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Methanol to DME dehydration unit

Gas-phase dehydration of e-methanol or bio-methanol into fuel-grade DME, 1 to 400 t/h of methanol: mass balance, recycle, column heat, and conversion cost per tonne of DME from Schemme 2020 and Semmel et al. 2023, plus the full cost at your methanol price.

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Open Jack

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  • CurrencyEUR 2017
  • Battery limitfully financed
  • 66 documented assumptions
  • Updated2 Nov 2026

Mass and energy balance

What the asset draws and delivers for the case and load you choose.

Reference case

capacity factor: 91.3 %

Hours a year at design feed. 8000 h is the basis of both Schemme 2020 and Semmel et al. 2023. Fixed costs per tonne rise as hours fall: this is the lever project mode sets from the methanol supply upstream.

Flows

  • In: Methanol—
  • In: Medium-pressure steam heat (evaporator and reboilers)—
  • In: Electricity for pumps and auxiliaries—

Asset

Methanol-to-DME dehydration unit (gas-phase, fuel grade)

  • Out: Fuel-grade DME—
  • Out: Process water—

Annual quantities at the current usage.

Fresh methanol (e-methanol or bio-methanol) fed to the unit, in tonnes per hour: the size of the asset, with the same key and unit as the methanol-to-olefins and methanol import calculators so project mode can chain them. Default 17.5 t/h, the plant of Semmel et al. 2023 (100 600 t DME a year). The cost law is published for 16.6-37.5 t/h of DME (23-52 t/h of methanol); outside it is extrapolated.

DME output
— t/h
Heat duty
— MW
Parallel trains
— -
Catalyst inventory (indicative)
— t

CAPEX

Specific cost at this size, what backs it, and how it behaves with scale.

Specific CAPEX at this size

—

Reference size 16.6 t/h

Model constant

Model value: Schemme 2020 FCI of the DME sub-plant scaled with exponent 0.732. Customized: the FCI of your own quote per t/h of DME capacity, used as is at any size; it is then no longer sourced.

Specific FCI by methanol feed

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  1. Ex-factory
  2. Installed
  3. Fully financed· this figure
CAPEX at the battery limit—

Included

  • Equipment and installation
  • Indirect and owner's costs
  • Contingency

Not included

  • Nothing

Added at project level

  • Nothing: project mode uses the figure as is

Project figures

Values passed to project mode when this asset is added to a project.

Concept sketch, not to scale · drag to rotate

Methanol in
—
Medium-pressure steam heat (evaporator and reboilers) in
—
Electricity for pumps and auxiliaries in
—
Fuel-grade DME outMain product
—
Process water out
—
CAPEX to the battery limit
—
Fixed O&M
—
Variable O&M, excluding feedstocks
0 EUR/year
Asset lifetime
20 years

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Conversion cost of DME (excluding methanol)

A standalone indicator for a quick read. Project mode recomputes it for the whole system.

—

  • Capital part—
  • Maintenance, catalyst, taxes and insurance—
  • Labour and overheads—
  • Steam cost—
  • Electricity cost—

Linked to the balance above

capacity factor: 91.3 %

Hours a year at design feed. 8000 h is the basis of both Schemme 2020 and Semmel et al. 2023. Fixed costs per tonne rise as hours fall: this is the lever project mode sets from the methanol supply upstream.

Share of the methanol entering the reactor that reacts in one pass, limited by equilibrium (70-85 % on gamma-alumina at 250-360 C, Pontzen et al. via Schemme). It does not change the yield (the unreacted methanol is recycled), only the recycle flow, the methanol recovery column load and the catalyst inventory. The heat demand is the published value of the case, not recomputed.

Price of the medium-pressure steam that covers the heat demand. Default 15.8 EUR/GJ = 0.0158 EUR/MJ (Schemme 2020, Tab. 6-1). Semmel et al. use 23.1 EUR/t of MP steam, about 11.5 EUR/GJ. Heat integration with a methanol plant can bring it close to zero, which this slider does not cover.

Price of the electricity for pumps and auxiliaries (1.39 kWh per t DME). Default 0.0976 EUR/kWh (Schemme 2020, Tab. 6-1); Semmel uses 55.72 EUR/MWh. Its weight in the cost is below 1 EUR/t.

