Production of Dimethyl Sulfoxide from Lignin

1. Production of Dimethyl Sulfoxide from Lignin Team Bravo is: Stan Das, Jeff Umbach, Russ Boyer, Krista Sutton, Mike Czepizak Project Lead: Jake Biberstein Team Bravo: Presentation 5

2. Project Outline • Executive Summary • Discussion • Conclusions & Recommendations • Design Basis • Block Flow Diagram • Distribution & End Use Review • Constraints Review • Applicable Standards • Economic Evaluation • Utilities • Conceptual Control Scheme • Plant Layout • Process Flow Diagram • Calculations • Annotated Equipment List • Project Communication File • Sources + References Team Bravo: Presentation 5

3. Presentation Outline • Executive Summary • Discussion • Conclusions & Recommendations • Design Basis • Block Flow Diagram • Distribution & End Use Review • Constraints Review • Applicable Standards • Economic Evaluation • Utilities • Conceptual Control Scheme • Plant Layout • Process Flow Diagram • Calculations • Annotated Equipment List • Project Communication File • Sources + References Team Bravo: Presentation 5

4. Executive Summary • The overall goal of this process is to produce 2,200 lb/hr of >99.7% purity DMSO, 15% market capture. • Primary feedstock for process is black liquor, obtained from Kraft mill that our process will be co-located with. • Secondary feeds include sulfur, tall oil, ammonia, sodium hydroxide and air. • Location: Onsite with a Kraft mill in Louisiana • Capital costs: Approximately $28 million • Yearly profit: Approximately $7.5 million • Simple payback: ~4 years Team Bravo: Presentation 5

5. Discussion • Market analysis: 2,200 lb/hr, 8,000 hr/yr • Corresponds to 8,800 tons/yr, total market is 60,000 tons/yr (2008). • 15% market capture, too high or too low? • Demand of DMSO increasing. • Location analysis: Will be covered later in this presentation. • Economic analysis: Significant variance in feed costs and product sales. • Feed costs: Lignin content of black liquor and methoxy content of lignin can both vary. • Implies that raw material cost of black liquor can wildly vary to produce a known amount and purity of DMSO. • Product sales: Purity of DMSO determines sale price (touched on later). • We address this by assuming lowest possible grade (99.7%) and appropriate sale price for this grade ($1.75/lb). Team Bravo: Presentation 5

6. Conclusions and Recommendations • Process is a GO, provided that: • Plant is located onsite with a Kraft mill. • Black liquor purchased for only the energy content we remove (2.2 cents/lb). • Tall oil obtained for free and added to molten sulfur as polymerization inhibitor. • Waste streams returned to Kraft mill must not have their sulfur content changed appreciably. • Price for product is $1.75/lb for >99.7% purity. • These conditions allow for economically competitive production of DMSO. Team Bravo: Presentation 5

7. Design Basis • Everything in the previous slides, including: • Black liquor definition: 65% solids, 45% of solids is lignin. Lignin is 13.25% MeO groups (mass). • Sodium hydroxide definition: 50% saturated solution. • Ammonia definition: Pure, from a pipeline running through LA. • Spent black liquor stream returned to Kraft mill for burning in their recovery boiler. • Waste stream containing DMS and water needs to be rendered nontoxic before release. • Vented streams from PSA containing only nitrogen and argon. • All efforts made to design plant according to established standards for safe operation. Team Bravo: Presentation 5

8. Block Flow Diagrams Team Bravo: Presentation 5

9. Economic Evaluation • Capital Costs • $27,500,000 • Utilities • $642,000/year • Raw Materials • $14,900,000/year • Labor and Maintenance • $1,900,000/year • Distribution Costs • $1,900,000/year • Other Costs • $3,440,000/year • Total Operating Costs • $23,050,000/year • Total Product Sales • $30,400,000/year • Profit per Year • $7,350,000/year Team Bravo: Presentation 5

10. Distribution and End Use • Design Basis: Shipping product every 22 hours • Produce 2,204lb/hr or 45,000lb/day • Need to ship 100 - 55 gal drums/day • Average shipping quote $5,200/shipment • Annual Shipping Costs $1.9million/yr • With 20% cushion $2.25 million/yr Team Bravo: Presentation 5

11. Constraints Review • Location Sensitivity • Co-location with Kraft Mill • Large mass of black liquor used plus its cost in energy preclude transportation or straight-out purchase. • Co-location eliminates transportation costs and allows for recycling. • Also allows for usage of Tall Oil as polymerization inhibitor. • State of Louisiana • Cheap sulfur – petrochemical industry must desulfurize fuels. • Cheap ammonia – pipeline running through the state. Team Bravo: Presentation 5

12. Applicable Standards • The table at right summarizes grades of DMSO offered by Gaylord Chemical, the chief US supplier. • Design specification assumes “Industrial” grade. • Specification of DMS (dessicator exit conditions): 99.2% DMS, 0.07% water content maximum • Safety specification for hazardous gases: • NO2: 1 hr: 100 ppb. Annual: 53 ppb. [EPA]. 5 ppm [OSHA] • NH3: 50 ppb [OSHA] • NO: 25 ppm [OSHA] • DMS: TEL 10 ppm [ACGIH] Team Bravo: Presentation 5

13. Future Work • Heat Integration/Pinch Analysis/Utility Optimization • Market Growth Rate Research • Designing PSA system • More stringent specifications surrounding ammonia oxidation reactor. • Cooling media required (hot oil) • Metallurgy concerns (heat exchangers) • Fuel gas required to run fired heater • Waste treatment (DMS + Water mixture) • Hydraulics (pump and blower sizing) Team Bravo: Presentation 5