Troubleshooting and Optimization of the Reformer Combustion System of the Methanol Unit of Fanavaran Petrochemical by CFD Simulation and Design

The methanol industry relies heavily on advanced process simulation and detailed fluid dynamics modeling to optimize design, enhance operational efficiency, ensure safety, and reduce environmental impact. This review explained the existing literature on the application of two powerful computational tools: Aspen HYSYS for process simulation and Computational Fluid Dynamics (CFD) for equipment-level analysis. While HYSYS excels at modeling the overall plant-wide mass and energy balance, thermodynamics, and steady-state operation, CFD provides deep insights into the complex multiphase flow, mixing, and reaction phenomena within key unit operations like reformers and reactors. The integration of these tools offers a comprehensive approach from the molecular scale to the entire plant, driving innovation in methanol production technology.  As a result of the changes observed in the software, it is possible to reduce the pressure drop from ۲۰.۳ mmH۲O to ۱۸.۵۵ mmH۲O. Therefore, the draft of the reformer box changes from zero to minus ۱.۷۵ mmH۲O. In general, the combustion conditions in the box will be improved, and the work of the suction fans will be reduced. In this study, it was shown that the design made by the designer had problems in terms of heat transfer surface and tube design temperature, which reduced the production capacity of the unit. To compensate for the production, more feed was consumed in the reformer, which increased fuel and air consumption. Thus, by increasing the flue gas inside the combustion chamber and the gas duct, the flue gas pressure drops increase, and the suction from the convection section is not transferred to the combustion chamber. For this purpose, two new designs were made for the doghouse and the smoke transfer duct, and it was shown that with minor changes in the dimensions of these parts, the pressure drop can be reduced by about ۳ to ۵ mmH۲O.

کلیدواژه ها:

Syngas ، Steam Methane Reforming ، Natural gas ، Simulation ، CFD