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Synthesis of Propionic acid from Syngas

Synthesis of Propionic acid from Syngas. Date:05 April 2011 Team Echo: Sabah Basrawi Alex Guerrero Mrunal Patel Kevin Thompson Client Mentor: Shannon Brown. Presentation Layout. Project Goal Design Basis Process Flow Diagram Conceptual Control Scheme Plant Layout Economics.

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Synthesis of Propionic acid from Syngas

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  1. Synthesis of Propionic acid from Syngas Date:05 April 2011 Team Echo: Sabah Basrawi Alex Guerrero Mrunal Patel Kevin Thompson Client Mentor: Shannon Brown

  2. Presentation Layout • Project Goal • Design Basis • Process Flow Diagram • Conceptual Control Scheme • Plant Layout • Economics

  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. 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 • In = Out (per year) • 6.64E7 lb (CO+H2+C2H4+O2)= 6.64E7 lb Product

  6. Catalyst Information • Rhodium: Used in the production of Propionate • Extremely durable to poisonous material • Reaction conditions: 212°F, 290 psi • Cobalt Halide: Used in the oxidation of Propionate to Propionic acid • Dissolve cobalt halide in water to obtain ion • Poison: K2CO3 • Reaction Conditions: 122°F, 14.7 psi

  7. Block Flow Diagram

  8. Process Flow Diagram

  9. Process Flow Diagram

  10. Calculations

  11. Wind Rose

  12. Plant Plot

  13. Plant Layout

  14. Plant Layout

  15. Process Floor Plan

  16. Economics • NPV: $154 Million • IRR: 27% • Total Yearly Cost: $45 Million • Total Yearly Profit: $59.4 Million • Break-Even Point: ~4.1 Years

  17. Sensitivity Analysis (Capital Cost)

  18. Sensitivity Analysis (Feed Price)

  19. Sensitivity Analysis (Product Price)

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

  21. 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.

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

  23. QUESTIONS

  24. Flowsheeting

  25. Flowsheet (Left Side)

  26. Flowsheet (Center)

  27. Flowsheet (Right Side)

  28. Energy Sinks/Sources

  29. In=Out

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