Modeling, simulation, and systematic analysis of high-temperature adiabatic fixed-bed process of CO methanation with novel catalysts

Abstract The technology of coal to synthetic natural gas is important to relieve the energy crisis and improve the environment. During the coal to synthetic natural gas process, methanation plays a key role by converting CO and H2 into methane. A novel systematic analysis framework based on modeling and simulation is provided for optimization of the CO methanation process using novel high-temperature tolerant catalysts. In this framework, the reactor is described by the mass-balance, energy–balance, and pressure equations. Meanwhile, reactor integration and waste heat utilization are considered. Then, the model of methanation process is validated by the industrial data. Three schemes for methanation processes and two types of feedstocks are investigated. In addition, different operating temperatures are considered for different schemes and different feedstocks. Furthermore, the solution method is proposed to optimize the split and recycle ratios in different process schemes. To compare the performance of different schemes, economic analysis, including methane profit, steam profit, and compressing work consumption, is investigated. Comprehensively considering different profits, the total profit for different schemes is provided and the optimal scheme is obtained. The method for optimization of split and recycle ratios can be used in different methanation process of coal to synthetic natural gas industry.