Crude glycerol glucoside esters of cottonseed oil: Preliminary cost analysis

Glycerol glucoside esters prepared by transglycosylation of starch and glycerol, followed by interesterification with esters of cottonseed oil fatty acids, are well suited for use in the steadily growing food emulsifier market. They offer formulators and processors a wide range of compositions and physical properties for achieving more effective emulsification without increase in cost. Process flowsheets, capital costs, manufacturing costs, and general expenses are given for the production of 5.7 million pounds and 17.2 million pounds of crude glycerol glucoside esters annually in hypothetical 4-ton batch and 12-ton batch grass-roots plants, respectively. A material balance and preliminary plant layout for the 12-ton batch plant are also provided. The cost of crude esters ranges from 37.4 cents to 43.7 cents/lb, indicating that the crude esters would be competitive with many commercially available food emulsifiers. The process can be carried out in conventional batch process equipment without production of polluting byproducts. Fixed capital investment for a new 12-ton batch plant would be $2.5 million, and for a new 4-ton plant, $1.3 million.     

Applicability of Ozone and Biological Activated Carbon for Potable Reuse

The Upper San Gabriel Valley Municipal Water District in California is considering groundwater replenishment as a potential strategy to augment its potable water supply. This case study demonstrates the broad applicability of ozone and biological activated carbon (BAC) for such potable reuse systems based on recently developed criteria and models for bulk organics, trace organic contaminants, disinfection byproducts, and cost. Using an advanced treatment train composed of ozone (ozone to total organic carbon ratio of 1.0) and BAC (empty bed contact time of 20 min), a 10 million gallon per day potable reuse facility can achieve savings of $25–$51 million in capital costs, $2–$4 million per year in operations and maintenance costs, and 4–8 GWh per year in energy consumption in comparison to alternative treatment trains with reverse osmosis. This ozone-based treatment train is also capable of achieving public health criteria recently developed by the California Department of Public Health and the National Water Research Institute for potable reuse applications.     

Modeling,optimization, and cost analysis of an IGCC plant with a membrane reactor for carbon capture

This article presents a theoretical study on the integration of a membrane reactor (MR) for carbon capture into an integrated gasification combined cycle (IGCC) plant. First‐principles, simplified systems‐level models for the individual IGCC units and the MR are introduced for their subsequent plantwide integration. The integrated plant model is then used for simulation studies that assume different MR characteristics. Using this model, an optimization problem is formulated to analyze the MR effects when adding it to the IGCC plant, while satisfying all of the process constraints in streams and performance variables. The solution of this optimization problem indicates improvements in the original case studies, including capital cost savings as high as $18 million for the optimal case under nominal process conditions. To determine the cost implications of inserting the MR into the IGCC plant, a differential cost analysis is performed taking into account major plant capital and operating costs. This analysis considers the same amount of coal and power generation for cases with and without the MR. The results of this analysis based on a present value of annuity calculation show break even costs for the MR within the feasible range for membrane fabrication, even for short membrane lifetimes. © 2016 American Institute of Chemical Engineers AIChE J, 62: 1568–1580, 2016     

Dual purpose power/water plants utilizing both distillation and reverse osmosis

The energy consumption of several alternate dual purpose plants are compared for application in the range of 10–50MW with 1 to 20 MGD water production. This shows that the combined gas turbine-steam turbine system is considerably more energy efficient than a steam only system. Single stage R.O., used in conjunction with this combined cycle offers the minimum overall energy consumption but has the disadvantage of producing product water with high TDS. By utilizing both R.O. and distillation, energy consumption lower than with distillation alone is achieved and product water purity is acceptable. p]A specific design of a combined dual purpose plant is presented. This plant would have a net electrical output of 29,050 kw and 3.25 MGD of 440 ppm TDS, requiring 297.1 BTU/hr. The total capital costs of this combined plant is estimated at $41,150,000 and annual operating costs at $15,087,000. The unit production costs with fuel at $2.50/MM BTU would be 4.08¢/kw-hr and $2.44 per 1000 gal. This represents an annual savings of $1,961,000 over single purpose production or 44.5% reduction in water production costs with the same electrical production costs. p]It is concluded that the combined dual purpose plant presented is the most efficient, economical and flexible method of producing power and water in the range of 10 to 50 MW and 1 to 20 MGD.     

