Student Name
Course
Process Principles
Student Number
Semester 1
2021
Methanol synthesis remains one of the world’s most important chemical manufacturing processes. Traditionally, it is made from fossil fuel resources such
as natural gas or coal. The location of methanol plants is highly dependent upon the cost of the raw materials and local regulations. Methanol is made by a
multi-stage process: (1) Production of syngas; (2) Conversion of syngas to crude methanol; (3) Purification of methanol to remove by-products. Catalysts
are required to facilitate manufacture of syngas and methanol. The presence of impurities in the feed can result in poisoning of the catalyst activity.
Elevated temperatures and high pressure are required in the catalytic stages. Methanol is flammable and care needs to be taken when handling and
storing.
You have been assigned the task of creating a case study regarding the design and implementation of a 2,000 tpd methanol plant based upon the ICI
Process. Assume 330 days per annum operation and that methane or coal is delivered to site and available from a suitable storage container. The location
is Australia.
(1)
You need to first of all make groups of 4 students
a. Email Graeme with the names of the group members
(2)
Then each student should conduct a FILA table which evaluates 3 of the “Facts”
(3)
As you have four people in a group then all 12 Facts in the problem definition will be addressed
(4)
This FILA analysis will then provide the basis for writing the assessment item “Case Study”
Facts: List the facts that you can extract from the problem statement
Ideas: What hypothesis can you derive from each fact?
Learning Issues: Develop Research Questions that you need to answer to support or disprove your hypothesis
Facts
Catalysts
Required
(No.7)
Ideas
If catalysts are utilised,
then this greatly enhances
process efficiency whilst
perform better than plants
that do not constitute a
catalyst within their
production process.
If new catalysts with
superior properties are
being researched and
created, then the market
for current catalysts will
collapse.
If cheaper catalyst
alternatives are utilised,
then the plant
performance will be worse.
If the catalyst is created
from sustainable
resources, then the quality
of the product as well as
the viability of the industry
will be improved.
If catalysts are used, then
this may be detrimental to
the industry as it may
increase carbon or
hazardous footprint.
If catalysts with superior
properties are used, this
will effectively improve the
methanol quality from
Learning Outcomes (Issues)
1. What are the processes
associated within the
creation of methanol?
2. What types of catalysts are
used?
3. What do they cost?
4. How supplies the catalysts?
5. How are the catalysts
created?
6. Are there cheaper catalyst
alternatives?
- Is the performance on
par?
7. Is there an optimal
requirement
or
environment
(operating
conditions) to maximise the
efficiency of the catalyst?
8. What are the advantages of
using this catalyst source?
9. What is the limitation for
using this catalyst source?
10. What is the environmental
footprint for using the
catalyst?
11. Are there other alternative
catalysts being researched?
- What are the
advantages of new
research in comparison
to present catalysts?
Actions
1 (a) Methanol Production
2 (a) Catalyst Used:
https://www.sciencedirect.com/science/article/pii/S1364032115000209
10 (a) Greener Catalyst:
https://www.sciencedirect.com/science/article/pii/S1364032115000209
11 (a) Alternative Catalyst:
https://www.sciencedirect.com/science/article/pii/S1364032115000209
production in comparison
to using standard catalyst.
If catalysts are utilised,
then this may effectively
reduce the risks that are
associated, in comparison
to not using a catalyst.
Impurities is a
problem
(No.8)
If high quality and
sustainable resources are
used, then the chances of
impurities entering the
system will be minimised.
If impurities are present
within the system, then
the impurities may be
utilised for other
endeavours (recycled or
extract certain chemicals
etc).
If there are impurities
present, then the product
quality of the methanol
will decrease substantially
and may negatively affect
the industry.
If impurities are present,
then appropriate
equipments or chemical
treatment can protect the
system from the damaging
effects that the impurities
may cause (Reduce risk)
1. What are the causes for
impurities to appear in a
methanol plant?
2. What type of impurities that
can be found within
methanol production?
3. What are some hazardous
factors that are associated
with the impurities?
4. Can the impurities be
recycled for other uses?
5. Are there relevant chemical
treatments or equipment
that is utilised to solve
impurities within a system?
6. Are there restrictions or
procedures in place that can
minimise the possibility of
impurities?
7. What
are
the
risks
associated
with
the
presence of impurities in a
methanol plant?
8. Is there a particular process
in which the presence of
2000 tpd ICI
Process in
Australia
(No.12)
If appropriate
containment/ removal
procedures for impurities
are not achieved, then it
may be detrimental to
safety, product quality and
environmental.
If the conditions of when
the production of
methanol produces
impurities are not well
known, then the likelihood
of contamination within
the system will increase.
If there are 2000 TPD ICI
Process in Australia, do
they all utilise different
techniques?
If ICI process in Australia
cease to exist, then there
may be alternative process
designs that may be
available.
If
impurities
affects
product control?
the
9.
1.
2.
3.
4.
5.
What is TPD?
1. https://www.osti.gov/biblio/7021541-lignite-methanol-engineeringWhat is ICI?
evaluation-winkler-gasification-ici-methanol-synthesis-route-finalHow many plants are there?
report
What do those plants do?
2.
What is the ICI process for
making methanol?
6. Are
there
alternative
companies that provide ICI
process?
7. What are the alternative
process designs that can be
used?
8. Does each process differ
from each other?
9.
1 (a) Methanol Production [https://www.sciencedirect.com/science/article/pii/B9780444639035000182]
2 (a) Catalyst Used [https://www.netl.doe.gov/research/coal/energysystems/gasification/gasifipedia/methanol#:~:text=Catalyst%20systems%20used%20for%20methanol,carbon%2C%20nitrogen%2C%20and%20platinum.]
[https://news.stanford.edu/news/2014/march/methanol-new-catalyst-030214.html]