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Catalysis Surveys from Japan 2 (1998) 99106 99

Optimum catalytic reactor design for methanol synthesis with TEC


MRF-Zr reactor
Kunio Hirotani, Hitoshi Nakamura and Kazuo Shoji
Toyo Engineering Corporation (TEC), 2-8-1 Akanehama, Narashino-shi, Chiba 275-0024, Japan

The concept of Multi-stage indirect cooling and Radial Flow (MRF) is ideal for designing a catalytic reactor in which an exothermic
equilibrium reaction takes place. The reaction is controlled to go on along the path of the maximum reaction rate in the catalyst bed
where synthesis gas flows radially in the catalyst beds from the outer side to an inner center pipe across boiler (cooling) tubes to recover
the reaction heat as qualitative steam. The MRF concept has already been proven in a commercial scale methanol plant and is unique
not only for saving energy but also for considerable scale-up for which the enhanced design, MRF-Zr , provides. MRF-Zr is now
offered for single train 5,000 t/d reactors used in so-called jumbo methanol plants.
Keywords: methanol synthesis catalyst, MRF concept, steam rising reactor, radial flow reactor, bayonet boiler tube

1. Introduction periments with respect to heat transfer and reaction kinetics


during 19801981, the MRF concept was demonstrated at a
Methanol is no doubt an excellent fuel which may re- 50 t/d plant with a side stream reactor located in a 1000 t/d
place gasoline or fossil oil in the 21st century because: methanol plant in Osaka, Japan, in 19821983 [3]. The
(1) it can be handled as a liquid at atmospheric pressure design procedure with the MRF concept was then fully de-
and at ambient temperature; (2) it can be produced from veloped and completed in 1985 and TEC endeavored to
synthesis gas which can be converted from any carbona- find the first client to install a commercial-scale reactor
ceous substances including natural gas and coal; and (3) it employing this concept during 19861988. The first award
is a convenient and emission-free motor fuel. If fuel use of of a TEC reactor using the MRF concept was in 1989 for a
methanol is finally accepted for vehicles in large quantities, project in Trinidad with a capacity of 300 t/d. The concept
how can we build the large-scale methanol plants necessary was proven there with the fully anticipated performance of
to achieve reduction in capital cost per product? This is the the commercial scale plant in May 1990 [4]. TEC finally
key economic question at present. developed the enhanced version of the reactor, MRF-Zr ,
Since the first experiment by M. Pier in 1922 in Leuna, in 1993 based on the operating experience in Trinidad [5].
Germany, to synthesize methanol from CO and H2 , using The first reactor has been running over seven (7) years
zinc chromate as a catalyst, methanol had been produced in without any problem since its 1990 startup. The MRF-Zr
reactors operating under high pressure of 2535 MPa and Reactor was ordered for two (2) methanol projects in P.
high temperatures of 320450 C. For the first 45 years R. China in 1993 and 1996 respectively and the first one
the process required using relatively poison-resistant ZnO will be on stream in 1998. TEC is now prepared to of-
Cr2 O3 catalyst [1]. In 1966, Imperial Chemicals Industries fer, with the entirely same design philosophy and criteria,
introduced its low pressure methanol process in Billingham, the MRF-Zr Reactor on a single train for methanol plants
England, using a more active (but less poison-resistant) from a small 300 t/d size to the largest 5,000 t/d plant,
ZnOCuO catalyst under 510 MPa and 220300 C [2]. which means doubling capacity compared with existing so-
ICI overcame the poison problem for the low pressure syn- called world scale plants of 2,0002,500 t/d, in order to
thesis catalyst with the development of the combined desul- meet the required economies of scale [6].
phurization technology applying ZnO and CoMo catalysts
which are well-known today. While the invention of the
low pressure process was a considerable breakthrough for 2. Methanol synthesis catalyst
energy saving, further improvements on plant efficiency and
optimization have been made and are still continuing in ad- The major reactions occurring in methanol synthesis re-
dition to efforts to improve the activity and selectivity of actor are:
the catalysts.
CO + 2 H2
CH3 OH H = 90.6 kJ/gmol
TEC sought to improve the performance of methanol
CO2 + 3 H2
CH3 OH + H2 O H = 49.4 kJ/gmol
synthesis reactors by optimizing operating conditions of
CO2 + H2
CO + H2 O H = 41.2 kJ/gmol
the above low pressure synthesis catalyst and consequently
patented the concept of MRF (Multi-stage indirect cooling The main two reactions are exothermic and decrease in vol-
& Radial Flow) for reactors in 1979. After intensive ex- ume, and thus the methanol formation is favored with lower

