Methanol PDF

UNIVERSITY OF INDONESIA
METHANOL
Methanol
Introduction
Production
Uses
The Market
Capital Investment and Production Cost
Technology
Advantages
Introduction
The first member of the homologous

series of aliphatic alcohols, with the
formula CH3OH.
It is produced commercially from a
mixture of carbon monoxide (CO) and
hydrogen (H2).
Introduction
Methanol is a
highly flammable liquid,

boiling point 64.7C (149F),
is miscible with water and most organic
liquids,
highly poisonous substance, and
sublethal amounts can cause permanent
blindness.
Introduction
BASF pada tahun 1923 mengenalkan

proses sintesis methanol dari CO dan H2
yang
merupakan
aplikasi
kedua
terbesar mengenai katalis dan teknologi
tekanan tinggi dalam industri kimia.
Introduction
Proses tersebut merupakan penelitian lanjut

dari hidrogenasi CO,
CO dan H dapat bereaksi pada tekanan 100 300

bar untuk menghasilkan produk yang beragam
dari methanol sampai alkohol yang lebih tinggi,
tergantung pada katalis yang digunakan dan
kondisi operasi
juga komponen-komponen yang terhidrogenasi
dan hidrokarbon.
Penelitian ini dilakukan oleh Fischer-Tropsch

pada sekitar awal 1930 an.
Introduction
Seperti
proses
amonia,
sintesis
methanol
juga
tergantung
pada
pengembangan katalis yang digunakan.
Katalis methanol harus selektif dan aktif.

Salah satunya, yang mengandung zinc
oxide dan chromia, tahan sampai sekitar
40 tahun.
Introduction
Tahun 1996 ICI memperkenalkan katalis
cooper/zinc
oxide/alumina
dengan
aktivitas yang lebih besar.
Dengan
katalis ini methanol dapat
bereaksi pada temperatur yang lebih
rendah (kurang dari 300oC) dan tekanan
yang lebih rendah (50-100 bar).
Introduction
Hasilnya, jika dibandingkan dengan
proses sebelumnya yang memerlukan
tekanan tinggi.
proses menjadi lebih efisien,

lebih murah dan
lebih rendah biaya modal yang akan
diinvestasikan.
Introduction
Methanol is one of the major industrial

organic chemicals.
Its major derivatives are
methyl tertiary butyl ether (MTBE),

formaldehyde, and
acetic acid.
Introduction
Other derivatives and uses include
chloromethanes,
methyl methacrylate,
methylamines,
dimethyl terephthalate,
solvents (such as glycol methyl ethers),
antifreeze, and
fuels.
Introduction
Methanol is produced naturally in the

anaerobic metabolism of many varieties
of bacteria.
As a result, there is a small fraction of

methanol vapor in the atmosphere.
Over the course of several days,
atmospheric methanol is oxidized by
oxygen with the help of sunlight to carbon
dioxide and water.
Introduction
Methanol burns in air forming carbon

dioxide and water:
2 CH3OH + 3 O2 2 CO2 + 4 H2O
A methanol flame is almost colorless.
Care should be exercised around burning

methanol to avoid burning oneself on the
almost invisible fire.
Introduction
Methanol is often called wood alcohol

because it was once produced chiefly as
a byproduct of the destructive
distillation of wood.
It is now produced synthetically by a
multi-step process.
Introduction
In short,
natural gas and steam are reformed in a

furnace to produce hydrogen and carbon
monoxide; then,
hydrogen and carbon monoxide gases
react under pressure in the presence of a
catalyst.
The reforming step is endothermic and the
synthesis step is exothermic.
Production
Today, synthesis gas is most commonly

produced from the methane component
in natural gas rather than from coal.
Three processes are commercially
practiced.
Production
At moderate pressures of 1 to 2 MPa

