What should the pressure difference in the methanol synthesis tower not exceed?
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The pressure difference in our synthesis tower has reached 0.4 Mpa, and it shows a tendency to increase further. Could any expert tell us the reason for this increase in pressure difference? How much is the maximum allowable pressure difference?
If the pressure difference in the low-pressure methanol column is already very high, it is likely that the catalyst has suffered significant pulverization. An increase in the pressure difference in the synthesis tower raises the power consumption of the circulator, leading to more severe catalyst pulverization. The maximum allowable pressure difference must be determined based on the strength of the catalyst. It is recommended to inspect the reactor when replacing the catalyst.
Stabilize the circulation volume, reduce the fresh gas fed into the tower, and lower the amount of syngas as well as its density; production is still possible. Otherwise, if these values continue to rise, they will do so at an increasingly rapid pace, and production will lose its meaning. You can communicate with QQ51266974
Beyond 0.8 MPa, production essentially becomes meaningless: the catalyst is crushed, the cyclic energy load becomes excessive, and mechanical damage is severe.
Besides the reasons for catalyst pulverization, what other process-related factors could cause an increase in reactor pressure difference?
With such a large pressure difference now, there must be a problem!
Is your reactor overheating? Excessive temperature leads to localized sintering of the catalyst, which increases the pressure difference in the synthesis tower
Our factory’s current value is around 0.09, and the conversion rate is quite satisfactory.
Besides catalyst pulverization, what other process-related factors can cause an increase in reactor pressure difference? Regarding the device structure? Catalyst loading? Porous ceramic balls? What does it matter?
The reasons for the increase in pressure difference in the synthesis tower include: catalyst pulverization； over-temperature sintering ； Instrument issue ； The content of inert components increases ； The hydrogen-to-carbon ratio increases ； Equipment damage ； If the insulating layer around the catalyst is filled too thickly, it will sinter ； It has nothing to do with whether the refractory balls are perforated or not
Our target is ≤0.2 MPa; the actual value is 0.1. The reasons for the increased pressure difference include catalyst pulverization, high hydrogen sulfide levels, low carbon dioxide levels, which lead to carbon deposition on the catalyst, poor quality of the gas, high oil content, and carbon precipitation due to thermal decomposition
In a synthesis loop with a high content of inert gases, the pressure difference between towers increases; this pressure difference should be kept below 0.1 MPa.
Replying to floor 10: Our catalyst has not experienced overheating and sintering. The instrument issue has been checked; there is a leak in the synthesis tower, and the insulation layer might be installed a bit too high. No other problems exist.