ensure that the desired pressure is achieved.
• Reactor
The temperature inside the reactor is very important for the reaction to take place.
Hence, to maintain its optimal temperature, a horizontal vessel will be used in which a boiling
feed water (BFW) flow circulates.
Furthermore, the pressure inside the reactor is controlled by a pressure controller that
is connected to a compressor.
• Pump and valve
The valve that is connected to vessel C-005 must be placed after pump P-001 A/B to
prevent cavitation inside the pump as the valve might produce air bubbles.

4.3.2. Piping and Instrumentation Diagram (PID)

A piping and instrumentation diagram (PID) is a detailed diagram in the process
industry that shows the piping and process equipment together with the instrumentation and
control devices. For this project, we will only create a PID diagram on the last vessel
represented in Appendix 5.
• Drum
o Sensor
Sensors for level and temperature indicators such as TG and LG can be found on the
vessel for the operators working near the vessel. This will facilitate for them to verify and
detect any unusual behavior.
o Safety System
A safety system was installed on the vessel to monitor the liquid level. Thus, 3 level
transmitters (LT) can be found and only two of them will work simultaneously. These LT are all
connected to an interlock safety (LZ) which will be activated when the level reaches low-low

Groupe 1.9 - Academic Year 2022/2023 47

(LL) or high-high (HH). This will also send a signal on LZLL or LZHH which then triggered the
alarm in the control room to inform the operator that the liquid in the vessel is at a warning
level. This signal will also be sent to a shutdown valve. The extra LT will ensure the functionality
of this safety system in case of dysfunctionality.
A check valve was also installed at the feed current to prevent backflow which can
result in damage to the equipment.
We can also find a system of safety valves installed on top of the vessel. It will help to
reduce the pressure inside the vessel in case of pressure rise. As the vapor release contains
hydrogen gas, which is an inflammable gas, it will be sent to the torch.
o Control Valves
The level in the vessel will be measured by a level transmitter (LT) which then sends a
signal to a level indicator control (LIC). This controller will compare the value with the setpoint
that is fixed by the operator. Depending on the situation, an electric signal will be sent to a
control valve which then determines the opening of the valve. This valve must be placed after
the pump as it might produce air bubbles that can cause cavitation in the pump.
In addition, the pressure in the vessel can be controlled by a control valve. This valve
will receive an electric signal from a pressure indicator control (PIC) which will compare the
value with the setpoint that is fixed by the operator. In order for this indicator to receive the
value, a pressure transmitter (PT) will monitor the pressure inside the vessel and send an
electric signal.
It is essential that the control valve is checked and can be changed when it is needed.
Thus, isolation valves and a drainage system are added to facilitate the maintenance.
Furthermore, a bypass courant is also installed to ensure the continuous production of
methanol.

• Pump
o Backup pump
Stopping the production for maintenance can result in a significant loss in revenue.
Therefore, a backup pump was installed and will be used when the other is having
maintenance. For each pump, a system of drainage and isolation valves is added to ease
maintenance.
o Filters
A filter is installed at the pump inlet to obstruct and retain any unwanted substances
such as residues, particles, and erosions from the piping thus protecting the pump from
damage.
o Safety system
A safety system (HSL) is activated if the pump speed is too low, by sending an electric
signal to the pump motor.
o Sensors
The suction and discharged pressure can be monitored by a pressure gauge (PG) which
is a local indicator. This will help the operator to identify any unusual behavior on the pump.

Groupe 1.9 - Academic Year 2022/2023 48

 5. FINAL DISCUSSION AND CONCLUSION

5.1. General Discussion

Based on the fact that our project is built on PROII simulations, we need to be clear
that although we have obtained reasonable and appropriate results in the PROII simulations,
they are theoretical and idealistic. The final results of our simulations will be significantly
different from the actual industrial results due to the omission of some equipment and the
simplification of the reaction conditions for some of the equipment to facilitate the
calculations.
These errors have a continuous effect on the subsequent sizing of the equipment: first
of all, we know that in the project all the equipment sizes were calculated by using the
formulas provided and are far from the actual equipment used in industry that is actually
quantified and produced by businesses. The dimensions we have designed are therefore only
to be used as a reference. Moreover, as errors have already been made in the previous
simulations, the errors in dimensioning will be further magnified.
In the same way, for the subsequent economic analysis we need to recognise that the
calculation and evaluation of CAPEX and OPEX is also influenced by the theoretical
assumptions and simplifications that exist in the simulation.
For CAPEX analysis, the actual project equipment size and cost will usually need to be
calculated and adjusted in detail for specific design requirements and actual market
conditions. The CAPEX figures in the simulation results should therefore be considered as
preliminary estimates rather than final and accurate values. More detailed and accurate cost
estimates are required when making actual investment decisions, including negotiations and
quotations with equipment suppliers, etc.
For OPEX analysis, the results are similarly influenced. The OPEX figures in the
simulation results should also be considered as estimates and will need to be further adjusted
and verified in actual operations. Actual industrial operations require further adjustment and
validation.
The most accessible way to verify the results of our process is to compare the results
of our economic analysis with the market price of methanol. The following chart shows the
market price of methanol over recent years:

