Synthesis of Propionic acid from Syngas

Date:05 April 2011Team Echo:

Sabah BasrawiAlex Guerrero

Mrunal PatelKevin 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 PropionaldehydeCatalyst: Rhodium(1) CO + H2 +C2H4 CH3CH2CHO

Aldehyde oxidation Propionic AcidCatalyst: 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

17

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

18

Sensitivity Analysis (Capital Cost)

10% 20% 30% 40% 50% 60% 70% 80%0

10

20

30

40

50

60

70

80

90

100

Capital Cost Sensitivity

Series1

IRR

Cap

ital

Cos

t (M

M$)

19

Sensitivity Analysis (Feed Price)

20% 22% 24% 26% 28% 30% 32% 34%0.00E+00

2.00E+06

4.00E+06

6.00E+06

8.00E+06

1.00E+07

1.20E+07

Syngas Price Sensitivity

Series1

IRR

Syn

gas

Cost

($/

year

)

20

Sensitivity Analysis (Product Price)

0% 10% 20% 30% 40% 50% 60%0.00E+00

5.00E+02

1.00E+03

1.50E+03

2.00E+03

2.50E+03

Product Price Sensitivity

Series1

IRR

Aci

d (

$/to

n)

21

Contact Information Wiki link:

http://seniorecho.wikispaces.com/ Email: designecho@listserv.uic.edu

22

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.

23

References Pt. 2 http://www.engineeringtoolbox.com/air-co

mpressor-types-d_441.html

24

QUESTIONS

25

Flowsheeting

26

Flowsheet (Left Side)

27

Flowsheet (Center)

28

Flowsheet (Right Side)

29

Energy Sinks/Sources

30

In=OutIN Mass/ Year Out Mass/year

CO 2.5E7 lb Propionic Acid 6.64E7 lb

H2 1.9 E6 lb

C2H4 2.5 E7 lb

O2 7.2E6 lb