Continuous Polymerization of

IsobutyleneGroup 20

Jin Wai GohMoriah Bacon

Kim HollisMarissa Pittard

Nathaniel Robinson

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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