ASPEN-HYSYS Simulation of AREW's Multi-Stage Adiabatic Reactor with Inter-Stage Quenching for Methanol Synthesis

DOI: 10.14800/IOGR.1255

Abstract

The aim of this study is to design a simple and user-friendly model for simulating the adiabatic multiphase fixed-bed reactor utilized in methanol synthesis at the Methanol and Synthetic Resins Complex in Arzew, Algeria. The simulation is conducted using the ASPEN HYSYS V11 software. The process is based on the ICI (Imperial Chemical Industries) method, employing a copper oxide-based catalyst (CuO, ZnO, or Al₂O₃). Methanol is synthesized from syngas, which is a mixture of CO, CO₂, and H₂, and acts as the primary feedstock for methanol production in this reactor setup.

The developed model provides the capability to predict methanol yield, control high temperatures resulting from exothermic reactions within each catalyst bed, and determines the necessary amount of quenching gas injection to reduce the temperature. Through simulations, we achieved a crude methanol ratio of 3.41, closely matching the estimated ratio of 3.4 in the actual reactor. This outcome serves as strong evidence for the effectiveness of the designed model in simulating complex chemical reactors.

Building on these promising results, the study proceeded to the recycling simulation stage, where the mass of crude methanol was increased to 4.1%. This step indicates the model's capacity to handle and optimize the recycling process, which is crucial for enhancing the overall efficiency and sustainability of methanol production in the complex. By accurately predicting process parameters and performance, the developed model proves to be a valuable tool for advancing methanol synthesis technologies and promoting more efficient industrial practices