Baltzer Science Publishers BV


100 K. Hirotani et al. / Optimum catalytic reactor design

Figure 1. Catalyst Activity. A typical curve of deactivation of a methanol Figure 2. Reaction Equilibrium and Maximum Reaction Rate for Metha-
synthesis catalyst available commercially in the market. nol Synthesis. Methanol synthesis reactions from CO and H2 or CO2 and
H2 are exothermic. The reaction takes place favorably where the tem-
temperature and higher pressure. The maximum conversion perature is low. The reaction is also controlled by an equilibrium. The
reaction taking place in the area of low temperature progresses slowly
is determined by the equilibrium conditions. and according to increase of the temperature it progresses more rapidly.
ZnOCuO based catalysts have been developed by sev- However, in the area near the equilibrium line the reaction rate becomes
eral catalyst manufacturers to achieve reasonably high con- slow due to approach to equilibrium. In the area of low methanol concen-
versions within the range of low temperatures applied for tration the reaction rate is fast while it is slow in the area of high methanol
the low pressure process. Since the ZnOCuO catalyst also concentration. Thus, the maximum reaction rate line is existing almost in
parallel to the equilibrium line. R is relative reaction rate defined by a
catalyzes the water shift reaction (since low temperature function of total pressure, gas composition and temperature.
shift catalyst contains the same components in principle),
the shift reactions have to be considered together. An in- (5) Steam Rising Isothermal Boiler Coil Reactor
dividual kinetic model taking into account all three equa-
tions is used to describe performance of the catalyst by (6) Steam Rising Multi-stage Indirect-cooling Boiler Tube
each manufacturer who treats the model as a business se- Reactor.
cret. The catalyst activity is a function of the operation The maximum capacity of a single train reactor is one of the
time. Figure 1 illustrates a typical curve of deactivation of important characteristics to be discussed. As plant capacity
a methanol synthesis catalyst. increases, there is a breakpoint for each type of reactor
Control of the reaction temperature is one of the key where it becomes more economical to construct two parallel
issues for daily plant operation. While the catalyst has reactors instead of a single reactor. Allowable pressure drop
high thermal stability over a wide range of temperatures, is a major limit for the capacity of a single train reactor in
the operator has to keep in mind to maintain the temper- addition to the manufacturing limits of currently available
ature of the catalyst bed below a certain limit to avoid technology for high pressure vessels. Details are discussed
excessive sintering of the catalyst. The reaction tempera- below for each reactor type.
ture also affects selectivity for methanol since it is possible The reaction temperature profile or the reaction path in
for a variety of byproducts to be formed much more out- a reactor is also important for understanding the basic re-
side the desired temperature range depending on the sorts action characteristics of each type of reactor. Figure 2
and/or the amounts of reactive impurities contained in the illustrates the maximum reaction rate curve on methanol
feed synthesis gas or originated in the catalyst itself. concentration as a function of temperature at a constant
pressure together with related equilibrium curve.
If the reaction heat is not removed, methanol concen-
3. Review of methanol synthesis reactor
tration increases proportionally with temperature rise and
In order to understand specific features of the MRF-Zr directly approaches the equilibrium limit. Therefore the re-
Reactor it is worthwhile to review the characteristics of action heat has to be removed if the methanol yield is to be
various types of methanol synthesis reactors. Today six increased. Measures used to remove the heat are: (1) using
(6) types of methanol synthesis reactor are commercially in quench with low temperature synthesis gas, (2) by external
operation. They are: heat exchangers located between the catalyst beds, (3) by
pre-heating the feed gas or (4) by raising steam. Figure 3(a)
(1) Adiabatic Quench Cooling Reactor to figure 8(a) illustrate the different concepts of the reactor
(2) Adiabatic External and Indirect Cooling Reactor schemes and figure 3(b) to figure 8(b) trace each operating
line in the same correlation chart as figure 2.
(3) Tube Cooling Reactor
The adiabatic quench cooling reactor (figure 3(a)) is
(4) Steam Rising Isothermal Tubular Bed Reactor presently the most popular methanol reactor designed. Af-
K. Hirotani et al. / Optimum catalytic reactor design 101

