Pressure difference between the inlet and outlet of the methanol synthesis tower
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I would like to ask everyone: What is the purpose of designing the pressure difference between the inlet and outlet of a methanol synthesis tower (we use a tubular fixed-bed type)? What causes the fluctuations in its pressure difference? What is the normal value?
I’m also very curious and would appreciate it if that expert could give some guidance
The degree of catalyst carbon deposition, the occurrence of bridge shorts, and the efficiency of the reaction all depend on the size of the reactor; naturally, reactors of different sizes yield different results. Trends can be determined based on the data from the design as well as the outcomes of long-term operation~~
I think the designed data value is determined based on the design pressure of the synthesis tower; our current value is a little over 1 kilogram, while the design value is 200,000 tons
The magnitude of the pressure difference reflects the quality of the synthesis reaction, as well as the operating condition of the catalyst
Then the pressure difference is high; is the catalyst reaching the end of its life?
We just replaced our catalyst; we only noticed this aspect
Monitor the reaction conditions inside the synthesis tower； The resistance in the synthesis tower increases, such as due to catalyst deactivation ； At the beginning of catalyst use
In the designed reactor, after the catalyst is installed, the reduction in reaction volume under the design conditions and the resistance encountered while fluid passes through the bed layer combine to form a pressure difference; this pressure difference is used in calculating the power required for the compressor. Additionally, it provides guidance for actual operation, as changes in this pressure difference reflect changes in the bed layer. If the components and load remain unchanged but the pressure difference changes, then there is an abnormality in the bed layer. An increase in size indicates catalyst pulverization and sintering, while a decrease in size indicates a short circuit. Previously, the designed pressure difference was 0.2 MPa; during operation it was a little over 0.1 MPa. Now, the designed value is 0.03 MPa, while the actual value during operation is 0.05 MPa. The catalyst has not experienced short circuits or sintering – that value is probably just a theoretical estimate. The change in pressure difference after operation is more meaningful.
High pressure difference can be attributed to catalysts, packing, as well as issues with the reactor itself.