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Abstract
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Design of dual type methanol reactor includes a gas cooled reactor for methanol synthesis. The gas
cooled reactor faces with the problem of gas condensate formation and two phase flow in the practical
operating conditions owing to a high temperature drop in the last 2 m of the reactor length. In this study,
three strategies are proposed in order to prevent gas condensate formation in the gas cooled reactor
which is designed based on dual type design. The first strategy is utilization of a partial condenser before
the gas cooled reactor, the second strategy is injection of hot synthesis gas (HGS) to the last 2 m of the
reactor and the third is warming the shell side of the reactor with steam in a jacket (JS) around the last
2 m of the reactor. Simulation results show that, the most effective strategy (ES) is application of a partial
condenser to separate the methanol and water in the inlet of the gas cooled reactor by condensation. In
ES, the dew point temperature in the porous media reduces via in-situ methanol and water removal at
the inlet of the gas cooled reactor and gas temperature ascends along the length of the reactor. Moreover,
methanol production enhances about 7.9% and CO2 decreases 2.6% in ES rather than in the conventional
methanol synthesis reactor (CR). The elimination of the gas condensate formation on one hand and
enhancing the methanol production and decreasing CO2 emission on the other hand can be considered as
the superiority of the suggested ES to the CR and other strategies.
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