I would like to ask fellow sea professionals for an analysis of the reasons behind the high methanol consumption in my company’s methanol synthesis and purification system.
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After the major repair carried out by our company in August 2016, the system resumed normal operation. However, since then, the amount of methanol that needs to be added to the purification system has been much higher than it was before the repair. Upon on-site inspection, no leaks were found in the drainage systems, flanges, or equipment, and there was also no liquid present in the exhaust gas scrubber’s vent air. I would appreciate advice from all fellow sailors.
Has it been confirmed in the acidic gas? While investigating the causes after a major repair, it is possible to observe for some time; changes in system temperature and pressure may also have an impact
Check and confirm the methanol content in several streams exiting the system: exhaust gas, acidic gas, and purified gas； Additionally, factors such as the temperature of the acidic gas and whether the liquid level in the acidic gas separator is normal are also important influencing factors. At the same time, if a dry gas seal is used, it is necessary to check whether methanol is present in the seal separator tank, as it may have been carried into the flare through the seal emissions.
After the maintenance, the gas flow rate increased, the load rose, the gas velocity accelerated, and the system resistance decreased; therefore, the actual consumption must increase
Check the methanol content in several process gases and wastewater.
Was the methanol-water content measured before and after the major repair? Compare them
All gases from the off-limit areas and all discharged liquids are sampled for analysis of their methanol content; the demister at the top of our previous stripping tower was damaged