Comparative Kinetic Analysis and Process Optimization for the Production of Dimethyl Ether via Methanol Dehydration over a gamma-Alumina Catalyst

Various kinetic models of methanol dehydration to dimethyl ether over a commercial gamma-alumina catalyst were compared with a view to selecting the most appropriate model as a basis for process optimization. To achieve significant improvements in the conventional design, the Bercic-and-Levec kinetic model was employed and process intensification was applied to develop a more energy-efficient process, by enhancing the adiabatic reactor performance and maximizing the heat recovery from the highly exothermic reactor. The single-pass conversion of methanol was increased to 83 %, with an inlet temperature of 217 degrees C to the adiabatic reactor. Application of process intensification resulted in an improved flowsheet, which reduced the total energy requirements by 59.3 % and cut the CO2 emissions by 60.8 %.