(a)

(a)

(b)

Figure 4. Adiabatic External Indirect Cooling Reactors; (a) Process Con-


figuration and (b) Temperature Profile. The reactors are installed in series.
Cooling does not cause decrease of concentration of methanol produced
in each bed.

ure 3(b)). This reactor has many variables to control and it


is somewhat complex to optimize those. The largest pos-
sible capacity for this type reactor is estimated as 3,000
3,500 t/d due to manufacturing limitations in building a
high pressure vessel with the necessary diameter and to the
(b) drawback of an increase in pressure drop through the cat-
alyst beds which causes an increase of recirculator power
Figure 3. Quench Cooling Reactor: (a) Process Configuration and (b)
resulting in penalty for energy consumption.
Temperature Profile. By quenching cold and fresh synthesis gas to exit of
each catalyst bed, the temperature of reaction gas can be lowered, but the In the case of the adiabatic external and indirect cooling
concentration of methanol also decreases. reactor (figure 4(a)), all the gas is passed to the first adi-
abatic bed. The exit gas from the first bed enters the first
ter quench fractions are separated, the main flow of the feed heat exchanger where steam is usually raised. The total cat-
gas is fed to the reactor inlet and each quench fraction is alyst volume is smaller than in the adiabatic quench cooling
fed to each intermediate bed respectively. The efficiency reactor since all the gas passes through all of the catalyst.
of quench distributors for mixing the hot and cold gases is However, the reaction path is still away from the maximum
most important in this type of reactor. Poor distribution of reaction rate curve (figure 4(b)). The major drawback of
the quench gases will cause hot spots in the catalyst bed this system is the need to have much larger numbers of
and shorten the catalyst life as well as increase byproduct high pressure reactors, heat exchangers and interconnect-
formation. ing piping which inhibit cost savings.
In comparison with other types of reactors, the adiabatic The tube cooling reactor (figure 5(a)) uses reaction heat
quench cooling reactor does require a relatively large cat- directly to pre-heat the inlet gas of the reactor. The main
alyst volume since the temperature profile or the reaction advantage of this reactor is the need of a relatively small
path is away from the maximum reaction rate curve (fig- catalyst volume since the reaction curve closely follows the
102 K. Hirotani et al. / Optimum catalytic reactor design

(a)
(a)

(b)
(b)
Figure 6. Steam Rising Isothermal Tubular Bed Reactor: (a) Process
Figure 5. Tube Cooling Reactor: (a) Process Configuration and (b) Tem- Configuration and (b) Temperature Profile. Catalyst is loaded in the tube-
perature Profile. Catalyst is loaded in the shell-side. Sufficient heat trans- side. A large number of tubes, i.e., a large number of heat transfer surface
fer area (many tubes) are required to maintain preferable temperature pro- provided to load sufficient amount of catalyst, leads to almost isothermal
file. temperature profile which is far from the maximum reaction rate line.

maximum reaction rate curve (figure 5(b)). This type of re-


actor is very easy to control because all the temperatures in
the reactor are set only by the inlet temperature. A special
device is employed to ensure even gas distribution from the
cooling tube to the inlet of the catalyst bed. The limit of
single train capacity is due to the same reason as for the
adiabatic quench cooling reactor, but the capacity could be
up to approximately 2,0002,500 t/d due to restricted usage
of the reactor internal space which is shared by the cooling
tubes.
The most efficient mean to recover the reaction heat of
methanol synthesis is to use the heat directly in generating
steam in the synthesis reactor. The steam rising isothermal Figure 7. Isothermal Boiler Coil Reactor. Process configuration. Catalyst
tubular reactor (figure 6(a)) has such an advantage together is loaded in the shell-side.
with a considerably small catalyst requirement due to good
catalyst stability because of operation at low catalyst peak plant. A drawback with having a catalyst in the tubelar
temperature (figure 6(b)). The low peak temperature also reactor is to require a large number of tubes in order to
ensures a lower level of byproducts formation. The recov- accommodate the catalyst. This requirement is very expen-
ered heat is used to generate qualitative steam to be applied sive and the manufacturing restriction would limit a single
for steam reforming in the upstream unit of the methanol train capacity of this type reactor up to 1,2001,500 t/d.
K. Hirotani et al. / Optimum catalytic reactor design 103

