CHEMICAL ENGINEERINGV i r g i n i a C o m m o n w e a l t h U n i v e r s i t y
VCUTeam Members:
Michelle Halye
Michael Hanks
Krunal Patel
Desired Product
Reaction
Equipment List
Design of Experiment
• 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
Primary Company Use for Product
Pilot Process Design
Factors Responses
patternTime
(Hours)Temperature
(°C)Agitation
(rpm)Done?
Yield, ethanol
GC/MS, %
1 + - - 2 135 100 8-Dec 18.6 0.45
2 --+ 1 135 150 10-Dec 21.2 0.51
3 + + - 2 145 100 10-Dec 24.9 0.46
4 - + + 1 145 150 10-Dec 22.2 0.44
5 + + + 2 145 150 12-Dec 22.9 0.44
6 - + - 1 145 100 16-Dec 8.4 0.34
7 - - - 1 135 100 15-Jan 16.7 0.47
8 + - + 2 135 150 20-Jan 28.1 0.52
8b + - + 2 135 150 13-Feb 80.9 0.44
mid N/A 1.5 140 125 30-Jan 15.6 0.40
• For experiment 8b, the diethyl carbonate was in a 2:1 ratio with the Tris(hydroxymethyl)ethane
Advisors:
Dr. Kenneth Wynne
Dr. Wei Zhang
Mr. Rudy Krack
HEL SimularTM P&ID
Economic Analysis
10 Gallon Reactor
Ethanol Storage
Tris(hydroxymethyl)
EthaneStorage
DiethylCarbonate
Storage
Sodium HydroxideStorage
Pump 1
Pump 2
FC-1
FC-2
FC-3
FC-4
Waste Storage
P-1
P-2
P-3 P-4
P-5
P-6P-7 P-8
P-48
P-9
P-10
BoilerSteam
P-11
Pressure Regulator
1
P-65
FC-5
P-9
Water Tower
Water Reservoir
Pump 3
P-63
P-64
FC-6 Condenser 1
P-12
P-15
T
Temp-1
F
Flow-1
P-13 P-14
DEC & Ethanol
Crude Product
P-17 P-18P-21
FC-8
FC-7
P-19
P-22
P-23
P-20
P-49
P-54
FO-1
P-52
Level-1
DistillationTower
Purified Product
P-24
P-26
P-27
P-25
Condenser 2
FO-3
FC-11
FC-12
FC-14FC-16
FC-15
P-50
P-51
FO-2
P-45
P-47
Pump 4
P-46
FC-13
Pump 5
P-44
P-40
P-36
P-39
P-30
P-31
P-33
P-41P-42
P-43
P-35
P-28
P-34
P-32
P-38P-37
P-60
P-62
Pressure Regulator
3
P-67
T
Temp 2
P-16
FC--9
FC-10
F
Flow 2
P-29
T
Temp-3
P-59
T
Temp-4P-53
T
Temp-5
P-61
P-55
P-51
FO-4
P-56
T
Temp-6
P-57 P-58
Pressure Regulator
2P-66
Walk and Dump (Solid Component)
Multiple Component Pipeline
All other Pipelines colors correspond to their respective holding tank colors
LEGEND
Computer
WinISO2384
JulaboF32
Internal Heater
Thermocouple
Heating Oil
Round Bottom Flask
Water in
Water out
• 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 $.25 per gram.
• Both of these prices allow for payback in 4.7 years
•The yields were calculated based on the amount of ethanol driven off by the reaction
•The distillate contained more diethyl carbonate than was expected
- A subsequent experiment with diethyl carbonate in excess showed significantly improved results
- Due to time and material constraints, we were unable to perform a full suite of DOE experiments with diethyl carbonate in excess
•The DOE analysis was performed using the JMP statistical analysis software package
- The results showed that increasing the time or the agitation speed independently increased the yield substantially.
- However, the results did not show any synergistic effect from increasing these two parameters simultaneously
• We performed a 3 factor, 2 level full factorial Design of Experiment
• The DOE was performed only on the first step to:
- Keep the DOE manageable
- The HEL SimularTM had a temperature restriction preventing it performing the second step
• The co-polyoxetane the monomer is used in is still in research
- It has potential to be an anti-fouling paint coating additive with 2 wt% polymer
- The polymer is unique in that it becomes more hydrophobic the wetter the polymer becomes
Block Diagram
Profitability
Return on investment, ave. %/y -10.1
Payback period, y 4.7
Net return, 106$ -0.52 at mar = 15.0 %/y
• 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
Distillation Tower for Step one
Reactor
Product Storage
Carbon Dioxide Release
Distillation Tower for Step two
Diethyl carbonate return stream
Waste
Ethanol Storgae
Diethyl Carbonate
Storage
Tris. Storage
Sodium Hydroxide Storage
Production, kg/y 38.8Cost,
thousand $/yType Item
Variable Cost
Raw materials 1.25
Operating labor 57.6
Utilities 0.138
Maintenance and repairs
20.3
Operating supplies 2.03
Subtotal: 81.3
Fixed CostTaxes 40.5
Insurance 20.3
Subtotal: 60.8
Plant Overhead 7.79
Total Manufacturing Cost: 150
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