Project Title

Synthesis of Propionic acid from SyngasDate:08 March 2011Team Echo:Sabah BasrawiAlex GuerreroMrunal PatelKevin ThompsonClient Mentor: Shannon Brown1Focal PointsBasis InformationFlowsheetingEnergy Sinks/LoadsEquipment SizingAspen Icarus Process Estimator

Project GoalProduction of:Propionic Acid33,000 ton/yearUsing syngasLocation of Plant:Morris, ILNear:Lyondellbasell (for Ethylene)Team Foxtrot (for Syngas)

The goal of this project is to take the syngas from group Foxtrot, and utilize it for the production of Propionic Acid to be used in industrial processes.The syngas feed will be reacted with Ethylene to produce Propionaldehyde.This aldehyde will then be oxidized to become Propionic Acid.

We have decided to base our plant operations in Morris, ILClose to Lyondellbasell Plant which produces ethylene.**Also near rail line so team Foxtrot can obtain Illinois Basin #6 coal from southern Illinois.

3Design BasisPropionic Acid:Synthesized from syngas (1:1 ratio of CO & H2)EthyleneOxygenLow level of toxicity as mentioned by EPAMajor Uses:Preservative for animal & human food consumptionIntermediate product for ThermoplasticsBactericide, fungicide and pesticidesPropionicacid is a commonly used chemical in industry that will be synthesized fromsyngas (with a 1:1 ratio of CO and H2), ethylene and water catalyzed by metal ion in solutionPropionic acid:Naturally occurringMade from ethylene and carbon monoxideUses and advantages:AnalgesicIntermediate product for thermoplasticsPlastics are used in many daily processes and by creating an abundance of this resource it will increase affordability and stimulate the economy.

Industrially, the majority of propionic acid is used as a bactericide and fungicide to protect hay and grains that are being stored as well as an ingredient for pesticides.EPA determined it has low toxicity to fish, invertebrates, birds and mammals.

Use a quartz flow reactor- quartz frit heated with furnace, regulated by mass flow controllers

Shows the purposes of the process design, indicating the feed stocks, products, reactions, etc.Has all the basic requirements for the design of entire plant, individual processes and related facilities.4Liquid DeathNi(CO)4, or Nickel Carbonyl will kill in multiple ways.Heavier than airInhalationSkin absorptionNickel effects on hemoglobinAuto-ignition point at 140FIf inhaled, will sit in the bottom of the lungs where it will decompose and cause carbon monoxide poisoningIf you manage to survive the monoxide poisoning, the nickel will effect the hemoglobin in your bloodIf somehow manage to survive all of this, permanent brain damage is a given.Fume hoods are useless as the gas is much heavier than air, and if it spills out onto a hot surface, the gas will auto-ignite at 140 F

5Changes from last timeNickel carbonyl has been dropped as a catalyst and replaced by a Rhodium based catalystDue to the above change, the reactor type of the first reaction has been changedSeries compressors and coolers are being integrated into flowsheetCatalyst separation has been modeled

NOT APPEARING IN THIS PRESENTATION!!!

Due to the severe health risks associated with Nickel Carbonyl it has been dropped as a catalyst the safety requirements for the catalyst were deemed to be cost ineffective

As the new catalyst is in the solidified state, and the reaction conditions have significantly dropped Packed Bed reactors are being looked at to carry out the reaction

Previously, all components were modeled as one instead of in the series that will most likely be occurring in real life

The catalyst has been modeled into the aspen flowsheet in order to model if the separation conditions are appropriate6Chemical Information AnalysisReaction MechanismSyngas feed with Ethylene PropionaldehydeCatalyst: Rhodium(1) CO + H2 +C2H4 CH3CH2CHOAldehyde oxidation Propionic AcidCatalyst: Cobalt Ion(2) CH3CH2CHO + O2 CH3CH2COOHWeve decided not go forward with making ethylene, it was not cost effective since it was a process of making acetic acid and breaking it down to ethylene. We will be buying the ethylene instead.

7Catalyst InformationCobalt HalidesUsed in the oxidation of Propionate to Propionic acidReaction calls for Cobalt ionDissolve cobalt halide in water to obtain ionPoisons:Potassium CarbonateI finish here8Competing ProcessesIndustry standard:Hydrocarboxylation of ethylene using nickel carbonyl or ruthenium as catalyst:H2C=CH2+ H2O + CO CH3CH2COOHOur process :Hydroformylation involves the addition of a formyl group (CHO) and a hydrogen atom to a carbon-carbon double bond.Promotes chain extensionCompetition for feed stock, who else wants this feed stock?Availability of source, source depletionWhy this source as opposed to another sourceVariations in fischer-tropsch technologyMethanol homologation to ethanol, followed by hydrationDimethyl ether crackingDirect synthesis from CO/H2 mixtures over alkaline iron oxide catalysts

Billion ton vision, first bullet point

9Competing Processes Pt. 2Choice of Syngas:The feed for the process since its thermodynamically efficientWacker process:Similar to Hydroformylationuses a Tetrachloropalladate catalyst.Carbonylation Process:Produces Propionaldehyde, then oxidizes it in the presence of cobalt ions to produce Propionic Acid.Typically requires a carbonyl catalyst like Nickel Carbonylhttp://en.wikipedia.org/wiki/Propanoic_acidEthylene formation and propanoateRh vs Pd vs NiCO

10Flowsheeting

Flowsheet (Left Side)

12Flowsheet (Center)

Flowsheet (Right Side)

Energy Sinks/Sources

Equipment Sizing

Propionic Acid Consumption

The US is a major user of propionic acid and with rising demand the process will be economical in theory

blurry17Demand for Propionic Acidhttp://www.icis.com/Articles/2006/02/28/2012636/chemical-profile-propionic-acid.html

Make a new graph with 18Control SchemeOperation:337 days per year7 days per week4 shifts10 people per shiftContingency Plan:4 managers and 4 back up managers necessary

Arbys and Taco bell use propionic acidFarmers use propionic acid

Plans to have 40 workers across four differing shiftsPlans for plant to be operated 337 days per yearPlans to sell propionic acid to food companies

19Chemical Economics

20Plant Economics

Must determine the amount needed to pay back INTEREST, getting loan

21In the FutureRedone process with Rhodium Catalyst specificationsMore In-process heat exchange

Contact InformationWiki link: http://seniorecho.wikispaces.com/Email: designecho@listserv.uic.eduReferences"Acetic Acid Production."Acetic Acid Production. 2009. Web. 22 Jan. 2011. .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. .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.References Pt. 2http://www.engineeringtoolbox.com/air-compressor-types-d_441.html

25QUESTIONS