Similar near isothermal performance is obtained by load-


ing the catalyst in the shellside as a steam rising isother-
mal boiler coil reactor can demonstrate. An example of
commercial scale installation of this reactor type employs
spirally wounded tubes in a multilayer arrangement over
spacers running the length of the unit (figure 7). The ca-
pacity restriction of this type reactor is determined appar-
ently by pressure drop over the catalyst bed although the
authors have no information on this complex structure of
the reactor.
The TEC MRF-Zr Reactor is a steam rising multi-stage
indirect-cooling reactor using bayonet boiler tubes for the (a)
reaction heat removal together with radial flow of synthe-
sis gas across the catalyst bed in the shellside (figure 8(a)
and (c)). In a multi-stage indirect cooling system the reac-
tion conditions can be adequately controled along the path
of the maximum reaction rate curve in order to achieve
maximum conversion per pass and minimum catalyst vol-
ume per unit product (figure 8(b)). In addition, a radial
flow system ensures achievement of a higher heat transfer
coefficient (gas-cross-flow), less pressure drop and larger
catalyst volume within the restricted manufacturing limit
of a high pressure vessel diameter.
Because of these features, a single 5,000 t/d reactor
can be designed with currently available manufacturing
technology. Fabrication, maintenance and catalyst load-
ing/unloading are also much easier than those for the two (b)
steam rising isothermal reactors described above.

4. Features of MRF-Zr reactor

4.1. Steam rising methanol reactor

The heat of the exothermic reaction over the catalyst bed


is removed by means of cooling tubes arranged adequately
in the bed (figure 8(c)). Saturated boiler feed water (BFW)
is charged inside of the tubes as the cooling medium and
steam is risen by absorbing the reaction heat through the
tube wall. Temperature of the catalyst bed is controlled
by the steam pressure. Thus a steam drum is equipped for
steam recovery and pressure control as well as receiving
the boiler water.
A BFW circulation pump is also provided in order to
ensure adequate heat transfer in the steam rising system.
The steam thus risen has a quality level sufficient for the
steam reforming unit usually existing in the front-end of
the methanol plant and can save energy to generate or
import an equivalent amount of steam for the methanol
plant.

4.2. Radial gas flow


(c)
Due to the large cross surface area for gas flow in a ra-
Figure 8. TEC MRF-Zr Reactor: (a) Process Configuration, (b) Temper-
dial flow reactor, extremely small pressure drop through the ature Profile and (c) Conceptional Drawing. Catalyst is loaded in shell-
catalyst bed is expected. Figure 9 illustrates the estimated side and radial flow is applied for synthesis gas stream over the catalyst.
data vs. the actual operating data from the 50 t/d demon- The ideal temperature profile is accomplished with adequate number and
stration plant on the pressure drops of the reactor and the bayonet tubes.
104 K. Hirotani et al. / Optimum catalytic reactor design

is that scale up of the reactor is achieved without sacrific-


ing pressure drop by vertical extension until the limit of
the catalyst loading. In other words, the radial flow reactor
can load the maximum volume of the catalyst mechani-
cally within the manufacturing limit of the high pressure
vessel diameter on that date. Thus this concept leads to the
possibility of designing a large single train reactor.

4.3. Cross flow

Figure 10 illustrates the heat transfer coefficient ob-


served during the demonstration test together with a line
of the experimental equation used for the design of the
demonstration plant. Fundamental experiments had been
executed to determine the heat transfer coefficient on the
surface of the cooling tubes in the packed bed where gas
flows radially cross over the tubes. Only a few studies had
Figure 9. Pressure Drop of MRF-Zr Reactor. Overall and catalyst bed been reported in this field. The dotted line in figure 10
pressure drops in a 50 t/d demonstration plant (marked) are compared with indicates the heat transfer coefficient for the parallel flow
calculated values (real lines). system.
The observed figures of the heat transfer coefficient are
catalyst bed. These are fitted very well and prove that the well fitted with the experimental equation. It is also con-
pressure drop of the MRF-Zr Reactor is very small. firmed thereby that the heat transfer coefficient for the cross
This extremely small pressure drop through the catalyst flow is twice as large as that of the parallel flow at the same
bed allows more pressure drop over the inside of the reactor gas velocity.
which in turn enables the use of the orifice plate for even
distribution of the gas flow to the catalyst bed. This mild 4.4. Adequate boiler tube arrangement
operating environment avoids mal-distribution and ensures
long catalyst life. In accordance with figure 8(b), the temperature profile
The most important advantage of a radial flow reactor of the reactor follows the maximum reaction rate line by