(1020 atm) and high temperatures
(around 850 C), methane reacts with
steam on a nickel catalyst to produce
syngas according to the chemical
equation:
CH4 + H2O CO + 3 H2
Production
This reaction, commonly called steammethane reforming or SMR, is

endothermic and the heat transfer
limitations place limits on the size of the
catalytic reactors used.
Production
Methane can also undergo partial oxidation

with molecular oxygen to produce syngas, as
the following equation shows:
2 CH4 + O2 2 CO + 4 H2
this reaction is exothermic and the heat given off

can be used in-situ to drive the steam-methane
reforming reaction.
When the two processes are combined, it is
referred to as autothermal reforming.
Production
The ratio of CO and H2 can be adjusted

by using the water-gas shift reaction,
CO + H2O CO2 + H2,
to provide the appropriate stoichiometry

for methanol synthesis.
The carbon monoxide and hydrogen

then react on a second catalyst to
produce methanol.
Production
Today, the most widely used catalyst is

a mixture of copper, zinc oxide, and
alumina first used by ICI in 1966.
At 510 MPa (50100 atm) and 250 C,
it can catalyze the production of
methanol from carbon monoxide and
hydrogen with high selectivity
CO + 2 H2 CH3OH
Production
It is worth noting that
the production of synthesis gas from

methane produces 3 moles of hydrogen for
every mole of carbon monoxide,
while the methanol synthesis consumes
only 2 moles of hydrogen for every mole of
carbon monoxide.
Production
One way of dealing with the excess

hydrogen is to inject carbon dioxide into
the methanol synthesis reactor, where
it, too, reacts to form methanol
according to the chemical equation
CO2 + 3 H2 CH3OH + H2O
Production
Although natural gas is the most economical

and widely used feedstock for methanol
production, other feedstocks can be used.
Where natural gas is unavailable, light
petroleum products can be used in its place.
The South African firm Sasol produces
methanol using synthesis gas from coal.
Production
Methanol dapat dihasilkan dalam skala

industri secara besar besaran, melalui
konversi katalitik dari gas sintesis.
proses tersebut digolongkan menurut
tekanan yang digunakan :
1. Proses tekanan tinggi

300 atm)
2. Proses tekanan sedang
250 atm)
3. Proses tekanan rendah
100 atm)
: 25-30 Mpa (250
: 10-25 Mpa (100

: 5-10 Mpa
(50
Production
Pada sat ini proses pembuatan

methanol pada tekanan sedang dan
tekanan rendah saja yang digunakan.
Tetapi
sejalan
dengan
adanya
konservasi energi maka proses pada
tekanan rendah memberikan alternatif
yang paling baik dibandingkan dengan
tekanan sedang.
Production
Keuntungan paling utama dari proses

tekanan rendah adalah :
Biaya produksi dan investasi rendah

Peningkatan operasional dapat diandalkan
Fleksibilitas lebih besar dalam pemilihan
ukuran pabrik
Production
Proses pruduksi methanol

industri terdiri atas :
Produksi gas sintesis

Sintesis Methanol
dalam
Production
Produksi methanol dimulai dengan

produksi gas sintesis yang terdiri dari
hidrogen dan karbonmonoksida.
Teknologi yang sering digunakan dalam
proses gas sintesi antara lain :
Steam Reforming
Oksidasi Parsial
Gasifikasi Batubara
Production
Selanjutnya hasil dari syn-gas menjadi

feedstock pada methanol plant, dimana
reaksi sintesis methanol dalah
CO + 2H2 CH3OH
kkal/mol
H298 = -21.684
Production
Reaksi pembentukan methanol ini

memiliki konversi yang rendah.
Hal ini diakibatkan karena reaksi mudah
untuk mencapai kesetimbangan.
Production
Untuk mendapatkan konversi yang lebih

tinggi biasanya reaksi dilakukan pada tekanan
yang cukup tinggi dan temperatur yang
rendah.
Perkembangan teknologi reaksi sintesis
methanol pada tekanan tinggi mulai
ditinggalkan dengan ditemukannya katalis
yang lebih reaktif dan jenis reaktor yang
sesuai.
Production
Recycle
P-5
Flash colom
Heat Exchanger
Gas Sintesis
Reactor Sintesi Methanol
Crude Methanol
Production
Jenis katalis yang digunakan:
Katalis pada tekanan tinggi