基于相变材料的锂离子电池热管理性能

锂离子电池（lithium-ion battery,LIB）作为目前应用最广泛的储能电池之一,在电动汽车等行业发挥着至关重要的作用。电池的温度是影响LIB性能及安全性的重要因素,因此电池热管理（battery thermal management,BTM）至关重要。目前,利用相变材料（phase change material,PCM）进行相变冷却的热管理方式因其潜热高、不需消耗额外能量的优点已成为一种很有前途的方法。本文针对8节并联18650LIB的电池组性能进行了数值模拟及实验研究,探究了石蜡基复合相变材料（composite phase change material,CPCM）物性参数（包括热导率、熔点、相变潜热和材料厚度）对本文设计的电池组热管理性能的影响。结果表明,纯石蜡用于BTM可将3C放电下的电池最高温度降低28.0%,向石蜡中添加膨胀石墨后可使CPCM的热管理性能进一步提升,CPCM的热导率为2.0W/(m·K)时可将3C放电下的电池最高温度进一步降低5.42℃,继续增大CPCM热导率对热管理性能的提升较小。在综合考虑电池组的最高温度和温度均匀性的情况下,为得到在本文所设计的锂离子电池组最佳热管理性能,CPCM的热导率为2.0W/(m·K)、熔点应在36~38℃之间、相变潜热在212J/g左右、CPCM的厚度为4mm时最优。     

Cost effective recovery of lithium from lithium ion battery by reverse osmosis and precipitation: a perspective

Production of lithium from primary resources is lagging behind demand (12% versus 16% in 2016), cost of lithium is increasing (between 40 and 60% in 2016), battery energy density rapidly increasing versus declining cost, and estimated lithium ion battery (LIB) markets size ($77.42 billion by 2024) driven by projected demands for plug‐in electric vehicles (PEVs) clearly justifies recycling. PEV technology and projected demand raise several challenges, including lithium demand/scarcity and future technology to recover lithium from LIB waste. To address the circular economy, steady supply chain security, self‐reliance, environment safety, environment directive, energy security, resources conservation, futuristic carbon footprint, WEEE directives and waste crime, recycling of LIB is an absolute essential. During the last decade, LIB recycling research and industrial recycling of LIB have attracted the interest of researchers, industrialists, and environmentalists. All have reported progress in the recovery of valuable metals like Co, but have rarely focused on lithium recovery. Hence, this paper addresses logical hypothesis and application of available technology in a fashion where lithium recycling from LIB can be addressed. © 2017 Society of Chemical Industry     

Gravimetric blending meets processing needs

Custom moulders can realize significant cost savings and improve plant efficiencies through precise blending of colour concentrate and other additives. With rising costs of these materials, it becomes very important that these ingredients are dispensed highly accurately and that no waste occurs during colour change. John Smith of Conair Europe investigates the effect of material bulk density and geometry changes and variations of dispense methods to the process and offer solutions through properly designed ancillary equipment. He concludes that state-of-the-art gravimetric blenders result in significant savings in colorant/additive costs, improved product quality, shorter colour change time and higher efficiency of capital equipment.     

Optimized design of wastewater treatment systems: Application to the mechanical pulp and paper industry: I. Design and cost relationships

Four different end-of-pipe waste-treatment processes applicable to mechanical pulp and paper manufacture were modelled. Calculated costs for an average mill were capital $34–$44 million, operating cost $3.5–$6 million/year and discounted (10 years) $60–$85 million. Compared with mill reported values, capital and operating costs of activated sludge treatment (AST) were higher by 17 and 29%, respectively; those for aerated stabilization basin (ASB) were higher by 27 and 180%. Major variables affecting the costs were BOD and TSS levels and the wastewater-to-pulp ratio. It was concluded that ASB is more economical than AST and that anaerobic treatment plus AST could be advantageous at high BOD levels.     

