Renewable Acrylic Acid

263 Pages·2016·3.42 MB·English

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Department of Chemical & Biomolecular
Senior Design Reports (CBE)
Engineering
4-2012
RReenneewwaabbllee AAccrryylliicc AAcciidd
Andrew Cie
University of Pennsylvania
Stephen Lantz
University of Pennsylvania
Roy Schlarp
University of Pennsylvania
Metaxia Tzakas
University of Pennsylvania
Follow this and additional works at: https://repository.upenn.edu/cbe_sdr
Cie, Andrew; Lantz, Stephen; Schlarp, Roy; and Tzakas, Metaxia, "Renewable Acrylic Acid" (2012). Senior
Design Reports (CBE). 37.
https://repository.upenn.edu/cbe_sdr/37
This paper is posted at ScholarlyCommons. https://repository.upenn.edu/cbe_sdr/37
For more information, please contact [email protected].
RReenneewwaabbllee AAccrryylliicc AAcciidd
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Acrylic acid is an important industrial chemical, used as a raw material in a wide variety of consumer end
products. The present predominant source of acrylic acid is from the partial oxygenation of propene,
produced as a by-product in the industrial production of ethylene and gasoline. Both processes depend
heavily on the processing of petrochemicals as the base raw material. The purpose of this process is to
produce acrylic acid from renewable carbon sources (such as corn or sugarcane) in an economically
preferential manner. Our process has used genetically recombinant Escherichia coli (E. coli) to ferment
the carbohydrate content of the proposed feedstock to 3-hydroxypropionic acid (3-HP) which is then
dehydrated in the presence of strong acid catalyst (phosphoric acid) to form acrylic acid. The acrylic acid
is then purified to the standard required for use as a polymer raw material (99.98% by mass) with total
capacity of 160,000 MT/year of product.
This design analyzes two proposed locations, the US Midwest or Brazil, and their associated renewable
feedstocks, corn or sugarcane juice, respectively. This report investigates the relative economic
attractiveness of each option. The US case requires location near an existing industrial ethanol
fermentation plant to give easy access to dry-ground corn as a carbohydrate source. This case yields an
IRR of 17.56% and an overall NPV of $35.2 million at a 15% discount rate. The Brazil case has
comparatively cheaper feedstock, however because of seasonality and total usable carbohydrate content,
it requires a greater mass of feedstock and increased capital investment relative to the US case. The NPV
difference of the two cases is extremely sensitive to the assumed price of sugarcane juice which has
recently shown extraordinary volatility. Based on this analysis, the US location seems most promising;
however, detailed laboratory level studies are needed to confirm the profitability and assumptions made.
This working paper is available at ScholarlyCommons: https://repository.upenn.edu/cbe_sdr/37
Renewable Acrylic Acid

Andrew Cie | Stephen Lantz | Roy Schlarp
Metaxia Tzakas

School of Engineering and Applied Science
University of Pennsylvania
April 10, 2012

Advisor: Dr. Robert Riggleman
Primary Consultant: Stephen M. Tieri
Dupont Engineering Research & Technology

Professor Leonard Fabiano
Dr. Robert Riggleman
Department of Chemical and Biomolecular Engineering
University of Pennsylvania
Philadelphia, PA 19104
April 10, 2012
Dear Professor Fabiano and Dr. Riggleman,
Enclosed you will find the process design for the renewable production of acrylic acid.
The proposed design utilizes genetically recombinant Escherichia coli to ferment sugar from
renewable corn feedstock to 3-hydroxypropionic acid, which is then dehydrated selectively in the
presence of phosphoric acid catalyst to produce the desired acrylic acid product. The acrylic acid
product is then purified to specification for use as a polymer raw material. The proposed plant is
designed to operate in the US Midwest, in partnership with a corn dry-grind ethanol production
plant which will provide enzyme digested corn feedstock at local market price, and will produce
the specified 160,000 MT/year of polymer grade acrylic acid.
The proposed design process is expected to deliver an IRR of 17.56% with a total NPV of
$35.2 million at a 15% discount rate. Simulations of the process have been carried out using
SuperPro Designer and Aspen Plus v7.3. Economic analysis was carried out using Aspen IPE
and the methods and spreadsheets contained in Process Design Principles, 3rd Edition by Seider,
Seader, Lewin, and Widagdo.
Please feel free to contact us should any questions regarding the methodology of
completion or process specifics arise.
Sincerely,