Katalis pada tekanan rendah
Production
Digunakan alkali/ZnO-CuO/Cr2O3 dapat

beroperasi pada tekanan 120-300 bar dan
temperatur 300-425oC.
Katalis ini tahan terhadap sulfur dan klorin
yang terdapat dalam syn-gas.
Production
Produksi metanol dengan zinc-oksida-krom

oksida pada proses bertekanan tinggi tidak
lagi bersifat ekonomis.
Generasi baru katalis mengandung copper
dengan keaktifan dan selektifitas yang
lebih tinggi.
Production
Digunakan alkali/CuO-ZnO/Al2O3 dapat

beroperasi pada tekanan 50-100 bar dan
temperatur 275-310oC (120-300 bar dan
suhu 300-425oC, utk tek.tinggi).
Penggunaan katalis ini membutuhkan
kondisi syn-gas yang murni dari sulfur dan
klorin (H2S < 0.1 ppm).
Production
Karena keaktifan katalis, sintesis metanol

dapat berlangsung pada suhu 220-230oC
dan 5 Mpa.
Selektifitas yang tinggi memberikan
kemurnian metanol lebih besar dari 99.5%.
Pembentukan produk sampingan seperti
DME, alkohol tinggi, senyawa karbonil dan
metana dapat dihilangkan.
Production
Produksi methanol secara komersial

dapat dilakukan melalui berbagai
macam proses.
Proses yang paling banyak digunakan di
industri methanol adalah ICI.
Production
Proses proses yang lain diantaranya

adalah :
Proses
Proses
Proses
proses
Lurgi,
Kellog,
Nissui Topsoe dan
Mitsubishi Gas Company (MGC).
Production
Jalur sintesis methanol dari proses

proses
tersebut
sama,
yang
membedakan hanya
jenis katalis,
reaktor yang dipergunakan dan
kondisi operasi reaksi.
Production
Perbandingan penggunaan proses sintesis methanol didunia
Kellogs
3% MGC
8%
ICI
61%
Lurgi
27%
Other
1%
Production
Dari diagram
sebagian
besar
(61%)
proses
menggunakan teknologi ICI pada tekanan
rendah,
diikuti dengan proses tekanan rendah
yaitu teknologi Lurgi (27%) dan

Kellog (3%).
Production
Proses tekanan sedang sudah jarang

digunakan hanya sebagian kecil sebesar
8% menggunakan teknologi MGC.
Proses Tekanan Rendah ICI
Campuran gas sintesis umpan segar ditekan dari 50100 atm melalui sebuah kompresssor dan diumpan
kedalam reaktor berpendingin (quench type converter)
yang beroperasi pada 270oC.
Quench converter berupa single bed yang
mengandung katalis pendukung yang bersifat

inert.
Aliran produk kemudian didinginkan dan methanol akan

terkondensasi.
Aliran gas purge direcycle ke reformer untuk mengubah

methanol yang terakumulasi dalam gas sintesis.
Crude methanol akan dipurifikasi dengan cara distilasi.
Karena
dianggap
kurang menguntungkan
ICI
mengganti jenis reaktor yang digunakan dari quench
reactor menjadi tube berpendingin yang pada prinsipnya
sama dengan yang digunakan oleh Lurgi.
Proses ICI bertekanan rendah ada yang

menggunakan reaktor packed bed
adiabatic tersusun seri.
Suhu masukan ke bed ditentukan oleh
suhu dingin dari syn-gas yang
diinjeksikan.
Tidak ada penukar panas diantara bed

dan hal ini membuat reaktor menjadi
lebih sederhana daripada desain proses
lainnya.
Proses Tekanan Rendah Lurgi
Dalam proses yang ditawarkan oleh

Lurgi untuk sintesis methanol,
reaktor sintesis dioperasikan pada rentang

suhu dari 230 270oC dan dengan tekanan
operasi 50-100 bar.
Perancangan reactor berbeda dengan

