Integrated Methanol and Methyl Acetate Production Process
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Solution Overview
Problem
Current processes for producing methyl acetate and methanol from synthesis gas face inefficiencies due to the need for additional synthesis gas feeds, purge gas disposal, and undesirable side-reactions, leading to losses of valuable components and reduced productivity.
Innovation Solution
An integrated process where synthesis gas and dimethyl ether are fed into a carbonylation reaction zone to produce methyl acetate, with the resulting gas stream scrubbed to remove methyl acetate before being used in a methanol synthesis zone, eliminating the need for additional synthesis gas and reducing by-product formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If synthesis gas is used as feed for both carbonylation and methanol synthesis, then process integration and productivity improve, but additional synthesis gas feed requirements and purge gas disposal issues worsen
Solution Approach 1:
The patent combines the carbonylation process and methanol synthesis process into an integrated system where the synthesis gas stream from carbonylation is directly fed to the methanol synthesis reactor after selective removal of methyl acetate. This merging eliminates the need for separate synthesis gas feeds and purge gas disposal, resolving the contradiction between improved productivity and reduced substance requirements.
Solution Approach 2:
The patent selectively removes and recycles valuable components (methyl acetate, carbon monoxide, hydrogen) from the synthesis gas stream that would otherwise be discarded in purge gas. By recovering these components through selective absorption and recycling them to the methanol synthesis unit, the process eliminates substance loss while maintaining high productivity.
2Loss of substance
If synthesis gas from carbonylation is directly used for methanol synthesis, then carbon monoxide loss is minimized, but by-product formation increases
Solution Approach 1:
The patent extracts and removes methyl acetate from the synthesis gas stream using selective absorption before the gas is fed to the methanol synthesis reactor. This extraction eliminates the harmful effect of methyl acetate causing by-product formation in the methanol synthesis, while simultaneously preventing carbon monoxide loss by maintaining process integration.
3Device complexity
If methyl acetate is present in synthesis gas fed to methanol synthesis, then process integration is simplified, but catalytic performance and methanol productivity deteriorate
Solution Approach 1:
The patent introduces a selective absorption unit as an intermediary between the carbonylation and methanol synthesis processes. This intermediary selectively removes methyl acetate from the synthesis gas stream, protecting the methanol synthesis catalyst from deactivation while maintaining the overall process integration and avoiding direct contact between harmful substances and the catalyst.
4Stability of the object's composition
If purge gas is removed from carbonylation process, then methyl acetate accumulation is controlled, but valuable carbon monoxide and hydrogen are lost
Solution Approach 1:
The patent selectively discards only the harmful component (methyl acetate) from the purge gas stream through selective absorption, while recovering and recycling the valuable components (carbon monoxide, hydrogen) back to the methanol synthesis unit. This selective discarding and recovering approach controls methyl acetate accumulation without causing valuable substance loss.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach minimizes the loss of carbon monoxide, reduces by-product formation, and enhances the efficiency of methanol production by utilizing unreacted carbon monoxide and hydrogen from the carbonylation reaction, thereby improving overall process efficiency and productivity.
Implementation Method 1
scrubbing in a scrubbing zone at least a portion of the synthesis gas recovered from the carbonylation reaction product with a liquid scrubbing solvent to reduce the content of the methyl acetate in the synthesis gas
Implementation Method 2
reacting therein the synthesis gas and dimethyl ether in the presence of a carbonylation catalyst to form a gaseous carbonylation reaction product comprising methyl acetate
Implementation Method 3
contacting it therein with a methanol synthesis catalyst to form a methanol synthesis product comprising methanol and unconverted synthesis gas
Data Source
AI summary
Integrated process for the production of methyl acetate and methanol by carbonylating dimethyl ether with synthesis gas, recovering a methyl acetate stream and an unreached synthesis gas stream containing methyl acetate, and scrubbing the synthesis gas to remove methyl acetate. The scrubbed synthesis gas is passed for methanol synthesis.