Your assumption for the methanol price, used only for the full DME cost. Default 1038 EUR/t: Schemme's computed e-methanol cost (1.038 EUR/kg, 2017). IRENA 2021: e-methanol USD 800-1600/t with biogenic CO2, USD 1200-2400/t with DAC CO2; fossil methanol USD 100-250/t.

Real rate used in the capital recovery factor, costs being in constant 2017 euros. Default 8 % (Schemme 2020, Tab. 6-1); Semmel et al. use 5 %.

Conversion cost of DME (excluding methanol) by operating hours

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Benchmarks

This model's figures against published references and reference cases.

Conversion cost of DME (excluding methanol), EUR/t

54.4 Published reference value (benchmark, not used in the formulas)

75.7 Published reference value (benchmark, not used in the formulas)

Full DME cost (with methanol), EUR/t

1,464 Published reference value (benchmark, not used in the formulas)

1,828 Published reference value (benchmark, not used in the formulas)

2,322 Published reference value (benchmark, not used in the formulas)

Heat demand per tonne of DME, kWh/t

714 Published reference value (benchmark, not used in the formulas)

Reference cases at this size and usage

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All results

Every model output at the current settings, grouped, with the sensitivity charts.

50 outputs · 7 groups · 19 also shown above, dimmed

Conversion cost

9
Conversion cost of DME (excluding methanol)
ComputingEUR/t
Capital part
ComputingEUR/t
Maintenance, catalyst, taxes and insurance
ComputingEUR/t
Labour and overheads
ComputingEUR/t
Steam cost
ComputingEUR/t
Electricity cost
ComputingEUR/t
Labour share of the conversion cost
Computing%
Steam share of the conversion cost
Computing%
Fixed-cost load penalty
Computingratio

Full DME cost

4
Full DME cost (with methanol)
ComputingEUR/t
Methanol cost per tonne of DME
ComputingEUR/t
Methanol share of the full cost
Computing%
Methanol bill a year
ComputingEUR/year

Mass balance

10
DME output
Computingt/h
Methanol per tonne of DME
Computingt/t
Stoichiometric methanol per tonne of DME
Computingt/t
Yield against stoichiometry
Computing%
Process water
Computingt/h
Stoichiometric water per tonne of DME
Computingt/t
Mass balance closure
Computing%
Methanol a year
Computingt/year
DME a year
Computingt/year
Process water a year
Computingt/year

Reactor and recycle

6
Reactor feed
Computingt/h
Methanol recycle
Computingt/h
Recycle ratio
Computingt/t
Methanol recovery column feed
Computingt/h
Catalyst inventory (indicative)
Computingt
Catalyst space velocity
Computing1/h

Utilities

10
Heat demand per tonne of DME
ComputingkWh/t
Heat demand per tonne of DME (GJ)
ComputingGJ/t
Electricity per tonne of DME
ComputingkWh/t
Heat duty
ComputingMW
Electric power
ComputingkW
Heat a year
ComputingMWh/year
Electricity a year
ComputingMWh/year
Heat rejected a year (screening)
ComputingMWh/year
Load hours
Computingh/year
Load factor
Computing%

CAPEX

6
Fixed capital investment (FCI)
ComputingEUR
Specific FCI
ComputingEUR/(t/h)
Cost exponent applied
Computing-
Parallel trains
Computing-
FCI per annual tonne
ComputingEUR/(t/year)
Exponent vs the second FCI point
Computingratio

Yearly costs

5
Capital recovery factor
Computing1/year
Annualised FCI
ComputingEUR/year
Operating labour
ComputingEUR/year
Fixed O&M including labour
ComputingEUR/year
Conversion cost a year
ComputingEUR/year

Sensitivities

6 charts
Conversion cost components vs operating hours

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Conversion cost vs methanol feed

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FCI and specific FCI vs methanol feed

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Full DME cost vs methanol price

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Recycle and column load vs per-pass conversion

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Conversion cost vs steam price

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Sources

About

Calculator context

Fixed-bed unit that turns methanol (e-methanol or bio-methanol) into fuel-grade dimethyl ether (DME), an LPG substitute and diesel fuel, by the slightly exothermic reaction 2 CH3OH -> CH3OCH3 + H2O. The train is a feed evaporator, an adiabatic gamma-alumina reactor (250-360 C, 10-20 bar), a DME column and a methanol recovery column whose methanol goes back to the reactor; water leaves at the bottom. It is process P0 of Semmel et al. (2023, KIT / Fraunhofer ISE) and the DME plant of Schemme (2020, FZ Juelich).