ICI.
Dalam teknologi pertama ICI, katalis

ditumpuk menjadi sebuah unggun serta
dimasukan pada berbagai lokasi sepanjang
unggun dengan tujuan agar diperoleh
distribusi suhu yang merata.
Sedangkan Lurgi menggunakan reaktor shell
and tube , tube diisi dengan katalis dan
panas reaksi diserap oleh air yang bersirkulasi
secara alami pada bagian shell.
Pada dasarnya reaktor juga memainkan

peranan
kedua
yaitu
sebagai
pembangkit uap (steam regenarator)
bertekanan 40-50 bar.
Lurgi menggunakan reaktor quasi-isothermal dengan

katalis di dalam tube yang didinginkan dengan sirkulasi
boiling water.
Proses Lurgi akan menghasilkan methanol yang murni dengan

proses sintesis methanol dan proses pemurniannya
Proses Tekanan Rendah Kellog
M.W. Kellog Co. memperkenalkan reaksi

sintesis yang sangat berbeda, tetapi pada
dasarnya merupakan reaktor tipe adiabatik.
Reaktor berbentuk bulat dan didalamnya
berisi unggun katalis tunggal.
Sintesis gas mengalir melalui beberapa bed
reaktor yang tersusun aksial berseri.
Kebalikan dari proses ICI, panas reaksi yang
dihasilkan
dikontrol
dengan
pendingin
intermediat (intermediate coolers).
Proses Tekanan Rendah Kellog
Proses ini menggunakan katalis tembaga dan

beroperasi pada rentang suhu 200-280oC
serta tekanan 100-150 atm.
Suhu didalam unggun katalis dikendalikan
melalui
penggunaan
sebuah
reaktor
berpendingin (quench type converter) dengan
menyerap panas reaksi dalam intermediate
stage boiler.
Proses Tekanan Sedang Nissui-Topsoe
Skema reaktor dari proses Halder Topsoe dari

Denmark didesain oleh Nihin Suiso Kogyo of
Japan.
Reaktor bertipe adiabatis dengan aliran radial
berjumlah tiga masing-masing memiliki satu
unggun radial dan penukar panas internal.
Tiap reaktor mengandung satu satu unggun
katalis.
Tekanan operasi dari proses ini diatas 150
bar dan suhu 200-310oC.
Proses Tekanan Sedang Nissui-Topsoe
Produk pertama perlu didinginkan sebelum

reaktor kedua, hasil pendinginan berupa uap
(steam) bertekanan rendah.
Katalis yang digunakan berupa Cu-Zn-Cr yang
aktif pada 230-280oC dan 100-200 atm.
Sintesis gas mengalir secara radial melalui
katalis bed.
Proses Tekanan Sedang Mitsubishi

Gas Company
Perusahaan Jepang MGC pada awalnya

menggunakan proses dengan tekanan sedang
yang beroperasi pada 150 atm kemudian
dikembangkan untuk tekanan kurang dari
100 atm.
Saat ini MGC menggunakan rentang tekanan
50-200 atm dan suhu 235-270oC.
Hingga saat ini telah dioperasikan tiga buah,
dua diantaranya berlokasi di Jepang dan
sisanya di Arab.
Pemlihan Teknologi
Dalam proses sintesis metanol, pemilihan

teknologi pertama dilakukan pada proses
produksi gas sintesis menghasilkam hidrogen
dan karbon-monoksida.
Untuk menghasilkan gas sintesis, bahan baku
berasal dari gas alam.
Steam reforming akan menghasilkan hidrogen
lebih banyak daripada oksidasi parsial yang
menghasilkan lebih banyak karbonmonoksida.
Pemlihan Teknologi
Hidrogen
dalam
jumlah
banyak
dibutuhkan dalam sintesis metanol
sebab diperlukan rasio H2 : CO2 sebesar
3:1 dan rasio H2 : CO sebesar 2:1.
Oleh karena itu, proses steam
reforming
dipergunakan
untuk
memproduksi gas sintesis.
Pemlihan Teknologi
Dalam pemilihan teknologi sintesis

metanol, parameter yang digunakan
adalah:
keaktifan katalis,
jenis reaktor, dan
tekanan operasi yang dipergunakan.
Pemlihan Teknologi
Untuk sintesis metanol,
keaktifan
dan
selektifitas
katalis
memegang
peranan
penting
dalam
efisiensi proses,
sehingga proses tidak berlangsung pada
tekanan tinggi atau sedang.
Pemlihan Teknologi
Katalis yang digunakan pada tekanan

