Summary

Since 1996, Methanex Corporation and Synetix Inc. have been cooperating on the development of a new synthesis gas process based on reforming in an integrated gas-to-gas heat exchanger, the so-called Advanced Gas Heated Reformer or AGHR. This has resulted in the construction and operation of a flexible materials demonstration plant at Methanex Corporation's methanol production plant located in New Plymouth, New Zealand, and the development of some new analytical techniques for the rapid determination of metal dusting resistance in materials.

Initial results from this facility have been evaluated together with previous operating experience that Synetix has with the basic technology in Ammonia synthesis plants, to provide Methanex with the confidence to push ahead with the design of a full-scale methanol plant at it's new production site on the Burrup Peninsula in Western Australia. The benefits of the technology are increased gas efficiency, significantly reduced unit capital costs, scale increase, and lower operating costs as a result of improved reliability.

The technology being demonstrated depends wholly on some breakthrough technology in materials of construction to avoid metal dusting as the key piece of equipment, the AGHR, is operating totally in the known metal dusting region. Methanex and Synetix believe that confirmed success with this technology will open up opportunities for further expansion of methanol and methanol derivative scale as well as the potential for the use of the technology as the synthesis gas step in the production of Fischer Tropsch liquids. The technology will also contribute to the more rapid development of technologies for other chemical synthesis based on methanol and DME such as Methanol to Olefins, Gas to Olefins and the Methanol to Propylene technology being promoted by Lurgi Oel and Gas.

This paper covers some of the history of development and the current state of the technology and some comparisons of expected results with conventional steam reforming and other synthesis gas technologies.

History of In 1996, Methanex Corporation undertook an evaluation of current and developing synthesis gas Development technologies with a particular reference point based on its unique position as the operator of nine different methanol plants based in North America, Chile and New Zealand. The plants had similar operating performance histories and, in particular, had all lived through at least one major event that caused significant shutdowns and repair costs. We also had an extensive history of general maintenance issues effecting the reliability and on-stream time of methanol plants. The way in which the company had come together also brought together a number of operating philosophies and basic steam reforming technologies so that the commonality could be ascr

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