______________ ______________ ______________ ______________
Andrew Cie Stephen Lantz Roy Schlarp Metaxia Tzakas
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Cie, Lantz, Schlarp, Tzakas Renewable Acrylic Acid
Table of Contents
Abstract ........................................................................................................................................... 9
Introduction and Background Information ................................................................................... 10
Project Charter .......................................................................................................................... 13
Innovation Map ............................................................................................................................. 15
Concept Stage ............................................................................................................................... 19
Market and Competitive Analysis ............................................................................................ 20
Customer Requirements ............................................................................................................ 23
Preliminary Process Synthesis .................................................................................................. 24
Assembly of Database............................................................................................................... 27
Feasibility, Development, Manufacturing and Product Introduction ........................................... 29
Process Flow Diagram and Material Balances ......................................................................... 30
Overall Process Outline ........................................................................................................ 32
Section 1 - Mixing / Blending Section .................................................................................. 34
Section 2 – Seed Fermentation ............................................................................................. 36
Section 3 – Process Fermentation ......................................................................................... 40
Section 4 – Purifying Section ............................................................................................... 42
Section 5 – Evaporation Section ........................................................................................... 44
Section 6 – Reaction (Dehydration) Section ......................................................................... 48
Section 7 – Distillation (Purification) Section ...................................................................... 50
Process Description ................................................................................................................... 53
Section 1 - Fermentation Process .......................................................................................... 55
Section 2 – Reaction (Dehydration) ...................................................................................... 58
Section 3 – Distillation (Purification) ................................................................................... 59
Energy Balance and Utility Requirements ................................................................................ 61
Energy Balance ..................................................................................................................... 62
Utility Requirements ............................................................................................................. 65
Equipment List and Unit Descriptions ...................................................................................... 69
Total Equipment List ............................................................................................................ 70
Unit Descriptions .................................................................................................................. 73
Unit Specification Sheets .......................................................................................................... 97
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Renewable Acrylic Acid Cie, Lantz, Schlarp, Tzakas
Distillation Towers................................................................................................................ 98
Heat Exchangers: ................................................................................................................ 101
Pumps .................................................................................................................................. 115
Flash Vessels ....................................................................................................................... 141
Reflux Accumulators .......................................................................................................... 146
Reboilers ............................................................................................................................. 149
Reaction Vessel ................................................................................................................... 152
Seed Fermenters .................................................................................................................. 153
Fermentation Vessels .......................................................................................................... 156
Storage Tanks...................................................................................................................... 157
Centrifuge ........................................................................................................................... 159
Air Filter.............................................................................................................................. 160
Mixers ................................................................................................................................. 161
Capital Investment Summary .................................................................................................. 163
Equipment Cost Summary .................................................................................................. 164
Fixed Capital Investment .................................................................................................... 166
Other Important Considerations .............................................................................................. 169
Environmental Considerations ............................................................................................ 170
Safety and Health Concerns ................................................................................................ 170
Process Controllability ........................................................................................................ 171
Plant Start-Up...................................................................................................................... 172
Operating Cost and Economic Analysis ................................................................................. 175
Operating Costs ................................................................................................................... 176
Economic Analysis ............................................................................................................. 182
Economic Sensitivities ........................................................................................................ 185
Location Selection .............................................................................................................. 191
Conclusions and Recommendations ........................................................................................... 193
Acknowledgements ..................................................................................................................... 194
Bibliography ............................................................................................................................... 196
Appendix ..................................................................................................................................... 201
Appendix I - Problem Statement............................................................................................. 202
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Cie, Lantz, Schlarp, Tzakas Renewable Acrylic Acid
Appendix II – Aspen Input / Report Summary ....................................................................... 205
Input Summary.................................................................................................................... 206
