KOCH MODULAR PROCESS SYSTEMS

Transcription

1 KOCH MODULAR PROCESS SYSTEMS Designing Separation Systems for Bio-Produced Chemicals Prepared for: Pacific Rim Summit on Industrial Biotechnology Date: December E i s e n h o w e r D r i v e, S u i t e 3 5 0, P a r a m u s, N J Te l : ( ) F a x : ( ) w w w. m o d ul a r p r o c e s s. c o m

2 WHO IS? Koch Modular Process Systems (KMPS) is a joint venture with Koch- Glitsch LP, one of the world's most prominent suppliers of mass transfer equipment. Koch-Glitsch's parent company is Koch Industries, one of the largest privately held corporations in the United States. For over 20 years KMPS has successfully designed and constructed mass transfer systems for the worldwide Chemical Processing Industry. Our customer s rely upon KMPS for our quality products and technical expertise. 2

3 What We Do Specialists in Process Design and Construction of Modular Mass Transfer Systems for Solvent Recovery, Wastewater Stripping, Product Purification, Organic Chemical Separations, Acid Gas Treating and Environmental Applications. KMPS also provides engineered components and engineering services, including equilibrium data development, process development and pilot plant testing. Objective: Provide economic solutions to separation problems. 3

4 Who We Are Chemical Engineers Process Project Control & Automation Business Development Other Engineers Mechanical Civil / Structural Electrical Instrumentation Design Drafting Piping Design Vessel Structural Process / P&ID Other Technical Pilot Plant Operations Analytical Chemist Quality Control 4

5 Areas of Expertise Process Simulation Continuous Distillation Steam Stripping Batch Distillation High Vacuum Distillation Azeotropic Distillation Extractive Distillation Liquid-Liquid Extraction Gas Absorption Reaction Kinetics Reactive Distillation Process Chemistry Thermal Design of Shell/Tube Exchangers 5

6 Process Applications We service the Chemical, Electronics, Alternative Energy, Pharmaceutical, Petrochemical, Biotech, Food and Flavor & Fragrance with typical applications such as: Purification of Silicon & Silanes Separations for Biomass Fermentor Products & Cellulosic Ethanol Production High Vacuum Separations of Citrus Oils and Flavor & Fragrance Products Solvent Recovery Systems Aqueous Waste VOC Removal Pharmaceutical Intermediates Multicomponent Separations Solvent Drying Pilot Plants/Semi-Works Purification of Organic/Inorganic Products Organic/Inorganic Chemical Manufacture Acid Gas (e.g., CO2 & H2S) Removal from Syngas, Natural Gas, Flue Gas or LPG 6

7 Products Modular Mass Transfer Systems Liquid-Liquid Extractors KARR Column, SCHEIBEL Column Engineered Equipment Process Control Systems DeltaV, PLC & DCS Engineering Services: Process Development & Process Simulations VLE Data Generation/Regression Process Feasibility Studies Engineering Packages Pilot Plant Testing KARR and SCHEIBEL are registered trademarks of Koch-Glitsch, LP. Heat Exchanger Thermal Design Troubleshooting Existing Equipment Startup Assistance and Operator Training 7

8 Modular Mass Transfer Systems Extensive experience providing distillation systems designed to recover high purity chemicals. This particular project employed extractive distillation. 8

9 Proven Separations Experience Acetaldehyde Aniline Carbon TetraCl Esters Acetic Anhydride Benzene Chloroform Ethanol Acetic Acid Benzophenone Cyclohexane Ethyl Acetate Acetone BHT Cresols Ethylbenzene Acetonitrile Br Hydrocarbons Cumene Ethyl Dichloride Acrylonitrile Butadiene DCPD Formaldehyde Amines Butanol Dioxane Formic Acid Ammonia Butyl Acetate DMAC Furfural Amyl Acetate Caffeine DMF Amyl Alcohol Carbon Dioxide DMSO 9

