Methanol process M7000

The M7000 is the process for natural gas based methanol plants for production up to 10000 t/d.
It is referenced up to 7000 t/d.
Syngas generation is performed through combined reforming (primary reformer + auto-thermal reformer).
Its Energy efficiency is up to 7.0 gcal/t.
Single isothermal methanol converter is suitable up to 7000 t/d.

The M7000 is Casale’s process for world scale plants with a capacity up to 10’000 MTD. The process is based on the combined reforming and on a IMC methanol converter for synthesis; the performances are enhanced by application of Casale technologies and tailored process solutions. The syngas generation through combined reforming is based on the following concept: all the feed natural gas is pre-reformed, the pre-reformed feed is then split in two fractions; one is sent to the steam reforming, while the second by-passes it. An Auto-Thermal Reformer (ATR) blown with oxygen from an Air Separation Unit (ASU) is installed downstream the primary reformer, to treat both the reformer effluent and the reformer by-pass. The syngas generated by this process is already balanced for methanol synthesis. However, a HRU (Hydrogen Recovery Unit) is provided to further reduce the size of the primary reformer.
The main steps, as shown in the block flow diagram, are:

  • Natural Gas Desulphurization and Saturation
  • Synthesis gas generation through combined reforming
  • Heat recovery and cooling
  • Synthesis gas compression
  • Methanol synthesis
  • Hydrogen recovery Unit
  • Distillation (3 columns)

Embedded Casale’s technologies

Several Casale’s well-proven and highly efficient technologies and proprietary items are the key underpinnings of the M7000 scheme, namely:

  • Casale design of primary reformer
  • Auto-thermal reformer burner
  • Pre-reformer
  • IMC converter (steam rising)

Key features

The M7000 is characterised by high reliability, superior performances, streamlined design for cost effectiveness and reduced environmental impact. The design can be customized to specific Client’s needs and integrated with ASU and any downstream unit.

The process is extremely flexible and the scheme may be adapted to specific market needs and/or customer requirements. Other distinctive features are:

  • The product is Grade AA methanol but other specification, like Grade A or IMPCA, can be achieved
  • The energy consumption is in the range of 7.0.-7.2 Gcal/Mton (25.4-26.1 MM BTU/Short ton) on LHV basis, including the steam consumption associated to ASU Air Compressor Turbine
  • The steam balance is adjiusted in order to provide the steam export to ASU. In addition it can be optimized from zero export to maximum export
  • Flexibile to use any first-class commercially available catalyst
  • Thanks to the saturator column, which allows the distillation bottom water recycle, the demiwater net consumption is minimum (lower than 0.1 Mton/Mton of methanol)
  • Compact and simple lay-out, with all sections arranged in a way to minimize the overall footprint as well as optimize the connections across the different sections of the plant
  • Primary importance is given to the process control, as the safety and reliability of the plant as well as its efficiency and economics depend on it
  • Full life-cycle support by means of Casale’s Remote Plant Monitoring and/or Casale’s Customer Care services
pdf Methanol Process (1.10 MB)

Technologies