Distillation Column Results (D-101) .................................................................................. 213
Flash Vessel Results (FE-101) ............................................................................................ 221
Pump Results (PD-101) ...................................................................................................... 223
Reactor Vessel Results (R-101) .......................................................................................... 224
Aspen IPE Summary ........................................................................................................... 226
Appendix III - Batch Process Scheduling ............................................................................... 228
Appendix IV - Design Calculations ........................................................................................ 231
Heat Exchanger Sizing ........................................................................................................ 231
Distillation Column Sizing and Tray Efficiency ................................................................ 232
Reflux Pumps and Pump Calculations ................................................................................ 233
Reflux Accumulators and Reactor Vessel .......................................................................... 233
Centrifuge ........................................................................................................................... 233
Mixers and Storage Tanks .................................................................................................. 234
Fermenter Sizing ................................................................................................................. 234
Aspen IPE (Purchase and Bare Modules Costs) ................................................................. 235
CE Index Adjustments ........................................................................................................ 236
Utility Requirements ........................................................................................................... 236
NPV Calculations................................................................................................................ 238
IRR Calculations ................................................................................................................. 239
Appendix V - Material Safety Data Sheets ............................................................................. 240
Tables
Table 1. Porter’s Five Forces Summary ....................................................................................... 22
Table 2. SWOT Analysis Summary.............................................................................................. 22
Table 3. Overall Process Stream Table ......................................................................................... 31
Table 4. Mixing Section Stream Table ......................................................................................... 35
Table 5. Seed Fermentation Stream Table – Part 1 ...................................................................... 37
Table 6. Seed Fermentation Stream Table – Part 2 ...................................................................... 38
Table 7. Process Fermentation Stream Table ............................................................................... 41
Table 8. Purification Section Stream Table .................................................................................. 43
Table 9. Evaporation Section Stream Table – Part 1 .................................................................... 45
Table 10. Evaporation Section Stream Table – Part 2 .................................................................. 46
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Renewable Acrylic Acid Cie, Lantz, Schlarp, Tzakas
Table 11. Reaction (Dehydration) Section Stream Table ............................................................. 49
Table 12. Distillation (Purification) Section Stream Table – Part 1 ............................................. 51
Table 13. Distillation (Purification) Section Stream Table – Part 2 ............................................. 52
Table 14. Process Energy Requirements ...................................................................................... 63
Table 15. 50 psi Steam .................................................................................................................. 65
Table 16. 150 psi Steam ................................................................................................................ 65
Table 17. Cooling Water ............................................................................................................... 65
Table 18. Electricity ...................................................................................................................... 66
Table 19. Equipment Cost Summary – Estimated Bare Module Costs ........................................ 71
Table 20. Total Equipment Cost Summary................................................................................. 165
Table 21. Fixed Capital Investment Summary ........................................................................... 166
Table 22. Total Capital Investment Summary ............................................................................ 167
Table 23. Working Capital Summary ......................................................................................... 168
Table 24. Variable Cost Summary .............................................................................................. 176
Table 25. Fixed Cost Summary .................................................................................................. 177
Table 26. Cash Flow and NPV Summary ................................................................................... 184
Table 27. NPV Sensitivity Analysis (Acrylic Acid vs. Corn Price) ........................................... 186
Table 28. NPV Sensitivity Analysis (Product Price vs. Media) ................................................. 187
Table 29. NPV Sensitivity Analysis (Product Price vs. Waste Water) ....................................... 187
Table 30. NPV Sensitivity Analysis (Product Price vs. Steam Price) ........................................ 188
Table 31. IRR Sensitivity Analysis ............................................................................................. 189
Table 32. Fermenter Bare Module Costs Sensitivity .................................................................. 190
Table 33. Location Selection Analysis ....................................................................................... 192
Table 34. Sample IPE Costing Output ........................................................................................ 226
Table 35. Sample IPE Sizing Output .......................................................................................... 227

Figures
Figure 1. Innovation Map ............................................................................................................. 15
Figure 2. Airlift Fermenter Schematic .......................................................................................... 26
Figure 3. Overall Process Flowsheet ............................................................................................ 30
Figure 4. Mixing Section Flowsheet ............................................................................................. 34
Figure 5. Seed Fermentation Section Flowsheet........................................................................... 36
Figure 6. Process Fermentation Section Flowsheet ...................................................................... 40
Figure 7. Purifying Section Flowsheet.......................................................................................... 42
Figure 8. Evaporation Section Flowsheet .................................................................................... 44
Figure 9. Reaction (Dehydration) Section .................................................................................... 48
Figure 10. Distillation (Purification) Section................................................................................ 50
Figure 11. Gantt Chart – Fermentation Process ............................................................................ 57
Figure 12. Gantt Chart – Fermentation Process .......................................................................... 228
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