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Abstract
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The Auto Thermal Reactor (ATR) in a methanol manufacturing facility was simulated and optimized using Computational Fluid Dynamics (CFD). Informed by previous studies and experimental findings, appropriate models for kinetics, combustion, and turbulence were initially selected, and governing equations were solved by the finite volume method. Simulations demonstrated that alterations in geometry and feedstock conditions significantly influence the temperature distribution, pressure, and chemical behavior within the reactor. To enable a thorough analysis, refractory layers were incorporated into the modeling process, and key sections were scrutinized to pinpoint hot spots. The adoption of an elbow diameter of 1660 mm for the reactor's inlet line significantly reduced the likelihood of hot spot formation. Further modifications, such as the adjustment of oxygen-to-carbon molar ratios, contributed to an enhanced performance of the reactor. A thermal stress investigation revealed improved strength and stability of the refractory layer material when it was replaced with CURON 180 GM in important places, especially the reactor inlet throat. The results improve reactor safety and efficiency, providing valuable insights for optimizing the design and operation of similar reactors and thus offering practical applications in the petrochemical industry.
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