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Synthesis of Propionic acid from Syngas

Synthesis of Propionic acid from Syngas. Date:08 March 2011 Team Echo: Sabah Basrawi Alex Guerrero Mrunal Patel Kevin Thompson Client Mentor: Shannon Brown. Focal Points. Basis Information Flowsheeting Energy Sinks/Loads Equipment Sizing Aspen Icarus Process Estimator.

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Synthesis of Propionic acid from Syngas

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  1. Synthesis of Propionic acid from Syngas Date:08 March 2011 Team Echo: Sabah Basrawi Alex Guerrero Mrunal Patel Kevin Thompson Client Mentor: Shannon Brown

  2. Focal Points • Basis Information • Flowsheeting • Energy Sinks/Loads • Equipment Sizing • Aspen Icarus Process Estimator

  3. Project Goal • Production of: • Propionic Acid • 33,000 ton/year • Using syngas • Location of Plant: • Morris, IL • Near: • Lyondellbasell (for Ethylene) • Team Foxtrot (for Syngas)

  4. Design Basis • Propionic Acid: • Synthesized from • syngas (1:1 ratio of CO & H2) • Ethylene • Oxygen • Low level of toxicity as mentioned by EPA • Major Uses: • Preservative for animal & human food consumption • Intermediate product for Thermoplastics • Bactericide, fungicide and pesticides

  5. Liquid Death • Ni(CO)4, or Nickel Carbonyl will kill in multiple ways. • Heavier than air • Inhalation • Skin absorption • Nickel effects on hemoglobin • Auto-ignition point at 140°F

  6. Changes from last time • Nickel carbonyl has been dropped as a catalyst and replaced by a Rhodium based catalyst • Due to the above change, the reactor type of the first reaction has been changed • Series compressors and coolers are being integrated into flowsheet • Catalyst separation has been modeled

  7. Chemical Information Analysis • Reaction Mechanism • Syngas feed with Ethylene  Propionaldehyde Catalyst: Rhodium (1) CO + H2 +C2H4  CH3CH2CHO • Aldehyde oxidation  Propionic Acid Catalyst: Cobalt Ion (2) CH3CH2CHO + ½ O2  CH3CH2COOH

  8. Catalyst InformationCobalt Halides • Used in the oxidation of Propionate to Propionic acid • Reaction calls for Cobalt ion • Dissolve cobalt halide in water to obtain ion • Poisons: • Potassium Carbonate

  9. Competing Processes • Industry standard: Hydrocarboxylation of ethylene using nickel carbonyl or ruthenium as catalyst: H2C=CH2 + H2O + CO → CH3CH2COOH • Our process : • Hydroformylation involves the addition of a formyl group (CHO) and a hydrogen atom to a carbon-carbon double bond. • Promotes chain extension

  10. Competing Processes Pt. 2 • Choice of Syngas: The feed for the process since it’s thermodynamically efficient • Wacker process: • Similar to Hydroformylation • uses a Tetrachloropalladate catalyst. • Carbonylation Process: • Produces Propionaldehyde, then oxidizes it in the presence of cobalt ions to produce Propionic Acid. • Typically requires a carbonyl catalyst like Nickel Carbonyl

  11. Flowsheeting

  12. Flowsheet (Left Side)

  13. Flowsheet (Center)

  14. Flowsheet (Right Side)

  15. Energy Sinks/Sources

  16. Equipment Sizing

  17. Propionic Acid Consumption

  18. Demand for Propionic Acid

  19. Control Scheme • Operation: • 337 days per year • 7 days per week • 4 shifts • 10 people per shift • Contingency Plan: • 4 managers and 4 back up managers necessary

  20. Chemical Economics

  21. Plant Economics

  22. In the Future • Redone process with Rhodium Catalyst specifications • More In-process heat exchange

  23. Contact Information • Wiki link: http://seniorecho.wikispaces.com/ • Email: designecho@listserv.uic.edu

  24. References • "Acetic Acid Production." Acetic Acid Production. 2009. Web. 22 Jan. 2011. <http://www.starcontrols.com/Application/Application_min_e.asp?MinID=34>. • Boyaval, P., and C. Corre. Production of Propionic Acid. 1995. Print. • Perlack, Robert D., Lynn L. Wright, Robin L. Graham, Bryce J. Stokes, and Donald C. Erbach. Biomass as a Feedstock for a Bioenergy and Bioproducts Industry: The Technical Feasibility of a Billion-Ton Annual Supply. Print. • "Propanoic Acid." Wikipedia, the Free Encyclopedia. Web. 22 Jan. 2011. <http://en.wikipedia.org/wiki/Propanoic_acid>. • Registration Review Document for Propionic Acid and Salts. Mar. 2008. Print. • Spivey, James J., Makarand R. Gogate, Ben W. Jang, Eric D. Middlemas, Joseph R. Zoeller, Gerald N. Choi, and Samuel S. Tam. Synthesis of Acrylates and Methacrylates from Coal-Derived Syngas. 1997. Print.

  25. References Pt. 2 • http://www.engineeringtoolbox.com/air-compressor-types-d_441.html

  26. QUESTIONS

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