Methanol synthesis reaction

As an example of the application of a fixed-bed tubular reactor, consider the production of methanol. Synthesis gas (a mixture of hydrogen, carbon monoxide, and carbon dioxide) is reacted over a copper-based cat dyst. The main reactions are... 

Methanol (qv) is one of the 10 largest volume organic chemicals produced in the wodd, with over 18 x 10 t of production in 1990. The reactions for the synthesis of methanol from CO, CO2, and H2 are shown below. The water gas shift reaction also is important in methanol synthesis. 

Liquid Fuels via Methanol Synthesis and Conversion. Methanol is produced catalyticaHy from synthesis gas. By-products such as ethers, formates, and higher hydrocarbons are formed in side reactions and are found in the cmde methanol product. Whereas for many years methanol was produced from coal, after World War II low cost natural gas and light petroleum fractions replaced coal as the feedstock. 

Because the synthesis reactions are exothermic with a net decrease in molar volume, equiUbrium conversions of the carbon oxides to methanol by reactions 1 and 2 are favored by high pressure and low temperature, as shown for the indicated reformed natural gas composition in Figure 1. The mechanism of methanol synthesis on the copper—zinc—alumina catalyst was elucidated as recentiy as 1990 (7). For a pure H2—CO mixture, carbon monoxide is adsorbed on the copper surface where it is hydrogenated to methanol. When CO2 is added to the reacting mixture, the copper surface becomes partially covered by adsorbed oxygen by the reaction C02 CO + O (ads). This results in a change in mechanism where CO reacts with the adsorbed oxygen to form CO2, which becomes the primary source of carbon for methanol. 

Methanol Synthesis. Methanol has been manufactured on an industrial scale by the cataly2ed reaction of carbon monoxide and hydrogen since 1924. The high pressure processes, which utili2e 2inc oxide—chromium oxide catalysts, are operated above 20 MPa (200 atm) and temperatures of 300—400°C. The catalyst contains approximately 72 wt % 2inc oxide, 22 wt % chromium (II) oxide, 1 wt % carbon, and 0.1 wt % chromium (VI) the balance is materials lost on heating. 

Thermal chlorination of methane was first put on an industrial scale by Hoechst in Germany in 1923. At that time, high pressure methanol synthesis from hydrogen and carbon monoxide provided a new source of methanol for production of methyl chloride by reaction with hydrogen chloride. Prior to 1914 attempts were made to estabHsh an industrial process for methanol by hydrolysis of methyl chloride obtained by chlorinating methane. 

Methanol. Methanol is produced by stoichiometric reaction of CO and H2. The syngas produced by coal gasification contains insufficient hydrogen for complete conversion to methanol, and partial CO shifting is required to obtain the desired concentrations of H2, CO, and CO2. These concentrations are expressed in terms of a stoichiometric number, ((H2 — CO)/(H2 + CO2), which has a desired value of 2. In some cases CO2 removal is required to achieve the stoichiometric number target. CO and H2 are then reacted to form methanol in a catalytic methanol synthesis reactor. 

Dente and Ranzi (in Albright et al., eds.. Pyrolysis Theory and Industrial Practice, Academic Press, 1983, pp. 133-175) Mathematical modehng of hydrocarbon pyrolysis reactions Shah and Sharma (in Carberry and Varma, eds.. Chemical Reaction and Reaction Engineering Handbook, Dekker, 1987, pp. 713-721) Hydroxylamine phosphate manufacture in a slurry reactor Some aspects of a kinetic model of methanol synthesis are described in the first example, which is followed by a second example that describes coping with the multiphcity of reactants and reactions of some petroleum conversion processes. Then two somewhat simph-fied industrial examples are worked out in detail mild thermal cracking and production of styrene. Even these calculations are impractical without a computer. The basic data and mathematics and some of the results are presented. 

The production of methyl acetate from synthesis gas is currently being practiced commercially. Following methanol synthesis, as shown by Reac tion (27-35), the reactions are ... 

For a first test of the reactor and all associated service installations it is recommended that experiments for methanol synthesis should be carried out even if this reaction is not especially interesting for the first real project. The reason for this recommendation is that detailed experimental results were published on methanol synthesis (Berty et al, 1982) made on a readily available catalyst. This gives a good basis of comparison for testing a new system. Other reactions that have been studied in detail and for which the performance of a catalyst is well known can also be used for test reactions. 

The catalyst should be the copper-based United Catalyst T-2370 in 3/16 , reduced and stabilized, in extrudate form. Initially, 26.5 g of this should be charged to the catalyst basket. This catalyst is not for methanol synthesis but for the low temperature shift reaction of converting CO to CO2 with steam. At the given conditions it will make methanol at commercial production rates. Somewhat smaller quantity of catalyst can also be used with proportionally cut feed rates to save feed gas. 

Methanol synthesis served as the model for the true mechanism. Stoichiometry, thermodynamics, physical properties, and industrial production rates were all taken from the methanol literature. Only the reaction mechanism and the kinetics of methanol synthesis were discarded. For the mechanism a four step scheme was assumed and from this the... 

Here the integration method will be shown that was used for the workshop program (Berty et al, 1989) to integrate the UCKRON rate equations. Since this is about methanol synthesis the reaction is shown here with the stochiometric coefficients ... 

Remarks The aim here was not the description of the mechanism of the real methanol synthesis, where CO2 may have a significant role. Here we created the simplest mechanistic scheme requiring only that it should represent the known laws of thermodynamics, kinetics in general, and mathematics in exact form without approximations. This was done for the purpose of testing our own skills in kinetic modeling and reactor design on an exact mathematical description of a reaction rate that does not even invoke the rate-limiting step assumption. 