Figure 10. Heat Transfer Coefficient in the term of Nusselt Number: N u = h0 (d0 /2)/k vs. Peclet Number: P e = (d0 v/2/)(Cp /k) where h0 :
Packed Bed Overall Heat Transfer Coefficient (kcal/m2 /h/ C) d0 : External Tube Diameter (O.D.) (m). k: Gas Thermal Conductivity (kcal/m/h/ C).
: Gas Density (kg/m3 ). v: Gas Velocity (m/h). : Gas Viscosity (kg/m/h) Cp : Gas Specific Heat (kcal/kg/ C).
K. Hirotani et al. / Optimum catalytic reactor design 105

Figure 11. A Top Internal View of MRF-Zr Reactor. The photograph was of a reactor designed for Chuandong Chemical Industry Corp., Sichuan
Province, China.

arranging the boiler tubes adequately. TEC has completed to continue operations with the catalyst until the real life
its own design simulator to execute a variety of complicated of the catalyst expired. At present, over 4 years later, it is
case studies in connection with optimum tube arrangement. still continuing operation.
Due to this optimization, the reactor can achieve higher
conversion of synthesis gas per pass on the same volume
of catalyst or can require a smaller volume of catalyst for 5. Commercially proven performance of the MRF
the same conversion per pass. concept

4.5. Bayonet boiler tubes In May 1990 a prototype reactor using the MRF con-
cept was linked with the existing synthesis loop of the No.1
The MRF-Zr Reactor uses bayonet tubes as an opti- methanol plant at Trinidad Tobago Methanol Co., Ltd. im-
mum device for the boiler tubes. This design permits free mediately upon completion of the catalyst reduction. It was
thermal stress together with the advantage of self drainage clearly observed that operating conditions of the existing
by the tubes themselves, and further permits inspection and plant were improved dramatically because of excellent per-
maintenance of the tubes without unloading the catalyst. formance of the new reactor. The improved performances
Figure 11 shows a top view of the bayonet tube. The bayo- for the scheme of 300 t/d MRF plus 1,080 t/d quench cool-
net tube assembly enables the elimination of a tube sheet on ing reactor (having the catalyst volume for 1,200 t/d) are
the one side of the reactor and leads to economical design summarized as follows, compared with the original 1,200
accordingly. A forced water circulation system is applied t/d quench cooling reactor:
to ensure steady flow pattern. Boiler water is charged from (1) 34 kPa of pressure drop for the reactor maintained con-
a water chamber to the inner tubes and a mixture of steam stantly during the catalyst life (more than 4 years),
and boiler water flows downward through annular spaces
after boiling in the tubes. The mixture is then collected in (2) 14% less pressure drop achieved for the entire synthesis
the mixture chamber. loop,
(3) 11% higher gas flow rate achieved through the existing
4.6. Operation benefits circulator consequentially,

According to the operating experience over 7 years in the (4) 33% less purge gas rate achieved due to efficient con-
Trinidad plant, a reactor using the MRF concept is remark- version,
ably stable in operation. The Trinidad operator confirmed (5) 8.5% higher crude methanol production per unit feed
simple, easy, steady and very reliable operation as well as gas rate,
easy catalyst handling during loading and unloading com-
(6) 14% less steam import to the plant achieved due to
pared with other types of methanol synthesis reactors which
quality steam generated in the new reactor.
they have in their plants. In 1993, at the end of the 3 years
expected life of the catalyst, the Trinidad operator replaced After the start-up the reactor is still in continuous op-
the catalyst for the first batch even though its activity had eration over 7 years without any trouble and maintaining
not decreased, however for the second batch, it was decided excellent performances.
106 K. Hirotani et al. / Optimum catalytic reactor design

