Synthesis Of Propionic Acid from Syngas

1. Synthesis Of Propionic Acid from Syngas Sabah Basrawi, Alex Guerrero, Mrunal Patel, Kevin Thompson University of Illinois at Chicago Economics Design Basis Process Flow Diagram • 33,000 tons/year • Inlet feeds of Syngas taken from Team Foxtrot and ethylene taken from Lyondellbasell • Formation of the Propionaldehyde will take place under a Rhodium based catalyst • Propionaldehyde then oxidized using a Cobalt ion catalyst • Capital Cost: $57.8 million • NPV: -$20 million • IRR: 4% • Yearly Profit: $28.8 million • Yearly Cost:$28.6 million • Yearly Syngas Cost: $ 5 million Motivation We use relatively cheap reactants to produce a product that is of higher market value. With the amount that we are producing we would be a major component of the world market for propionic acid. Block Flow Diagram Process Floor Plan Plant Layout • Plant to be located in Morris, IL just north of Lyondellbasell • Just southeast of Team Foxtrot’s Syngas plant • Adjacent to two railroads lines for feed and product transport • Near Interstate 80 for freight transfer Project Struggles Uses of Propionic Acid • First couldn’t decide whether of not to produce ethylene ourselves • Catalyst information, “Proprietary.” • Liquid Death (Nickel Carbonyl) • First catalyst chosen can kill people in multiple ways • If inhaled (also permeates through skin), carbon monoxide poisoning, nickel will affect heme groups on blood. • Ignites at 140°F • Side reaction selectivity was discovered late in the project, caused an entire process overhaul • Mold inhibitor for various animal feed • Preservative in cheeses and baked goods to prevent mold • Precursor in many industrial processes • Pharmaceuticals • Plastics • Plasticizers • Textile and rubber auxiliaries