Methanol Plant Capacity Enhancement By: Mr. C D ... - Fibre2fashion

Two catalyst charging nozzles were used with hoppers and 2 ½” dia flexible hoses for charging the catalyst -
SACK WISE under the supervision of Linde. A table was prepared to log the number of bags charged per
round and the subsequent dip achieved, which showed the packing uniformity. This proved to be a very
successful method of charging with good packing density with less than 20 mm of variation in the final height
adjustment. A flat and heavy plumb with strong cotton thread was used for taking the dip.
Approximately equal quantities of 20 kg balls/catalyst were filled in HDPE sacks before the start of loading.
About 5.2 m 3 alumina balls were filled first in four rounds of sack charging. The catalyst bed was leveled so
that the balls were just inside the tube coiled bundle. The first dip of catalyst was taken after charging
almost half of the catalyst. Thereafter, while monitoring the height, charging continued to completion over
approximately two (2) days.
Commissioning activities
The synthesis loop was made available earlier than the distillation loop (6 ½ days) while the total shutdown
period was compressed to 8 days by effective identification of the priority of each job. The effectiveness of
the pre-commissioning activities was evident during post-commissioning. There were no plugged strainers,
control valves by-passing, nor false signals during or after the startup of the plant. Re-commissioning of the
plant was completed in less than 4 days time. While, the distillation section modifications were being
completed, the synthesis loop pre-commissioning activities were completed. While the catalyst heat up and
reduction was proceeding, crude methanol production was coming online.
Peak production levels for the plant were achieved while testing the plant at different feed gas mixtures. The
plant has met all process guarantees. Of particular interest has been an improved yield of methanol due to a
higher conversion rate and stable reaction conditions. Less by-product formation has led to a reduction of
loading in the distillation section.
Conclusion
From this experience, we see that the plant capacity can be increased by understanding the basic principles
of reaction kinetics and unit operations. Through integration of technology and the use of improved catalyst,
this little plant had been transformed into a giant producer. Proper planning of critical activities like catalyst
charging, pre-commissioning of loops, commissioning and guarantee test runs can ensure success.
About the Authors:
The authors are associated with GNFC Ltd.
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