Mass balance. With total recycle and a selectivity close to 100 %, the unit consumes 1.391 t of methanol per tonne of DME (Schemme Tab. 5-7, equal to stoichiometry) and rejects 0.391 t of water. The per-pass conversion (70-85 %, equilibrium-limited) sets the recycle, the load on the methanol recovery column and the catalyst inventory, not the yield.

Utilities. The heat demand of the evaporator and reboilers comes from the selected published flowsheet: 762 kWh/t (Semmel P0), 546 kWh/t (Schemme, MP steam 1.964 MJ/kg) or 904 kWh/t (Michailos et al.). Electricity is 1.39 kWh/t.

Cost. The fixed capital investment is Schemme's 9.91 MEUR at 16.6 t/h of DME, scaled with his published exponent 0.732 (valid 16.6-37.5 t/h of DME; extrapolated below; parallel trains at constant specific cost above). O&M follows the Turton factors and the Alkhayat & Gerrard labour correlation Schemme uses. Labour does not depend on size, so it dominates the cost of small units. The headline is the conversion cost per tonne of DME without methanol, in constant 2017 euros at a real discount rate; project mode prices the methanol as an inlet. The full DME cost adds methanol at a price you set: that price is your assumption, defaulting to Schemme's computed e-methanol cost.

Benchmarks. Semmel et al. publish a net conversion cost of 75.7 EUR/t for the same process in 2020 euros with a different cost model (class 3-4 estimate, 5 % interest), and 54.4 EUR/t for a heat-integrated liquid-phase design outside this calculator's scope. Different currency year and cost method: the comparison is qualitative. Schemme's full chain gives 1464 EUR/t of DME, lower than this calculator's full cost at the same methanol price because there the methanol plant supplies the steam.

Model

129 variables — inputs, calculations and outputs, with their dependencies.

129 variables shown of 129
VariableValueUnitDepends on
17.5t/h—
8000h/year—
1——
80%—
15.8EUR/GJ—
0.0976EUR/kWh—
1038EUR/t—
0.08ratio—
0——
643000EUR/(t/h)—
VariableFormulaUnitDepends on
if((<=)+(<=)+(>)+(<)+(>)+(<)+(>)+(<)+(<)+(<)+(<)+(<)+(>)+(<=)>0,1,0)bool
min(,)t/h
*/EUR/(t/h)
*(/)^MEUR
*EUR/year
*EUR/year
*EUR/year
*EUR/year
*EUR/year
*(++)EUR/year
*(++)EUR/year
++EUR/year
++++EUR/year
*t/year
*EUR/year
*EUR/year
VariableFormulaUnitDepends on
*/t/t
/(*)t/t
/*%
/t/h
*t/h
/t/t
(+)/*%
/(*)t/h
-t/h
/t/t
+t/h
/(*)/1/h
/t
min(,)h/year
/*%
*t/year
*t/year
*t/year
if(==,*/,if(==,,))kWh/t
*GJ/t
*/kWh/t
*/MW
*kW
*MWh/year
*/MWh/year
+MWh/year
max(,ceil(/))-
if(>=,,clamp(*(/)^(-),,))EUR/(t/h)
if(>=,,if(>,,))-
*EUR
/max(,)EUR/(t/year)
/ratio
if(<,/,(*(+)^)/max((+)^-,))1/year
*EUR/year
*sqrt(+*)*EUR/year
+EUR/year
/max(,)ratio
/max(,)*EUR/t
/max(,)*EUR/t
/max(,)*EUR/t
*EUR/t
*EUR/t
++++EUR/t
/max(,)*%
/max(,)*%
+++EUR/year
*EUR/t
+EUR/t
/max(,)*%
*EUR/year

Assumptions

66 assumptions used in the calculations

  • Protects divisions against a zero denominator.

    Market range Not applicable (numerical parameter).

    0.000001
    Numerical constant

  • Lower limit used in the input guard.

