Systematic staging design applied to the fixed-bed reactor series for methanol and one-step methanol/dimethyl ether synthesis

This work investigates possible design advances in the series of fixed-bed reactors for methanol and dimethyl ether synthesis. Specifically, the systematic staging design proposed by Hillestad [1] is applied to the water-cooled and gas-cooled series of reactors of Lurgi's technology. The procedure leads to new design and operating conditions with respect to the current best industrial practice, with relevant benefits in terms of process yield, energy saving, and net income. The overall mathematical model for the process simulation and optimization is reported in the work together with dedicated sensitivity analysis studies.