10 Proven Separations Experience Geraniol Isopropyl Ether Napthalenes Pyridines Glycols Isopropyl Acetate n-methyl Pyrrolidone Refrigerants H2S Isopropyl Alcohol Nitroethane Styrene Hexane Limonene Nitromethane THF HMDO Linalool Nitrophenol Thionyl Chloride Heptane MEK Perfumes Toluene Indene Methanol Phenol Trichloroethane Ionones Methyl Acetate Phenylenediamine Trichloroethylene IPA Methylene Chloride Piperidine Water Isophorone MIBK Propanol Xylene & Xylenols 10

11 KMPS and Bio-Technology Recently large emphasis on production of chemicals from biomass (fermentation, algae) Many Bio-Technology companies need help developing optimal separation process for recovery and purification KMPS has the expertise, experience and pilot plant facility to optimize the design of the separation systems 11 11

12 Biofuel & Biochemical Our liquid-liquid extraction and distillation technologies are critical resources for the product recovery and purification needs of this important and developing sector of the industry 12

13 KMPS Pilot Plant (Houston, TX) KMPS maintains a pilot plant dedicated to distillation and extraction R & D and applications testing. We generate data for accurate scale-up

14 Full range of services: Feasibility Studies Process Design VLE/LLE Data Development Pilot Plant Testing Process Expertise: Distillation Liquid-Liquid Extraction Steam Stripping Absorption Successful Pilot Plant Testing = Process Performance Guarantee 14 14

15 Fermentation Process with LLE Recycle Solvent Fermentation Spent Broth Solvent Stripping Recycle Solvent Liquid-Liquid Extraction Extract Distillation (Solvent Recovery) Broth Treatment Filtration Centrifuge Cell Disruption Additional Dist. Product(s) Purification 15 15

16 Recovery of Carboxylic Acids from Fermentation Broth Broth generated by fermenting cellulosic materials ~5% acids LLE Goal: >95% recovery (high purity) and minimal solvent use Ethyl acetate solvent but emulsified easily Preliminary Data in RDC Columns Difficult operation due to emulsification < 90% acid recovery High S/F ratio 2.0 KARR Column Required 16 16

17 Recovery of Carboxylic Acids from Broths Using a Low Boiling Solvent Fermentation Broth Extract 5 % carboxylic acids Recycled Ethyl Acetate Solvent: Ethyl Acetate Extraction Raffinate Raffinate Stripping Aqueous Raffinate Solvent Recovery Carboxylic Acids 17 17

18 Pilot KARR Column for Carboxylic Acids - 1 diameter x 12 Plate Stack Organic Out (Extract Phase) Hot Oil Aqueous Out (Raffinate) Whole Broth Feed Ethyl Acetate 18 18

19 Extraction Testing Results KARR Column is correct design for this process which failed in RDC column S/F ratio improved to 1.5 (client expected 2) 96-97% recovery at room temperature and 98-99% recovery at C. Approximately 7 theoretical stages generated. Design capacity 26.5 m 3 /m 2 hr Complete system (LLE + distillations) designed, fabricated, and installed including KARR Column installed on right LLE testing identified unknown component 19 19

20 Recovery of Carboxylic Acids from Fermentation Fabrication and installation of a complete modular system including LLE column, solvent recovery column and steam stripping column. Modules contain all equipment, exchangers, pumps, and tanks along with piping, instrumentation, and electrical wiring preinstalled. 20

21 Summary - Options for LLE Testing KMPS Pilot Plant Houston, Texas Purchase Pilot Column from KMPS Rent Pilot Column from KMPS Column alone or complete set-up KMPS personnel are available for set-up and testing at client facility 21 21

22 CONCLUSIONS KMPS expertise is in design and supply of separation systems The pilot plant allows us to optimize processes using actual process liquid and provide process performance guarantees Modular construction provides fully assembled units shipped directly to the job site