Production Process of Methanol

Methanol production process description table, which gives some brief about the
chemical reactions and catalysts used in each method, which are established in
modern production plants:
Feed
stocks
Syngas

Syngas

Methane
Methane

Process
technology and
main
reactions
Methanol synthesis
CO + 2H2
CH3OH
CO + 3 H2 CH3OH + H2O
Two step methanol synthesis
CH3OH + CO
HCOOCH3
HCOOCH3 + 2H2 2CH3OH
Direct oxidation
CH4 + O2 CH3OH
Bio processing

Catalyst
Cu/ ZnO/Al2O3
Cu/ ZnO/Cr2O3
Potassium methaoxide,
Cu chromite
Metal oxides,
(eg MoO3 based)
Enzymes eg.,
cytochrome P450,
methanotropes

Production of Syngas (synthesis gas) from natural gas:

Synthesis gas (Syngas) is obtained from natural gas. Natural gas is desulphurised by
passing over activated carbon, preheated and mixed with steam and CO2 under 2 atm
pressures. CO2 required for the reaction is obtained by burning natural gas in excess of
air.
CH4+2O2 (air) CO2+ H2O
3CH4+CO2+2H2O 4CO + 8H2

Mass balance block diagram of methanol produced from carbon monoxide and hydrogen, units in Kg/h

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Pure

The hydrocarbon feed is mixed with steam and fed to the reforming furnace. The nickel
catalyst is packed in vertical tubes of 3-4 inches diameter and about 20-25 feet long.

Heat for endothermic reaction is supplied by combustion gas. The reaction temperature
is maintained in the range of 700 -1000oC; high temperature alloy steel is used for the
tubes and the steel wall of the furnace is refractory lined. A space velocity of 500-600
Kg/hr is maintained. The effluent reformer gas is cooled to 35oC and pumped to a hot
potassium carbonate scrubbing system to remove CO2.
Methanol from Syngas:
A flow sheet for production of methanol from Synthesis gas is as shown. Hydrogen and
Carbon monoxide in a mole ratio of 2.25(12% greater than theoretical) is compressed to
3000-5000 psi, mixed with recycle gas, and fed to a high pressure converter. Internal
preheat is usually employed. The reactor is copper lined and contains a mixed catalyst
of Zinc, chromium, Manganese or Aluminum oxides. The temperature is maintained at
300-3750c by proper space velocity and heat exchange design.
The reaction is highly exothermic and takes place with a decrease in volume. The
enhanced pressure would, therefore result in more favorable equilibrium (Le Chatliers
principle). The exit gases are cooled by heat exchange with reactants, then with water to
0-20 0C and then condensed in high pressure condensers, where methanol
is condensed at 3000-4000 psi. The liquid methanol is drawn off and the residual gases
are recycled. The methanol condenses under full operating pressure to maximize yields
(50%conversion per pass). The liquid methanol is depressurized, purified by
permanganate to remove traces of Ketones, aldehydes, and other such impurities, sent to
a stripper to remove light ends such as dimethylether, and to fractionators to separate
methanol from higher Mol.Wt.compounds. The methanol from stripper on distillation
gives 99% pure methanol. The yield is around 98% with recycling. Dimethlether (1-2%)
and higher alcohols, such as n-propanol and isopropanol (0.3-0.5%) are obtained as
byproducts.