Groupe 1.9 - Academic Year 2022/2023 49

 Figure 27.Monthly methanol spot prices worldwide from January 2020 to June 2022, by region

We find that our methanol is calculated to be priced at approximately $2200 per ton
compared to commercial methanol at approximately $400 per ton. This indicates that there is
still room for improvement in our process and indirectly proves that our calculations contain
a large margin of error.

5.2. Conclusion
The goal of the project was to study and simulate the process of industrial methanol
production. Through an in-depth study of methanol synthesis reactions, operating conditions,
and other aspects, we were able to understand and optimise the key factors in the methanol
production process. The following is a conclusion of the project:
In the early stages of the project, we conducted extensive literature research to
understand the concept, preparation process and application areas of e-methanol. We
learned that methanol is a versatile compound that can be used not only as a raw material for
the production of chemical derivatives but also as a fuel substitute. This provided the basis for
defining our project objectives and approach.
During the simulation, we used PROII software for process simulation and optimisation.
This software provides powerful modelling tools and calculation capabilities that can help us
to analyse and optimise key parameters in the process. PROII simulations enabled us to predict
and evaluate the product quality and capacity under different operating conditions and to
rationalise our process with the aim of increasing process performance, improving yields, and
saving energy.
In the middle of the project, we studied and tried to make PFD and PID, which helped
us to gain an insight into the basic principles and procedures of industrial processes. Learning
about the role and interrelationship of different equipment and instrumentation in the
process has also helped us to develop an overall understanding of the engineering field.

Groupe 1.9 - Academic Year 2022/2023 50

 We ended up defining the dimensions of the equipment to be used and by carrying
out an economic analysis (both CAPEX and OPEX) gave us a more visual and tangible
understanding of the process we were simulating and designing. This gave us the opportunity
to apply our theoretical knowledge in practice and gave us a complete experience of the
industrial process design process as part of the project.
Overall, the project provided valuable learning and research opportunities, giving us a
deeper understanding of the processes and key factors involved in preparing industrial
methanol. We also learned some of the skills used in process design while working on the
project, which enhanced our general skills. Finally, working in teams developed our
collaborative spirit as well as our communication and coordination skills. It was a very
rewarding experience.

6. BIBLIOGRAPHIC REFERENCES

I. YONG Bai, QIANG Bai, Chapter 18 - Hydraulics, Subsea Pipelines and

Risers. Elsevier Science Ltd, 2005, Pages 277-316, Available in
<https://doi.org/10.1016/B978-008044566-3.50020-8>, access in May,
2023.
II. WATER SCIENCE SCHOOL, Water Density, USGS. Available in
<https://www.usgs.gov/special-topics/water-science-
school/science/water-density>, access in June, 2023.
III. KELLARIS, M. Salaire moyen en France 2023 (brut et net) par secteur
et par région. Din:<https://businesscool.com/decryptage/salaire/salaire-
moyen-median-france/#:~:text=Selon%20les%20chiffres%20de%20L>.
Acesso em: 6 jun. 2023.
IV. CHEMICAL PROCESS ENGINEERING Design and Economics Harry
Silla, (Ed. M. Dekker 2003)
V. CHEMICAL ENGINEERING DESIGN Principles, Practice and
Economics of Plant and Process Design G. TOWLER, R. SINNOTT,
2008, Elsevier
VI. PÉREZ-FORTES, Mar, SCHÖNEBERGER, Jan C., BOULAMANTI,
Aikaterini et TZIMAS, Evangelos, 2016. Methanol synthesis using
captured CO2 as raw material: Techno-economic and environmental
assessment. Applied Energy. Jan 2016. Vol. 161, pp. 718‑732. [Consulté
le 1 février 2023]. DOI 10.1016/j.apenergy.2015.07.067.
VII. Stefano Sollai, Andrea Porcu, Vittorio Tola, Francesca Ferrara, Alberto
Pettinau. Renewable methanol production from green hydrogen and
captured CO2: A techno-economic assessment. Journal of CO2
Utilization, Volume 68, 2023.