rendah
CuO-ZnO/Al2O3 memiliki keaktifan dan

selektivitas yang lebih tinggi
dibandingkan dengan katalis pada tekanan
tinggi ZnO-CuO/Cr2O3.
Pemlihan Teknologi
Selektifitas
yang
tinggi
akan
menghasilkan
metanol
dengan
kemurnian yang tinggi dan produk
samping yang terjadi dapat dikurangi.
Pemlihan Teknologi
Katalis CuO-ZnO yang digunakan pada

tekanan rendah mempunyai kelebihan
dibadingkan katalis lain, yaitu:
Mempunyai struktur yang sangat baik

(well-definedstructural)
yaitu
susunan
elektron yang menunjang keaktifan katalis
dan selektifitas yang tinggi pada metanol.
Mempunyai bentuk (morfologis) yang baik.
Pemlihan Teknologi
Dari parameter katalis, pemilihan

teknologi sintesis metanol dilakukan
pada tekanan rendah, yaitu antara
teknologi ICI,
Lurgi dan
Kellog.
Pemlihan Teknologi
Pemilihan jenis reaktor akan mempengaruhi

biaya investasi untuk mendesain reaktor
tersebut.
Pertimbangan jenis reaktor:
Desain reaktor yang sederhana sehingga tidak

membutuhkan kontrol suhu yang rumit.
Jenis pendingin yang digunakan akan menentukan
sistem pengontrolan suhu dalam sistem ketika
terjadi kenaikan suhu yang besar.
Pemlihan Teknologi
Pada reaktor quench converter (reaktor

berpendingin) pada ICI,
umpan yang masuk langsung bertemu

dengan unggun katalis
sehingga menyebabkan kerusakan pada
katalis dan
menyebabkan reaksi terhenti.
Pemlihan Teknologi
Pada reaktor shell and tube pada Lurgi,
pendingin menggunakan boiling water

yang mengalir di dalam shell
dapat menyerap panas yang dihasilkan
reaksi di dalam tube yang berisi katalis
sehingga reakor dapat mempertahankan
suhunya.
Pemlihan Teknologi
Pada teknologi Kellog digunakan

pendingin intermediate coolers yang
akan memperbesar investasi desain
reaktor.
Pemlihan Teknologi
Dari pertimbangan diatas, dapat ditarik

kesimpulan bahwa
teknologi Lurgi tidak membutuhkan desain

reaktor yang rumit
dimana kontrol suhu dapat dilakukan
dengan mengalirkan boiling water pada
shell.
Pemlihan Teknologi
Keunggulan teknologi Lurgi lainnya yaitu
dihasilkannya steam bertekanan sedang yang

memberikan solusi bagi penghematan energi.
Steam
yang
dihasilkan
digunakan
untuk
pemanasan umpan reaktor dan sebagai reboiler
dalam proses distilasi metanol.
Perolehan steam ini memperkecil beban pendidih
(boiler) untuk memproduksi steam.
Uses
Methanol is used on a limited basis to fuel

internal combustion engines, mainly by virtue
of the fact that it is not nearly as flammable
as gasoline.
Methanol blends are the fuel of choice in
open wheel racing circuits like Champcars, as
well as in radio controlled model airplanes
(required in the "glow-plug" engines that
primarily power them), cars and trucks.
Uses
Dirt circle track racecars such as Sprint cars, Late

Models, and Modifieds use methanol to fuel their
engines.
Drag racers and mud racers also use methanol as
their primary fuel source.
Uses
Methanol is required with a supercharged engine in a

