The most Advanced Technologies for ... - CASALE GROUP

quantities of heat in different parts of
the converter.
Pseudo-isothermal methanol synthesis converter
The amount of cooling fl uid fed to the
different parts of the plates can be
controlled, so that it is possible to modify
the temperature profi le in the catalyst
bed, adapting it to specifi c needs and
making possible to combine, in a single
design, the same operating fl exibility of a
quench converter with the high effi ciency
of an isothermal design with indirect
cooling.
The catalyst beds can be designed
either according to the standard axial
confi guration or to the axial-radial bed
concept, depending on requirements.
With this design, Methanol Casale can
cope with increasing demands for very
large increases in plant capacity and of
grass root plants with mega capacities,
offering a very cost-effective solution.
Four pseudo-isothermal methanol
converters are in operation with
capacity up to 3,400 t/d, and one has
been designed for a new plant under
construction to produce 7,000 t/d in a
single vessel.
ATR unit
In order to drastically increase the
capacity of conventional synthesis gas
generation units in methanol plants,
one of the most effi cient ways is the
installation of an additional autothermal
reformer (ATR) unit. Methanol Casale has
developed a proprietary design for ATR
units, which is based on a very effi cient
burner design.
The Casale ATR design is conceptually
very simple: the oxygen stream is
introduced at a high velocity axially at
the top of the cylindrical combustion
chamber, while the process gas is
introduced from one side at the top of the
cylindrical chamber, prior to the burner
tip, and perpendicular to the oxygen
tube. To reduce the non-uniformities
introduced by the asymmetric inlet of
the process gas, the burner is provided
with a distributor placed upstream of the
burner tip.
The main features of the Casale design
for ATR burners are:
• fast and even mixing between oxygen
and process gas;
• uniform temperature and composition
with better approach to equilibrium;
• shorter fl ame length, with low risk
of damage to the catalyst resulting in
maximum catalyst performance over
a longer period, together with lower
pressure drop.
• low temperature of the reformer
refractory lining, with no hot spots on the
lining surface.
• a water-cooled burner tip to ensure
high fl exibility in operation and high
reliability (an almost unlimited operating
life is expected).
This technology is already operating
in four methanol plants and in two
ammonia plants.
ATR burner
Large capacity increase using Methanol
Casale technologies
Utilising the most appropriate of its
proprietary technologies, combined
with the correct modifi cation to the
process steps, Methanol Casale makes
drastic capacity increases in existing
plants possible. In two of the most
recent projects, a capacity increase
7
of 25% has been obtained, with fi nal
capacities between 3,000 t/d and 3,500
t/d. Furthermore, Methanol Casale is
presently studying a capacity increase of
almost 100%.
4. New plant construction
Boosted by the creativity necessary
to improve existing plants and by the
experience gained from the successful
applications of many new concepts,
in recent years the Casale Group has
developed innovative processes for
grass-roots fertilizer and methanol
plants to respond to the growing demand
for new plants in low gas cost areas.
Ammonia Casale has traditionally
been involved in designing grass-roots
ammonia plants, with more than 200
units build in the fi rst half of its history.
More recently, even though it has been
mostly focused on plant revamping, it
has also increasingly developed and
supplied technologies for grass-roots
plants.
Ammonia Casale has participated to the
design to 7 grass-roots plants through
its licensees and designed 36 coalbased
plant, supplying the design of the
synthesis loops. Some of these loops
have been designed to run with syngas
coming from gasifi cation plants making
use of alternative feedstocks.
Ammonia Casale has also completely
designed a 2,050 t/d grass-roots plant
that is in operation since more than two
years. Four more 2050 MTD plants have
been designed by Casale and are work on
them is in progress. This plant has been
designed around conventional steam
reforming technology, but incorporates
all the most advanced technologies of
Ammonia Casale to make it as effi cient
as possible. Through a joint development
with Lurgi, Ammonia Casale has also
developed a very innovative process that
allows the design of single trains plants
with capacities of 4,000 t/d and higher.
In the fi eld of methanol, Methanol
Casale has designed and supplied two
grass-roots plants, of 1,350 and 1,600
t/d capacity, as well as the world’s
largest methanol plant, currently at
an early stage of realisation, with a
capacity of 7,000 t/d. Thanks to its
pseudo-isothermal converter and to its
innovative ATR design Methanol Casale
is in a position to design very large
methanol units, 7,000 t/d and more, in
a real single train with a single vessel
converter.