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Continuous Polymerization of
IsobutyleneGroup 20
Jin Wai GohMoriah Bacon
Kim HollisMarissa Pittard
Nathaniel Robinson
2
Introduction & Motivation
• Goal: optimize polyisobutylene (PIB) production
• Anti-misting agents are critical to the production of hydrocarbon fuels
• Batch process limitations: time, safety, and health
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Overview: Feed Purification
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Overview: Polymerization and Purification
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Unique Design Aspects
• Production rate = 20,000 lbs PIB per day
• Upstream flash unit– Removes 88% of oxygen from fresh feed– Reduces load on molecular sieve
• Dec. capital and utility requirements• Dec. monomer loss
• Monomer and diluent recycle bypass sieve– Minimal loss of diluent– Simplifies design
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Fixed Capital Investment Summary
Feed Purification44%
Reaction11%
Product Purification18%
Recycle16%
Storage11%
Total Bare Module Cost by Process SectionTotal Bare Module Cost, CTBM $26.7M
Total Direct Permanent Investment, CDPI $26.7M
Total Depreciable Capital, CTDC $29.3M
Total Permanent Investment, CTPI $32.2M
Total Capital Investment, CTCI $32.6M
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Financial Analysis Summary
Annual Production Cost $31.6M
Return on Investment 7.90%
IRR 9.8%
Max. affordable feed price $7.29/kg IB
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Safety & Environmental Considerations
• ThermOx eliminates release of harmful materials to atmosphere
• Methyl Chloride– Maintained below auto-ignition temperature– Continuous operation reduces exposure– Store in detached building
• Aluminum Chloride– Injected with automatic system– Less than 2 ppm throughout process
• Conservation of materials and waste
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Conclusions & Recommendations
• Greatly improved production capacity, efficiency, safety–Reduces operator manual labor–Reduces toxic chemical exposure
• Can afford to pay $7.29/kg IB
• Future designs should focus on improving feed purification process section
• Recommend investigating ways to decrease ethanol capital costs
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Additional Financial Information
● Total Permanent Investment: $32.3 million
● Total annual costs: $31.6 milliono $24.5 million in raw materialso $1 million in utilitieso $1.2 million in labor and operations
● Sales: $35.7 million
● Return on investment: 7.90%
● Max. afforded feed price: $7.29/kg of Isobutylene
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Annual Cash Flows
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Utilities Summary