Methanol Production from Coal
Methanol Production Costs Report | Issue G | Q4 2024
| Report Details |
| 1,500 kta China-based plant | Q4 2024 | 107 pages |
This report presents a cost analysis of a 1,500 kta (kilo metric ton per annum) China-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.
Report Abstract
This feasibility study approaches the economics of Methanol production in China via coal gasification. In this process, coal is initially gasified to produce syngas. This syngas is then converted to Methanol in a dual reactor system comprising an isothermal reactor in series with a gas-cooled reactor.
The report provides a comprehensive study of Methanol production and related Methanol production cost, covering three key aspects: a complete description of the Methanol production process examined; an in-depth analysis of the related Methanol plant capital cost (Capex); and an evaluation of the respective Methanol plant operating costs (Opex).
The Methanol production process description includes a block flow diagram (BFD), an overview of the industrial site installations, detailing both the process unit and the necessary infrastructure, process consumption figures and comprehensive process flow diagrams (PFD). The Methanol plant capital cost analysis breaks down the Capex by plant cost (i.e., ISBL, OSBL and Contingency); owner's cost; working capital; and costs incurred during industrial plant commissioning and start-up. The Methanol plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Process Schematic
The process under review comprises 4 main sections: (1) Coal Gasification; (2) Raw Syngas Purification; (3) Methanol Synthesis; and (4) Methanol Purification.
Coal Gasification. Initially, coal is received from the storage area, prepared and conveyed to the gasifier. As coal is fed to the gasifier, it dries due to the vaporization of water and undergoes pyrolysis, producing coke. Steam and oxygen are fed to the gasifier and react with the char, producing mainly carbon monoxide and carbon dioxide. The gasification reactions are carried out at high temperatures and medium pressures, with gaseous reaction products ascending countercurrent to the coal introduced in the gasifier.
Raw Syngas Purification. The outlet from the gasification is cooled and divided into two streams, one is fed to the shift reactor along with steam, where carbon monoxide is converted into carbon dioxide and hydrogen, and the other by-passes the shift reaction. The shifted gas is then mixed back with the by-pass and sent to the acid gas removal for the removal of H2S, COS, and some of the CO2. A Claus plant is used for recovering Sulfur from the stream rich in H2S.
Methanol synthesis. The syngas feed is compressed and mixed with recycle gas and fed to the methanol synthesis reaction system, where CO and CO2 react with hydrogen to generate methanol. The system outlet gas is mainly comprised of methanol, water vapor, unconverted hydrogen, CO and CO2. This stream is cooled, and methanol and water are separated from the gases by condensation. The separated gas is recycled with a small purge. The water-methanol condensate stream is sent to be purified.
Methanol Purification. The purification area is composed of three distillation columns. The topping column removes the dissolved gases from the crude methanol stream. In the pressurized methanol column, part of the methanol produced is obtained from the top of the column while the bottoms, still containing methanol, is sent to the atmospheric column to recover the remaining methanol.
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Production Process Information
Process Consumptions
Labor Requirements
Plant Capital Cost Summary
Operating Cost Summary
Production Costs Datasheet
Plant Capital Cost Details
Operating Cost Details
Plant Cost Breakdowns
Plant Capacity Assessment
Process Flow Diagrams
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Methanol production plant examined
Plant Capital Cost Details
Detailing of fixed capital (ISBL, OSBL & Owner’s Cost), working capital and additional capital requirements
Plant Cost Breakdowns
Breakdown of Methanol process unit (ISBL) costs and infrastructure (OSBL) costs; plant cost breakdown per discipline
Operating Costs Summary
Summary presenting the operating variable costs and the total operating cost of the Methanol production plant studied
Operating Cost Details
Detailing of utilities costs, operating fixed costs and depreciation
Plant Capacity Assessment
Comparative analysis of capital investment and operating costs for different Methanol plant capacities
Production Process Information
Block Flow Diagram, descriptions of process unit (ISBL) and site infrastructure (OSBL)
Process Consumptions
Raw materials and utilities consumption figures, by-products credits, labor requirements
Process Diagrams
Process flow diagrams (PFD), equipment list and industrial site configuration
Other Methanol Production Cost Reports
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The cost analyses presented in this report target a 1,600 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.
Methanol Production from Refuse-Derived Fuels
This report provides the economics of Methanol from refuse-derived fuels (RdF) for a waste-to-methanol (WtM) process in the United States. In this process, RdF is first gasified to syngas, which is then converted to Methanol.
Details: 350 kta United States-based plant | Q4 2024 | 107 pages | Issue F From $1,199 USD
The cost analyses presented in this report target a 350 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.
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