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Process Optimization

Advisors: Dr. Kenneth Wynne Dr. Wei Zhang Mr. Rudy Krack. Team Members : Michelle Halye Michael Hanks Krunal Patel. Process Optimization. Block Diagram. Pilot Process Design. Equipment List. Pfaudler RT-14-10 Jacketed Reactor 5 Stage Batch Distillation Tower

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Process Optimization

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  1. Advisors: Dr. Kenneth Wynne Dr. Wei Zhang Mr. Rudy Krack Team Members: Michelle Halye Michael Hanks Krunal Patel Process Optimization Block Diagram Pilot Process Design Equipment List • Pfaudler RT-14-10 Jacketed Reactor • 5 Stage Batch Distillation Tower • Adjustable Pressure Steam Boiler • Water Tower & Reservoir • 3 Pressure Regulators • 2 Condensers • 5 Pumps • 10 Fail Close Ball Valves • 5 Fail Close Needle Valves • 4 Fail Open Needle Valves Reaction Economic Analysis Design of Experiment • The yields were calculated based on the amount of ethanol driven off by the reaction • The distillate contained more diethyl carbonate than was expected - A subsequent experiment with diethyl carbonate in excess showed significantly improved results - Due to time and material constraints, we were unable to perform a full suite of DOE experiments with diethyl carbonate in excess • The DOE analysis was performed using the JMP statistical analysis software package - The results showed that increasing the time or the agitation speed independently increased the yield substantially. - However, the results did not show any synergistic effect from increasing these two parameters simultaneously • We performed a 3 factor, 2 level full factorial Design of Experiment • The DOE was performed only on the first step to: - Keep the DOE manageable - The HEL SimularTM had a temperature restriction preventing it performing the second step Desired Product Primary Company Use for Product HEL SimularTM P&ID • The co-polyoxetane the monomer is used in is still in research - It has potential to be an anti-fouling paint coating additive with 2 wt% polymer - The polymer is unique in that it becomes more hydrophobic the wetter the polymer becomes • The cost per gram of product is $12.56 if the plant produces 10 gallons or 38.8 kg of product per yea • However, if the coating goes from 2 wt% to 100 wt%, the demand would go to 500 gallons or 1949 kg per year, that would take the price down to $.25 per gram. • Both of these prices allow for payback in 4.7 years • Assuming this paint coating would be put on all current naval and commercial ships, we estimated that 10 gallons a year of product would be needed • For experiment 8b, the diethyl carbonate was in a 2:1 ratio with the Tris(hydroxymethyl)ethane

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