    Market range Not applicable.

    0
    Numerical constant

  • Unit value used in the CRF, the customised-CAPEX switch and the exponent algebra.

    Market range Not applicable.

    1
    Numerical constant

  • Converts a percent (0-100) into a fraction.

    Market range Exact.

    0.01
    Numerical constant

  • Converts a fraction into a percent.

    Market range Exact.

    100%
    Numerical constant

  • Upper limit of the operating hours and basis of the load factor.

    Market range 8760 (8784 in a leap year).

    8760h/year
    Numerical constant

  • Converts kW into MW and kWh into MWh.

    Market range Exact.

    1000kWh/MWh
    Numerical constant

  • Converts per-kg source values (MJ/kg DME) into per-tonne values.

    Market range Exact.

    1000kg/t
    Numerical constant

  • Converts MJ into kWh (1 kWh = 3.6 MJ).

    Market range Exact.

    3.6MJ/kWh
    Numerical constant

  • Converts the heat demand in kWh into GJ to price it as steam in EUR/GJ.

    Market range Exact.

    0.0036GJ/kWh
    Numerical constant

  • Converts the published FCI in million euros into euros.

    Market range Exact.

    1000000EUR/MEUR
    Numerical constant

  • Used for the stoichiometric methanol demand 2 CH3OH -> CH3OCH3 + H2O.

    Market range 32.04 g/mol.

    32.04kg/kmol
    Numerical constant

  • Used for the stoichiometric methanol demand and water co-production.

    Market range 46.07 g/mol.

    46.07kg/kmol
    Numerical constant

  • Used for the stoichiometric water co-production check.

    Market range 18.015 g/mol.

    18.015kg/kmol
    Numerical constant

  • Stoichiometric coefficient of methanol per mole of DME.

    Market range Exact (reaction stoichiometry).

    2mol/mol
    Numerical constant

  • Methanol consumed per tonne of DME in the simulated DME plant with full recycle; equals the stoichiometric value 2 x 32.04 / 46.07 = 1.391.

    Market range 1.391 t/t (stoichiometric minimum at 100 % selectivity).

    1.391t/t
    Model constant

  • Process water leaving the bottom of the methanol recovery column, per tonne of DME.

    Market range 0.391 t/t (stoichiometric: 18.015 / 46.07).

    0.391t/t
    Model constant

  • With total recycle and no purge, the overall yield equals selectivity; side products (methane, CO, coke) are neglected.

    Market range Close to 100 % on gamma-Al2O3 at 250-360 C; zeolites form more by-products.

    100%
    Model constant

  • Lower end of the per-pass conversion domain; below it the input is refused.

    70%
    Model constant

  • Upper end of the per-pass conversion domain (equilibrium limit at adiabatic reactor temperatures); above it the input is refused.

    85%
    Model constant

  • Per-pass conversion at which Semmel's catalyst mass is quoted; used to derive the space velocity that sizes the catalyst inventory.

    Market range 0.8 in Semmel P0; 0.70-0.85 per Pontzen.

    80%
    Model constant

  • Catalyst inventory of the reference plant; scaled with the reactor feed at constant space velocity (indicative).

    Market range 4.0 t at 17.5 t/h fresh methanol (Semmel P0); no independent range cited.

    4t
    Model constant

  • Fresh methanol feed of the reference plant, used with the catalyst mass to get the space velocity.

    Market range Single reference plant.

    17.5t/h
    Model constant

  • Heat demand of the conventional gas-phase process (evaporator + column reboilers) at X = 0.8; value of the Semmel P0 reference case.

    762kWh/t
    Model constant

  • Heat demand of the Michailos et al. reference case, the high end of the published range.

    904kWh/t
    Model constant

  • Medium-pressure steam demand of the Schemme DME plant; 1.964 MJ/kg = 545.6 kWh/t, the low end of the heat demand range (Schemme reference case).

    1.964MJ/kg
    Model constant

  • Electricity of pumps and auxiliaries = 1.39 kWh per t DME; negligible next to the heat demand.

    Market range About 1.4 kWh/t; no independent range cited.

    0.005MJ/kg
    Model constant

  • Case 1: Semmel et al. 2023 conventional gas-phase process P0 (heat 762 kWh/t).

