Date:25 January 2011

Team Echo:

Sabah Basrawi

Alex Guerrero

Sarah Hanif

Mrunal Patel

Kevin Thompson

Client Mentor: Shannon Brown

1. Design Basis2. Block Flow Diagram3. Process Flow Diagram4. Material and Energy Balance5. Calculations6. Annotated Equipment List7. Economic Evaluation8. Utilities

9. Conceptual Control Scheme10. General Arrangement11. Distribution and End-use Issues Review12. Constraints Review13. Applicable Standards14. Project Communications File15. Information Sources and References

Design BasisCompeting ProcessesBlock Flow Diagram

Synthesize 30,000 ton/year of Propionic Acid from syngas retrieved from group “Foxtrot.”

Split syngas feed to synthesize Ethylene needed to carry out reaction.

The reactant will react with a second syngas feed to create a propionic acid precursor.Precursor undergoes oxidation to yield

propionic acidThe product can either be sold or used to

create plastics, preservatives or painkillers.

Propionic acid is a commonly used chemical in industry that will be synthesized from syngas, ethylene and  water catalyzed by metal ion in solution

Propionic acid facts:Naturally occurringMade from ethylene and carbon monoxideAnalgesicIntermediate product for thermoplastic

Plastics used in daily processes; will increase affordability and stimulate economy

Industrially, the majority of propionic acid is used as a bactericide and fungicide to protect hay and grains that are being stored as well as an ingredient for pesticides (EPA).

These uses have, according to the EPA, “low toxicity to fish, invertebrates, birds and mammals,” as well as to non-target organisms and is not expected to result in any adverse health effects.

Coal based syngas Major feedAbundant

EthyleneCheap to buy, but making will allow more

independence from the market.Wacker Process

Similar to hydroformylationHydroformylation promotes chain extension

and uses Rh based catalyst.Wacker process uses a Tetrachloropalladate

catalyst

Syngas is chosen as the feed for the process because it is the most thermodynamically efficient

Rhodium is the most commonly used catalyst in hydroformylationWhile Rh was considered for this process due its

high poison tolerance it is very expensiveAerobic Oxidation is what we have chosen to

oxidize propionate. Other methods include:Larson Process: Ethylene, CO and steamReppe Process: Ethanol. CO, BF3Fischer-Tropsch Process: Byproduct of the reactionPyrolysis: Byproduct of the reaction

Turbo CompressorsTurbo ExpandersReactorsStorage TanksWater ReservoirHeat ExchangersDistillation Column

Once the amounts of feed stock have been determined, equipment costs can be calculated as well as any feeds costs that will be added outside of the syngas obtained from group Foxtrot.

If Ethylene is to be purchased it will run around $650-750/ton

The current price of Propionic acid is $2000-2100/ton

Material Balance(1) 2 CO + 4 H2 + RCOOH C2H5OOCR + 2H2O(2) C2H5OOCR C2H4 +HOOCR(3) CO + H2 +C2H4 CH3CH2CHO

Calcalation: TBDUtilities: TBD

Conceptual control scheme: Dual man and mechanically run process

Constraints: Managing syngas composition for each feed

Analgesic propertiesUsed in pharmaceutical Used in plasticsSynthesis of propionates to make methyl

methacrylateCommonly used as pesticides and

bactericidesAnticonvulsantPreservativesUsed as solvents

Wiki link: http://seniorecho.wikispaces.com/Email: designecho@listserv.uic.edu

"Acetic Acid Production." Acetic Acid Production. 2009. Web. 22 Jan. 2011. <http://www.starcontrols.com/Application/Application_min_e.asp?MinID=34>.

Boyaval, P., and C. Corre. Production of Propionic Acid. 1995. Print. Perlack, Robert D., Lynn L. Wright, Robin L. Graham, Bryce J. Stokes,

and Donald C. Erbach. Biomass as a Feedstock for a Bioenergy and Bioproducts Industry: The Technical Feasibility of a Billion-Ton Annual Supply. Print.

"Propanoic Acid." Wikipedia, the Free Encyclopedia. Web. 22 Jan. 2011. <http://en.wikipedia.org/wiki/Propanoic_acid>.

Registration Review Document for Propionic Acid and Salts. Mar. 2008. Print.

Spivey, James J., Makarand R. Gogate, Ben W. Jang, Eric D. Middlemas, Joseph R. Zoeller, Gerald N. Choi, and Samuel S. Tam. Synthesis of Acrylates and Methacrylates from Coal-Derived Syngas. 1997. Print.