4/27/2010 Team Bravo: Presentation 5 1

Production of Dimethyl Sulfoxide from Lignin

Team Bravo is:

Stan Das, Jeff Umbach, Russ Boyer, Krista Sutton, Mike Czepizak

Project Lead: Jake Biberstein

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Project Outline

Executive Summary Discussion Conclusions &

Recommendations Design Basis Block Flow Diagram Distribution & End Use

Review Constraints Review Applicable Standards Economic Evaluation

Utilities Conceptual Control

Scheme Plant Layout Process Flow Diagram Calculations Annotated Equipment List Project Communication File Sources + References

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Presentation Outline

Executive Summary Discussion Conclusions &

Recommendations Design Basis Block Flow Diagram Distribution & End Use

Review Constraints Review Applicable Standards Economic Evaluation

Utilities Conceptual Control

Scheme Plant Layout Process Flow Diagram Calculations Annotated Equipment List Project Communication File Sources + References

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Executive Summary•The overall goal of this process is to produce 2,200 lb/hr of >99.7% purity DMSO, 15% market capture.

•Primary feedstock for process is black liquor, obtained from Kraft mill that our process will be co-located with.

•Secondary feeds include sulfur, tall oil, ammonia, sodium hydroxide and air.

•Location: Onsite with a Kraft mill in Louisiana

•Capital costs: Approximately $28 million

•Yearly profit: Approximately $7.5 million

•Simple payback: ~4 years

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Discussion•Market analysis: 2,200 lb/hr, 8,000 hr/yr

•Corresponds to 8,800 tons/yr, total market is 60,000 tons/yr (2008).

•15% market capture, too high or too low?

•Demand of DMSO increasing.

•Location analysis: Will be covered later in this presentation.

•Economic analysis: Significant variance in feed costs and product sales.

•Feed costs: Lignin content of black liquor and methoxy content of lignin can both vary.

•Implies that raw material cost of black liquor can wildly vary to produce a known amount and purity of DMSO.

•Product sales: Purity of DMSO determines sale price (touched on later).

•We address this by assuming lowest possible grade (99.7%) and appropriate sale price for this grade ($1.75/lb).

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Conclusions and Recommendations•Process is a GO, provided that:

•Plant is located onsite with a Kraft mill.

•Black liquor purchased for only the energy content we remove (2.2 cents/lb).

•Tall oil obtained for free and added to molten sulfur as polymerization inhibitor.

•Waste streams returned to Kraft mill must not have their sulfur content changed appreciably.

•Price for product is $1.75/lb for >99.7% purity.

•These conditions allow for economically competitive production of DMSO.

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Design Basis•Everything in the previous slides, including:

•Black liquor definition: 65% solids, 45% of solids is lignin. Lignin is 13.25% MeO groups (mass).

•Sodium hydroxide definition: 50% saturated solution.

•Ammonia definition: Pure, from a pipeline running through LA.

•Spent black liquor stream returned to Kraft mill for burning in their recovery boiler.

•Waste stream containing DMS and water needs to be rendered nontoxic before release.

•Vented streams from PSA containing only nitrogen and argon.

•All efforts made to design plant according to established standards for safe operation.

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Block Flow Diagrams

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Economic EvaluationCapital Costs

$27,500,000Utilities

$642,000/yearRaw Materials

$14,900,000/yearLabor and Maintenance

$1,900,000/yearDistribution Costs$1,900,000/year

Other Costs$3,440,000/year

Total Operating Costs$23,050,000/year

Total Product Sales$30,400,000/year

Profit per Year$7,350,000/year

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Distribution and End Use•Design Basis: Shipping product every 22 hours

•Produce 2,204lb/hr or 45,000lb/day

•Need to ship 100 - 55 gal drums/day

•Average shipping quote $5,200/shipment

•Annual Shipping Costs $1.9million/yr

•With 20% cushion $2.25 million/yr

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Constraints Review•Location Sensitivity

•Co-location with Kraft Mill

•Large mass of black liquor used plus its cost in energy preclude transportation or straight-out purchase.

•Co-location eliminates transportation costs and allows for recycling.

•Also allows for usage of Tall Oil as polymerization inhibitor.

•State of Louisiana

•Cheap sulfur – petrochemical industry must desulfurize fuels.

•Cheap ammonia – pipeline running through the state.

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Applicable Standards

Grade % Purity, min % Water, max

ACS-Spectrophotometric 99.9 0.1

ACS-Reagent 99.9 0.1

Anhydrous 99.9 0.005

EL-10 99.9 0.05

EL-50 99.9 0.05

Industrial 99.7 0.1

Enviro-S 99.7 0.15

Pharmasolvent 99.98 0.03

Procipient USP 99.9 N/A

•The table at right summarizes grades of DMSO offered by Gaylord Chemical, the chief US supplier.

•Design specification assumes “Industrial” grade.

•Specification of DMS (dessicator exit conditions): 99.2% DMS, 0.07% water content maximum

•Safety specification for hazardous gases:

•NO2: 1 hr: 100 ppb. Annual: 53 ppb. [EPA]. 5 ppm [OSHA]

•NH3: 50 ppb [OSHA]

•NO: 25 ppm [OSHA]

•DMS: TEL 10 ppm [ACGIH]

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Future Work•Heat Integration/Pinch Analysis/Utility Optimization

•Market Growth Rate Research

•Designing PSA system

•More stringent specifications surrounding ammonia oxidation reactor.

•Cooling media required (hot oil)

•Metallurgy concerns (heat exchangers)

•Fuel gas required to run fired heater

•Waste treatment (DMS + Water mixture)

•Hydraulics (pump and blower sizing)