Top Alcohol Dragster and, until the end of the 2005
season, all vehicles in the Indianapolis 500 had to
run methanol.
Mud racers have mixed methanol with gasoline and
nitrous oxide to produce more power than gasoline
and nitrous oxide alone.
Uses
Methanol is a traditional ingredient in

methylated spirit or denatured alcohol.
During World War II, methanol was
used as a fuel in several Nazi Germany
military rocket designs, under name MStoff, and in a mixture as C-Stoff.
Uses
One of the drawbacks of methanol as a

fuel is its corrosivity to some metals,
including aluminium.
Methanol, although a weak acid, attacks
the oxide coating that normally protects
the aluminium from corrosion:
6 CH3OH + Al2O3 2 Al(OCH3)3 + 3 H2O
Uses
The resulting methoxide salts are soluble in

methanol, resulting in clean aluminium
surface, which is readily oxidised by some
dissolved oxygen.
Also the methanol can act as a oxidiser:
6 CH3OH + 4 Al 2 Al2(OCH3)3 + 3 H2
So the corrosion continues until the metal is
eaten away.
Uses
When produced from wood or other organic

materials, the resulting organic methanol
(bioalcohol)
has
been
suggested
as
renewable alternative to petroleum-based
hydrocarbons.
However, one cannot use BA100 (100%
bioalcohol) in modern petroleum cars without
modification.
Uses
Methanol is also used as a solvent and as an

antifreeze in pipelines.
The largest use of methanol by far, however,
is in making other chemicals.
About 40% of methanol is converted to
formaldehyde, and from there into products
as diverse as plastics, plywood, paints,
explosives, and permanent press textiles.
Uses
In some wastewater treatment plants,
a small amount of methanol is added to

wastewater
to provide a food source of carbon for the
denitrification bacteria,
which convert nitrates to nitrogen.
Uses
In the 1990s, large amounts of

methanol were used in the United
States to produce the gasoline additive
methyl tert-butyl ether (MTBE).
The 1990 Clean Air Act required certain
major cities to use MTBE in their
gasoline to reduce photochemical smog.
Uses
However, by the late 1990s, it was found that

MTBE had leaked out of gasoline storage
tanks and into the groundwater in sufficient
amounts to affect the taste of municipal
drinking water in many areas.
Uses
Moreover, MTBE was found to be a

carcinogen in animal studies.
In the resulting backlash, several states
banned the use of MTBE, and its future
production remains uncertain.
Uses
Direct-methanol fuel cells are unique in their

low temperature, atmospheric pressure
operation, allowing them to be miniaturized
to an unprecedented degree.
This, combined with the relatively easy and
safe storage and handling of methanol may
open the possibility of fuel cell-powered
consumer electronics.
Uses
Other chemical derivatives of methanol

include dimethyl ether, which has replaced
chlorofluorocarbons as an aerosol spray
propellant, and acetic acid.
There are now plans to use the chemical in
eco-friendly fuel cells for laptop computers,
the cells will break down methanol via an
electrochemical process.
The Market
Methanol is
an important multipurpose base chemical,

a simple molecule which can be recovered
from many resources, predominantly
natural gas.
The Market
By tradition, methanol is principally

used to produce
formaldehyde,
methyl tertiary butyl ether (MTBE) and
acetic acid
The Market
To a lesser extend, methanol is used as a

general solvent and as fuel and for producing
other chemicals.
Global demand for methanol amounts to
about 32 million tons per year, with growth
rates at or near GDP.
The demand corresponds to the capacity of
about 35 million tons which is available
worldwide.
The Market
Asia is becoming the main growth driver

for the demand for methanol and its
derivatives.
Average growth rates are expected to
be for:
Methanol: 3.8 %/a based on about 10

million tons in 2003,
Acetic acid: 4.8 %/a,
Formaldehyde: 4.4 %/a.
The Market
Reducing the cost of production by installing

Mega production facilities fed with lowcost natural gas is opening up new
promising methanol outlets. such as for the
production of:
Ethylene and/or propylene, methanol to

propylene, e. g. by applying Lurgi MTP
technology.
Dimethyl ether as a substitute for diesel fuel
Liquid fuels
The Market
Reducing the cost of production by installing

Mega production facilities fed with lowcost natural gas is opening up new
promising methanol outlets. such as for the
production of:
Hydrogen or
Feed material for power generating systems or
Use in integrated schemes combined with an
ammonia/urea complex, for example.
The Market
Methanol consumption for fuel cells to be

used in automobiles, for power generation
and portable equipment is bound to increase
in the near future.
Proved reserves of natural gas in the Middle
East exceed 71 trillion cubic meters
equivalent to a 41 % share of the total
world gas reserves with Iran and Qatar
having the largest potential reserves i. e.
about 30 %.
The Market
Middle East and some regions of South

