Small Scale Methanol Production: Process modelling and design of an autonomous, renewable container sized methanol plant

At the United Nations Climate Change Conference held in Paris in 2015, ambitious goals for the worldwide CO2 emissions were set. To achieve these goals, a huge reduction in CO2 emissions must be realized. For the energy market, the current aim is to use renewable electricity instead of fossil fuels. However, there are multiple sectors where electricity is not a suitable form of energy, due to storage issues. For example, the chemical industry is heavily based on fossil fuels as a resource to synthesize chemicals. It is therefore useful to investigate the feasibility of renewable synthetic fuels. The goal of this thesis is to design a process that converts the hydrocarbon fuel combustion products CO2 and H2O into a fuel that is a liquid at atmospheric conditions. Methanol is selected as the liquid fuel because of its basic molecule structure. It requires much more energy to obtain methanol from CO2 and H2O than it does from natural gas. The process is determined to be container-sized to become cost competitive through mass production. The technical feasibility of a mass produced, autonomous, renewable and container-sized methanol production plant is studied in this thesis. The whole process is divided into sub processes. H2O is obtained from desalination of seawater. The H2O is split into H2 and O2 using alkaline electrolysis. The CO2 is adsorbed from the air and recovered using pressure and temperature swing. The required energy is obtained using solar PV and solar thermal. The H2 and CO2 are finally converted to methanol in the methanol synthesis sub process. The intermittent character of solar energy yields a dynamically operated process. The methanol synthesis sub process is studied further because of the small scale and dynamic operation that are new concepts for this technology. The other sub processes are considered as black boxes with fixed in- and outputs. The steady state operation of the whole process is modeled using Aspen Plus™ and the distillation process is modelled in MATLAB®. Using the results from Aspen, pinch analysis is performed for optimal use of the available heat. From the results of the model, it is found that an autonomous container-sized methanol production plant is technically feasible. 140 kg of methanol can be produced daily with a purity of at least 96.6 %, using a set-up of three 40 feet sea containers, two of which are dedicated to the capture of CO2. 288 kW of electrical power and 24 kW of heat is required for the operation. This is equal to a solar park with an area of 1663 m2 assuming an average 6 hours of solar irradiance. Using the LHV of methanol in the calculation, the total efficiency of the process is estimated at 45 %. The results from the MATLAB® model of the distillation cannot be validated because the used equation of state of REFPROP underestimates the concentration of methanol in each iteration, yielding an invalid mass balance. Fixing this issue results in an invalid energy balance. It is therefore concluded that REFPROP is not suitable for iterative calculations of distillation columns.Mechanical Engineering | Sustainable Process & Energy Technolog