Steady-State Modeling of a Natural Convection-Driven, Condensing Methanol Reactor

In this paper, a flexible steady-state model of a highly integrated, natural convection-driven condensing methanol reactor was developed. The flowsheet model includes 1D submodels of the different sections of the integrated reactor–condenser and includes a method to estimate the maximum possible natural convection-driven flow. Experimental data are used to create a shortcut description for the heat transfer coefficients in the model. The model results indicate that when heat losses can be mitigated, autothermal operation is possible. The major part of the heat integration takes place in the economizer section; however, a significant amount of heat transfer occurs at the catalyst bed also. The model predicts that the loop mass flow and single-pass conversion strongly depend on the catalyst bed inlet temperature. Experimentally measured catalyst preheater and condenser duties suggest, however, that the model-calculated mass flow is likely too low and that it is less dependent on the catalyst bed inlet temperature than the model predicts. A possible cause for this is the neglect of radial temperature gradients in the catalyst bed in the model, overestimating the conversion. Another possible cause is a measurement error in the bed inlet temperature, causing the actual temperature to be lower than the measured value. Natural convection calculations show that the maximum achievable flow strongly depends on the single-pass conversion and that given a single-pass conversion, a minimum temperature difference is required for flow in the right direction. Sensitivity analyses (neglecting heat losses to the environment) show that with the current heat transfer description, the feasible operating range for autothermal, natural convection-driven flow is sizeable. However, at lower recycle mass flows, heat transfer is too fast, leading to premature condensation in the economizer section. If the heat transfer coefficient is smaller than the currently predicted value, autothermal operation is possible in a wide range of conditions. If heat losses are mitigated, the maximum productivity of 2000 kgMeOHmcat.−3h−1 is achievable at high pressure, a moderate catalyst bed inlet temperature and a low condenser temperature.