America and Africa will raise their methanol
production significantly because of:
low feedstock cost and

low capital cost thanks to the economies of scale
provided by Mega plants.
According to CMAI some 15 million tons of

capacity, nearly 50 % of world demand, will
be added within a period of five years.
The Market
Considering the plentiful natural gas

reserves and the evermore stringent
environmental regulations to curb the
wide-spread flaring-off, for example,
methanol production is a real alternative

for converting natural gas or associated
gas to a commodity with high value
added.
The Market
Monetizing the abundant natural gas in stranded

gas regions, where the main end-user markets are
geographically remote from the source, is highly
attractive.
Methanol is a versatile natural gas product with value

added.
Methanol has excellent characteristics being easily
transportable in comparison with gas, for example.
Methanol production cost in the range of US$ 50 per ton
opens up a completely new field for further down-stream
derivatives like propylene or other new applications.
Starting from the same feedstock price for

natural gas,
Capital Investment
and Production
Cost
the production cost of methanol based on Lurgi

MegaMethanol technology is by far lower,
typically in the range of 25 %,
compared to the cost based on combined
reforming and conventional steam reforming,
respectively,
at half the capacity of the MegaMethanol plant.
The differences clearly show the economy of

scale effect for the single train plant.
Capital
Investment and
Production Cost
The
double
capacity
of
the
MegaMethanol plant only requires
additional capital expenditure of about
50 % of the plant investment cost
based on the reforming technologies
mentioned above.
These
figures
demonstrate
the
superiority of Lurgi MegaMethanol
technology.
Capital
Investment and
Production Cost
Since 1995
the capacities of methanol plants have

been increased from 2,000 t/d to 5,000 t/d
in 2003
and will rise further to 10,000 t/d in the
near future.
Capital
Investment and
Production Cost
The companies operating Mega plants

are
experiencing
a
tremendous
reduction in production cost ex gate
from about US$ 110/t to 50/t and
ultimately less than 40/t, as shown in
the diagram.
Capital
Investment and
Production Cost
The conversion of natural gas to methanol

and downstream petrochemicals is highly
economic on a natural gas price level below
US$ 1/million BTU.
Some regions such as the Middle East,
locations in South America or Africa allow for
natural gas prices of between US$ 0.2 and
0.7/million BTU, compared to an oil price of
between US$ 12 and 14/barrel.
Capital
Investment and
Production Cost
This price scenario of gas-based

methanol
production
cost
and
equivalent oil cost will certainly have an
impact on the downstream products
and process routes based on oil.
Capital
Investment and
Production Cost
Lurgi offers all technologies for

methanol production including synthesis
gas production based on:
conventional steam reforming,

combined reforming,
autothermal reforming.
Capital
Investment and
Production Cost
Accordingly, Lurgi accepts single line

responsibility for small plants or for
MegaMethanol facilities on a LSTK basis if
specified.
In view of this know how and the experience
gained with the design, supply and
commissioning of numerous plants, Lurgi is
able to offer the optimum concept combined
with project development and financing for
any feedstock, capacity and other conditions
specified by the client.
Capital
Investment and
Production Cost
Aiming at reducing the synthesis gas

and methanol production cost further,
even below an oil equivalent of US$
10/barrel,
a
high
pressure
demonstration plant is being operated.
The test results supplement the design
basis for extremely large synthesis gas
capacities.
Capital
Investment and
Production Cost
The development of a two-stage reactor

system for methanol synthesis is
another example and proof that Lurgi
research and development activities
continuously focus on lowering capital
and operating cost for large scale
production facilities.
Capital
Investment and
Production Cost
Lurgi is in the unique position to license

the MegaSyn and MegaMethanol
technologies in order to increase the
benefit for the client.
Capital
Investment and
Production Cost
Lurgi also offers complete routes or

integrated schemes of proprietary
technologies such as
the conversion of natural gas to propylene

via methanol or
integrated schemes combining various
products like ammonia and methanol, for
example.
Capital
Investment and
Production Cost
The advantages are quite obvious:
All process streams and compounds are

useful, i. e. no generation of by-products
and therefore no environmental impact.
Feed and utility consumption can be
optimized due to plant and heat
integration.
Mega systems will reduce the production
cost additionally.
Capital
Investment and
Production Cost
Contracts for 16 methanol plants including 3

