Simulation and Optimization of Methanol Production Processes

Abstract Addressing high energy use and inefficient distillation in methanol production, this study innovatively integrates modeling, dividing‐wall column (DWC) technology, and energy optimization for a 400 000 t/a plant. Developed integrated synthesis‐distillation model replaces traditional atmospheric column with DWC. Process simulation optimized key parameters: pressure, temperature, recycle ratio, feedstock (CO 2 /CO), and water dosage. A DWC dynamic control system ensured stability, whereas plant‐wide energy optimization was implemented. Results: DWC boosted top‐product methanol yield 9.22 %, total output 5.14 %, and cut fusel oil methanol 62.73 %. Energy optimization reduced utilities 35.63 % (heating −36.69 % and cooling −34.59 %), raised inter‐stream heat recovery 4.85×, and lowered emissions 42.29 %. Strong economics: NPV > 0 and IRR > 12 %. This process effectively reduces energy consumption and improves yield, providing a feasible solution for clean production of industrial methanol.