University of Wyoming Laramie, WY. May 5th, 2017. CHE 4080 PROCESS DESIGN II SPRING 2017 Lignin to Adipic Acid PetroPalooza: Jose Cabrera Rodas Amanda McAliney Kristina Quick Holly Ramseier Sedona Rockwood Department of Chemical Engineering Professor: Dr. David Bell Associate Professor Department of Chemical Engineering College of Engineering and Applied Sciences Page 1 of 79 TABLE OF CONTENTS 1. Executive Summary (SR) ....................................................................................................... 7 2. Scope of Work (AM) ............................................................................................................... 8 2.1. Design Problem ............................................................................................................... 8 2.2. Constraints ....................................................................................................................... 8 3. Introduction (JC) ..................................................................................................................... 11 4. Base Case Description ............................................................................................................ 15 4.1. Bioreactor (JC) ............................................................................................................. 16 4.2. Activated Carbon Packed Bed Reactor (AM).............................................................. 19 4.3. Sulfuric Acid Storage Tank (KQ) ................................................................................ 21 4.4. Mixing Tank 1 (KQ) .................................................................................................... 22 4.5. Cooling Crystallizer (KQ) ........................................................................................... 22 4.6. Rotary Drum Vacuum Filter 1 (KQ) ........................................................................... 23 4.10 Ethanol Storage Tanks (HR) ........................................................................................ 24 4.11 Continuous Stirred Tank Reactor (HR) ....................................................................... 25 4.12 Rotary Drum Vacuum Filter 2 (HR) ............................................................................ 26 4.13 Trickle Bed Reactor (SR)............................................................................................. 27 4.14 Evaporation Crystallizer (AM) .................................................................................... 29 5. Design Alternatives ................................................................................................................. 30 5.1. Bioreactor (JC) ............................................................................................................. 30 5.2. Activated Carbon Packed Bed Reactor (AM).............................................................. 31 5.3. Cooling Crystallizer (KQ) ........................................................................................... 32 5.4. Rotary Drum Vacuum Filter 1 (KQ) ........................................................................... 33 4.15 Ethanol Storage Tanks (HR) ........................................................................................ 33 4.16 Continuous Stirred Tank Reactor (HR) ....................................................................... 33 4.17 Rotary Drum Vacuum Filter 2 (HR) ............................................................................ 33 4.18 Trickle Bed Reactor (SR)............................................................................................. 34 4.19 Evaporation Crystallizer (AM) .................................................................................... 34 6. Permitting and Environmental Concerns (SR) ....................................................................... 36 6.1. Environmental Concerns ................................................................................................. 36 6.2. Hazardous Waste Permitting ............................................................................................ 36 6.3. Air Quality Permitting ..................................................................................................... 37 6.4. Environmental Comparison to Petrochemical Process .................................................... 40 7. Safety and Risk Management (KQ) ........................................................................................ 43 7.1. Chemical Concerns .......................................................................................................... 43 7.2. Biological Concerns ......................................................................................................... 46 Page 2 of 79 7.3. Unit Operation Concerns ................................................................................................. 47 8. Economics (AM) ..................................................................................................................... 50 8.1. General Information and Approaches ........................................................................... 50 8.2. Major Equipment Cost .................................................................................................. 50 8.3. Total Fixed Capital Investment .................................................................................... 51 8.4. Operating Cost .............................................................................................................. 51 8.5. Cash Flow Analysis ...................................................................................................... 52 8.6. NPV and IRR ................................................................................................................ 53 8.7. Sensitivity Analysis ...................................................................................................... 54 9. Global Impacts (HR) ............................................................................................................... 56 9.1. Old Petrochemical Process ........................................................................................... 53 9.2. New Biochemical Process ............................................................................................ 54 10. Conclusions and Recommendations (JC) ............................................................................... 59 11. Future Work (HR) ................................................................................................................... 60 12. Acknowledgements ................................................................................................................. 60 13. References ............................................................................................................................... 61 14. Appendices .............................................................................................................................. 64 Page 3 of 79 TABLE OF FIGURES 1. Second-generation lignocellulosic ethanol plant flowsheet .................................................... 11 2. Lignin aromatics ..................................................................................................................... 12 3. Conversion of lignin to aromatics and muconate ................................................................... 13 4. Separation and purification scheme for process ..................................................................... 14 5. Simplified flowsheet ............................................................................................................... 15 6. Stirred tank bioreactor............................................................................................................. 17 7. Cross-flow filter ...................................................................................................................... 18 8. Particle size distribution for filter ........................................................................................... 18 9. Chemical reaction in packed bed reactor ................................................................................ 19 10. UV absorption sensor .............................................................................................................. 20 11. Packed bed adsorption column ............................................................................................... 21 12. SAFE-Tank ............................................................................................................................. 22 13. Muconate to muconic acid chemical reaction ......................................................................... 22 14. Jacket scrapping-cooling crystallizer ...................................................................................... 23 15. Rotary drum vacuum filter ...................................................................................................... 24 16. Stainless steel ethanol tank ..................................................................................................... 25 17. CSTR....................................................................................................................................... 26 18. Rotary drum vacuum filter ...................................................................................................... 27 19. Hydrogenation of muconic acid .............................................................................................