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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
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)
(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.
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