Simulation and Optimization of Methanol Production Processes

Addressing high energy use and inefficient distillation in methanol production, this study innovatively integrates modeling, dividing‐wall column (DWC) technology, and energy optimization for a 400 000 t/a plant. Developed integrated synthesis‐distillation model replaces traditional atmospheric column with DWC. Process simulation optimized key parameters: pressure, temperature, recycle ratio, feedstock (CO 2 /CO), and water dosage. A DWC dynamic control system ensured stability, whereas plant‐wide energy optimization was implemented. Results: DWC boosted top‐product methanol yield 9.22 %, total output 5.14 %, and cut fusel oil methanol 62.73 %. Energy optimization reduced utilities 35.63 % (heating −36.69 % and cooling −34.59 %), raised inter‐stream heat recovery 4.85×, and lowered emissions 42.29 %. Strong economics: NPV > 0 and IRR > 12 %. This process effectively reduces energy consumption and improves yield, providing a feasible solution for clean production of industrial methanol.