Methanol synthesis will be used many times as an example to explain some concepts, largely because the stoichiometry of methanol synthesis is simple. The physical properties of all compounds are well known, details of many competing technologies have been published and methanol is an important industrial chemical. In addition to its relative simplicity, methanol synthesis offers an opportunity to show how to handle reversible reactions, the change in mole numbers, removal of reaction heat, and other engineering problems. 

To facilitate the use of methanol synthesis in examples, the UCKRON and VEKRON test problems (Berty et al 1989, Arva and Szeifert 1989) will be applied. In the development of the test problem, methanol synthesis served as an example. The physical properties, thermodynamic conditions, technology and average rate of reaction were taken from the literature of methanol synthesis. For the kinetics, however, an artificial mechanism was created that had a known and rigorous mathematical solution. It was fundamentally important to create a fixed basis of comparison with various approximate mathematical models for kinetics. These were derived by simulated experiments from the test problems with added random error. See Appendix A and B, Berty et al, 1989. 

Conclusions from the test problems are not limited by any means to methanol synthesis. These results have more general meaning. Other reactions also will be used to explain certain features of the subjects. Yet the programs for the test problem make it possible to simulate experiments on a computer. In turn, computer simulation of experiments by the reader makes the understanding of the experimental concepts in this book more profound and at the same time easier to grasp. 

Arva, P. and F. Szeifert, 1989, Effect of Water-gas Reaction on Methanol Synthesis Chem. Eng. Comm., 16, pp 195-206. 

Synthesis gas is an important intermediate. The mixture of carbon monoxide and hydrogen is used for producing methanol. It is also used to synthesize a wide variety of hydrocarbons ranging from gases to naphtha to gas oil using Fischer Tropsch technology. This process may offer an alternative future route for obtaining olefins and chemicals. The hydroformylation reaction (Oxo synthesis) is based on the reaction of synthesis gas with olefins for the production of Oxo aldehydes and alcohols (Chapters 5, 7, and 8). 

A low-pressure process has been developed by ICl operating at about 50 atm (700 psi) using a new active copper-based catalyst at 240°C. The synthesis reaction occurs over a bed of heterogeneous catalyst arranged in either sequential adiabatic beds or placed within heat transfer tubes. The reaction is limited by equilibrium, and methanol concentration at the converter s exit rarely exceeds 7%. The converter effluent is cooled to 40°C to condense product methanol, and the unreacted gases are recycled. Crude methanol from the separator contains water and low levels of by-products, which are removed using a two-column distillation system. Figure 5-5 shows the ICl methanol synthesis process. 

The process of direct synthesis of DME includes reactions of methanol synthesis and methanol dehydration, which are catalyzed by two different catalysts. Although the technology for the production of methanol is generally considered mature, most of thran are gas phase process, and the performances of these catalysts are restricted remarkably in liquid phase process. Development of high performance bifunctional catalyst system is very... 

This is illustrated by the TPD spectra of formate adsorbed on Cu(lOO). To prove that formate is a reaction intermediate in the synthesis of methanol from CO2 and H2, a Cu(lOO) surface was subjected to methanol synthesis conditions and the TPD spectra recorded (lower traces of Fig. 7.13). For comparison, the upper traces represent the decomposition of formate obtained by dosing formic acid on the surface. As both CO2 and H2 desorb at significantly lower temperatures than those of the peaks in Fig. 7.13, the measurements represent decomposition-limited desorptions. Hence, the fact that both decomposition profiles are identical is strong evidence that formate is present under methanol synthesis conditions. 

The reaction mechanism of methanol synthesis is complex since two processes are involved and coupled. Formally, the reaction can be written as the hydrogenation of CO by the overall reaction ... 

The hydrogenation of dioxomethylene, step (33) is, most likely, the rate-limiting step, although the hydrogenation of formate in (32) is a also candidate. By assuming that Eqs. (24), (23) and (29) are slow for the water-gas shift reaction and that (33) is slow for methanol synthesis, we arrive at the following set of equations, in which one site is assumed to consist of two copper atoms ... 

Figure 8.10. Methanol synthesis rate over a Cu(lOO) single crystal in the zero conversion limit as a function of the H2 mole fraction. The full line corresponds to the kinetic model in Eqs. (23-35) with reaction (33),...

CO in the synthesis gas mixture for the methanol synthesis does not seem to take part directly in the reaction, but it does influence the process through two effects First the water-gas shift reaction and, secondly, through its effect on the surface morphology (and possibly also composition). For thermodynamic reasons, however, it would be desirable if CO could be hydrogenated directly via Eq (18) instead of going through two coupled equations (3) and (19), since it would yield a higher equilibrium concentration of methanol at the reactor exit. 

When methanol is produced from a mixture of CO2, CO and H2, the reverse water-gas shift reaction complicates the system, since it competes with the methanol synthesis. 

A system has been constructed which allows combined studies of reaction kinetics and catalyst surface properties. Key elements of the system are a computer-controlled pilot plant with a plug flow reactor coupled In series to a minireactor which Is connected, via a high vacuum sample transfer system, to a surface analysis Instrument equipped with XFS, AES, SAM, and SIMS. When Interesting kinetic data are observed, the reaction Is stopped and the test sample Is transferred from the mlnlreactor to the surface analysis chamber. Unique features and problem areas of this new approach will be discussed. The power of the system will be Illustrated with a study of surface chemical changes of a Cu0/Zn0/Al203 catalyst during activation and methanol synthesis. Metallic Cu was Identified by XFS as the only Cu surface site during methanol synthesis. 

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