Optimization and 3E analysis on variable operational conditions of a large, medium and small size Green Methanol Plant

This paper presents a technical optimizationand comprehensive economic, exergy andexergonomic (3E) analysis of greenmethanol synthesis plants designed for large, medium, and small productioncapacities: 285,400; 56,700; and 16,300 tons/year, respectively. The optimization process explores operational parameters that encompass both economic and production aspects.The 3E analysis evaluates economic factors influenced by plant operational conditions, exergy assessment to evaluate the optimal efficiency and performance, and exergonomic assessment of the cost-performance relationship. A validated mathematical model in MATLAB and ASPEN Plus is utilized for process optimization and evaluation. The findings indicate the large and medium sized plants as the most viable options, with levelized costs of 714.97 and 705.67 €/ton and methanol yields of 0.663 and 0.584 [-], respectively. The key factors influencing costs and production are H2 usage and reactor operational pressure. The plant performance evaluations show exergy efficiencies of 73%, 73%, and 71.4%, with destroyed exergy values of 78,676 kW, 15,965 kW, and 5070 kW for the large, medium, and small-sized plants, respectively.