Clariant, a specialty chemical company dedicated to sustainability, has announced that its MegaZonE technology is performing exceptionally well at CNOOC’s China Blue Chemical Ltd. methanol plant. This cutting-edge system employs multiple layers of methanol catalysts with varying activity levels to enhance heat management and overall catalyst efficiency. Installed at CNOOC's methanol facility in Hainan, China, in April 2021, MegaZonE has been running optimally for over 36 months. The plant, a joint venture with the KB Group, manufactures 600 KTA of methanol from natural gas utilizing Air Liquide’s Lurgi process and Clariant’s MegaMax® catalysts.

Since the introduction of MegaZonE at the CNOOC plant, there has been a notable enhancement in carbon conversion efficiency. Average makeup gas consumption has been reduced by 67 Nm³ per metric ton of methanol compared to previous levels. Additionally, pressure drops have significantly decreased, removing the risk of bottlenecks caused by high pressure drop in the reactor. The plant has also experienced a 20% reduction in by-product formation, leading to a significant improvement in methanol quality. Collectively, these improvements have resulted in substantial economic benefits.

Georg Anfang, Vice President of Syngas and Fuels at Clariant Catalysts, stated, “At Clariant, our commitment to advancing methanol production extends beyond just developing catalysts. We also concentrate on optimizing the entire process and the integration of our catalysts within the complete reactor system. MegaZonE exemplifies this approach and has marked a significant advancement for the methanol industry. We are proud to partner with CNOOC and are thrilled to see the outstanding performance and commercial success that we anticipated.”

China BlueChemical Ltd., a subsidiary of China National Offshore Oil Corporation (CNOOC), is a leading modern enterprise specializing in the advanced processing of natural gas, and the production of mineral fertilizers and chemical products. The company boasts an annual production capacity of 1.84 million tons of urea, 1 million tons of phosphate and compound fertilizers, 1.4 million tons of methanol, and 270,000 tons of acrylonitrile.

Developed in collaboration between Clariant and Air Liquide, MegaZonE technology optimizes Clariant’s high-performance MegaMax catalysts using a distinctive layering approach. Moderately active catalysts are positioned in the hotter regions of the converter to prevent hotspots and reduce thermal stress, which can extend catalyst life by up to 2 years. Meanwhile, more active catalysts are situated in the lower part of the converter to boost reaction rates, enhance cumulative methanol production by up to 15%, and cut by-product formation by up to 30%.

MegaZonE technology is a versatile, drop-in solution that fits seamlessly into nearly any methanol production facility. Existing plants can utilize customized refill options to enhance their processes, while new facilities benefit from a more streamlined and durable design. MegaZonE is compatible with various feed sources, including stranded gas, unused syngas, and CO2-rich gases. This flexibility helps producers significantly lower their CO2 footprint and achieve their sustainability goals.