Skip to main content

MegaZonE™

Novel catalyst-layering technology for enhanced methanol synthesis

Clariant’s efforts to continuously improve methanol catalyst performance are not limited solely to catalyst formulation, but also focus on the overall process and how the catalysts can be optimally utilized in the complete reactor system.

The result is a major breakthrough in methanol synthesis: MegaZonE™ technology. Based on Clariant’s MegaMax® catalyst series, and jointly developed with Air Liquide E&C, the innovative method uses several layers of catalysts with different activity levels to optimize heat management and overall catalyst performance in the methanol synthesis reactor. With MegaZonE technology, the properties of each catalyst layer are tailored to the specific conditions along the reaction pathway, resulting in longer lifetimes of the catalysts, and higher methanol yields for our customers.

Product Benefits

Clariant_Icon_Less Heating_Improved Isolation_Thermal_Thermometer_06-10-2020

Less thermal stress
due to mild operation condition

Clariant_Icon_Endurance_Sand Glass_06-10-2020

Increased catalysts lifetime
of 12-18 months due to less thermal stress

Clariant Icon Target

Low by-product formation thermal stress
up to 10% higher selectivity

Customer Benefits

Clariant_Icon_Support Profitable Growth_06-10-2020

INCREASED CUMULATIVE METHANOL PRODUCTION
up to 10%-15%

Clariant_Icon_ROI_cropped_072020

SIGNIFICANT MONETARY BENEFITS
for methanol producers

Clariant Image Chemical Plant 20220315

MORE COMPACT PLANT DESIGN WITH SAME CAPACITY
and feed gas flexibility

Clariant_Icon_Less Emissions_Low Emission Technology_06-10-2020

ENERGY SAVINGS
improved energy efficiency of 0.15%

How MegaZonE works

To optimize the process conditions of the methanol synthesis reaction, several layers of catalysts with different activity levels are arranged in the tubular reactor. Different activity levels are achieved by distinctive catalyst generations or shapes:

  • MegaMax catalysts with lower activity in top portion of reactor to avoid hotspots
  • MegaMax catalysts with higher activity in the middle and bottom of the reactor to intensify reactions
Clariant Image Graph MegaZonE MeOH Yield 570x363 20220315

Increased production rate and catalyst lifetime

The unique MegaZonE layer arrangement reduces the thermal stress on catalysts on the catalysts at the main reaction front, leading to an optimized use of the highly active catalyst in the top part of the reactor and of the reaction rate in the bottom part. The flattened temperature profile and the improved overall performance result in extended catalyst lifetime and increased methanol yield over the lifetime.

Learn more about our MegaZonE Technology

Clariant Image 1 MegaMax Catalysts 20201027(1)

Watch how

OUR MEGAZONE
TECHNOLOGY ENHANCES
METHANOL PRODUCTION

Play
x

Read our latest Articles and News

  • Clariant & Air Liquide present MegaZonE™: Novel catalyst layering technology for enhanced methanol synthesis performance

    Clariant’s long-term partnership with Air Liquide Engineering & Construction has resulted in another major breakthrough in methanol synthesis: the MegaZonE technology. Based on Clariant’s MegaMax® catalyst series, this innovative method uses several layers of catalysts with different activity levels to optimize heat management and overall catalyst performance in the methanol synthesis reactor. Furthermore, the properties of each catalyst layer are tailored to the specific conditions along the reaction pathway, which results in a significantly longer catalyst lifetime (by up to 2 years) and an increased cumulative methanol production (up to 15%), thus potentially leading to monetary benefits of up to several million US dollars. With this performance outlook, MegaZonE was successfully applied to two world-scale methanol plants in Asia this year, showing already excellent and stable performance.

    more

Download File

Learn about our Catalysts

  • MegaMax 800

    MegaMax® 800 is a state-of-the-art methanol synthesis catalyst that offers much higher activity than previous solutions – even at low reactor temperatures and pressures.

    more
  • MegaMax 900

    MegaMax® 900 is Clariant’s latest generation of methanol synthesis catalysts.

    more