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]