Improvised the design of an existing isobutylene polymerization plant by Baker Hughes and optimized its economic viability.

1. Continuous
Polymerization of
Isobutylene
Group 20
Jin Wai Goh
Moriah Bacon
Kim Hollis
Marissa Pittard
Nathaniel Robinson

2. 2
Introduction & Motivation
• Goal: optimize polyisobutylene (PIB) production
• Anti-misting agents are critical to the production of
hydrocarbon fuels
• Batch process limitations: time, safety, and health

3. 3
Overview: Feed Purification

4. 4
Overview: Polymerization and Purification

5. 5
Unique Design Aspects
• Production rate = 20,000 lbs PIB per day
• Upstream flash unit
– Removes 88% of oxygen from fresh feed
– Reduces load on molecular sieve
• Dec. capital and utility requirements
• Dec. monomer loss
• Monomer and diluent recycle bypass sieve
– Minimal loss of diluent
– Simplifies design

6. 6
Fixed Capital Investment Summary
Feed
Purification
44%
Reaction
11%
Product
Purification
18%
Recycle
16%
Storage
11%
Total Bare Module Cost
by Process SectionTotal Bare Module Cost, CTBM $26.7M
Total Direct Permanent Investment, CDPI $26.7M
Total Depreciable Capital, CTDC $29.3M
Total Permanent Investment, CTPI $32.2M
Total Capital Investment, CTCI $32.6M

7. 7
Financial Analysis Summary
Annual Production Cost $31.6M
Return on Investment 7.90%
IRR 9.8%
Max. affordable feed price $7.29/kg IB

8. 8
Safety & Environmental Considerations
• ThermOx eliminates release of harmful materials to
atmosphere
• Methyl Chloride
– Maintained below auto-ignition temperature
– Continuous operation reduces exposure
– Store in detached building
• Aluminum Chloride
– Injected with automatic system
– Less than 2 ppm throughout process
• Conservation of materials and waste

9. 9
Conclusions & Recommendations
• Greatly improved production capacity, efficiency, safety
–Reduces operator manual labor
–Reduces toxic chemical exposure
• Can afford to pay $7.29/kg IB
• Future designs should focus on improving feed
purification process section
• Recommend investigating ways to decrease ethanol
capital costs

10. 10
Additional Financial Information
● Total Permanent Investment: $32.3 million
● Total annual costs: $31.6 million
o $24.5 million in raw materials
o $1 million in utilities
o $1.2 million in labor and operations
● Sales: $35.7 million
● Return on investment: 7.90%
● Max. afforded feed price: $7.29/kg of Isobutylene

11. 11
Annual Cash Flows

12. 12
Utilities Summary