    Market range Not applicable.

    1
    Numerical constant

  • Case 2: Schemme 2020 DME plant (MP steam 1.964 MJ/kg = 546 kWh/t).

    Market range Not applicable.

    2
    Numerical constant

  • Case 3: Michailos et al. 2019 as cited by Semmel (904 kWh/t).

    Market range Not applicable.

    3
    Numerical constant

  • Lowest valid reference case identifier.

    Market range Not applicable.

    1
    Numerical constant

  • Highest valid reference case identifier.

    Market range Not applicable.

    3
    Numerical constant

  • Fixed capital investment of the DME sub-plant at the lower reference point, bottom-up equipment-cost method (Schemme §3.3).

    Market range 9.91 MEUR2017 at 16.6 t/h DME; Semmel's P0 (AACE class 3-4, +/-30 %) is a separate estimate.

    9.91MEUR
    Model constant

  • DME output of the cost anchor; reference size of the scaling law.

    Market range Cost anchor.

    16.6t/h
    Model constant

  • Second published FCI point; used only in a consistency output against the published exponent.

    Market range 17.9 MEUR2017 at 37.5 t/h DME.

    17.9MEUR
    Model constant

  • Upper end of the published scaling interval, taken as the largest single train: above it the model adds identical trains in parallel (cost exponent 1).

    Market range Upper limit of the 133-300 MW interval.

    37.5t/h
    Model constant

  • Cost-capacity exponent of the DME sub-plant between 16.6 and 37.5 t/h DME. Below 16.6 t/h it is extrapolated; above 37.5 t/h the model switches to parallel trains (exponent 1), as Schemme finds exponents near 1 once columns reach their maximum size (methanol 300-441 MW, d = 0.991).

    Market range 0.732 on 133-300 MW; about 1 above (parallel trains).

    0.732
    Model constant

  • Floor of the clamp on the specific FCI; the model value stays between about 480 000 and 1 390 000 EUR per t/h over the 1-400 t/h methanol slider, so the floor never binds.

    Market range Never binds inside the slider range (checked at 1 and 400 t/h).

    200000EUR/(t/h)
    Model constant

  • Ceiling of the clamp on the specific FCI; never binds inside the slider range (model maximum about 1.39 MEUR per t/h at 1 t/h methanol).

    Market range Never binds inside the slider range.

    3000000EUR/(t/h)
    Model constant

  • Service life of the plant, used in the CRF and exported to project mode as the asset lifetime.

    Market range 20 years in both sources.

    20years
    Model constant

  • Operating hours of both reference studies; fixed costs per tonne are quoted at this basis then scaled by the load penalty.

    Market range 8000 h/a in both sources.

    8000h/year
    Model constant

  • Yearly maintenance as a share of FCI.

    Market range Turton factor; no independent range cited.

    0.061/year
    Model constant

  • Yearly auxiliaries, including catalyst replacement, as a share of FCI.

    Market range Turton factor; no independent range cited.

    0.0091/year
    Model constant

  • Yearly local taxes and insurance as a share of FCI.

    Market range Turton factor; no independent range cited.

    0.0321/year
    Model constant

  • Plant overhead as a share of labour, supervision and maintenance.

    Market range Turton factor; no independent range cited.

    0.6
    Model constant

  • Administration as a share of labour, supervision and maintenance.

    Market range Turton factor; no independent range cited.

    0.15
    Model constant

  • Supervision as a share of operating labour.

    Market range Turton factor; no independent range cited.

    0.18
    Model constant

  • Laboratory as a share of operating labour.

    Market range Turton factor; no independent range cited.

    0.2
    Model constant

  • Yearly cost of one operator.

    Market range German 2017 labour cost; no independent range cited.

    77592EUR/year
    Model constant

  • Operators needed per shift position for continuous operation.

    Market range Alkhayat & Gerrard correlation.

    5.15
    Model constant

  • Constant term of the Alkhayat & Gerrard operator correlation; the particulate term 31.7 P^2 is zero (no solids handling).

    Market range Correlation constant.

    6.29
    Model constant

  • Coefficient of the number of non-particulate process steps in the operator correlation.

    Market range Correlation constant.