硫酸装置技改措施与体会

介绍了硫铁矿制酸装置沸腾焙烧、净化、干吸、转化和节能等方面的技改措施.重点对强化焙烧和沸腾炉改造、泡沫塔改造、干吸塔波纹填料改造、转化工序氧硫比控制和转化器改造作了论述.提倡在最大限度利用原有设备的基础上进行技术改造,在节省投资的同时提高硫酸产量.     

Economics of occupational cotton dust control in cottonseed oil mills

An economic analysis of the total cost for various dust control systems for a 500 ton/day model cottonseed oil mill has been performed. All cost data have been adjusted to reflect May 1981 prices. Cost data are presented for the dust collection system, cyclone(s), baghouse(s) and prime air mover(s) for each major processing area at 3 different air-to-cloth ratios. Data were obtained for equipment and installation costs from mills using the various devices and/or complete systems wherever possible. In cases where these data were not available, estimates were obtained from several firms that manufacture and install similar equipment. At the recommended air-to-cloth ratio of 20:1, the initial capital cost was estimated as $707,900, the annual operating expenses as $226,490 and the life cycle cost as $607,510.     

Computer-aided electrochemical process design: simulation and economic analysis of an electrocatalytic soybean oil hydrogenation plant

The process flowsheet for a soybean oil electrohydrogenation plant has been devised and heat and mass balance calculations on unit operations equipment were performed using a commercially available process simulation software package (PRO/II from Simulation Sciences, Inc.). The design and anticipated performance (current efficiency and power requirements) of the electrochemical flow cells were based on a laboratory-scale radial-flow-through Raney nickel powder electrocatalytic hydrogenation reactor. A semiempirical porous electrode model, that reproduced laboratory-scale reactor data, was incorporated into the PRO/II software as a unit operations subroutine module. Operation of a 3.0×106kgy–1 electrochemical plant was simulated on a computer for different soybean oil/electrolyte feeds and reactor current densities. Based on the PRO/II results, an economic analysis of the process, including capital, installation and operating costs of all equipment was carried out. The lowest total production cost for a brush hydrogenation oil product (20% reduction in the number of double bonds) was obtained at a current density of 15mAcm–2 and a feed composition of 10wt:vol% soybean oil in solvent/supporting electrolyte (US0.13kg–1 for an assumed five year straight line depreciation of capital equipment). This cost was higher than that for a comparable-size chemical catalytic soybean oil hydrogenation plant (US0.019kg–1). When the cost of the soybean oil starting material (US0.68kg–1) was factored into the economic analysis, the production plus raw material cost of the electrocatalytic process was only 16% greater than that for the chemical catalytic plant. The production cost for the electrosynthesized hydro-oil product may be tolerable because the oil has a high nutritional value (a lower trans isomers content) which may command a higher selling price.     

Energy conservation in solvent extraction plants

Solvent extraction plants have been designed for a long time at low capital cost, often at the expense of higher operating costs. Due to rising energy prices, the processing cost structure is changing to such an extent that the designs should be reconsidered. Conservation of steam, on the liquid side (distillation and condensation) and on the solid side (desolventizing, toasting, drying, and cooling), is discussed for existing plant designs.     

A Process Model for Approximating the Production Costs of the Fermentative Synthesis of Sophorolipids

Sophorolipids are microbial glycolipids that possess surfactant-type properties. Sophorolipids have been tested successfully in a number of potential industrial and niche applications but are generally acknowledged to require higher production costs when compared to petroleum-based surfactants. The objective of this study was to develop a process economic model for the fermentative synthesis of sophorolipids using contemporary process simulation software and current reagent, equipment, and supply costs, following current production practices. Glucose (Glc) and either high oleic sunflower oil (HOSO) or oleic acid (OA) were used as feedstocks and the annual production capacity of the plant was set at 90.7 million kg/year with continuous operation of 24 h a day for 330 days per year. Major equipment costs were calculated to be US$17.1 million but other considerations such as capital, labor, material and utilities costs were also included. The single greatest contributor to the overall production/operating cost was raw materials, which accounted for 89 and 87 % of the total estimated production expenditures for the HOSO and OA-based fermentations, respectively. Based on this model and yields of 100 g/L, the cost of large-scale sophorolipid synthesis via fermentation from Glc:HOSO was calculated to be US$2.95/kg ($1.34/lb) and from Glc:OA to be US$2.54/kg ($1.15/lb). The model is flexible and can be adjusted to reflect changes in capital, production and feedstock costs as well as changes in the type of feedstocks used.     

