Methanol Converter Types

1. 1. Gerard B. Hawkins Managing Director

2. 2. Quench Converter ARC Converter Tube Cooled Toyo MRF-Z Adiabatic
Beds

3. 3. Exit Catalyst Discharge Chute Catalyst Discharge Chute Manway Manway Inlet
Inert Balls

4. 4. Vessel Wall Shot Pipe Sparge Pipe Sparge Holes Mesh

5. 5. 180 200 220 240 260 280 300 320 0 2 4 6 8 10 Temperature (C)
MethanolConcentration(mol%) Max Rate Curve Methanol Equilibrium

6. 6. MUG Flash Drum Separator

7. 7. Benefits are Simple Reliable Well proven Capacity up to 3000 mtpd

Recover heat into saturator circuit The catalyst doesnt see all the gas. Poor catalyst
loading can lead to cold core developing

8. 8. Significant flow mal-distribution Some zones are cold Can lose reaction
Some zones are hot High byproducts levels High rate of catalyst deactivation

9. 9. Cool NormalNormal Catalyst density Low flow

10. 10. It is not caused by the quench lozenges being poor distributors of the cool
incoming gas. The reverse is true - the lozenges are very good distributors. The
problem is that voidage variations across the bed can cause varying flows down
different parts of the reactor. ARC retrofit developed to overcome problem.

11. 11. Catalyst Support Plates Individual / Separate Catalyst Beds Gas Mixing System

12. 12. x x xx x x x xx x x xx x x x xx x x x xx x x x xx x x x xx x x x xx x x x xx x x x
xx x x xx x x x xx x x x xx x C a t aly s t be d

13. 13. Inlet Temperature Exit Temperature Bed 3 237 C Bed 1 223 C Bed 4 230 C
Bed 3 270 C Bed 1 270 C Bed 2 223 C Bed 4 260 C Bed 2 270 C Bed 3 261 C
Bed 1 251 C Bed 4 269 C Bed 3 289 C Bed 1 291 C Bed 2 262 C Bed 2 301 C *
Figures in red are from current operating records (Sept. '96) * Figures in black are
from ARC design case

14. 14. Temperature % Methanol Equilibrium Line Quench Converter ARC Converter
Increase in Methanol %

15. 15. 0 10 20 30 40 50 0 50 100 150 200 temperature stand. dev. C %increaseinby-

products

16. 16. QCC + ICI 51-7 ARC + ICI 51-7 Ethanol 200 69 ppm Propanol 71 28 ppm
Butanol 71 33 ppm MEK 13 <5 ppm Decane C10 2.6 0.9 ppm Undecane C11 1.8 0.6
ppm Dodecane C12 1.2 0.4 ppm Tridecane C13 0.7 0.3 ppm Comp A Comp A

17. 17. 0 200 400 600 800 1,000 1,200 1,400 1,400 1,450 1,500 1,550 1,600 1,650 Days
on line Production(te/day)
18. 18. Key features improved gas mixing no penalty on pressure drop better utilisation of
the converter volume minimise the by-product levels

19. 19. Arc Revamp Catalyst Loading Lozenge removal Converter inspection Fit ARC
internals Catalyst loading Bed 5 Bed 4 Bed 3 Bed 2 Bed 1 0 7 14 21 activity days

20. 20. ARC converters have exhibited an instability This is highlighted by inlet and
outlet temperatures varying as per a sine wave Feedback occurs over warm loop
interchanger Normally stable but can become unstable Leads to loss of strike in
converter Action is to reduce circulation rate

21. 21. Manway Outlet Manway Inlet Catalyst Discharge Port

22. 22. Heat Recovery Unit Crude Crude Cooler Loop Interchanger Syn Gas Purge

23. 23. 180 200 220 240 260 280 300 320 0 2 4 6 8 10 Temperature (C)
MethanolConcentration(mol%) Max Rate Curve Methanol Equilibrium

24. 24. Cheaper loop with heat transfer and reaction Smooth catalyst temperature
profile Good catalyst utilisation Mechanically simple All converter effluent
available at high temperature Can be used to heat saturator water

25. 25. Mixing shall be effective Mixer should either not impede loading or be easy
to install and remove. Mixer should enhance safe operation and be mechanically
robust. Leakage of gas bypassing mixer should be minimized.

26. 26. Steam Outlet Central Pipe Catalyst Loading Gas Inlet Gas Outlet & Catalyst
Unloading BFW Inlet Cooling Tube Catalyst Inert Balls

27. 27. Outlet Collector Scallops Adiabatic Beds Cooled Bed Cooling Tube

28. 28. 180 200 220 240 260 280 300 320 3 4 5 6 7 8 9 10 Temperature (C)
MethanolConcentration(mol%) Max Rate Curve Methanol Equilibrium

29. 29. 28-32 Bara steam raised Good approach to equilibrium Low pressure drop,
0.5 to 0.75 bar Catalyst discharge complex Small number of tubes (c.f. Lurgi
converter)

30. 30. Crude Crude Cooler Loop Interchanger Syn Gas Purge Steam

31. 31. 180 200 220 240 260 280 300 320 0 2 4 6 8 10 Temperature (C)
MethanolConcentration(mol%) Max Rate Curve Methanol Equilibrium

32. 32. Cross flow means high heat transfer coefficient Smaller surface area Good
utilisation of shell volume Raised steam at between 30-40 bara But Costly (not as
expensive as Uhde/Lurgi) Large interchanger required Pressure is slightly lower
than Uhde/Lurgi

33. 33. Casale Horizontal Adiabatic Converter

34. 34. 180 200 220 240 260 280 300 320 0 2 4 6 8 10 Temperature (C)
MethanolConcentration(mol%) Max Rate Curve Methanol Equilibrium

35. 35. All the gas sees all of the catalyst Cheap vessels - can be spherical Vessels can
be designed the same Reduces CAPEX But Large loop interchanger Multiple
vessels (excluding Casales Horizontal Converter) Beds are shallow and so mal
distribution can be a problem

36. 36. Relative Catalyst Volumes Base Case 2800 te/day plant (Chile 3) Fixed circulation
rate (recycle ratio = 4.2) Reactor Catalyst Volume (m3) ARC 242 TCC 175 SRC 150

37. 37. Loop pressurised to 7 bar with nitrogen Heated to 180C Add small amount
of H2 for calibration Heat to give peak temperature of 220C Add hydrogen to 2%
Monitor temperatures When exotherm profile moves through bed start soak
Increase H2 and temperature

38. 38. Similar to Reduction Use air instead Again exothermic Also requires soak
Can not fully guarantee full oxidation Procedure is available

39. 39. Process Information Disclaimer Information contained in this publication or as

otherwise supplied to Users is believed to be accurate and correct at time of going to
press, and is given in good faith, but it is for the User to satisfy itself of the suitability
of the Product for its own particular purpose. GBHE gives no warranty as to the
fitness of the Product for any particular purpose and any implied warranty or
condition (statutory or otherwise) is excluded except to the extent that exclusion is
prevented by law. GBHE accepts no liability for loss or damage resulting from
reliance on this information. Freedom under Patent, Copyright and Designs cannot be
assumed