Mega-Methanol facilities have been awarded
to Lurgi since 1994.
Lurgi is the only company which boasts 3
MegaMethanol reference plants.
Lurgi has a 60 to 70 % market share of the
methanol capacities globally installed and
leads the market as number 1.
The compressed, desulfurized - optionally

prereformed -feedstock, predominantly natural
gas, is reformed to synthesis gas using oxygen
as the reforming agent.
The optimum synthesis gas composition is

achieved by recycling hydrogen that can be
separated from the purge gas stream of the
methanol synthesis loop.
The synthesis gas is compressed and

enters the methanol synthesis loop.
The innovative Lurgi MegaMethanol technology

is mainly based on the two-stage reactor system
consisting of a gas-cooled and a water-cooled
reactor.
This system results in outstanding technical and

economic features due to the extremely favorable
temperature profiles over the catalyst beds.
Methanol distillation provides the specified

product quality which may range from fuel grade
methanol to highly pure methanol.
Advantages
Tugas
Jelaskan
mengapa
pada
reaksi
pembuatan metanol yang eksotermis
lebih disukai pada tekanan tinggi dan
suhu rendah
CO + 2H2 CH3OH
kkal/mol
H298 = -21.684
Berapa harga pasar metanol/ton

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UNIVERSITY OF INDONESIA

The first member of the homologous

highly flammable liquid,

BASF pada tahun 1923 mengenalkan

Proses tersebut merupakan penelitian lanjut

CO dan H dapat bereaksi pada tekanan 100 300

Penelitian ini dilakukan oleh Fischer-Tropsch

Katalis methanol harus selektif dan aktif.

proses menjadi lebih efisien,

Methanol is one of the major industrial

methyl tertiary butyl ether (MTBE),

Other derivatives and uses include

Methanol is produced naturally in the

As a result, there is a small fraction of

Methanol burns in air forming carbon

2 CH3OH + 3 O2 2 CO2 + 4 H2O

A methanol flame is almost colorless.

Care should be exercised around burning

Methanol is often called wood alcohol

natural gas and steam are reformed in a

Today, synthesis gas is most commonly

At moderate pressures of 1 to 2 MPa

This reaction, commonly called steammethane reforming or SMR, is

Methane can also undergo partial oxidation

this reaction is exothermic and the heat given off

The ratio of CO and H2 can be adjusted

to provide the appropriate stoichiometry

The carbon monoxide and hydrogen

Today, the most widely used catalyst is

It is worth noting that

the production of synthesis gas from

One way of dealing with the excess

Although natural gas is the most economical

Methanol dapat dihasilkan dalam skala

1. Proses tekanan tinggi

: 25-30 Mpa (250

: 10-25 Mpa (100

Pada sat ini proses pembuatan

Keuntungan paling utama dari proses

Biaya produksi dan investasi rendah

Proses pruduksi methanol

Produksi gas sintesis

Produksi methanol dimulai dengan

Selanjutnya hasil dari syn-gas menjadi

Reaksi pembentukan methanol ini

Untuk mendapatkan konversi yang lebih

Reactor Sintesi Methanol

Jenis katalis yang digunakan:

Katalis pada tekanan tinggi

Katalis pada tekanan tinggi

Digunakan alkali/ZnO-CuO/Cr2O3 dapat

Katalis pada tekanan tinggi

Produksi metanol dengan zinc-oksida-krom

Katalis pada tekanan rendah

Digunakan alkali/CuO-ZnO/Al2O3 dapat

Katalis pada tekanan rendah

Karena keaktifan katalis, sintesis metanol

Produksi methanol secara komersial

Proses proses yang lain diantaranya

Jalur sintesis methanol dari proses

yaitu teknologi Lurgi (27%) dan

Proses tekanan sedang sudah jarang

Proses Tekanan Rendah ICI