Solar desalination using the vacuum freezing ejector absorption (VFEA) process

This paper consists of design analysis and economic evaluation of a solar-assisted vacuum freezing ejector absorption (VFEA) desalination plant with a capacity of 1 mgd and located in Abu Dhabi, UAE adjacent to the coast of the Gulf. The effect on the design and plant cost of variations in several of the operating parameters was investigated. These parameters are: the sea water salinity, the sea water temperature, and solar collector outlet temperature. Two collector outlet temperatures were used, namely 90°C and 120°C typical of flat plate and evacuated tube collectors, respectively. The absorber loop of the VFEA system uses a sodium hydroxide solution with concentration ranging from 0.5 (dilute stream) to 0.6 (concentrated stream).The results indicate that the capital cost of the VFEA system increases by increasing the sea water salinity and sea water temperature. The capital cost of the system decreases when using the higher value of collector outlet temperature (120°C) typical of evacuated tube collectors. The thermal load on the concentrator is also affected by the sea water salinity and collector outlet temperature with the load increasing with increasing the sea water salinity. The load drops substantially for the collector outlet temperature of 120°C as compared to 90°C.Life cycle savings in fuel costs of the solar-assisted VFEA plant were also estimated using a set of economic ground rules with the objective of specifying the optimum collector area which yields the maximum life cycle savings. It was observed that the optimum area increases with increasing the sea water salinity.     

Means by which reverse osmosis desalting costs can be substantially reduced well. before the year 2000

Examination of the market, state-of-the-art in current practice, and a well documented recent study agree on cost for sea water desalting by reverse osmosis which is approximately $4.00 per thousand gallons of purified water produced. At this cost one generally only produces, reliably, water to meet the rather lenient purity standard of less than 1000 mg/l total dissolved solids after demineralization and conditioning if the recovery fractions and membrane replacement frequency are to have any degree of respectability and acceptability. The study predicts that future “fully developed costs” will be approximately $1.00 per thousand gallons of purified water, largely on the basis of a substantial investment in time and money for research and development over a period of many years.

The thrust of this paper is that present technological product, process, and engineering capability can be used in high recovery full two-stage systems to reduce these costs by 40% to approximately $2.60 per thousand gallons of purified water produced, with such conditioned water meeting the 500 mg/1 TDS and the 250 mg/1 chloride ion upper limits. This thesis is examined and illustrated in detail in several iterations, including sea waters containing 35,000 and 42,000 mg/1 TDS respectively. The above approach produces substantial savings in power requirements, membrane replacement and pre-treatment capital and operating costs which far outweigh the added capital amounts to be amortized. These improvements can be realized starting now with minimum development cost or effort. Further cost reductions to be achieved thereafter by research and development effort are also considered.     

Investigation on drying of middle distillate by Pervaporation

The drying of middle distillate (MD), from which diesel fuel is made, by Pervaporation (PV) was experimentally investigated in a laboratory plant applying organic membranes. The work was conducted in cooperation with a refinery in which MD is catalytically desulphurized by hydrogenation. The H2S formed is separated by steam stripping. The resulting water content in the MD is removed by decanting and subsequent vacuum drying. The objective was to investigate whether drying to low ppm water content is technically possible by the process of PV and to find out about the feasibility of replacing the vacuum drying by PV to save energy. The drying to low ppm water content was accomplished successfully. Permeate total and pure water fluxes are reported. Economic estimations compared vacuum drying costs taken from an existing plant with a design for a full scale multi-module PV plant. The run time of a plant for the point, at which energy savings make up for higher investment costs is estimated.     

