1. Team Members: Michelle Halye Michael Hanks Krunal Patel Desired Product Reaction Equipment List Design of Experiment Pfaudler RT-14-10 Jacketed Reactor 5 Stage Batch Distillation Tower Adjustable Pressure Steam Boiler Water Tower & Reservoir 3 Pressure Regulators 2 Condensers 5 Pumps 10 Fail Close Ball Valves 5 Fail Close Needle Valves 4 Fail Open Needle Valves Primary Company Use for Product Pilot Process Design FactorsResponses pattern Time (Hours) Temperature (°C) Agitation (rpm) Done? Yield, ethanol GC/MS, % 1+ - -21351008-Dec18.6 0.45 2--+113515010-Dec21.2 0.51 3+ + -214510010-Dec24.9 0.46 4- + +114515010-Dec22.2 0.44 5+ + +214515012-Dec22.9 0.44 6- + -114510016-Dec8.4 0.34 7 - - -113510015-Jan16.7 0.47 8+ - +213515020-Jan28.1 0.52 8b+ - +213515013-Feb80.9 0.44 midN/A1.514012530-Jan15.6 0.40 For experiment 8b, the diethyl carbonate was in a 2:1 ratio with the Tris(hydroxymethyl)ethane Advisors: Dr. Kenneth Wynne Dr. Wei Zhang Mr. Rudy Krack HEL Simular TM P&ID Economic Analysis The cost per gram of product is $12.56 if the plant produces 10 gallons or 38.8 kg of product per yea However, if the coating goes from 2 wt% to 100 wt%, the demand would go to 500 gallons or 1949 kg per year, that would take the price down to $.25 per gram. Both of these prices allow for payback in 4.7 years The yields were calculated based on the amount of ethanol driven off by the reaction The distillate contained more diethyl carbonate than was expected - A subsequent experiment with diethyl carbonate in excess showed significantly improved results - Due to time and material constraints, we were unable to perform a full suite of DOE experiments with diethyl carbonate in excess The DOE analysis was performed using the JMP statistical analysis software package - The results showed that increasing the time or the agitation speed independently increased the yield substantially. - However, the results did not show any synergistic effect from increasing these two parameters simultaneously We performed a 3 factor, 2 level full factorial Design of Experiment The DOE was performed only on the first step to: - Keep the DOE manageable - The HEL Simular TM had a temperature restriction preventing it performing the second step The co-polyoxetane the monomer is used in is still in research - It has potential to be an anti-fouling paint coating additive with 2 wt% polymer - The polymer is unique in that it becomes more hydrophobic the wetter the polymer becomes Block Diagram Profitability Return on investment, ave. %/y-10.1 Payback period, y4.7 Net return, 10 6 $-0.52at m ar =15.0%/y Assuming this paint coating would be put on all current naval and commercial ships, we estimated that 10 gallons a year of product would be needed Production, kg/y38.8Cost, thousand $/y TypeItem Variable Cost Raw materials1.25 Operating labor57.6 Utilities0.138 Maintenance and repairs 20.3 Operating supplies2.03 Subtotal:81.3 Fixed Cost Taxes40.5 Insurance20.3 Subtotal:60.8 Plant Overhead7.79 Total Manufacturing Cost:150