Zeolite ProductionTeam 12

Bi Chen, Kevin Hendrawan, James Inglett, Noemi Mendoza, Kuang Sheng

Outline

▪ Introduction

▪ Background on Product

▪ Outline of our processes

▪ Optimization

▪ Waste Treatment

▪ Location

▪ Floor Plans

▪ Economics

Mission Statement

Our goal is to produce high quality zeolite x and mordenite for catalysis

that competes in the global market in terms of production volume,

purity, and quality.

Zeolite X & Mordenite

▪ Zeolites are crystalline solids made of Si, Al, and O

▪ Ratios

▪ Useful as molecular sieves

▪ Zeolites have many applications in different areas

▪ Petrochemical cracking

▪ Gas purification

▪ Ion-exchanged water softener

▪ Catalysts

https://upload.wikimedia.org/wikipedia/commons/f/fa/Zeolite-ZSM-5-vdW.png

Our ProductZeolite X Mordenite

Si/Al Ratio 2.5 5

Application

Used as catalysts in fluid catalytic

cracking and hydrocracking units

in industrial refineries.

Used as catalysts for the acid-

catalyzed isomerisation of

alkanes and aromatics in the

chemical industry.

Expected Growth & World Market

Stead, Jerre. "Zeolites." - Chemical Economics Handbook (CEH). IHS, 11 Oct. 2013. Web. 10 Feb. 2016. <https://www.ihs.com/products/zeolites-chemical-economics-handbook.html>.

"Zeolite Market Size, Share | Industry Research Report, 2022." Zeolite Market Size, Share | Industry Research Report, 2022. Grand View Research, 13 Nov. 2015. Web. 07 June 2016.

Zeolite X Process

Kaolin:30kg/h

Silica : 20 kg/hWater: 1 kg/hSodium Hydroxide: 9 kg/h

Annual Operating time: 7920 hAnnual Production: 460,780 kgSelling Price: $5 / kg

50-80℃20 h

Zeolite: 58.18 kg/h

Mordenite Process

Kaolin:0.52kg/h

Ethanol :1.38kg/hSilica : 0.96kg/hWater: 0.22kg/hSodium Hydroxide: 0.16kg/h

Mordenite:1.78kg/h

Annual Operating time:7920 hAnnual Production:14,112 kgSelling Price: $3 / kg

130-170℃72 h

Plant layout & Floor plans

Calcinator

Zeolite X

Mordenite

Zeolite X P&ID

Optimization▪ Scaling to meet demands for both Zeolite X and Mordenite markets

▪ Used metakaolin for SiO2 and Al2O3 source for starting material to save costs

▪ Changed mordenite catalyst to using ethanol instead of 1,8-diamino-p-menthane

▪ 90% recycle line of NaOH wastewater

▪ Pump lines and heat exchange systems

▪ Replaced coal-furnace calcination

process with electric-heated calcination

to minimize environmental impact.

Waste treatment

▪ Wastewater expelled from bleed line and overall factory process is basic, pH 11-14

▪According to the EPA and the MEP, industrial discharge must meet the pH of 6-9.

▪This is achieved by using carbonic acid to lower the wastewater pH to appx. 8.5.

▪H2CO3 + 2NaOH → Na2CO3 + 2H2O

▪ Other constituents in the waste discharge are not regulated by EPA or MEP

▪SiO2 and Na2O are naturally occurring, low toxicity, negligible effect on environment.

▪Al2O3 is insoluble, does not bioaccumulate, and found in nature.

▪Address this by sedimentation before discharge.

Location

▪ Largest industrial city in South China (Guangzhou)

▪ Serves as an important national transportation hub and trading port

▪ Close to Suppliers

▪ Expanding Mechanical Equipment Industry

▪ Petrochemical Industry

Chemical Industrial Area

Economics

Construction Time Breakeven Point

Economics

▪ Total annual revenue from zeolite sales: $2.5 million▪ Total annual revenue from mordenite sales: $47,000▪ Net present value $11.89 million▪ Payback period of 1 year▪ Rate of return on investment 43.09%

Conclusion

▪ High demand for zeolite in China as well as expected market growth

▪ Producing over 474,000 kg of zeolite and mordenite per year

▪ Total revenue $2.6 million

▪ Breakeven in year before year 4, 1 year after start of operation

▪ For an expected factory life of 15 years profit of ~$12 million

▪ Rate of return on investment 43.09%

QUESTIONS