Process Optimization

1
Advisors Dr. Kenneth Wynne Dr. Wei Zhang Mr.
Rudy Krack
Team Members Michelle Halye Michael Hanks Krunal
Patel

• Process Optimization

Block Diagram
Pilot Process Design
Equipment List

• Pfaudler RT-14-10 Jacketed Reactor
• 5 Stage Batch Distillation Tower
• Adjustable Pressure Steam Boiler
• Water Tower Reservoir
• 3 Pressure Regulators
• 2 Condensers
• 5 Pumps
• 10 Fail Close Ball Valves
• 5 Fail Close Needle Valves
• 4 Fail Open Needle Valves

Reaction
Economic Analysis
Production, kg/y Production, kg/y 38.8 Cost, thousand /y
Type Item Item Cost, thousand /y
Variable Cost Raw materials Raw materials 1.25
Variable Cost Operating labor Operating labor 57.6
Variable Cost Utilities Utilities 0.138
Variable Cost Maintenance and repairs Maintenance and repairs 20.3
Variable Cost Operating supplies Operating supplies 2.03
Subtotal Subtotal Subtotal 81.3
Fixed Cost Taxes Taxes 40.5
Fixed Cost Insurance Insurance 20.3
Subtotal Subtotal Subtotal 60.8
Plant Overhead Plant Overhead Plant Overhead 7.79
Total Manufacturing Cost Total Manufacturing Cost Total Manufacturing Cost 150
Design of Experiment

• The yields were calculated based on the amount of
  ethanol driven off by the reaction
• The distillate contained more diethyl carbonate
  than was expected
• - A subsequent experiment with diethyl
  carbonate in excess showed significantly improved
  results
• - Due to time and material constraints, we were
  unable to perform a full suite of DOE
  experiments with diethyl carbonate in excess
• The DOE analysis was performed using the JMP
  statistical analysis software package
• - The results showed that increasing the time or
  the agitation speed independently increased the
  yield substantially.
• - However, the results did not show any
  synergistic effect from increasing these two
  parameters simultaneously

• We performed a 3 factor, 2 level full factorial
  Design of Experiment
• The DOE was performed only on the first step to
• - Keep the DOE manageable
• - The HEL SimularTM had a temperature restriction
  preventing it performing the second step

Desired Product
Primary Company Use for Product
Profitability Profitability Profitability Profitability Profitability
Return on investment, ave. /y -10.1
Payback period, y 4.7
Net return, 106 -0.52 at mar 15.0 /y
HEL SimularTM PID

• The co-polyoxetane the monomer is used in is
  still in research
• - It has potential to be an anti-fouling paint
  coating additive with 2 wt polymer
• - The polymer is unique in that it becomes more
  hydrophobic the wetter the polymer becomes

Factors Factors Factors Factors Factors Responses Responses Responses
  pattern Time (Hours) Temperature (C) Agitation (rpm) Done? Yield, ethanol GC/MS,
1 - - 2 135 100 8-Dec 18.6 0.45
2 -- 1 135 150 10-Dec 21.2 0.51
3 - 2 145 100 10-Dec 24.9 0.46
4 - 1 145 150 10-Dec 22.2 0.44
5 2 145 150 12-Dec 22.9 0.44
6 - - 1 145 100 16-Dec 8.4 0.34
7 - - - 1 135 100 15-Jan 16.7 0.47
8 - 2 135 150 20-Jan 28.1 0.52
8b - 2 135 150 13-Feb 80.9 0.44
mid N/A 1.5 140 125 30-Jan 15.6 0.40

• The cost per gram of product is 12.56 if the
  plant produces 10 gallons or 38.8 kg of product
  per yea
• However, if the coating goes from 2 wt to 100
  wt, the demand would go to 500 gallons or 1949
  kg per year, that would take the price down to
  .25 per gram.
• Both of these prices allow for payback in 4.7
  years

• Assuming this paint coating would be put on all
  current naval and commercial ships, we estimated
  that 10 gallons a year of product would be needed

• For experiment 8b, the diethyl carbonate was in a
  21 ratio with the Tris(hydroxymethyl)ethane