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Process Design and Technoeconomic Analysis for the
Downstream Recovery and Purification of Diethyl Malonate
Team 7Chris Bilham
Brian CoventryMark Kelsic
Yekaterina PokhilchukDan Sriratanasathavorn
Matthew Lipscomb, PhD.CEO & Founder
DMC Limited
❖ Agenda
• Introduction• Project Goals• Purification Method 1 • Purification Method 2• Environmental• Economics• Conclusions• Acknowledgements
diethyl malonate
Image from: http://www.sigmaaldrich.com/catalog/product/aldrich/d97754?lang=en®ion=US
http://www.directindustry.com/prod/solaris-biotechnology/product-54387-443440.html https://en.wikipedia.org/wiki/Malonic_acidhttp://culmotrialattorneys.com/bpa-may-alter-gene-regulation/ https://en.wikipedia.org/wiki/Continuous_stirred-tank_reactor
Uses● pharmaceuticals● fragrances● dyes● adhesives
❖ Diethyl Malonate (DEM)
❖ Project Goal Statement
Two methods for purification of diethyl malonate (DEM) from a fermentation reactor are to be designed and economically analyzed.
Deliverables● Economical, environmental, and safety analysis
DEM production specifications● 10,000,000 kg/year● >99% purity
Image from: http://www.sigmaaldrich.com/catalog/product/aldrich/d97754?lang=en®ion=US
❖ Experimental Data and Solvent Selection
Models:● Decanter● LLE & distillation
Solvent Selection:● Separation factor● Boiling point● Cost
Solvent of choice - Pentane
K = 2.64 (DEM in petane-water solution)
❖ Method 1 - Decant
Assumptions:● No salts entrain with the water to the
evaporator● No salts entrain with the DEM product● All salts leave with waste stream
❖ Method 1 - Decant
❖ Method 2 - Liquid-Liquid Extraction (LLE)
Assumptions:● Salts do not enter pentane phase● Water does not enter pentane phase● Pentane does not enter water phase
❖ Method 2 - Liquid-Liquid Extraction (LLE)
❖ Series Process - Decanting followed by LLE
❖ Environmental and Safety
Hazardous Waste● Listed by the EPA● Ignitability● Corrosivity● Reactivity● Toxicity
Safety ● 12 M HCl is extremely corrosive ● 1 M NaOH
Image from: http://rapidwasteenviro.com/wp-content/uploads/2014/12/hazardous-waste-types.png
❖ Wastewater
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Industrial Wastewater for Boulder● Permit $7,050 per year ● Publicly owned treatment works
(POTW)● Specific pollutant limitation● pH 5.5- 10● $70 per 1000 gallons
❖ Operating expense sensitivity analysis parameters
Parameters that were investigated:
● Feed DEM production price● Feed stream DEM %● LLE column stages● LLE column solvent to feed ratio● Decanter pH● Decanter temperature
Note: The following slides to not take into account waste disposal fees which did not vary during sensitivity analysis
❖ Sensitivity to feed composition and price
• Series Process is cheapest at every condition
• Solid line shows low DEM production price ($1.90/kg)
• Dotted line shows high DEM production price ($3.10/kg)
❖ Operating cost breakdown
Series Process Only LLE Only Decant
99.95% DEM recovery 99.96% DEM recovery 94.76% DEM recovery
• Distillation represents the biggest operational expense
• DEM sent to waste considered an operational expense
❖ Liquid-Liquid Extraction sensitivity
• Careful balance between losing DEM and distillation costs
• Increasing LLE stages lowers operating costs but increases capital costs
• Series Process most economical at 99.1% recovery in LLE unit
Increasing DEM recovery
Increasing distillation costs
Series Process
❖ Decanter sensitivity
• Most economical to not change temperature of feed
• Decreasing pH lowers DEM solubility in water
• Process economics may continue to improve at lower pH
Series Process
❖ Effect of wastewater treatment
• Boulder has very expensive wastewater prices
• Wastewater increases the unit operating cost by a constant amount for each process
Series Process Only LLE Only Decant
+$0.11/kg+$0.11/kg +$0.14/kg
❖ Economics
• Lowest initial capital investment is for LLE only process.
• Lowest operational cost is for the Series process
Adding in capital costs for equipment and installation...
❖ Economics
• Fastest return on investment is always the LLE only, when considering all associated costs.
❖ Conclusion
• Decanting alone is a poor choice.
• Series and LLE have similar operational costs
• Our model suggests that LLE is the best option including all costs.
• Plant should be considered somewhere with lower waste disposal costs.
• Capital costs should be further investigated to determine tradeoff of long term operation against initial investment
• Further investigation into salting and pH effects on the solubility of DEM is warranted.
❖ Acknowledgements
● Professor Thomas Belval - University of Colorado Boulder● Dr. Mathew Lipscomb - DMC Limited● Professor Rainer Volkamer - CU● Dr. Molly Larsen - CU● Zachary Finewax - CU● Theodore Koenig - CU
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