uses for acetone

80
Uses for Acetone April 15 th , 2008 Authors: Neal Behrend Brian Mahoney Iryney Makarukha Sunil Subramanian Advisor: Professor Raymond Gorte Project Originator: Bruce Vrana

Upload: neal

Post on 17-Aug-2015

293 views

Category:

Documents


4 download

DESCRIPTION

Exploration of a process to turn acetone into polypropylene. Process is currently under US Patent.

TRANSCRIPT

Uses for Acetone April 15th, 2008 Authors: Neal Behrend Brian Mahoney Iryney Makarukha Sunil Subramanian Advisor: Professor Raymond Gorte Project Originator: Bruce Vrana Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian - 1 -A) Abstract: The goal of this project is to develop a process for utilizing 164,800 metric tons per year of acetone produced as a by-product in the synthesis of n-butanol.The potential of various products were considered, but conversion to polymer-grade propylene was determined to be the best option based on market-share considerations. The designed process involves hydrogenation of the acetone to isopropanol over a nickel/silica catalyst, then dehydration of the alcohol to propylene over a -alumina catalyst.Approximately 106,815 metric tons of polymer grade propylene are produced annually. To determine the economics of the process, it was assumed that the acetone was received for its fuel value, which would be worth $807,300 assuming a price of $8/106 BTU.The process to produce propylene is expected to yield annual profits of $28,623,000, assuming a price of $0.49/lb propylene.The total capital investment of this process is $53,315,000.The NPV of this project is $93,830,000 with an IRR of 21.9%. Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian - 2 -B)Introduction: Motivation for Design:ABE Technologies has recently built a plant to produce n-butanol for fuel purposes.This plant will result in an estimated by-product of 164,800 metric tons of acetone per year.The cost of acetone is assumed to be at the fuel value of $8/106 BTU, or $0.106/lb of acetone.Because this large amount of acetone corresponds to 2.6% of the world acetone market, it is expected that the price of acetone will decrease if this supply is sold (ICIS).There exist several possible options of making use of this acetone; however, converting the acetone to propylene was the most profitable route considered. Acetone Overview:Acetone (C3H6O), also known as 2-Propanone, is a colorless and flammable liquid that is soluble in water and ethanol, and reacts explosively in strong oxidizing agents.Acetone is primarily used for the formation of methyl methacrylate and bisphenol-A.Methyl methacrylate is usually polymerized to make homopolymers and copolymers, and bisphenol-A is used in the polycarbonate sector. Propylene Overview:Propylene (C3H6), also known as propene, is a colorless and highly flammable gas at room temperature and pressure.Propylene is mostly used to make polypropylene, which is a versatile bulk polymer with a wide range of applications.Some other propylene derivatives include propylene oxide, acrylic acid, acrylonitrile, and cumene.Propylene oxide is used primarily in producing propylene glycol and in the urethanes industry.Acrylic acid can be used to produce esters and resins required for Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian - 3 -paints, coatings, and other adhesive applications.Acrylonitrile is used in variety of elastomeric polymers and fiber applications.Consequently, there exists a wide variety of uses for propylene, which is reflected in the large market size for this compound. Methods of Production:An effective way to convert acetone into propylene is to first hydrogenate the acetone to form an isopropyl alcohol, and then dehydrate the isopropanol to get propylene and water. A patent by Fukuhara (European Patent # 6878851) describes a process for hydrogenating acetone to form isopropanol in a multi-tubular reactor.The chemical reaction that occurs is: CH3COCH3 (l) + H2 (g) C3H8O (l) (1) According to the patent, isopropanol is prepared through catalytic hydrogenation of acetone by feeding hydrogen gas and acetone liquid into a reactor having a fixed catalyst bed from its top to form a gas/liquid downflow while maintaining the catalyst bed in a trickle bed state (Patent # 6878851).Advantages of this patented process include a production of isopropanol at a high reaction rate in high yields.Other factors taken into consideration were that this process involves moderate temperatures and pressures, ensuring reasonable utility costs.Preferable temperature and pressure ranges are 35-150C and 2-50 kg/cm2 respectively. A second patent by Fukuhara et al illustrates a process to convert isopropanol into propylene (US Patent # 5227563).This reaction is represented as: C3H8O (g) C3H6 (g) + H2O (g) (2) Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian - 4 -The patent reveals a process to prepare propylene in high yield and selectivity by dehydrating isopropanol in the presence of a -alumina catalyst. Advantages to using the process described in this patent include a high propylene yield, a catalyst that will not corrode the reactor, and lower temperatures than required in conventional processes.Alternate patents that utilize the presence of strong acids to dehydrate alcohols use catalysts that are corrosive, resulting in the reactor being built with corrosive-resistant material.This gaseous phase reaction can occur at a range of temperatures of which 290C was chosen because it results in a propylene gas product with a purity of 99.5%.Polymer grade propylene requires a purity of 99.8%, with less than 1 ppm of water present, so the purification of this propylene product is required (TEPPCO). In order to appropriately account for side-reactions, the isopropanol product from Reaction (1) needs to be vigorously purified.Unfortunately, acetone cannot be separated from a mixture of isopropanol and water due to their closeness in boiling points.In order to separate an isopropanol/acetone/water mixture, a third patent was used.This patent by Berg suggests that an extractive agent such as 1-nitropropane can be used to increase the relative volatility of the components and make the distillation process more effective (Patent # 5897750).This compound is also stable and can be recycled, making it an ideal candidate as an extractive agent for this separation. Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian - 5 -Competitive Landscape:The global demand of acetone is projected to be 6,230,000 metric tons in 2009 (Table B1).While the market price of acetone is approximately $0.49/lb, the cost of obtaining the acetone as a by-product from the ABE technology n-butanol production is only $0.106/lb (ICIS). As mentioned before, acetone is used primarily to form methyl methacrylate.However, since new processes to form methyl methacrylate are constantly being developed, the global demand of acetone is expected to decrease.Thus, rather than simply selling off or burning the excess acetone, an alternative suggested by consultants of ABE Technologies, numerous alternative options were considered to maximize profits. Propylene was chosen as a product because of its potential for profits and its enormous market size.The global demand of propylene is predicted to reach CompoundPrice/Resale Value Global Market Size (metric tons) Amount Consumed/Produced Annually (metric tons) Percent of Market ReactantAcetone$0.106 / lb6,230,000164,8222.65 ReactantHydrogen$1.125 / lb50,000,0005,8600.01 Extractive Distillation Input 1-Nitropropane $18.50 / lb - - - ProductPropylene$0.49 / lb70,000,000106,8150.15 Alternate Product Methyl Methacrylate $1.18 / lb2,700,00082,4003.05 Alternate Product Isopropanol$0.62 / lb2,150,000170,0807.91 Alternate Product Bisphenol-A$0.88 / lb4,360,00082,4001.89 Table B1:Illustrated in this table is the pricing data of several compounds involved in this process and alternate processes considered.The market share of different potential products and reactants are also displayed. The Amount Consumed/Produced category for acetone, hydrogen, propylene, and isopropanol were derived from the Aspen Simulation in the Appendix.Other products were estimated theoretically based on chemical equations. Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian - 6 -88,000,000 metric tons in 2011.An insufficient supply is the reason behind increasing propylene prices (ICIS).The strong expected future growth of propylene demand and the increasing propylene prices make it an ideal candidate for a product. In addition to expected increases in propylene prices, the enormous market size of propylene minimizes the risk of prices being driven down by the production proposed.For example, if the global market size of propylene were to decrease by 1 million metric tons, there would not be much of an impact on the percentage of market that our process consumes.On the contrary, if the demand of methyl methacrylate, isopropanol, or bisphenol-A were to decrease by 1 million metric tons, there would be a crucial change in the percentage of market this product consumes. Furthermore, the large market size of propylene offers a great amount of flexibility in the given initial amount of acetone.For instance, if 100 million gallons of acetone were produced by ABE technologies instead of the expected 50 million gallons, the propylene market share would still be only 0.30%, which is still too small to have a significant impact on the propylene market price.This additional flexibility is extremely important considering that many years may pass before this process is implemented. While propylene was chosen, other alternative products were considered.Industrial processes converting acetone to methyl methacrylate, isopropanol, and bisphenol-A have already been optimized.However, these three chemicals all have a smaller market size than acetone.Since as much as 50 million gallons of acetone are going to be converted to product each year, production of one of these three chemicals would result in market saturation causing a downward movement of market prices of the product, which would have an unfavorable effect on total profits. Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian - 7 - Design Assumptions: It was assumed that the market share of a potential product would affect the market price, such that greater percentages of market share consumed would cause greater decreases in the market price of the product.With this assumption, it was highly recommended to produce a chemical with an extremely large market in order to minimize the effect on prices.Propylene was an optimal choice because of its enormous market.The amount of propylene we are producing is only 0.15 % of the world market size for it, which will have a very small effect on its market price. It was recommended to us to assume a pure acetone byproduct from the biofuel manufacturing process of ABE technology.While the validity of this assumption depends on the process design of the ABE fermentation project to make n-butanol, we were given that the total cost of acetone is $8/106 BTU.This cost may be interpreted as the cost of purifying the crude acetone to pure acetone. The production of propylene following our design utilizes a nickel on silica catalyst in the first reactor and a -alumina catalyst in the second reactor.The -alumina catalyst can be regenerated and is assumed to last the life of the project. Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian - 8 -Project Charter: Project Name:New Product Design Use for Acetone Project Champions:Bruce Vrana, DuPont Engineering Technology Project Team:Neal Behrend, Brian Mahoney, Iryney Makarukha, Sunil Subramanian Specific Goals:To design a plant that can consume 50 million gallons of acetone per year while maximizing profits. Project Scope:In Scope: Consumption of acetone is at 50MM gal/year Maximizing profit oProfit margins of final product exceed profit margins on fuel cost of acetone oEvaluate multiple reaction strategies in terms of base reactant costs, capital investment, and life of project Evaluate impact on global market for all products and reactants oAssumption: Production of any chemical will affect market prices.For production above 2% of global market, rigorous economic analysis will be required Out-of-Scope: Developing experimental chemical reactions which utilize acetone to create products The marketing, distribution and innovation costs in developing consumer packages for consumer markets Deliverables:Business Opportunity Assessment How much will our production impact global prices? Risk Reward Analysis Will returns on capital be sufficient to warrant investment? Manufacturing Analysis Are all economically feasible production chains optimized? Reaction Selection Analysis Why was each reaction chosen to be investigated? Why was the final reaction process chosen? Timeline:Have deliverable report by April 5, 2008. Figure B1)The project charter identifies the primary goals, scope, and deliverables that this design is meant to achieve Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian - 9 -Technology Readiness Assessment: New product design Use for Acetone Innovation map Customer value proposition Material Technology Technical Differentiation Products New Cheap Supply of acetone Affecting less than 10% Affecting more than 10% Products from single step reactions Products made from multiple reactions After market and plant costs, product is feasible Affect on global market makes not feasiblePlant cost and profitability makes product not feasible Figure B2)The innovation map is a visual depiction of the path of choosing a product.Given a cheap supply of acetone, products from single step reactions were considered that consume less than 10% of the global market. Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian - 10 -C)Process Description Flow Diagram and Material Balances: Overview: The process of converting acetone to polymer grade propylene consists of two main reactions: hydrogenating acetone to form isopropanol, and then dehydrating isopropanol to form propylene.The overall process is shown in Figure C1.It includes the two reactors as well as numerous other equipment units and streams.As shown in the figure, acetone and hydrogen are fed into the first reactor (R-100) in order to produce isopropanol. The vapor product is then recycled back into the reactor, while the liquid product is run through two distillation columns (D-100 and D-101) for separation of isopropanol from the mixture. 1-Nitropropane is also involved for breaking the azeotrope that prevents isopropanol and acetone from separating. Since this extractive agent is expensive, the bottoms stream from the second column is recycled back into the first column. The isolated isopropanol exits the second column in the overhead stream and is fed into the second reactor (R-101), where it is dehydrated to form propylene, which then is run through a flash (F-101). The vapor output from the flash goes through a series of turbines for compression, while the liquid product is pumped up, with both eventually being fed into the last distillation column (D-102), which separates off the polymer grade propylene from water and other impurities.The propylene is maintained in liquid form where it is then transported by railcar to be sold. (See Attached Excel/Visio) Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 11 Figure C1)The overall process flowsheet is crucial for the following sections in the design report.Stream and block names used in this figure will be referenced throughout the report. Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 12 The material and energy properties of all streams involved in the process are also included for reference purposes (Table C1) and should better facilitate understanding of the process as each of the two sections is described in detail.For simplification purposes, the detailed process description has been divided into two sections, in accordance with the two reactions taking place: Section 1: Reaction of Acetone and Hydrogen to form Isopropanoland Isolation of Isopropanol Product (Fig. C2) Section 2: Reaction of Isopropanol to form Propylene and Isolationof Propylene Product (Fig. C3) Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 13 Substream: MIXED S-100 S-101 S-102 S-103 S-104 S-105 S-106 S-107 S-108 S-109 S-110 S-111 S-112 S-113 S-114Mole Flow lbmol/hrHydrogen 0 734.803062 2206.26804 1492.87923 1471.21611 21.6631157 0 0.1578906 1.12E-18 21.5052251 0.1578906 1471.21611 0 0 0Acetone 716.628294 0 735.452381 22.0635714 10.4043565 11.659215 3.23E-09 8.41967647 2.06848038 1.17111303 8.41967647 10.4043565 3.23E-09 2.06848037 3.23E-09Isopropanol 0 0 316.454002 1029.84281 301.769112 728.073701 0.10381151 14.6659905 712.823548 0.68392602 14.6659905 301.769112 0.10381151 712.719736 0.10381151Propylene 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0Water 0 0 0 0 0 0 0 0 0 0 0 0 0 0 01-Nitropropane 0 0 8.82E-07 8.82E-07 6.43E-08 8.18E-07 5.99971591 8.18E-07 5.99973979 5.86E-09 8.18E-07 6.43E-08 5.83593087 0.16380891 5.99971591Mole FracHydrogen 0 1 0.6771485 0.5866424 0.824955 0.0284518 0 6.79E-03 1.55E-21 0.92059 6.79E-03 0.824955 0 0 0Acetone 1 0 0.2257253 8.67E-03 5.83E-03 0.0153129 5.30E-10 0.362237 2.87E-03 0.0501327 0.362237 5.83E-03 5.44E-10 2.89E-03 5.30E-10Isopropanol 0 0 0.0971261 0.4046875 0.169211 0.9562352 0.0170084 0.6309701 0.988808 0.0292773 0.6309701 0.169211 0.0174774 0.9968777 0.0170084Propylene 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0Water 0 0 0 0 0 0 0 0 0 0 0 0 0 0 01-Nitropropane 0 0 2.71E-10 3.47E-10 3.60E-11 1.07E-09 0.9829916 3.52E-08 8.32E-03 2.51E-10 3.52E-08 3.60E-11 0.9825226 2.29E-04 0.9829916Mass Flow lb/hrHydrogen 0 1481.275 4447.572 3009.465 2965.795 43.67024 0 0.3182885 2.25E-18 43.35195 0.3182885 2965.795 0 0 0Acetone 41621.8 0 42715.1 1281.453 604.2854 677.1677 1.88E-07 489.0151 120.1374 68.01829 489.0151 604.2854 1.88E-07 120.1374 1.88E-07Isopropanol 0 0 19017.59 61889.35 18135.09 43754.26 6.238648 881.3662 42837.79 41.10116 881.3662 18135.09 6.238648 42831.55 6.238648Propylene 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0Water 0 0 0 0 0 0 0 0 0 0 0 0 0 0 01-Nitropropane 0 0 7.86E-05 7.86E-05 5.73E-06 7.29E-05 534.5394 7.29E-05 534.5415 5.22E-07 7.29E-05 5.73E-06 519.9471 14.59441 534.5394Total Flow lbmol/hr 716.6283 734.8031 3258.174 2544.786 1783.39 761.396 6.103527 23.24356 720.8918 23.36026 23.24356 1783.39 5.939742 714.952 6.103527Total Flow lb/hr 41621.8 1481.275 66180.27 66180.27 21705.17 44475.1 540.7781 1370.7 43492.47 152.4714 1370.7 21705.17 526.1858 42966.28 540.7781Total Flow cuft/hr 845.6369 57592.68 25366.27 21685.91 20497.36 1188.549 10.02472 30.09057 1204.728 704.5427 30.36773 20338.75 9.751265 961.7888 9.982209Temperature F 77 77 217.9161 302 302 302 276.1173 159.8593 345.1424 1.60E+02 169.0942 303.6636 275.6336 188.2237 270.9548Pressure psi 16.16554 73.47974 711.1672 711.1672 711.1672 711.1672 250 2.20E+02 220.4392 220.4392 718.2788 718.2788 17.63514 1.76E+01 17.63514Vapor Frac 0 1 0.7246057 0.7008015 1 0 0 0 0 1 0 1 0 0 0Liquid Frac 1 0 0.2753943 0.2991985 0 1 1 1 1 0 1 0 1 1 1Solid Frac 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0Enthalpy Btu/lbmol -1.06E+05 0 -34054.54 -4.89E+04 -1.81E+04 -1.21E+05 -6.55E+04 -1.21E+05 -1.22E+05 -7421.753 -1.21E+05 -1.81E+04 -6.55E+04 -1.31E+05 -65698Enthalpy Btu/lb -1827.771 0 -1676.567 -1879.765 -1488.506 -2070.711 -738.8202 -2051.213 -2.02E+03 -1.14E+03 -2044.372 -1.49E+03 -739.5156 -2184.657 -741.5048Enthalpy Btu/hr -7.61E+07 0 -1.11E+08 -1.24E+08 -3.23E+07 -9.21E+07 -4.00E+05 -2.81E+06 -8.77E+07 -1.73E+05 -2.80E+06 -3.23E+07 -3.89E+05 -9.39E+07 -4.01E+05Entropy Btu/lbmol-R -74.23365 -3.196092 -27.18599 -38.66006 -16.97506 -89.45201 -114.1152 -89.06271 -89.29539 -8.494141 -88.43467 -16.97158 -114.1322 -101.1665 -114.4361Entropy Btu/lb-R -1.278127 -1.585457 -1.338416 -1.486569 -1.394744 -1.531383 -1.287969 -1.510276 -1.48008 -1.301394 -1.499626 -1.394457 -1.288358 -1.683394 -1.291591Density lbmol/cuft 0.8474421 0.0127586 0.1284452 0.1173474 0.0870058 0.6406098 0.6088479 0.7724532 0.5983855 0.0331566 0.7654034 0.0876843 0.6091253 0.7433566 0.6114406Density lb/cuft 49.21947 0.0257198 2.608987 3.05E+00 1.06E+00 3.74E+01 5.39E+01 45.55246 3.61E+01 2.16E-01 4.51E+01 1.07E+00 5.40E+01 44.6733 5.42E+01Average MW 58.08004 2.01588 20.31207 26.00623 12.17074 58.41257 88.60091 58.97116 60.33148 6.526956 58.97116 12.17074 88.58731 60.09673 88.60091Liq Vol 60F cuft/hr 849.4234 630.3976 3151.4 2565.936 1643.433 922.5031 8.725336 28.04509 882.5046 20.67388 28.04509 1643.433 8.49061 874.014 8.725336 Table C1)A summary of the stream data of this process is presented.Please refer to Figure C1 for stream names. Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 14 Substream: MIXED S-115 S-116 S-117 S-118 S-119 S-120 S-121 S-122 S-123 S-124 S-125 S-126 S-127 S-128Mole Flow lbmol/hrHydrogen 0 0 0 0 0 0 0 0 0 0 0 0 0 0Acetone 2.06848037 2.06848037 2.06848037 2.06848037 1.91888373 0.14959664 1.91888373 0.14959664 1.91888373 1.91888373 0.00332809 2.06515228 0 716.628294Isopropanol 712.719736 712.719736 7.12719736 7.12719736 5.96826206 1.1589353 5.96826206 1.1589353 5.96826206 5.96826206 9.67E-06 7.12718769 0 0Propylene 0 0 705.592539 705.592539 687.462274 18.1302647 687.462274 18.1302647 687.462274 687.462274 640.99663 64.595909 0 0Water 0 0 705.592539 705.592539 163.112188 542.480351 163.112188 542.480351 163.112188 163.112188 3.25E-05 705.592506 0 01-Nitropropane 0.16380891 0.16380891 0.16380891 0.16380891 0.0175579 0.14625101 0.0175579 0.14625101 0.0175579 0.0175579 2.28E-10 0.16380891 0.16378504 0Mole FracHydrogen 0 0 0 0 0 0 0 0 0 0 0 0 0 0Acetone 2.89E-03 2.89E-03 1.46E-03 1.46E-03 2.24E-03 2.66E-04 2.24E-03 2.66E-04 2.24E-03 2.24E-03 5.19E-06 2.65E-03 0 1Isopropanol 0.9968777 0.9968777 5.02E-03 5.02E-03 6.95E-03 2.06E-03 6.95E-03 2.06E-03 6.95E-03 6.95E-03 1.51E-08 9.14E-03 0 0Propylene 0 0 0.4967057 0.4967057 0.8007909 0.0322565 0.8007909 0.0322565 0.8007909 0.8007909 0.9999947 0.0828636 0 0Water 0 0 0.4967057 0.4967057 0.1900013 0.9651552 0.1900013 0.9651552 0.1900013 0.1900013 5.08E-08 0.9051343 0 01-Nitropropane 2.29E-04 2.29E-04 1.15E-04 1.15E-04 2.05E-05 2.60E-04 2.05E-05 2.60E-04 2.05E-05 2.05E-05 3.56E-13 2.10E-04 1 0Mass Flow lb/hrHydrogen 0 0 0 0 0 0 0 0 0 0 0 0 0 0Acetone 120.1374 120.1374 120.1374 120.1374 111.4488 8.688579 111.4488 8.688579 111.4488 111.4488 0.1932957 119.9441 0 41621.8Isopropanol 42831.55 42831.55 428.3155 428.3155 358.6682 69.64728 358.6682 69.64728 358.6682 358.6682 5.81E-04 428.3149 0 0Propylene 0 0 29691.79 29691.79 28928.85 762.9331 28928.85 762.9331 28928.85 28928.85 26973.55 2718.237 0 0Water 0 0 12711.45 12711.45 2938.512 9772.935 2938.512 9772.935 2938.512 2938.512 5.86E-04 12711.45 0 01-Nitropropane 14.59441 14.59441 14.59441 14.59441 1.564306 13.03011 1.564306 13.03011 1.564306 1.564306 2.04E-08 14.59441 14.59228 0Total Flow lbmol/hr 714.952 714.952 1420.545 1420.545 858.4792 562.0654 858.4792 562.0654 858.4792 858.4792 641 779.5446 0.163785 716.6283Total Flow lb/hr 42966.28 42966.28 42966.28 42966.28 32339.05 10627.23 32339.05 10627.23 32339.05 32339.05 26973.74 15992.54 14.59228 41621.8Total Flow cuft/hr 962.6247 80772.4 1.50E+05 32496.47 3.76E+05 185.1254 45481.96 185.5458 48361.15 20200.11 975.3501 367.8121 0.2346597 852.2996Temperature F 189.057 662 554 140 140 140 280.8624 143.4949 249 318.7172 135.4785 358.0683 77 86.41047Pressure psi 1.10E+02 106.5456 102.8716 95.52367 14.69595 14.69595 150 360 135 355 350 350 17.63514 718.2788Vapor Frac 0 1 1 0.3341961 1 0 1 0 1 1 0 0.00E+00 0 0Liquid Frac 1 0 0 0.6658039 0 1 0 1 0 0 1 1 1 1Solid Frac 0 0 0 0 0 0 0 0 0 0 0 0.00E+00 0 0Enthalpy Btu/lbmol -1.31E+05 -99948.66 -41227.8 -57106.23 -12888.56 -1.18E+05 -10584.43 -1.18E+05 -11133.78 -9911.054 4950.459 -1.06E+05 -72454.27 -1.06E+05Enthalpy Btu/lb -2183.97 -1663.13 -1363.067 -1888.037 -342.1425 -6223.062 -280.9766 -6219.578 -295.5596 -263.101 117.642 -5185.435 -813.2329 -1822.904Enthalpy Btu/hr -9.38E+07 -7.15E+07 -5.86E+07 -8.11E+07 -1.11E+07 -6.61E+07 -9.09E+06 -6.61E+07 -9.56E+06 -8.51E+06 3.17E+06 -8.29E+07 -1.19E+04 -7.59E+07Entropy Btu/lbmol-R -101.1048 -62.28211 -16.10283 -3.75E+01 -2.72E+01 -3.71E+01 -2.84E+01 -3.70E+01 -2.89E+01 -2.92E+01 -4.65E+01 -3.13E+01 -1.27E+02 -73.71878Entropy Btu/lb-R -1.682368 -1.036364 -0.5323894 -1.240296 -0.7217445 -1.964157 -0.7528182 -1.958453 -0.7673905 -0.7746937 -1.104612 -1.524604 -1.428605 -1.269262Density lbmol/cuft 0.7427111 8.85E-03 9.46E-03 0.0437138 2.28E-03 3.036133 0.0188751 3.029255 0.0177514 0.0424987 0.6571999 2.12E+00 0.6979685 0.8408174Density lb/cuft 44.63451 5.32E-01 2.86E-01 1.32E+00 8.60E-02 5.74E+01 7.11E-01 5.73E+01 6.69E-01 1.60E+00 2.77E+01 4.35E+01 6.22E+01 48.83471Average MW 60.09673 60.09673 30.24634 30.24634 37.67016 18.90747 37.67016 18.90747 37.67016 37.67016 42.08072 20.51523 89.09412 58.08004Liq Vol 60F cuft/hr 874.014 874.014 1129.292 1129.292 947.1573 182.1352 947.1573 182.1352 947.1573 947.1573 830.2218 299.0706 0.2347266 849.4234 Table C1 (continued) Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 15 Section 1: Reaction of Acetone and Hydrogen to form Isopropanol and Isolation of Isopropanol Product The purpose of this section is to hydrogenate acetone to form isopropanol (See Figure C2).A feed of 41,622 lb/hr of acetone (S-100) is pumped to a pressure of 50.5 kg/cm2 by pump P-104 and enters the first reactor (R-100). Enough hydrogen is fed into the reactor to maintain the 3:1 ratio of hydrogen to acetone recommended in the patent.The reaction occurs at a temperature of 150C and a pressure of 50 kg/cm2 (Acetone to Isopropanol: Patent # 6878851). The main reaction that occurs in this vessel is: CH3COCH3 (l) + H2 (g) C3H8O (l) Catalyst:Nickel on Silica Support(Reaction 1) The reactor is designed as a multi-tubular reactor as specified in the United States Patent 6878851 (see Appendix), where hydrogen gas bubbles up and the acetone flows down through a packed bed of solid nickel on silica catalyst.The conversion of acetone is about 97% under these conditions. The separation after this reaction should yield a pure isopropanol stream and recycle as much of the remaining hydrogen and acetone as possible.The product stream (S-103) enters a flash separator (F-100) at a temperature of 150C and 50 kg/cm2.In actuality, however, this flash tank is merely a representation of how the reactor runs, and there would be no flash vessel in the actual plant. The temperature is maintained by flowing boiler feed water over the tubes in which the reaction is taking place.The vapor stream from the separation is a vapor mixture of acetone, hydrogen, and isopropanol, Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 16 which is ultimately compressed and recycled into the reactor.The compressor (C-100) has a discharge pressure of 50.5 kg/cm2. The liquid stream (S-105) coming out of the flash separator consists of 95.5% isopropanol, and the remaining portion is a mixture of acetone and hydrogen.The isopropanol needs to be further purified before it can be sent into the second reactor for dehydration to form propylene.To conduct the separation, two distillation columns (D-100 and D-101) are used along with the introduction of 1-Nitropropane, which is an extractive distillation component.An extractive distillation component is needed to break the azeotrope that occurs between isopropanol and acetone. A pure isopropanol feed to R-101 is desired to limit impurities and also due to lack of patent information for the otherwise impure reaction case.The column (D-100) removes some acetone, hydrogen, and a small amount of isopropanol, which is pumped and recycled into the initial feed mix.This column is designed to have a small fraction of hydrogen purged (S-109) to avoid accumulation. This also greatly reduces the heat duty of the condenser as condensing hydrogen would require a refrigerant.The bottoms stream of the column is fed into a second column (D-101), where further purification of isopropanol occurs.The second distillation column (D-101) removes the extractive agent 1-Nitropropane from the isopropanol product.1-Nitropropane comes out of the bottom of the column and is recycled back to the first distillation column.About 97% of the 1-Nitropropane fed to the first column is recovered in the second.The rest exists in trace amounts throughout the rest of the process.Isopropanol comes off from the top of the column at 99.97% purity. Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 17 KEYR-100D-100 D-101F-100C-100P-102 H-1001-NitropropaneHydrogenAcetoneP-101P-100S-12886718LStreamTemperature (F)Pressure (psi)V=Vapor L=LiquidAcetone to Isopropanol with SeparationsS-1017773VS-102218711V,LS-107160220LS-104302711VS-111303718VS-110169718LS-103302711V,LS-109160220VS-105302711LS-106276250LS-108345220LS-11427118LS-1277718LS-11227618LS-11318818LS-115189110LS-116662107VIsopropanol to Second ReactorP-104S-1007716L Figure C2)The first section of the overall process will conduct the reaction of acetone to isopropanol and perform the required separation to obtain a pure isopropanol stream into section 2.Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 18 Section 2:Reaction of Isopropanol to form Propylene and Separation and Isolation of Propylene Product The purpose of this section is to convert isopropanol to propylene (See Figure C3).The reactor conditions specified by the patent suggest a temperature between 290C and 360C with a pressure of 7 atm.After coming off of the second column (D-101), the 99.97% pure isopropanol stream is pressurized to 7.5 atm by a pump (P-102) to account for piping length and heated to 350C by heater (H-100) before it is fed into the second reactor (R-101).This yields a 99.8% conversion of isopropanol into propylene and water.The reaction occurring in this step is as follows: C3H8O (g) C3H6 (g) + H2O (g)Catalyst:-Alumina (Reaction 2) The purity of propylene should be at least 99.8%, which is considered polymer grade.The product stream (S-117) of the reactor is comprised of equal parts of propylene and water and trace amounts of acetone, isopropanol, and 1-nitropropane.This stream is too hot to be fed directly into a column so it is cooled to 140F. This causes some vapor to form. As a result this product cannot go through a compressor or pump without first being separated. Therefore, it is flashed at a temperature of 140F and a pressure of 1 atm to get separated into liquid and solid.The liquid stream (S-120) is pumped up to a discharge pressure of 360 psia and sent to the final distillation column (D-102), where propylene is isolated from water, isopropanol, and trace amounts of other chemicals.The vapor stream (S-119) of the flash tank undergoes a multi-stage compression.This multi-stage compression is modeled using a turbine (C-101) with a discharge pressure of 150 Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 19 psia, a heater at 249F and 135 psia, and another turbine (C-102) with a discharge pressure of 355 psia. In between the turbines is a shell and tube heat exchanger (H-102) which cools the product of the first turbine (C-101) while keeping it at vapor phase so that it is not too hot before being fed into the second turbine.The product stream of this multistage compression (S-124) is also fed into the column for the final separation of propylene.Propylene liquid (S-125) exits the top of the distillation column with a purity of 99.9996%. A liquid propylene product is desired, and to obtain the purity of polymer grade the column is pressurized at 350 psia.Polymer grade propylene also requires less than 1 ppm of water, which is achieved in our product.The bottoms stream (S-126), which is over 90% water, is sent into a wastewater facility for treatment. Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 20 Figure C3)This figure illustrates the process units and streams involved with the reaction ofisopropanol to form propylene and the purification of the product propylene stream. Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 21 D)Energy Balance and Utility Requirements: This process requires a large amount of utilities.The process uses cooling water in all of the condensers as well as in heat exchangers which cool and condense streams.Boiler feed water, higher purity cooling water, is used to cool our reactor and prevent build up. Steam is used in the distillation columns but is required at different pressures depending on the heat duty required.Natural gas is used in a heater (H-100) before the second reactor, as well as in the second reactor to maintain the appropriate temperature.Electricity is used in all of the pumps and compressors throughout the process.Waste water treatment is also required because of the water produced in the second reaction. See Figure D1 for further information. Cooling Water:Cooling water is used in several sections of the process. Each of the distillation columns uses cooling water in the condensers.Cooling water is also used in two of the heat exchangers in the process. In all of these blocks the cooling water enters at 90F and is heated to 120F. As a result, the heated cooling water cannot be used anywhere in our plant except to slightly heat up the feed to R-100.A cooling duty of 74,433,062 Btu/hr is required for the entire process. This corresponds to 297,851 gal/hr and an annual cost of $117,413 at a price of $0.50/thousand gals. Boiler Feed Water:Boiler feed water is used to cool the first reactor. This water needs to be at a higher purity to prevent any possibility of deposit buildup deposits on the tubes and maintain a very large heat exchange.A total of 13,447,747 Btu/hr of heat needs to be Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 22 removed from the reactor, assuming that the heat of vaporization is 936 Btu/lb at 130C and assuming a driving temperature of 20C.Using this information and the density of water at 8.33 lbs/gal, the price of boiler feed water was calculated as $54,410.94. Steam:Steam is used in the reboilers of each distillation column. In D-100 and D-102, higher pressure steam at 150 psia is required.A valve depressurizes it to the proper saturation temperature.This means that 28,679 lb/hr of high pressure steam will be needed, which results in $904,432.44 annual cost for 150 psia steam at $4/thousand lbs. In D-101, lower pressure steam at 50 psia is fed because the reboiler does not run at as high of a temperature. 18,690 lbs/hr of low pressure steam are used at $2.50/thousand lbs, which results in an annual cost of $368,386. Natural Gas: The process requires a heater to heat up the feed to R-101 as well as for this reactor to be insulated with heat to maintain the reactor temperature at 290C. Natural gas was used as a fuel for these processes, which requires a combined heat duty of 35,262,303 Btu/hr.Using natural gas at a higher heating value of 1,050 Btu/SCF and a heat transfer efficiency of 70%, an annual cost of $1,021,254 was calculated. This is our most expensive utility; however it may be somewhat offset by selling stream S-109 for heating value. This stream is comprised of hydrogen, acetone, isopropanol, and trace amounts of 1-Nitropropene. If this stream is sold for its heating value, the price of heating drops to $114,161.81/year. Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 23 Electricity: All of our pumps, condensers and motors use electricity. Our plant uses 1,255.73 Hp per hour after efficiency is taken into account. At a price of $0.04/kW-hr this comes out to an annual cost of $295,302 for electricity. Waste Water Treatment: We are producing 15,983 lbs/hr of dirty water in our process. The cost to remove the 3,273 lbs/hr of impurities at $0.10 per pound of organic solvent results in an annual cost of $2,591,869 for waste water treatment. Integration:At the moment, almost no heat and utility integration in our plant is utilized because very little is possible. The boiler feed water is converted to steam at 39 psia. This is too low to be used in any of the reboilers and will just be recycled, processed and fed back to the reactor. The heat exchangers and condensers in the same manner do not produce useable heat, and the cooling water will just have to go back to the process. If we could use the water of S-126 after treatment in place of this cooling water, a great deal of money can be saved.However, this would require a water treatment plant on site, and the costs of that were not estimated.Some of the excess heat from the stack of H-100 may be used to pre-heat some of the streams flowing into R-100 however Aspen made it difficult to model this.In the future, research of the reaction of acetone to isopropanol and whether or not higher temperatures result in the same conversion and selectivity should be conducted.If reactor R-100 can be set at a higher temperature, heat integration throughout the process can be conducted and it would significantly improve the energy efficiency and cost efficiency of the plant. Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 24 Cooling WaterHeat Duty Flow rate (Gal/hr)D-100 9,491,220 37,980.07D-101 23,900,000 95,638.26D-102 18,027,813 72,140.11H-101 22,537,729 90,186.99H-102 476,300 1,905.96Totals: 74,433,062 297,851.39Cost: $117,413.02Natural GasDuty SCF/hrH-100 22373873.4 30,440.64R-101 12888429.8 17,535.28Totals: 35,262,303 47,976Cost: $1,021,253.87Boiler Feed WaterDuty Flowrate (Lbs / hr)R-100 13,447,747 14372.24541Cost: $54,410.94Low Pressure SteamDuty Flowrate (lbs/hr)D-100 12,100,000 13764.51D-102 12,879,205 14914.85Totals: 24,979,205 28679.36Cost: $904,432.44High Pressure SteamDuty Flowrate (lbs/hr)D-101 17,340,000 18690.33513Cost: $368,386.51ElectricityHorsepowerReboiler Pump D-100 0.6275Reboiler Pump D-101 0.0076Reboiler Pump D-102 0.2300Reflux Pump D-100 0.0051Reflux Pump D-101 0.4648Reflux Pump D-102 1.4618Pump P-100 3.6840Pump P-101 0.5700Pump P-102 12.5110Pump P-103 14.5479Pump P-104 79.6270Comp C-100 12.4219Comp C-101 778.6860Comp C-102 412.4530Column Pump CP-100 2.87601320.1737$295,459.48Total:Cost: Figure D1) Above the utility usage and total cost can be seen for each process unit. Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 25 E)Equipment List and Unit Descriptions: Brief Overview:The following information is a summary of the design specifications for each process unit.The units are listed in sequential order from the beginning of the process (i.e. feed streams into the reactor) to the propylene product stream from the final distillation tower.Refer to Figure C1 for unit names, Section F: Specifications for further quantitative information of each of these units, and Appendix 4 for sample calculations for each type of unit. Storage Tank ST-100: This tank is not represented in Figure C1; however, it is implied that a storage tank will be necessary to hold the acetone feed. It has a volume of 1,275,193 gallons, which is 1.2 times the amount of acetone needed for a week of production. The pressure of this tank will be under 30 psia.The flow of acetone in the feed stream from this tank will be 41,621.8 lb/hr.This storage tank was priced using a correlation for a carbon steel physical tank using the volume as the independent variable.As a result of the amount of acetone processed per week, the storage tank should be located next to the rail system which comes into our plant. Pump P-104:A reciprocating pump used to pressurize the acetone from S-100 before it enters R-100. It raises the pressure from atmospheric to 718 psia.It is modeled as a two stage pump, HSC oriented, with an RPM of 3,600 due to the high head and large flow rate of 105.42 gal/min. The type factor is 8.9 and the horsepower is 79.63.The pump is made of cast steel and has a head of 2054 feet.A size factor was used to estimate the Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 26 cost based on flow rate and head.It uses a fan cooled electric motor to drive it.The pump operates at 70% efficiency. Reactor R-100: The hydrogenation reaction is carried out in a multi-tubular packed bed reactor, which is designed as a shell-and-tube heat exchanger in order to be able to precisely control the temperature within the reactor, based on U.S. Patent #6878851. The reactor is composed of three sections: top chamber, reacting tubes, and bottom chamber.The liquid mixture of acetone reactant and fraction of recycled isopropanol are fed in through the top chamber and drip down the tubes at trickle-flow velocity, while gaseous hydrogen enters through the bottom chamber and bubbles up counter-currently at 1.2 in/s through the packed bed reactor tubes, where the catalyzed reaction takes place.The temperature and pressure are maintained at 150C and 711 psia, respectively, allowing for 97% conversion of acetone to isopropanol. The pressure drop of 0.24 psia can be regarded as negligible. The middle section of the reactor consists of 1,628 open-ended vertical 21.4-ft long stainless steel tubes of 1.76 in. inner and 2.00 in. outer diameters.These are arranged on a square 2.50 in. pitch packed with a bed of 0.7 inch Figure E1) A rough schematic of the multi-tubular reactor R-100 is presented. Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 27 spherical catalyst particles.The catalyst used in this reaction is nickel on silica support.The overall shell is made of carbon steel, with inner shell diameter of 120 inches. The size calculations are estimated based on the amount of annual flow of hydrogenated product provided by the process, or 157 kilotons per year. Based on this value, the inner shell diameter and catalyst needed for the reaction to complete were derived, governing the calculation of the rest of parameters. The reaction is highly exothermic with the heat of reaction of -17,000,000 Btu/hr. However excess hydrogen acts as a heat sink providing that only 13,447,747 Btu/hr be removed. The reactor acts as a heat exchanger as well, with boiler feed water flowing on the shell side to keep the reactor temperature capped at 150C to prevent undesirable products and excess hydrogenation decomposition of acetone. Using a fixed bed pseudo-homogeneous model correlation, the overall heat transfer coefficient is calculated to be 65.6 Btu/(ft2!F!hr).A large amount of heat needs to be removed by the cooling water; however, given the large size of the reactor, based on the amount of catalyst needed, the area necessary for the heat transfer is far from a limiting factor. As a result, the tubes are designed of slightly greater diameter than typical for heat exchangers, so that the number of tubes required for this reaction could be estimated using tube layout correlations from Perrys Handbook.Please see A4.8 for detailed calculations and Section F: Specifications for quantitative information. Flash Tank F-100:Flash Tank F-100 is not a separate unit, but is part of the two block representation of the first reactor. The reaction is a tri-phase reaction, and therefore takes place at vapor liquid equilibrium. To represent this, the exit stream of the reactor was sent Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 28 to F-100.S-104 and S-105 represent the gas and liquid flow out of the reactor, respectively. Compressor C-100:This compressor is used to recompress vapor coming off the top of the reactor. This vapor contains mostly excess hydrogen and some isopropanol and acetone which escape in the vapor phase. The vapor of S-111 is compressed to 7 psia higher than S-104 to account for tubing length as it is recycled and to account for the pressure drop of the reactor.The horsepower is 12.42 and the flow rate is 20,497 ft3/hr.The compressor was modeled as a screw compressor because of the low horsepower that is needed using Figure 16.9 in Seider. Cost was estimated using brake horsepower for a correlation. It is made of stainless steel and using an electric motor drive. Distillation Column D-100:This is the first distillation column in a two step separation to isolate isopropanol from acetone and hydrogen in order to have a pure isopropanol feed to the second reactor.There are 28 real stages in this column.The column diameter is 4.34 ft, the column thickness is 0.25 in, and the column height is 68 ft.The calculated tray efficiency is 73%. An extractive agent 1-Nitropropane is introduced in the 8th stage via S-106 to crack the azeotrope between acetone and isopropanol.This separating agent pulls isopropanol, the lighter key, down the column.It is interesting to notice that the small amounts of hydrogen which enter the column as a Henrys component end up concentrated in the top stage of the column.As a result, the top stage has very different properties than the rest of the column, and its viscosity and K values were not used to Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 29 estimate tray efficiencies.The build up of this hydrogen also led us to purge off some gas from the top of our column in S-109.This lowered the heat duty in the top of the column as the hydrogen was difficult to condense.Acetone and hydrogen coming off the top of the column in S-107 are recycled back into the reactor.The tray efficiency was calculated using the O'Connell correlation averaging values from the top, middle, and bottom of the column. The trays are sieve and made of 316 stainless steel.Because of the size of the column, it will need to be broken into two parts.A pump, CP-100, is used to pump the liquid coming down from stage 14 into stage 15. The pump was modeled with a head of 38 feet.The column was pressurized so that cooling water could be used in the condenser.Steam is fed to the column at 150 psia and then dropped to the pressure of 119 psia in the reboiler. Size and cost of the column were estimated using Seiders correlation for vertical pressure vessels using weight as the independent variable.The column was designed using carbon steel, and the thickness was estimated based upon the inner diameter. Pump P-100: This pump is used to recycle the hydrogen and acetone which come off the top of D-100 via S-107.It raises the pressure to 718 psia so that it is at a higher pressure than the reactor as well as pressurized enough to account for piping length.The volumetric flow rate is 3.94 gal/min, the horsepower is 3.684, and the head is 1573.8 ft.The pump is designed as a centrifugal pump.It is a two stage, HSC oriented, pump with an RPM of 3,600 due to the high head that it develops.The pump is made of cast steel and the type factor is 8.9.A size factor was used to estimate the cost, based upon flow rate and head.A fan cooled electric motor is used to drive it. Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 30 Distillation Column D-101:Distillation column D-101 is used as a second step in isolating and purifying isopropanol from the other components present in the stream.There are 29 real stages and the tray efficiency is 42%.The column diameter is 6.44 ft, the height is 70 ft, and the thickness is 0.375 in. In this column, isopropanol is separated from our extractive agent 1-Nitropropane. It is condensed in the top of the column so that it can then be pumped and pressurized before it is vaporized and enters the second reactor.The tray efficiency, size, and cost were all estimated in the same way as D-100.The coefficients for the reboiler and condenser were estimated in the same way and used the same coefficients as that of D-100.Once again, 316 stainless steel was used for the sieve trays and the carbon steel was used for the column. In the reboiler, 50 psia steam is fed and dropped to a pressure of 47 psia. Pump P-101: Pump P-101 is there to pressurize the 1-Nitropropane feed going into D-100 to a pressure of 250 psia.This is a reciprocating pump with a horsepower of 0.57, a head of 617.64 ft, and a flow rate of 1.22 gal/min.Stream S-112 comes off of D-101 and is recycled back and combined with the pure 1-Nitropropane feed of S-128 to make S-114. This pump is made of cast steel.The pump is a centrifugal pump with two stages due to the large pump head.It operates at 3,600 RPM and has an HSC orientation.Cost estimates were done in the same manner of P-100. Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 31 Pump P-102: Pump P-102 is used to pressurize S-113 to 110 psia before in enters H-100 to be vaporized for R-101. This is a reciprocating pump with a horsepower of 12.51, a head of 312.11 ft, and a flow rate of 119.88 gal/min.The second reaction takes place at 7 atmospheres and is a gas phase reaction.It is more cost efficient to first pump the reactant before vaporizing it.The pump is a 1 stage, 3,600 RPM, HSC pump and is made of cast steel.Cost estimates were done in the same manner as P-100. Heater H-100:Heater H-100 is designed to vaporize our isopropanol so that the gas phase reaction can take place converting it to propylene.The heater is operated at 106 psia and heats S-115 to 662F, completely vaporizing it.The cost was estimated using Seiders correlation for a pyrolysis heater using heat absorbed as the size factor.The heater is designed to use natural gas at 1,050 Btu/SCF.The thermal efficiency was estimated to be 70%. The heat duty is 22,373,873 Btu/hr. Reactor R-101:This reactor is a 6 meter inner diameter with 4.07 meter height carbon steel tube.It is modeled as a vertical pressure vessel with a thickness of 0.5 inches.It is packed with 9,719 kg of high purity (99.75% by mass) -alumina nanopowder having a mean pore diameter of 69 and a specific surface area of 275m2/g. The reactor will run at 290C and at a pressure of 7 atmospheres. This was calculated from US Patent # 5,227,563 which identified a required residence time of 169 seconds. The radius of the tube was calculated using a correlation specified again in US Patent # 5,227,563 which required that1 . 2Pr 6 . 32MRT for a 99% conversion at 290C, where M is the molar flow rate, R is the universal gas constant, T is the temperature, P is the pressure of the reactor Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 32 and r is the radius.The reactor is heated to keep the temperature constant due to the endothermic reaction.A natural gas heater design is needed to keep the reactor at a constant temperature.The flow sheet calculated the heat duty for this heater as 12,888,429 Btu/hr.The heater was priced from the heat duty in the same manner as H-100 and added to the total cost of the reactor.This heater runs hot steam along the outside of the reactor and continually supplies heat to the reactor. Fortunately, the reaction occurs at a range of temperatures and so this is an acceptable method of maintaining temperature even though it causes a temperature gradient within the reactor.The reactor was priced in a similar manner as the distillation columns, with an added cost of -alumina catalyst. Heat Exchanger H-101: Once the reaction takes place, the hot gas in S-117 coming off R-101 needs to be cooled down before it is sent to D-102.Cooling water is used to cool this stream in a shell and tube fixed head heat exchanger. A fixed head was chosen because it should be the easiest to clean. The U was estimated as 50 Btu/F-ft2-hr from table 13.5 in Seider.The heat exchanger is at a pressure of 95.5 psia.Once cooled, S-118 develops a liquid as well as a vapor phase.It has a carbon steel shell and stainless steel tubes.This led to the addition of F-101 to separate the liquid and gas phases so they could be separately pressurized to 350 psia before entering D-102.There are 583 tubes in this heat exchanger, each with a length of 20 ft.The tubes have an inner diameter of 0.76 in and an outer diameter of 1 in.The area of a tube is 3.8 ft2.The area of the heat exchanger is 2,344 ft2. Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 33 Flash Tank F-101: The flash tank is designed to take the cooled product off of R-101 in S-118 and separate it into liquid and vapor streams.This is so that the product can be pressurized before entering distillation column D-102 without the danger of causing a vapor lock.The tank is modeled as a horizontal pressure vessel. The tank thickness was estimated at 0.5 inches because the tank is operating at 1 atm and a higher thickness was not thought to be needed.The tanks size is bigger than the outlined correlations for horizontal tanks in estimating the cost of ladders and platforms.Therefore, the correlation for vertical pressure vessels was used to estimate the cost of platforms and ladders.The tank is made of carbon steel. The volumetric flow rate is 33,526.5 ft3/hr.This flash tank has a diameter of 15.27 ft, a length of 30.53 ft, and a thickness of 0.5 in.The residence time is approximately 5 minutes. Turbine C-101:Turbine C-101 is the first in a series of turbines to pressurize S-119, which is the gas phase coming off of F-101.This stream needs to be pressurized so it can enter D-102. It raises the pressure from 14.7 psia to 150 psia.The gas needed to be pressurized to over 350 psia, and although the pressure ratio was 20, it was decided to use two instead of three turbines in series.A turbine was used instead of a regular compressor due to the high volume flow.The horsepower is 778.69, the flow rate is 375,925 ft3/hr, and this is a reciprocating compressor.An isentropic efficiency of 85% was used.The correlation used to estimate cost was that of the reciprocating condenser based upon horsepower. This piece of equipment is made of stainless steel and has an electric motor drive. Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 34 Heat Exchanger H-102: The purpose of H-102 is to cool down S-121 as it comes out of C-101 so that it is not too hot before entering C-102. The temperature of 249F was chosen because that is right above the dew point of the gas, and keeps the vapor fraction at 1.H-102 is modeled with the same coefficients as H-101 and uses cooling water. H-102 is modeled as a fixed head shell and tube heat exchanger with carbon steel shell and stainless steel tubes.There are 237 tubes in this heat exchanger, each with a length of 20 ft.The tubes have an inner diameter of 1.4 in and an outer diameter of 1.5 in.The area of a tube is 7.33 ft2.The pressure is 135 psia and the area of the heat exchanger is 59.5 ft2. Turbine C-102: Turbine C-102 is the same as C-101 in build and estimation. It pressurizes S-123 to a final pressure of 355 psia so that it can go enter D-102 at a higher pressure than the column. Once again, an isentropic efficiency of 85% was used.It is a stainless steel, electric motor drive reciprocating condenser.The flow rate is 48,361 ft3/hr and the horsepower is 412.45. Pump P-103: Pump P-103 serves the same purpose as the series of condensers does for the gas coming out of F-101 for the liquid in S-120. It raises the pressure to 360 psia to account for the flow through piping and still be at a higher pressure than D-102. It was modeled as a cast iron, 3,600 RPM, 2 stage HSC pump.The horsepower is 14.55, the head is 866.19 ft, and the flow rate is 23.14 gal/min.Cost estimates were done in the same manner as P-100. Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 35 Distillation Column D-102:Distillation Column D-102 is the final step in our process. Its main purpose is to separate propylene from water and all other trace chemicals. The propylene is to be polymer grade purity and in the liquid form so that it could be shipped right away.As a result, the column was pressurized to 350 psia.It was modeled the same way as D-100 and used the same correlations and calculations to estimate tray efficiency and cost. The column height is 50 ft, the thickness is 0.3125 in, and the diameter of the column is 7.07 ft.There are 19 real stages and the tray efficiency was calculated as 55%. The tray type is sieve and the trays are made with 316 stainless steel. Storage Tank ST-101: This storage tank is to store 1.2 times a days worth of production of liquid propylene before it is shipped out. The tank is fed with stream S-125 from D-102. It is pressurized to 300 psia to keep the propylene in liquid form. Like ST-100, it is also spherical and carbon steel; however, a different correlation was used because of the higher pressure of the vessel. The volume of this vessel is 202,318 gallons and the pressure of the vessel is 300 psia. Reflux Pumps: Each of the distillation columns needed a reflux pump. The pump costs were estimated by finding the reflux volumetric flow rate. This was calculated by finding the vapor leaving the top tray and subtracting from it the flow leaving the top of the column. A head of 15 feet was estimated as the power the pump would need. The pumps were all thought to be 1 stage centrifugal pumps with VSC and a 3,600 shaft RPM. They were cast iron and had fan cooled motors.Pricing was done in the same manner as P-100.Please refer to Section F: Specification Sheets for further information. Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 36 Reboiler Pumps: Each of the distillation columns also needed a reboiler pump. The cost and sizing was done exactly the same as the reflux pumps except a head of 20 feet was used. They are the same type of pumps with the same type of motor as the reflux pumps. Please refer to Section F: Specification Sheets for further information. Reflux Accumulators: Reflux accumulators were added to each distillation column. They were modeled as horizontal pressure vessels. They used the flow rate from the reflux pumps to estimate the volume needed. A residence time of 5 minutes was used for each one. Please refer to Section F: Specification Sheets for further information. Reboilers:Each column was fit with a kettle reboiler.It was modeled as a kettle shell and tube heat exchanger with a carbon steel shell and stainless steel tubes. They were priced by calculating the area from heat duty and driving temperature of 35F instead of a Tlm. Each used a U value of 100 Btu/F-ft2-hr was used based on Seider table 13.5. The pressure of steam needed was calculated by finding the heat of vaporization of steam at the temperature needed, then finding the corresponding pressure. The lowest pressure steam possible was then used in each. From this, the required pounds of steam were calculated for utility costs.Please refer to Section F: Specification Sheets for further information. Condensers: Each distillation column also has a condenser. The pressures of each column were varied so that cooling water could be used in each condenser. The Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 37 condensers were modeled as fixed head shell and tube heat exchangers with carbon steel shells and stainless steel tubes. The area was calculated and then used to estimate the cost. A U value of 50 Btu/F-ft2-hr was used for each one. The heat needed to be removed was used to calculate the amount of cooling water needed.Please refer to Section F: Specification Sheets for further information.Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 38 F) Specification Sheets Distillation Column D-100 N Stages Real: 28 Type of Tray: Sieve Tray Material: 316 Stainless Steel Tray Efficiency: 73% Column Diameter (ft): 4.34 Column Height (ft): 68 Column Thickness (in): 0.25 Column Material: Carbon Steel Stream: Stage TheoreticalHydrogen Acetone Isopropanol 1-NitroPropane Propylene Water In (lbs/hr) Out (lbs/hr) S-105S-106S-107 S-108S-109 10.08 1 L 20 1 V 43.70 0.30 43.4 677.20 489.0120.168.0 43754 6.2881.442837.041.1 0 534.50 534.50 0 0 0 0 0 0 0 0 0 0 Tray Cost: Ladder/Platform Cost: Column Cost:$37,645.33 $17,681.62 $33,043.01 Fbm: Cost Bare Module: 4.16 $ 367,619.02 Indexed CBM: Costing Method: $ 489,817.44 A4.4 Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 39 Distillation Column D-100 Reflux PumpHead (ft): 15 Flow rate (gal/min): 76.73 Efficiency: 70% Horsepower: 0.007332 Cost Motor: $2.50CBM: $6,284.20Costing Method: Type: ReciprocatingOrientation: HSC Material: Cast Steel RPM: 3,600 CP Pump: $6,284.20Cost Indexed: $8,373.10A4.6 Reboiler Pump Head (ft): 20 Flow rate (gal/min): 150.16 Efficiency: 70% Horsepower: 0.627483 Cost Motor: $309.57 CBM: $58,329.87Costing Method: Type: Reciprocating Orientation: HSC Material: Cast Steel RPM: 3,600 CP Pump: $17,366.15 Cost Indexed: $77,719.02A4.6 Reflux Accumulator Flow rate (ft3/hr): Length (ft): 4 Cost Ladders:$2,096.20Cost Bare Module: $52,375.94Costing Method: Residence Time (min): 5Diameter (ft): 8 Fbm: 3.05 Indexed: $69,918.57A4.7 Condenser Type: Shell Tube / Fixed Head Heat Duty (Btu/hr): 9,491,220 Pressure: 220 Length: 8 CBM: $192,603.72Costing Method:

