1. Production of Adipic Acid and 1,6-Hexanediol from 1,3-Butadiene Final Project Analysis
NoDoz, Corp. Group 8
Greg Bogaert
Todd Francis
Ramana Vishnubhotla
Jonathan West
12/13/02

2. Introduction Process Description Have supply of 1,3-butadiene (BD)
Invest and profit from this market
Adipic acid (AA)
Used in nylon-6,6 production
1,6-Hexanediol (HDO)
Used in pharmaceutical/agricultural chemical production

3. Objectives
Design a process to produce adipic acid and 1,6-hexanediol from a 1,3-butadiene feed stock
900 Mlb/yr of adipic acid
300 Mlb/yr of 1,6-hexanediol
Develop an economic analysis detailing the process and plant
Provide a detailed analysis discussing the recommendations

4. Summary Design Process Economic feasibility 7 Stage Production Plant
1000 Mlb/yr of adipic acid
300 Mlb/yr of 1,6-hexanediol
100 Mlb/yr of diethyl adipate
Economic feasibility
$1454 million/yr in Revenue
$772 M initial investment
$934 million/yr operating cost
$442 Net Present Value (NPV)

5. Economic Feasibility Total operating life of 10 years
One year startup
Negligible land costs
Discounted Payback Period (DPBP) = 3 years
Present Value Ration (PVR) = 1.7
Net present value (NPV) = $442 M
Initial investment = $772 M
Operating cost = $934 M/yr
Revenue = $1454 M/yr

6. Fixed Capital Investment
       Name $ (M)   
ISBL Components
Plant Equipment, Insulation, and Installation  129   
Piping, Insulation, and Installation   116 
Instrumentation and Control   
Contingency
Total ISBL Costs 
Total OSBL Costs    
TOTAL FIXED CAPITAL INVESTMENT   
539

7. Working Capital TOTAL WORKING CAPITAL
General Expenses $ (M) Administrative Expenses
Sales and Marketing 
Research and Development
Total General Expenses 
Manufacturing Costs   
Plant Overhead 
Fixed Charges   
Direct Production Costs
Total Manufacturing Costs 
TOTAL WORKING CAPITAL 
233

8. Operating Costs TOTAL OPERATING COSTS
General Expenses $ (M) Administrative Expenses
Sales and Marketing 
Research and Development
Total General Expenses 
Manufacturing Costs   
Plant Overhead 
Fixed Charges   
Direct Production Costs
Total Manufacturing Costs 
TOTAL OPERATING COSTS 
934

9. Revenue Products Flow Rate (LB/hr) Cost ($/LB) $ (M) Adipic Acid
122,357
$0.78
774
1,6- Hexanediol
42,212
$1.65
568
Diethyl Adipate
15,349
$0.89
112
TOTAL REVENUE
1,454

10. Discounted Cash Flow $ (M) Operating Life (Yrs) 600 400 200 2 4 6 8 10
$ (M) 2 4 6 8 10 12
-200
-400
-600
-800
Operating Life (Yrs)

11. Conclusions Technically feasible Economically feasible
7 stage production plant
Documented research
Intensive computer stimulations
Economically feasible
3 DPBP
1.7 PVR
$442 M NPV

12. Recommendations
Recommend further development in the production of adipic acid and 1,6-hexanediol
Recommend further research of alternative designs

13. References
[Barkel M] Barkel, Barry M. Assignment Memo Adipic Acid/1,6-Hexanrdiol 2002
[Barkel CM] Barkel, Barry M. Cost Manual 2002
[MICHI] Barkel, Barry M. MICHISITE data 2002
[Barkel OH] Barkel, Barry M. Lecture/Office Hours 2002
[CEH] Chemical Economics Handbook, SRI International 2001
[Davis] Davis, et al., DUPONT, Adipic Acid-Physical Properties, Ullmann’s Encyclopedia of Industrial Chemistry, VCH, 2002
[Musser] Musser, Michael Tuttle, Adipic Acid-Quality Specifications, Ullmann’s Encyclopedia of Industrial Chemistry, VCH, 2002
[Merck] Merck Index, Merck Publications 2002
[Peters] Peters, Max S., Timmerhaus, Klaus D., Plant Design and Economics for Chemical Engineers, McGraw-Hill, 1991
[Schwank OH] Schwank, Johannes Lecture/Office Hours 2002
[Shiokawa] Shiokawa, et al., Process for the Production of Esters, US Patent # 5,463,095, 1995
[Shiomi] Shiomi, et al., Process for Producing Diol Compounds, US Patent # 5,536,888, 1996
[Turton] Turton, et al., Analysis, Synthesis, and Design of Chemical Processes, Pretence Hall, 1998
[Werle] Werle, et al., Alcohols, Polyhydric, Ullmann’s Encyclopedia of Industrial Chemistry, VCH, 2002

14. Any Questions?