UAE University College of Engineering Industrial Training and Graduation Project Unit Gradation Project II –Fall 09 (CH

1. UAE University College of Engineering Industrial Training and Graduation Project Unit Gradation Project II –Fall 09 (CHM2-1) Production of Methanol From Natural Gas Project Advisor: Dr. Basim Abu Al-Jdayil Project Coordinator: Dr. Hazim Al-Attar Major: Chemical Engineering Team member ID Number Monir Fahad Saeed 200416723 Mohamed Mohamed Ali 200440040 Khalid Al-Hosani 200400507 Jasem Al-Obaidli 200410006

2. Contents • Outcomes and deliverables . • Process Technology. • Process Description • Review on GP1 • Detailed Design • Environmental Impact & HAZOP • Cost Estimation • Conclusion & Recommendation

3. Outcome and deliverables • Complete the design specifications for each of the main units • Select appropriate material of construction for each unit • Conduct cost estimation for the plant • Calculate the capital and operating cost of the plant • Find the profit after tax for the whole plant • Conduct HAZOP study for the distillation column • Demonstrate possible environmental hazards in the plant

4. Process Technology • Lurgi Process • Based on auto thermal reforming of natural gas or oil-associated gas. • Capacities goes up from 2.46x1012to 3.65x1012ton/yr • Installation cost is US $350000 • The bad thing about this process is its complex and it has high capital cost

6. Process Technology • Holdor-Topsoe process: • Good for low capacity process • Easy to operate • Low capital cost • Based on steam reforming • Low catalyst cost compared to lurgi process • Both processes work on low pressure

8. Process Description • Reformer Unit R-101 • The function of steam reformer is to crack the natural gas (mostly methane) using steam to produce synthesis gas (CO, CO2 and H2) . • there is another type of reformer which uses partial oxidation to convert the natural gas to methanol. • Steam reformer operates at 850oC and 3 bar • it is a fixed bed reactor with catalyst (Ni/Al2O3) in a furnace. • That methane will be completely converted to synthesis gas. • The methane is preheated before entering the reformer.

9. Process Description • Methanol Synthesis Unit (R-102) • Methanol converter is a reactor that produces crude methanol from synthesis gas. • It is basically a combination of tubular reactor and heat exchanger. • The synthesis gas enters the tube side and converts to methanol and water on (ZnO/Al2O3) catalyst. • Since the reaction is exothermic the reactor cools down using cooling water to maintain optimum temperature of 250oC. • The operating pressure in the reactor is 5 bar which give the optimum conversion 50% of synthesis gas to methanol.

10. Process Description • Heat recovery (E-101) and Compression (C-101) unit • The equipment reduces the temperature of synthesis gas from 850oC to 80oC • The cooling water temperature goes enters at 30oC and out at 40oC • The pressure inside the tubes is 3 bar. • The synthesis gas is then sent to the compression unit to increase the pressure to 5 bar

11. Process Description • Purification unit (V-101) and (T-101) • The function of 2-phase separator is (V-101) is to separate the un-reacted synthesis gas and crude methanol (methanol and water). • The stream which leaves the methanol reactor (R-102) contains un-reacted synthesis gas (gas phase) and crude methanol in (liquid phase) which its way for separation. • The crude methanol cools down to 60oC • The function of Distillation column (T-101) is to separate methanol from water with purity of 99.6 %. • The feed of distillation column enters above at 121oC. • Methanol will be sent to storage tanks as final product and water will be sent to waste water treatment unit for further separation.

12. Review on GP1

13. Stream table for the process

14. Stream table for the process

15. Energy Balance for the main units

16. Steam Reformer Design

17. Design Calculations • Ni/Al2O3 Catalyst properties

18. Design Calculation Volume of reactor.

19. Design Calculation

20. Design Calculation Table-2: Dimensions of steel pipe (Kern, 1965):

21. Design Calculation Number of tubes

22. Design Calculation Calculate weight of catalyst

24. Methanol Converter Design

25. Catalyst Properties

26. Design Calculation for Volume of reactor.

27. Design Calculation

28. Design Calculation Table-1: Dimensions of steel pipe (Kern, 1965):

29. Design Calculation Number of tubes

30. Design Calculation Calculate weight of catalyst

31. Design Calculation Calculate the shell diameter

33. Design Calculation Calculate the shell diameter

35. Heat Exchanger Design

36. Heat exchanger Design

37. Heat exchanger Design 1-Calculating the Duty of H.E

38. Heat exchanger Design 2-Logarithmic temperature difference 3-Heat transfer Area

39. Heat exchanger Design 4-Heat exchanger tube side dimensions Outside diameter pipe nominal side 1" and length 16 ft (4.88 m) do = 1.32 inch (33.528 mm) with thickness = 0.13 inch (3.302 mm)

40. Heat exchanger Design 5-Number of tubes:

41. Heat exchanger Design 6-Velocity inside tube 7-Triangular pitch was picked for tubes arrangements 8-Shell diameter

42. Heat exchanger Design 9-Calculating heat transfer convective coefficient (hi) in tube side

43. Heat exchanger Design 10-Calculating heat transfer convective coefficient (ho) in shell side

44. Heat exchanger Design 11-over all heat transfer coefficient calculation

45. Heat exchanger Design

47. Compressor Design

48. Compressor Deign

49. Compressor Deign 1-Specific heat ration (K) 2-Outlet temperature (T2)

50. Compressor Deign 3-Compressor ratio 4-Theoretical compressor work