Material S/T: Carbon /Stainless Steel Tlm:125.68 U(Btu/hr-0F-ft2):50 Area (ft2): 1510.41 Cost Indexed: $256,626.17A4.5.2 Reboiler Type: Shell Tube / Kettle Heat Duty (Btu/hr): 12,100,000 Pressure of Steam (psia): 119 Length (ft): 8 Delta H (Btu/lb): 879.07 CBM: $711,579.00 Costing Method:

Material S/T: Carbon /Stainless Steel T driving: 35 U (Btu/hr-0F-ft2): 100 Area (ft2): 3,457.14 Steam (Lbs): 13,764.51 Cost Indexed: $948,111.50 A4.5.1 Column Pump Head (ft): 38 Flow rate (gal/min): 361.83 Efficiency: 70% Horsepower: 2.88 Cost Motor: $345.58 CBM: $69410.60 Costing Method: Type: Reciprocating Orientation: HSC Material: Cast Steel RPM: 3,600 CP Pump: $20448.12 Cost Indexed: $92483.04 A4.6 Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 40 Distillation Column D-101 N Stages Real: 29 Type of Tray: Sieve Tray Material: 316 Stainless Steel Tray Efficiency: 42% Column Diameter (ft): 6.44 Column Height (ft): 70 Column Thickness (in): 0.375 Column Material: Carbon Steel Stream: Stage Theoretical Acetone Hydrogen Isopropanol 1-NitroPropane Propylene Water In (lbs/hr) Out (lbs/hr) S-108S-113S-112 4 1 12 120.1120.140 0 0 0 42837.842831.66.2 534.5214.59520.0 0 0 0 0 0 0 Tray Cost: Ladder/Platform Cost: Column Cost:$ 61,117.07 $ 11,464.59 $ 34,304.02 Fbm: Cost Bare Module: 4.16 $ 444,644.41 Indexed CBM: Costing Method:$ 592,446.46 A4.4 Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 41 Distillation Column D-101 Reflux PumpHead (ft): 15 Flow rate (gal/min): 119.87 Efficiency: 70% Horsepower: 0.66 Cost Motor: $299.47CBM: $7,298.83Costing Method: Type: ReciprocatingOrientation: HSC Material: Cast Steel RPM: 3,600 CP Pump: $7,298.83 Cost Indexed: $9,725.00A4.6 Reboiler Pump Head (ft): 20 Flow rate (gal/min): 1.22 Efficiency: 70% Horsepower: 0.0076 Cost Motor: $8.21 CBM: $15,070.73Costing Method: Type: Reciprocating Orientation: HSC Material: Cast Steel RPM: 3,600 CP Pump: $4,558.68 Cost Indexed: $20,080.32A4.6 Reflux Accumulator Flow rate (ft3/hr): 961.53 Length (ft): 9.35 Cost Ladders:$2,160 Cost Bare Module: $59,467.74 Costing Method: Residence Time (min): 5Diameter (ft): 4.67 Fbm: 3.05 Indexed: $79,385.67A4.7 Condenser Type: Shell Tube / Fixed Head Heat Duty (Btu/hr): 23,900,000 Pressure (Psia): 17.64 Length (ft): 8 CBM: $435,190.69 Costing Method:

