Steady state process modules for a Dry ash Lurgi-type moving bed coal coal gasifier, a High temperature shift reactor, a low pressure Copper based methanol reactor and a Hot gas recycle methanation reactor have been developed based on the detailed kinetics of the reactions concerned. The model results compare reasonably well with either published plant data or earlier model results. These modules were used for the following purposes:

(i) To design and/or simulate individual process units.

(ii) To examine the effects of different operating variables on individual process performance.

(iii) To optimize the operating cost of individual process units of a coal-to-methanol plant.

With minor modifications, these modules can be used as user-added subroutines in the process flowsheet packages e.g PROCESS, ASPEN, CHESS etc. In fact since this work was completed the methanol module has been incorporated as a user-added subroutine to PROCESS.

A brief state of the art analysis of different existing system, thermodynamics, kinetics and catalysis of the gasification, shift, methanol synthesis and methanation processes are also included in the appropriate chapters.