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 VIII. RUFER, Alfred, 2022. Quantitative Design of a New e-Methanol Production
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[Consulté le 5 février 2023]. DOI 10.3390/en15249309.
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FALK, Laurent, 2014. Methanol synthesis from CO2 and H2 in multi-
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n° 41, pp. 21261‑21273. [Consulté le 5 février 2023]. DOI
10.1016/j.ijhydene.2021.04.016.
XII. LEI, Hong, Zhaoyin HOU et Jianwei XIE (jan. 2016). « Hydrogenation of
CO2 to CH3OH over CuO/ZnO/Al2O3 catalysts prepared via a solvent-
free routine ». In : Fuel 164.Supplement C, p. 191-198
XIII. STEINBERG, Meyer. United States Patent Steinberg <<
ELECTROLYTIC SYNTHESIS OF METHANOL FROM CO >>.
Huntington Station, 1976, N.Y.
XIV. HOSEINY, S., ZARE, Z., MIRVAKILI, A., SETOODEH, P. et
RAHIMPOUR, M.R., 2016. Simulation–based optimization of operating
parameters for methanol synthesis process: Application of response
surface methodology for statistical analysis. Journal of Natural Gas
Science and Engineering. [en ligne]. août 2016. Vol. 34, pp. 439448.
[Consulté le 7 mars 2023]. DOI 10.1016/j.jngse.2016.06.075.
XV. Dieterich, Vincent & Buttler, Alexander & Hanel, Andreas & Hartmut,
Spliethoff & Fendt, Sebastian. (2020). Power-to-liquid via synthesis of
methanol, DME or Fischer–Tropsch-fuels: a review. Energy &
Environmental Science. 13. 10.1039/D0EE01187H.
XVI. Hank, Christoph, et al. ‘Economics & Carbon Dioxide Avoidance Cost of
Methanol Production Based on Renewable Hydrogen and Recycled
Carbon Dioxide – Power-to-Methanol’. Sustainable Energy & Fuels, vol.
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https://doi.org/10.1039/C8SE00032H.

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 7. APPENDICES
7.1. Appendix 1 : ProII Simulation Diagram

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 7.2. Appendix 2: PDS Vertical Drum

N°projet - Unité Type doc. N° équipement N° ordre Index rév.

PDS
Numéro doc. Client : Page
CLIENT
Revision

SITE
BALLON
UNITE C-005

1 REPERE
2 SERVICE
3 SERVICE CALCUL PROCEDE
4 Pression 17.5 barg 19.3 barg
5
PI T E
6 (1)
7 Température 49.5°C 64.5°C
8
LT
9

10 (1)
11 VIROLE/FONDS INTERNES (2)
12 Materiaux carbon steel carbon steel RD

13 Surép. corrosion 3mm 3mm Mini

Eliminateur
14

15 Nature du fluide Mixed

16 Masse volumique max à T 769.28 kg/m³
A
17 Masse volumique min à T (si -10% mas vol max)
18.35 kg/m³ LG

18 Viscosité > 200cP ? Yes / No

Entre LT

19 Calorifuge no
H
20 Revêtement
21 Elévation LT inf. au-dessus du sol = 2.42m mini
22 Notes F EXT.
23

24

25

26

27 NOMENCLATURE DES TUBULURES LG

28 REP Nb Ø SERVICE N
LT
29 A 1 6" Alimentation
30

31
F
32 D 1 2" Purge
33 E 1 2" Event
34 F 1 4" Sortie fond
35 H 1 8" Trou d'homme
36 L - - Ligne d'équilibre
37 N - - Nettoyage
38 S - - Soutirage
39 T 1 2" Sortie tête
40 V - - Entrée vapeur
41 RD 1 - Organe de sécurité A
r=

42 LG 1 - Niveau à glace
43 LT 4 - Transmetteur de niveau
44

45

46 TI 1 - Prise de température
47 PI 1 - Prise de pression (1) Pour les services concernés, préciser aussi les pressions partielles d'H2 et d'H2S
48 ainsi que les conditions de dépressurisation (T,P)
49 (2) Seulement en cas de demande Procédé specifique, specifier les internes et les
50 materiaux / surepaisseur de corrosion correspondant.

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 7.3. Appendix 3 : PDS Pump

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 7.4. Appendix 4 : Process Flow Diagram (PFD)

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 7.5. Appendix 5 : Piping and Instrumentation Diagram (PID)

Groupe 1.9 - Academic Year 2022/2023 57