    0.23
    Model constant

  • Number of non-particulate process steps of the DME plant; 16 is used at every size, so labour is fixed with respect to size (it does not grow with parallel trains, an optimistic simplification above 37.5 t/h DME). Because labour is fixed, the smallest units carry most of the cost: at 1 t/h of methanol, 7500 h and the highest prices on the sliders the conversion cost reaches about 660 EUR/t.

    16
    Model constant

  • Net conversion cost of the same process in 2020 euros, at 5 % interest, Semmel's utility prices and a class 3-4 estimate (+/-30 %). A different cost model and currency year from this calculator (2017 euros): the comparison is qualitative.

    Market range 75.7 EUR2020/t (P0) to 54.4 EUR2020/t (heat-integrated liquid phase).

    75.7EUR/t
    Published reference value (benchmark, not used in the formulas)

  • Best concept of Semmel et al., outside the scope of this calculator (liquid-phase reactor with heat integration); shows how much heat integration can save. 2020 euros.

    Market range 54.4 EUR2020/t.

    54.4EUR/t
    Published reference value (benchmark, not used in the formulas)

  • Full DME cost of Schemme's e-fuel chain, 2017 euros. Lower than this calculator at the same methanol price because steam is covered by the methanol plant (heat integration) in Schemme's chain.

    Market range 1464 EUR2017/t.

    1464EUR/t
    Published reference value (benchmark, not used in the formulas)

  • Full CO2-to-DME chain (hydrogen, CO2 capture, methanol and DME), not only the dehydration step; lower end of the confidence interval.

    1828EUR/t
    Published reference value (benchmark, not used in the formulas)

  • Upper end of the same confidence interval.

    2322EUR/t
    Published reference value (benchmark, not used in the formulas)

  • Heat demand of a third published gas-phase design, between the Schemme and Semmel cases.

    714kWh/t
    Published reference value (benchmark, not used in the formulas)

  • Semmel's MP steam price per tonne of steam; with about 2 GJ of latent heat per tonne it is about 11.5 EUR/GJ, the lower part of the steam price slider.

    23.1EUR/t
    Published reference value (benchmark, not used in the formulas)

  • Reference range for the methanol price assumption (e-methanol, BECCS CO2). In USD 2020; 0.876 EUR/USD (Semmel Table 2) gives about 700-1400 EUR/t.

    Market range USD 800-1600/t (BECCS CO2); USD 1200-2400/t (DAC CO2); fossil USD 100-250/t.

    800USD/t
    Published reference value (benchmark, not used in the formulas)

  • Conventional gas-phase dehydration of methanol to fuel-grade DME: feed evaporator, adiabatic gamma-Al2O3 fixed-bed reactor (250-360 C, 10-20 bar), column DC-01 (DME overhead), column DC-02 (methanol recovery, recycled; water at the bottom); no purge. This is Semmel's process P0 and Schemme's §5.3.2 plant. Mass balance from Schemme Tab. 5-7, heat demand from the selected published case, FCI from Schemme Tab. A-60 scaled with d = 0.732, O&M from Turton factors and the Alkhayat & Gerrard labour correlation (Schemme §3.3).

    Market range Not applicable.

    —
    Model scope

  • The FCI of Schemme's bottom-up equipment-cost method includes equipment, installation and the indirect costs of the plant, so the meta declares it fully_financed: project mode adds no further buildup. Working capital and land are not included.

    Market range Not applicable.

    —
    Model scope

  • The exponent 0.732 is published for 16.6-37.5 t/h of DME (133-300 MW). Below 16.6 t/h DME (23 t/h of methanol) the law is extrapolated and small units are likely under-costed; above 37.5 t/h the model adds parallel trains at constant specific cost, following Schemme's observation that exponents approach 1 once columns reach their maximum size.

    Market range Not applicable.

    —
    Model scope

  • All costs are constant 2017 euros (Schemme's cost basis) and the discount rate is real; no escalation is applied. User prices (steam, electricity, methanol) are taken in the same constant euros.

    Market range Not applicable.

    —
    Model scope

  • The per-pass conversion changes the recycle flow, the load on the methanol recovery column and the catalyst inventory, not the yield. The heat demand is the published value of each case at its own conversion (0.8 for Semmel); it is not derived from the slider, because no source gives that law.

    Market range Not applicable.

    —
    Model scope