Table 1
the case employing a quench cooling reactor. Our evalua-
Comparison of MRF-Zr Reactor and Quench Cooling Reactor. Mechan-
ical design and process performance of the MRF-Zr Reactor is compared
tion has indicated that total capital expenditure of 2,600 t/d
with Quench Cooling Reactor on which the unity is used for each relative methanol plant using the MRF-Zr Reactor is about 56%
factor of the MRF-Zr Reactor. cheaper than that using a quench cooling reactor.
Table 2 shows the relative energy savings of the MRF-
MRF-Zr Quench cooling
reactor reactor Zr Reactor on a basis of 2,600 t/d plant in comparison
with a quench cooling reactor. Energy saving by using the
Reactive catalyst volume 0.68 1.00
MRF-Zr Reactor would be about 78% superior to that of
Number of reactors 1 1
Relative reactor weights 1.25 1.00 a quench cooling reactor.
Relative heat exchanger area 0.91 1.00
Relative total plant cost 0.94 0.95 1.00
Natural gas consumption 0.93 1.00 7. Design of 5,000 t/d MRF-Zr reactor
Natural gas cost and catalyst cost 0.92 1.00
Table 2 indicates the brief design specification of a sin-
Table 2 gle train MRF-Zr Reactor to produce 5,000 t/d of refined
Specification of A 5,000 t/d MRF-Zr Reactor: Inlet and outlet gas com- methanol. The shell internal diameter of the reactor is only
positions, operating conditions and dimensions of the reactor are summa-
5 m and absolutely within current manufacturing restric-
rized.
tions for high pressure vessels. The height of the reactor is
Inlet Outlet
22.4 m including spaces for all internal devices and cham-
Composition (mol%) bers.
H2 83.2 77.3
CO 7.9 2.1
CO2 5.8 4.4
CH4 + N2 2.7 3.2
8. Conclusion
H2 O 0.1 2.8
MeOH 0.3 10.2 The MRF concept, which is ideal for design of a catalytic
reactor with exothermic equilibrium reaction in terms of
100.0 100.0 cost and energy savings, was first applied to a methanol
Pressure (MPa) 10.00 synthesis reactor and its performances have already been
Temperature ( C) 240 260 proven in a commercial scale operation for more than 7
Internal diameter (mm) 5,000 years. The enhanced design of the same concept is now
TT Length (mm) 22,400
available as the TEC MRF-Zr Reactor which can almost
double the capacity of the current maximum single train
6. Economics of MRF-Zr reactor methanol reactor to 5,000 t/d without any change of the
design philosophy for a small plant of 300500 t/d. The
Table 1 shows economics of the MRF-Zr Reactor on MRF-Zr Reactor promises to achieve a reduction in capital
a basis of 2,600 t/d plant in comparison with a quench cost per product by making possible the construction of
cooling reactor. The MRF-Zr Reactor has many tubes to- necessary jumbo methanol plants if fuel use of methanol is
gether with an associated tube sheet, but its weight is not finally accepted in the not so distant future.
so heavy as it restricts transportation and erection. It has
a relatively small volume of catalyst. A major drawback
of a steam rising reactor such as the MRF-Zr Reactor is References
the need to employ a much larger surface area in the in-
terchanger which is installed for heating all the synthesis [1] H. Roos, G. Steigelmann and R. Klause, 1993 World Methanol Con-
gas up to the inlet temperature before entering the reactor ference, Atlanta, Georgia, 1993.
by heat exchange with the reactor exit gas, whilst a quench [2] ICI Catalogue, ICI Low Pressure Methanol Process (1987).
[3] K. Ohsaki, K. Shoji, O. Okuda and Y. Kobayashi, AIChE 1984 Spring
cooling reactor needs to heat only part of the gas. How- National Meeting, Anaheim, California, 1984.
ever, due to less pressure drop of the MRF-Zr Reactor, [4] Y. Kobayashi and A.F. Greene, 1990 World Methanol Conference,
it is possible to reduce the surface area by giving more Marbella, Spain, 1990.
pressure drop in the interchanger to improve the concerned [5] Y. Kobayashi and H. Nakamura, AIChE 1993 Spring National Meet-
heat transfer coefficient within economic allowance which ing, Houston, Texas, 1993.
[6] K. Hirotani, M. Sasaki and N. Mochizuki, 1997 Asian Methanol Con-
is compensated against the power of the circulator. Our
ference, Singapore, 1997.
optimization results in 91% of surface area compared with

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