Patent ID: 7470825

Claim:
A process for producing methanol, comprising: flowing gas containing carbon monoxide, carbon dioxide and hydrogen through a gas feed inlet located in a bottom portion of a multistage fixed bed methanol synthesis reactor to contact a plurality of fixed methanol synthesis catalyst reaction beds within the reactor so as to form methanol in the flowing gas, wherein the plurality of reaction beds includes at least one upper and at least one lower bed as well as a series of reaction beds located between the at least one upper and at least one lower bed, with the series of reaction beds located between the at least one upper and at least one lower bed having at least one downcomer extending through or along side each reaction bed and internal to the reactor, flowing gas exiting each of the beds through separate methanol liquid layers above each reaction bed to remove at least a portion of the methanol from the gas and cool the gas, wherein the separate liquid layers are flowed in an overall counter current direction relative to the flowing gas; removing the flowing liquid layers from the beds by flowing the liquid through at least one associated downcomer, wherein each downcomer has an upper lip positioned to form an associated methanol liquid layer above each associated reaction bed and each downcomer extends below each associated reaction bed into a liquid seal to seal off vapor from passing through the liquid seal and around the associated reaction bed; removing gas reaction product from an upper portion of the reactor; and removing liquid reaction product from a lower portion of the reactor.