Final report6 - Department of Chemical and Biological...

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Unformatted text preview: Department of Chemical and Biological Engineering University of Wisconsin-Madison CBE 450-Process Design To: VP Polly Mer From: Aaron Kirchenberg, Peter Lawrence, Kristin Westphal Date: 12/1/2011 Subject: New Styrene Opportunity Executive Summary We have reviewed the submitted request to design a process capable of producing 250,000 MTA of styrene utilizing the CombiCat catalyst technology and the results are promising. Our design utilizes a series of 8 series reactors to minimize costs in relation to separation and to emphasize safety and environmental responsibility. Inter-stage flashes between chosen reactors in the process decreases the amount of hazardous by-product made making it less of a health and safety concern. This process also allows for reclamation of combustible gases and water for heating and cooling purposes respectively, which reduces costs. The estimated operating costs of the process creating the 99.8% pure styrene are $299 Million/year and the product sales are estimated at $331 Million/year. The gross earnings result is $32 Million/year and the estimated total capital investment of this process is $121 Million/year with a return on investment in three years. The net present value (NPV) is + $21M meaning investment in the process is feasible and it is a beneficial idea to invest. The best economic methodology involves starting with producing 99.8 mol% pure styrene process with a down payment of $14.6 Million then after 5 years, upgrade to the higher purity styrene. If this is chosen the reserve earnings will be over $114 Million at the end-life of the plant. The ability to reclaim energy from the products of the process reduces our dependency upon external energy, which will further reduce our environmental footprint. Additionally, the reduction of numerous, large and potentially hazardous equipment will increase worker safety while reducing maintenance costs. Table of Contents Page Number Introduction 3 Base Case Design 10 Process Description 23 Utilities Requirements 28 Equipment Description 30 Specification Sheets 34 Economic Analysis 38 Conclusions and Recommendations 42 References 43 Appendix A 44 Appendix B 51 Appendix C 53 Introduction A new process in styrene monomer synthesis was recently introduced by CombiCat, Inc. that had potential benefits including reducing production costs by 35%, energy consumption by 80%, carbon dioxide emissions by 80%, and capital costs by 50%. Along with the reduced costs, the potential feed stock, methanol, could be produced from renewable resources. CombiCat claimed their new technology involving a proprietary engineered zeolite catalyst made this possible and provided us samples to test the catalyst’s kinetic data. Because of the potential benefits listed and the growth in polystyrene demand at the Springfield facility, the process engineering group decided to analyze CombiCat’s claim to determine the attractiveness of the proposed technology....
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This note was uploaded on 03/05/2012 for the course BIO 234 taught by Professor Rage during the Spring '12 term at University of Wisconsin.

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Final report6 - Department of Chemical and Biological...

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