Material S/T: Carbon /Stainless Steel Tlm: 99.10 U(Btu/hr-0F-ft2): 50 Area (ft2): 4,823.54 Cost Indexed: $579,850.27A4.5.2 Reboiler Type: Shell Tube / Kettle Heat Duty (Btu/hr): 17,340,000 Pressure of Steam (psia): 47 Length (ft): 8 Delta H (Btu/lb): 927.75 CBM: $898,878.70 Costing Method:

Material S/T: Carbon /Stainless Steel T driving: 35 U (Btu/hr-0F-ft2): 100 Area (ft2): 4,954.29 Steam (Lbs): 18,690.34 Cost Indexed: $1,197,671 A4.5.1 Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 42 Distillation Column D-102 N Stages Real: 19 Type of Tray: Sieve Tray Material: 316 Stainless Steel Tray Efficiency: 55% Column Diameter (ft): 7.07 Column Height (ft): 50 Column Thickness (in): .3125 Column Material: Carbon Steel Stream: Stage in/out Acetone Hydrogen Isopropanol 1-NitroPropane Propylene Water In (lbs/hr) Out (lbs/hr) S-122S-124S-125S-126 65 110 8.7 111.40.2 120 00 00 69.6 358.70428.3 131.6014.6 762.9 28928.926973.6 2718.2 9773.0 2938.5012711.5 Tray Cost: Ladder/Platform Cost: Column Cost:$47,637.15 $8,665.86 $26,738.50 Fbm: Cost Bare Module: 4.16 $345,452.69 Indexed CBM: Costing Method:$460,282.91 A4.4 Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 43 Distillation Column D-102 Reflux PumpHead (ft): 15 Flow rate (gal/min): 586.33 Efficiency: 70% Horsepower: 2.09 Cost Motor: $359.60CBM: $8,795.71Costing Method: Type: ReciprocatingOrientation: HSC Material: Cast Steel RPM: 3,600 CP Pump: $8,795.71 Cost Indexed: $11,719.45A4.6 Reboiler Pump Head (ft): 20 Flow rate (gal/min): 44.79 Efficiency: 70% Horsepower: 0.23 Cost Motor: $276.93 CBM: $10,444.82Costing Method: Type: Reciprocating Orientation: HSC Material: Cast Steel RPM: 3,600 CP Pump: $2,888.16 Cost Indexed: $13,916.73A4.6 Reflux Accumulator Flow rate (ft3/hr): 4,703.17 Length (ft): 15.86 Cost Ladders:$2,405.34 Cost Bare Module: $99,876.83 Costing Method: Residence Time (min): 5Diameter (ft): 7.93 Fbm: 3.05 Indexed: $133,329.25A4.7 Condenser Type: Shell Tube / Fixed Head Heat Duty (Btu/hr): 18,027,813 Pressure (Psia): 350 Length (ft): 8 CBM: $1,153,092.37 Costing Method:

Material S/T: Carbon /Stainless Steel Tlm: 25.53 U(Btu/hr-0F-ft2): 50 Area (ft2): 14,121.90 Cost Indexed: $1,536,386.11A4.5.2 Reboiler Type: Shell Tube / Kettle Heat Duty (Btu/hr): 12,879,205 Pressure of Steam (psia): 149 Length (ft): 8 Delta H (Btu/lb): 863.52 CBM: $746,525.00 Costing Method:

Material S/T: Carbon /Stainless Steel T driving: 35 U (Btu/hr-0F-ft2): 100 Area (ft2): 3,679.77 Steam (Lbs): 14,914.85 Cost Indexed: $994,673.70 A4.5.1 Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 44 Reactor R-100 Type: Vertical Fixed Bed Shell-and-Tube Heat Exchanger Heat Duty(Btu/hr): 13,447,747 Catalyst: Vcatalyst (ft3): Nickel on Silica353 Diameter (ft): Height (ft): 10.0 21.4 Tube-Side (Reaction):Shell-Side (Cooling Water): Treactants (0F):Tproducts (0F):Pressure (Psia): Phase: 194 302 711 Vapor/Liquid Tcw,in (0F): Tcw,out (0F):FlowCW (lb/hr): Phase: 90 120 450,899 Liquid In (lb/hr)Out (lb/hr)Stream: Stage in/out S-102 In S-105 Liq S-104 Vap Acetone Hydrogen Isopropanol 1-NitroPropane Propylene Water 42715.1 4447.6 19017.6 0 0 0 677.2 43.7 43754.3 0 0 0 604.3 2965.8 18135.1 0 0 0 Tube Mat: Stainless Steel Tube ID (in): 1.76 Tube OD (in): 2.00 At (ft2/tube):9.86 Ui (Btu/ft2-hr-0F): 65.6 Shell Mat : Carbon Steel Tube Length (ft): 21.4 N Tubes: 1628 N Passes: 1 Cost of Purchase: Fbm: Cost Bare Module: Cost of Catalyst: $357,287.35 3.3 $1,179,048.26 $46,200.00Total CBM: Costing Method:$1,225,248.26A.8 Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 45 Reactor R-101 Type: Plug Flow Tube Reactor Heating Load: 12,888,429 Btu/hr Residence Time: 169 seconds Length: 4 meters Diameter: 6 meters Thickness: .1524 meters Stream: Acetone Hydrogen Isopropanol 1-NitroPropane Propylene Water In (lbs/hr)Out (lbs/hr) S-116 S-117 120.1120.1 0 0 42831.6428.3 14.614.6 0 29691.8 0 12711.5 Material: Catalyst: Catalyst pore diameter Stainless Steel Gamma Alumina Nanopowder 69 Cost of Purchase: Fbm: Cost Bare Module: Kilograms Catalyst: Cost of Catalyst: $ 88,141.904.16 $366,670.30 9718.99 $151,616.25 Indexed CBM: Costing Method:$1,162,420.34 A4.1 Heater A4.4 Reactor Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 46 Compressor C-100 Type: CompressorFlow Rate in (ft3/hr): 20,497 Horsepower: 12.42 Stream: Acetone Hydrogen Isopropanol 1-NitroPropane Propylene Water In (lbs/hr)Out (lbs/hr) S-100 S-128 604.3 604.3 2965.8 2965.8 18135.1 18135.1 0000 00 Material: Type: Motor Type:Stainless Steel Screw Electric Cost of Purchase Motor: Fbm: Cost Bare Module: $36,579.282.15 $78,645.46 Indexed CBM: Costing Method: $104,787.60A4.3.2 Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 47 Compressor C-101 Type: TurbineFlow Rate in (ft3/hr): 375,925 Horsepower: 778.69 Stream: Acetone Hydrogen Isopropanol 1-NitroPropane Propylene Water In (lbs/hr)Out (lbs/hr) S-119 S-121 111.4 111.4 00 358.7 358.7 1.6 1.6 28928.9 28928.9 2938.5 2938.5 Material: Type: Motor Type:Stainless Steel Reciprocating Electric Cost of Purchase Motor: Fbm: Cost Bare Module: $ 1,035,895.72 2.15 $ 2,227,175.79 Indexed CBM: Costing Method: $2,967,500.31A4.3.1 Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 48 Compressor C-102 Type: TurbineFlow Rate in (ft3/hr): 48,361 Horsepower: 412.45 Stream: Acetone Hydrogen Isopropanol 1-NitroPropane Propylene Water In (lbs/hr)Out (lbs/hr) S-123 S-124 111.4 111.4 00 358.7 358.7 1.6 1.6 28928.9 28928.9 2938.5 2938.5Material: Type: Motor Type:Stainless Steel Reciprocating Electric Cost of Purchase Motor: Fbm: Cost Bare Module: $ 623,053.99 2.15 $1,339,566.09 Indexed CBM: Costing Method:$1,784,844.64A4.3.1 Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 49 Pump P-100 Type: Reciprocating Flow Rate (gal/min): 3.94 Head (feet): 1573.76 Horsepower: 3.684 RPM: 3,600 Orientation: HSC Materiel: Cast Steel Efficiency: 70% Stream: Acetone Hydrogen Isopropanol 1-NitroPropane Propylene Water In (lbs/hr)Out (lbs/hr) S-107 S-110 489.0 489.0 0.30.3 881.4881.4 0 00 0 Cost of Purchase Pump: Fbm: Cost Bare Module:$23,509.133.3 $79,363.32 Cost of Purchase Motor: Fbm: Cost Bare Module: $385.983.3 $540.37 CBM Pump: Indexed CBM: Costing Method: $79,903.68$106,464.07A4.6 Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 50 Pump P-101 Type: Reciprocating Flow Rate (gal/min): 1.22 Head (feet): 617.64 Horsepower: 0.57 RPM: 3,600 Orientation: HSC Materiel: Cast Steel Efficiency: 70% Stream: Acetone Hydrogen Isopropanol 1-NitroPropane Propylene Water In (lbs/hr)Out (lbs/hr) S-114 S-106 00 00 6.2 6.2 534.5 534.5 00 00 Cost of Purchase Pump: Fbm: Cost Bare Module:$9,320.253.3 $31,884.72 Cost of Purchase Motor: Fbm: Cost Bare Module: $235.473.3 $329.66 CBM Pump: Indexed CBM: Costing Method: $32,174.38$42,869.30A4.6 Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 51 Pump P-102 Type: Reciprocating Flow Rate (gal/min): 119.88 Head (feet): 322.11 Horsepower: 12.51 RPM: 3,600 Orientation: HSC Materiel: Cast Steel Efficiency: 70% Stream: Acetone Hydrogen Isopropanol 1-NitroPropane Propylene Water In (lbs/hr)Out (lbs/hr) S-113 S-115 120.1 120.1 00 42831.6 42831.6 14.6 14.6 00 00 Cost of Purchase Pump: Fbm: Cost Bare Module:$5,235.61 3.3 $17,950.76 Cost of Purchase Motor: Fbm: Cost Bare Module: $145.723.3 $204.01 CBM Pump: Indexed CBM: Costing Method:$18,154.77$24,189.51A4.6 Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 52 Pump P-103 Type: Reciprocating Flow Rate (gal/min): 23.14 Head (feet): 866.19 Horsepower: 14.55 RPM: 3,600 Orientation: HSC Materiel: Cast Steel Efficiency: 70% Stream: Acetone Hydrogen Isopropanol 1-NitroPropane Propylene Water In (lbs/hr)Out (lbs/hr) S-120 S-122 8.78.7 0 0 69.669.6 13.013.0 762.9762.9 9772.99772.9 Cost of Purchase Pump: Fbm: Cost Bare Module:$7,119.70 3.3 $27,961.36 Cost of Purchase Motor: Fbm: Cost Bare Module: $966.743.3 $1,353.44 CBM Pump: Indexed CBM: Costing Method: $29,314.80$39,059.19A4.6 Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 53 Pump P-104 Type: Reciprocating Flow Rate (gal/min): 105.42 Head (feet): 2054.1 Horsepower: 79.63 RPM: 3,600 Orientation: HSC Materiel: Cast Steel Efficiency: 70% Stream: Acetone Hydrogen Isopropanol 1-NitroPropane Propylene Water In (lbs/hr)Out (lbs/hr) S-100 S-128 41621.8 41621.8 00 00 0000 00Cost of Purchase Pump: Fbm: Cost Bare Module:$33,090.71 3.3 $133,165.57 Cost of Purchase Motor: Fbm: Cost Bare Module: $5,187.493.3 $7,262.49 CBM Pump: Indexed CBM: Costing Method:$140,428.06$187,107.06A4.6 Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 54 Heater H-100 Type: PyrolysisHHV: 1,050 Btu/SCF Fuel: Natural Gas Heat Duty(Btu/hr): 22,373,873 Efficiency: 70% Stream: Acetone Hydrogen Isopropanol 1-NitroPropane Propylene Water In (lbs/hr)Out (lbs/hr) S-115 S-116 120.1 120.1 00 42831.6 42831.6 14.6 14.6 00 00 Cost of Purchase Heater: Fbm: Cost Bare Module:$459,790.842.19 $1,006,941.94Cost of Purchase Motor: Fbm: Cost Bare Module: $385.983.3 $540.37Indexed CBM: Costing Method: $1,341,654.54A4.1 Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 55 Heat Exchanger H-101 Type: Shell And Tube/Fixed head Tc in(0F): 90Tc out(0F): 120 Area(ft2):2,344 Pressure(Psia): 102 Heat Duty(Btu/hr): 22,537,729 Th in(0F): 608 Th out(0F):140 Tlm: 192.25 U(Btu/hr-0F-ft2): 50 Stream: Acetone Hydrogen Isopropanol 1-NitroPropane Propylene Water In (lbs/hr)Out (lbs/hr) S-100 S-128 120.1 120.1 00 428.3 428.3 14.6 14.629691.8 29691.8 12711.5 12711.5 Shell Mat:Carbon Steel Tube ID (in): .76 Tube OD (in): 1 At (ft2): 3.8 Tube Mat: Stainless Steel Tube Length (ft): 20 N Tubes: 583 Number of Passes 1 Cost of Purchase: Fbm: Cost Bare Module: $61,154.343.3 $201,809.32Indexed CBM: Costing Method: $268,891.76A4.5.3 Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 56 Heat Exchanger H-102 Type: Shell And Tube/Fixed head Tc in(0F): 90Tc out(0F): 120 Area(ft2):59.5 Pressure(Psia): 135 Heat Duty(Btu/hr): 476,300 Th in(0F): 281 Th out(0F):249 Tlm: 106.13 U(Btu/hr-0F-ft2): 50 Stream: Acetone Hydrogen Isopropanol 1-NitroPropane Propylene Water In (lbs/hr)Out (lbs/hr) S-121 S-123 111.4 111.4 00 358.7 358.7 1.6 1.6 28928.9 28928.9 2938.5 2938.5 Shell Mat : Carbon Steel Tube ID (in): 1.4 Tube OD (in): 1.5 At (ft2):7.33 Tube Mat: Stainless Steel Tube Length (ft): 20 N Tubes: 237 Number of Passes: 1 Cost of Purchase: Fbm: Cost Bare Module: $21,013.223.3 $69,343.62Indexed CBM: Costing Method:$92,393.78A4.5.3 Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 57 Flash Vessel F-101 Volumetric Flow Rate (ft3/hr): 33,526.5 Diameter (ft): 15.27 Length (ft): 30.53 Thickness (in): 0.5 Residence Time (min): 5 Column Material: Carbon Steel Stream: Stage in/out Acetone Hydrogen Isopropanol 1-NitroPropane Propylene Water In (lbs/hr) Out (lbs/hr) S-118 S-119S-120 InLiqVap 120.1 111.4 8.7 000 428.3 358.7 69.6 14.6 1.6 13.0 29691.8 28928.9 762.9 1277.5 2938.59772.9 Ladder/Platform Cost: Vessel Cost:$20,634.10 $90,022.51 Fbm: Cost Bare Module: 3.05 $ 274,568.65 Indexed CBM: Costing Method: $ 365,836.65 A4.7 Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 58 ST-100 Type: Spherical Holding Tank Volume Need (Gal): 1,062,661 Volume Made (Gal): 1,275,193 Storage Length: 1 Week Material: Carbon Steel Pressure (Psia): Under 30 Stream: Acetone Hydrogen Isopropanol 1-NitroPropane Propylene Water Out (lbs/hr) S-100 41621.8 0 0 0 0 0 Cost of Purchase Tank: Fbm: Cost Bare Module: $1,169,803 3.05 $ 3,567,898 Indexed CBM: Costing Method:$ 4,753,886 A4.2.1 Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 59 ST-101 Type: Spherical Holding Tank Volume Need (Gal): 168,599 Volume Made (Gal): 202,318 Storage Length: 1 Day Material: Carbon Steel Pressure (Psia): 300 Stream: Acetone Hydrogen Isopropanol 1-NitroPropane Propylene Water In (lbs/hr) S-125 0.2 0 0 0 26973.6 0 Cost of Purchase Tank: Fbm: Cost Bare Module: $509,225 3.05 $ 1,553,136 Indexed CBM: Costing Method:$ 2,069,407 A4.2.2 Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 60 Year Investment RevenuesFixed CostsVariable Costs Earnings2009 ($26.7) ($26.7)2010 ($37.3) ($37.3)2011 $42.4 ($2.4) ($28.5) $11.62012 $63.7 ($3.6) ($42.7) $17.42013 $94.3 ($5.3) ($63.3) $25.82030 $10.7 $94.3 ($5.3) ($63.3) $36.4 Table G1) Investment, revenues, fixed costs, variable costs and total earnings for the process are shown. All values are in million of dollars. G)Financial Analysis Breakdown of Financial Analysis: The financial analysis of this project is broken down into four subsections: capital investment, fixed costs, variable costs and revenues.Capital investment includes the costs of purchasing and installation of equipment for the plant as well as working capital for the operation of our plant.Fixed costs include the costs of plant operation and maintenance.Variable costs include the costs of purchasing raw materials, utilities and costs of sales through business administration.Revenues are composed primarily of the sale of propylene with a second revenue stream from the sale of impure side streams at fuel values.By combining these four factors, it is possible to derive the free cash flows. Using free cash flows over twenty years and the basic principles of finance we are able to find whether our process is economically viable and if it is, how profitable and under what circumstances. Capital Investment: Bare Module Costs:The total bare module costs for our plant are $25,152,000.A complete breakdown of the costs of each of the process units can be seen in the appendix and unit specification sheets.A graphical representation of the costs can be seen in Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 61 Figure G1.It can be seen that the costs are relatively evenly distributed between the different process units; however, distillation columns and holding tanks take up the lions share of the capital investment costs. The methods by which bare module costs were calculated can also be seen in the Equipment Costs section of the report. Total Permanent Investment:Total permanent investment was calculated from bare module cost through several steps. First, the total direct permanent investment was calculated.Direct permanent investment was calculated by summing bare module cost, site preparation costs (assumed to be 15% of bare module costs) service facilities cost (5% of bare module costs) and allocated costs (6% of bare module costs).The direct permanent investment was calculated to be $31,691,000.This was then augmented by 18% to account for contingency and contractors costs, which then provides the total 30%1%19%15%27%7%1%Distillation ColumnsPumpsCompressorsReactorsHolding TanksHeaters & Heat ExchangersHorizontal Pres. Vessel Figure G1)The units of this process take up different shares in the total cost of equipment.It is worth noting that distillation columns and holding tanks are the majority of the total cost. Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 62 Delay/Supply (days)Working CapitalAccounts Payable30 $43.44Accounts Receivable30 ($86.04)Inventory Acetone7 ($7.97)Inventory 1-Nitropropane7 ($0.44)Inventory Propylene1 ($3.17)Cash Reserves30 ($52.66) Table G3) All the contributing factors to Working Capital are seen above. All values are in hundred thousand dollars. depreciable capital cost of $37,395,000.The cost of land (2%), royalties (2%) and startup (10%) is then applied to arrive at a total permanent investment of $42,631,000. Working Capital: Working capital was calculated by incorporating inventories, accounts payable, accounts receivable and cash reserves on hand.Inventories were presumed to be at one week for acetone and 1-nitropropane.Inventory for hydrogen was not considered since it will be produced on site at another part of the plant and it will be delivered by pipeline.One day of final propylene product was assumed as the plant will be located on the Gulf Coast and the product will be sold via pipeline to polypropylene plants.Inventory was calculated to be $1,158,000. Accounts payable were assumed to be 30 days and were applied to everything bought on credit, which includes raw materials.This results in a savings to working capital of $4,344,000. Accounts receivable were assumed to be 30 days and were applied to all products that are sold. This was Total Bare Module Cost: ($25,151,530.04)Cost Site (15%) ($3,772,729.51)Cost Service (5%) ($1,257,576.50)Allocated Costs (6%) ($1,509,091.80)Total Direct Permanent Investment: ($31,690,927.85)Cost of contingencies (18%) ($5,704,367.01)Total Depreciable Capital: ($37,395,294.86)Cost of land (2%) ($747,905.90)Cost of royalties (2%) ($747,905.90)Cost of plant startup (10%) ($3,739,529.49)Total Permanent Investment: ($42,630,636.14) Table G2) A visual representation of how Total Permanent Investment is calculated from the Total Bare Module Cost is shown. Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 63 calculated to be $8,604,000.Cash reserves were assumed to be 30 days and included utilities, raw materials and all fixed costs. This was calculated to be $5,266,000. The total working capital was calculated to be $10,683,000.An excel spreadsheet explaining these calculations in more detail can be seen in A3. Total Capital Investment:The total capital investment was calculated by summing working capital and total permanent investment. It was calculated to be $53,314,000. An excel spreadsheet showing these results in further detail can be seen in A3. Fixed Costs: Operation:For the operational calculations, it was assumed that four operators per shift working eight hours shifts would be required.Four operators were chosen by realizing that at least two operators would be required for each reactor because of the very high flow rates present.Wages, salaries, benefits and technical assistance and the presence of a control laboratory were included in the costs of operations.The operations cost is $1,585,000 per year. Maintenance:In the calculation of maintenance costs, it was presumed that because this was a fluid process, the wages and benefits would be approximately 3.5% of the total depreciable capital.Benefits, materials, services and maintenance overhead at prevailing industry conventions were then added to obtain a total maintenance cost of $3,010,000 per year. Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 64 Operating Overhead:Operating overhead includes general plant overhead, the mechanical, employee relations and business services departments and the property taxes and insurance of the plant.Prevailing industry conventions were used in this calculation. The total operating overhead was found to be $1,263,000 per year. Total Fixed Costs:The fixed costs of the plant amount to $5,410,000 per year, which is only 7.6% of the total costs. An excel spreadsheet showing these results in further detail can be seen in A3. Variable Costs: Raw Materials:The plant utilizes several raw materials. Acetone and hydrogen are utilized as base reactants. 1-nitropropane is also used as an azeotrope cracking agent. The costs also include the price of transporting the acetone from the Corn Belt to the Gulf Coast by combination of rail and truck.Raw materials were valued at prevailing market prices with the exception of acetone which was assumed to be purchased at fuel value. It is worth noting that acetone and the cost to transport it to our plant takes up 71% of our raw material costs and acetone costs make up 49% of our total annual costs. $/lb$/yr Acetone$0.11($34,942,333) Transportation Cost Acetone$0.01($2,625,569) Hydrogen$1.13($13,189,312) 1-Nitropropane$18.15($2,097,615) Table G4) The prices and total costs for all raw materials consumed in the process are shown in the table. Acetone and the cost to transport it to the plant take up 71% of our raw material costs.Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 65 Utility Costs:Utility costs were calculated using prevailing market prices for boiler feed water, high and low pressure steam, cooling water, natural gas, and electricity. The largest utility cost is water treatment because of the large flows of water with organic solvents that must be cleaned before they can be purged.Our second largest utility cost is natural gas, which is used to preheat and then heat the contents of R-101.This is because this reaction is very endothermic and so large amounts of heat must be supplied.Total utilities costs are $5,353,000, which are only 7% of annual costs. General Expenses:General expenses are calculated as a percentage of total sales. This category includes the cost of selling product, direct and allocated research, administrative expenses and management compensation costs. All of these aspects combined make up 11.55% of sales, which for this process is $12,100,000, or 16% of the total costs. Total Variable Costs:The variable costs of our plant amount to $70,312,000 per year, which is 92% of our total costs. An excel spreadsheet showing these results in further detail can be seen in A3. $/yr Boiler Feed Water($38,826.75) High Pressure Steam($904,432.44) Low Pressure Steam($368,386.51) Cooling Water($117,413.02) Natural Gas Heaters($1,021,253.87) Pumps & Compressors($347,415.23) Water Treatment($2,591,869.14) Table G5) The utilities costs are broken down by use. Treating effluent water is the most expensive utility in our plant. Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 66 Revenues: Primary Revenues:The primary revenue of this process occurs from the sale of propylene, presumably for the manufacture of polypropylene. Our propylene produced conforms to the standards of polymer grade propylene and therefore can be sold for the high price of 49 per lb (ICIS).The sale of polymer grade propylene earns $104,000,000 per year. Secondary Revenues:A secondary revenue stream comes from the sale of impure hydrogen mixed with waste acetone and isopropanol.It is not economically viable to purify this stream so it is being sold for its fuel value. Due to the high heat of combustion of hydrogen, this product sells at 34 per lb.However, as a result of the low flow rate of this stream, only $114,000 per year is acquired from the sale of this product. Free Cash Flows: Discount Rate:Using the Capital Asset Pricing Model (CAPM), the specific discount rate is found by valuing the beta of our corporation and using the market premium and the risk free rate.Currently the beta of most chemical manufacturing companies is valued at 1.05 (Google Finance). The market premium is measured as 4.8% (Google Finance) and the risk free rate given recent shake ups in credit markets has fallen to 2.5% (Google Finance). According to CAPM, the discount rate is calculated to be approximately 7.5%. Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 67 Depreciation:The plant is depreciated using Modified Accelerated Cost Recovery System (MACRS) with a 10 year life. This helps reclaim the investment with the maximum speed that the IRS allows and creates the largest possible tax shield. Taxes:Taxes are calculated to be at the standard corporate rate of 37%.Furthermore depreciation is used as a way to decrease taxable income and therefore to save money in the long run. A sensitivity analysis was performed to look at the effect of increased government intervention or greater taxes in the future. Return on Investment (ROI) and Payback Period (PBP): Both ROI and PBP were calculated for the process in order to get a quick snapshot of the economic vitality of the project. Return on investment, which is defined as net earnings divided by total capital investment, was calculated to be 30%. In addition the payback period, which is defined as total depreciable capital divided by cash flow, was calculated to be 2.84 years. Both of these values were calculated using 8% depreciation. A more detailed analysis of ROI and PBP is seen in Appendix A3 Net Present Value (NPV) and Internal Rate of Return (IRR):The calculated discount rate of 7.5% and all the economic factors discussed previously achieve an NPV of $93,800,000 over 20 years of plant life. The IRR over the same plant life is 21.9%. An excel spreadsheet showing these results in further detail can be seen in A3. Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 68 Sensitivity Analysis:Sensitivity analysis was conducted with respect to several different variables.An analysis on the breakeven points and the overall effect on profitability as measured through NPV and IRR was also performed. The first variable that was examined was the price of acetone.This price can increase up to 53% to $0.162 before the breakeven point was reached.Similarly, the price of propylene could decrease by 21% to $0.388 before the breakeven point was reached.Investigating the costs of utilities, it was found that these costs could increase by 340% before the process is no longer profitable.In addition, capital expenses could increase by 182% before our NPV becomes negative. Taxes and hydrogen prices were also examined. It was found that taxes could increase from 37% to 83% or hydrogen prices could increase by 142% to force the break even point. All of these scenarios are highly improbable. Overall, the sensitivity analysis reveals that this process is very profitable and that only large shocks to the current economic or production situation can make this process no longer profitable.We were unable to come up with any other major changes to the economic situation that would cause this process to be unprofitable. Senior Design, Uses for AcetoneBehrend, Mahoney, Makarukha, Subramanian 69 Sensitivity Analysis0%10%20%30%40%50%-40% -20% 0% 20% 40% 60% 80% 100%Percent Change in VariableInternal Rate of ReturnAcetone PriceHydrogen PriceUtilities CostPropylene PriceTaxes Figure G2) The response of IRR to shocks in acetone, propylene, utilities and hydrogen costs. The response of IRR to an increase in taxes is also shown. It ca