丁二烯萃取蒸馏新工艺

巴斯夫（BASF）的丁二烯萃取蒸馏工艺是以NMP（N-甲基吡咯烷酮）为溶剂的工艺，三种普遍用于丁二烯萃取溶剂中NMP是唯一无毒的溶剂。BASF公司投入了大量的精力改进了以NMP为溶剂的丁二烯萃取蒸馏的工艺。新工艺包括萃取蒸馏区。脱气区。蒸馏区和溶剂回收区。新工艺设备减少，投资降低10%，维护费用减少15%，装置安全性得到改善。     

Aqueous extraction—An alternative oilseed milling process

Oil can be removed from oilseed materials by a process which consists of an aqueous extraction of the comminuted seed, followed by a centrifugal separation which divides the aqueous extract into oil, solid, and aqueous phases. The protein may be recovered in the solids or aqueous phase, depending upon the conditions selected. Unit operations of this process are grinding, solid-liquid separation, centrifugation, demulsification, and drying of products. Aqueous extraction has been applied, to date, to coconuts and peanuts. For coconuts, a procedure has been developed to recover 93% of the oil and 91% of the protein. The major protein product is 25% protein and, when reconstituted in water, forms an acceptable beverage. The estimated production cost of this product is $.24/1b. For peanuts, the recovery of oil was 89% and protein 92% for the concentrate procedure, whereas the corresponding values for the isolate procedure were 86% and 89%, respectively. The costs of production were estimated as $.17/1b of concentrate (67% protein) and $.28/1b of isolate (89% protein). Aqueous extraction offers several advantages over conventional solvent extraction-less initial capital investments, safer operation, capability of discontinuous operation, and production of a variety of products. Another advantage of aqueous processing is the capability for utilization of certain chemicals to remove or inactivate undesirable substances. In the case of peanuts, hydrogen peroxide and sodium hypoehlorite have proven to be effective for destruetion of aflatoxins. Aqueous processing has the potential for application to a variety of other oilseeds. One of seven papers presented at the symposium, “Processing Methods for Oilseeds,” AOCS Spring Meeting, April 1973.     

三种萃取精馏法生产1,3-丁二烯的经济评价

利用化工流程模拟软件Aspen Plus对国内常用的ACN法、DMF法、NMP法三种1,3-丁二烯萃取精馏工艺进行了全流程模拟优化和热集成分析。模拟结果表明,三种工艺的1,3-丁二烯产品质量均满足设计要求,且相关参数与实际生产操作数据吻合较好。在此基础上,以年度总费用(TAC)最小为目标函数,利用最新经济数据评价了三种工艺的经济技术水平。结果表明,三种工艺的年度总费用以NMP法最低,DMF法最高,NMP法具有明显的经济优势。     

Removal of N‐methylpyrrolidone hydrogen‐bonded to polyaniline free‐standing films by protonation–deprotonation cycles or thermal heating

Free‐standing films of polyaniline (PANI), in an emeraldine base state, prepared by evaporation of polymer solutions in N‐methylpyrrolidone (NMP) retain solvent even under dynamic vacuum drying as indicated by transmission Fourier transform infrared (FTIR) spectroscopy, where a band at 1670 cm^?1 is clearly observed. Upon protonation–deprotonation cycles in aqueous media the weight of the dry base film decreases indicating gradual loss of NMP. Transmission FTIR spectra shows also the washing out of NMP with a clear decrease in intensity of the hydrogen‐bonded >C?O stretching band (1670 cm^?1) of NMP. During this process the bands between 3500 and 3200 cm^?1, assigned to >N? H stretching in the PANI backbone, change intensity suggesting that intermolecular hydrogen‐bonded >N? H, with carbonyl oxygen of NMP, is replaced by free >N? H. This is clear evidence of specific interaction of NMP with the emeraldine base. A similar loss of NMP is observed during heating but evidence of polymer degradation is also present. A mechanism is proposed to account for the loss of hydrogen‐bonding ability upon protonation which requires delocalization of the radical cations in the protonated films. © 2001 Society of Chemical Industry