Post on 10-Jan-2017
Zeolite ProductionTeam 12
Bi Chen, Kevin Hendrawan, James Inglett, Noemi Mendoza, Kuang Sheng
Outline
▪ Introduction
▪ Background on Product
▪ Outline of our processes
▪ Optimization
▪ Waste Treatment
▪ Location
▪ Floor Plans
▪ Economics
Mission Statement
Our goal is to produce high quality zeolite x and mordenite for catalysis
that competes in the global market in terms of production volume,
purity, and quality.
Zeolite X & Mordenite
▪ Zeolites are crystalline solids made of Si, Al, and O
▪ Ratios
▪ Useful as molecular sieves
▪ Zeolites have many applications in different areas
▪ Petrochemical cracking
▪ Gas purification
▪ Ion-exchanged water softener
▪ Catalysts
https://upload.wikimedia.org/wikipedia/commons/f/fa/Zeolite-ZSM-5-vdW.png
Our ProductZeolite X Mordenite
Si/Al Ratio 2.5 5
Application
Used as catalysts in fluid catalytic
cracking and hydrocracking units
in industrial refineries.
Used as catalysts for the acid-
catalyzed isomerisation of
alkanes and aromatics in the
chemical industry.
Expected Growth & World Market
Stead, Jerre. "Zeolites." - Chemical Economics Handbook (CEH). IHS, 11 Oct. 2013. Web. 10 Feb. 2016. <https://www.ihs.com/products/zeolites-chemical-economics-handbook.html>.
"Zeolite Market Size, Share | Industry Research Report, 2022." Zeolite Market Size, Share | Industry Research Report, 2022. Grand View Research, 13 Nov. 2015. Web. 07 June 2016.
Zeolite X Process
Kaolin:30kg/h
Silica : 20 kg/hWater: 1 kg/hSodium Hydroxide: 9 kg/h
Annual Operating time: 7920 hAnnual Production: 460,780 kgSelling Price: $5 / kg
50-80℃20 h
Zeolite: 58.18 kg/h
Mordenite Process
Kaolin:0.52kg/h
Ethanol :1.38kg/hSilica : 0.96kg/hWater: 0.22kg/hSodium Hydroxide: 0.16kg/h
Mordenite:1.78kg/h
Annual Operating time:7920 hAnnual Production:14,112 kgSelling Price: $3 / kg
130-170℃72 h
Plant layout & Floor plans
Calcinator
Zeolite X
Mordenite
Zeolite X P&ID
Optimization▪ Scaling to meet demands for both Zeolite X and Mordenite markets
▪ Used metakaolin for SiO2 and Al2O3 source for starting material to save costs
▪ Changed mordenite catalyst to using ethanol instead of 1,8-diamino-p-menthane
▪ 90% recycle line of NaOH wastewater
▪ Pump lines and heat exchange systems
▪ Replaced coal-furnace calcination
process with electric-heated calcination
to minimize environmental impact.
Waste treatment
▪ Wastewater expelled from bleed line and overall factory process is basic, pH 11-14
▪According to the EPA and the MEP, industrial discharge must meet the pH of 6-9.
▪This is achieved by using carbonic acid to lower the wastewater pH to appx. 8.5.
▪H2CO3 + 2NaOH → Na2CO3 + 2H2O
▪ Other constituents in the waste discharge are not regulated by EPA or MEP
▪SiO2 and Na2O are naturally occurring, low toxicity, negligible effect on environment.
▪Al2O3 is insoluble, does not bioaccumulate, and found in nature.
▪Address this by sedimentation before discharge.
Location
▪ Largest industrial city in South China (Guangzhou)
▪ Serves as an important national transportation hub and trading port
▪ Close to Suppliers
▪ Expanding Mechanical Equipment Industry
▪ Petrochemical Industry
Chemical Industrial Area
Economics
Construction Time Breakeven Point
Economics
▪ Total annual revenue from zeolite sales: $2.5 million▪ Total annual revenue from mordenite sales: $47,000▪ Net present value $11.89 million▪ Payback period of 1 year▪ Rate of return on investment 43.09%
Conclusion
▪ High demand for zeolite in China as well as expected market growth
▪ Producing over 474,000 kg of zeolite and mordenite per year
▪ Total revenue $2.6 million
▪ Breakeven in year before year 4, 1 year after start of operation
▪ For an expected factory life of 15 years profit of ~$12 million
▪ Rate of return on investment 43.09%
QUESTIONS