JM & JC LP Methanol Process

Process & Operations Training

Revised 20th May 2004

Section 1

Personal Introduction

Tom White
Process Development
4 years with Jacobs
SIPChem

Feasibility

Tech Package

Detailed Design

Personal Learning

Physical
Visual

Verbal
Feel Free to share your knowledge for benefit of all..

Plant Introduction Methanol

Background, Usage
Total 2004 World Methanol Demand ~40 Million Tonnes
OTHER
DYES
SOLVENT USE
ACETIC ACID

MTBE

FORMALDEHDYE

Course Syllabus
1. Plant Introduction
2. NG Compression
3. Feed Purification
4. Reforming
5. Syngas Compression
6. Synthesis Loop
7. Distillation
8. Process Hot Water Circuit
9. Steam System
10. Plant Integration
11. Catalyst Issues
12. Reference Data
13. Team Work and Leadership

Plant Introduction Session Content

Course Objectives
Methanol Background
Overall Process Block Diagram
General Chemistry
General Hazards and Safety
Site Tour

Plant IntroOverall Course Objectives

Understand the process chemistry
Gain a working knowledge of the process technology
Recognise the key principles of operation of the process including

start-up and shut-down

Be able to use this understanding to assist with plant trouble

shooting and problem solving

Utilise this knowledge as a firm foundation for commissioning / plant

operation
This course will not tell you how to run the plant in every detail

Plant Introduction Temperatures,

Pressures & Flow Figures
The numbers for temperatures, pressures and flows used on
these presentations are often approximate. (ca. = circa = about )
This is done so as the remind you that on the plant the pressures,
temperature and flows will NOT be exactly as per documentation
This is because designs, material balances, etc. are based on a
specified natural gas composition, which will be slightly different in
practice, the fouling factors of heat exchangers will be different,
usually maximum production will be required which may well be
110% of design, etc.

Plant Introduction Design Cases

4 main Design Cases

MaxBOL

MinBOL

MaxEOL

MaxBOL

Max = Maximum CH4 Content . A lean gas

BOL = Beginning of Life

Special

High Sulphur

Others (Extreme Gas Case - Carbon Number 1.3)

Plant Introduction Overall Process

Block Diagram

Desulphurisation

Reforming

Synthesis

Water Circuit

Distillation

Plant Introduction General

Chemistry
Desulphurisation

R-SH + H2 R-H + H2S (Mercaptan reaction)

H2S + ZnO ZnS + H2O (About 25% pickup)

Reforming

CH4 + H2O CO + 3 H2
CO + H2O CO2 + H2

Synthesis

CO + 2 H2 CH3OH

Distillation

Heat sink
Purification
Removal of e.g. water, ethanol, amines

Plant Introduction General Hazards

& Safety
Safety

1st Rule of Safety

It is your Responsibility !

Plant Introduction Chemical

Hazards (1)
Methanol

Hazards (for details see Material Safety Data Sheet MSDS)

Toxic by inhalation
by ingestion
by skin contact

Flammable

Precautions
Wear gloves and eye protection
Wear breathing apparatus when necessary
Eliminate sources of ignition

Plant Introduction Chemical

Hazards (2)
Carbon Monoxide

Hazards (for details see MSDS)

Toxic by inhalation
Flammable
It has no smell (Use CO Monitor or Drager Tube)

Precautions

Breathing apparatus in case of emergency

Monitor where there is potential risk (Listen but do not go near!)

Eliminate sources of ignition

Plant Introduction Chemical

Hazards (3)

CARBONYLS (Ni(CO)5 & Fe(CO)5) (Mainly formed between 80 and 250 C)

Hazards
Toxic by inhalation
By skin contact

Flammable
No smell
Water-like at ambient conditions

Precautions
Materials of construction
Careful control of operating temperatures
Thorough purging of vessels

Plant Introduction Chemical

Hazards (4)
Hydrogen Sulphide

This occurs in the Natural Gas before it has been Desulphursised

Rotten Eggs smell (Do you know this smell??)

Detectable at low concentrations10ppm
Higher Concentrations anaesthetises nose so can not be smelt
So be concerned if you get sharp smell and then cannot smell it. (Hold breath and walk
away)

Hazard
Toxic

Precautions
Breathing apparatus in case of emergency
Monitor where there is potential risk (Listen but do not go near!)
Eliminate sources of ignition

Plant Introduction Plant Tour

Some things to note:

Layout short stainless steel pipe runs gives cheaper plant

Air cooler Finfan Hot air flows should not interfere but could happen in
unusual weather conditions. (Look at windsock and temp underneath)

Symmetrical Piping to HE Condenser finfans for good vapour distribution

into all the many bays

Expansion Loops on High Temperature piping

Space for Cranes/Catalyst loading/

Note the location of the Windsock. If any problem, hold your breath and
run across the wind flow

Plant Introduction Session

Summary
Course Objectives
Methanol Background
Overall Process Block Diagram
General Chemistry
General Hazards and Safety
Site Tour