AIChE design project: Grassroots Nylon 6 6 plant

Abstract

A preliminary design of a Nylon 6 6 plant to produce granules by extrusion was conducted for Calvert City, Kentucky. This process involves a reaction between adipic acid and hexamethylene diamine (HMDA) through a continuous process. This type of process was chosen over a batch process to make the system inherently safer, reduce process time, and decrease operating costs [1]. Through the use of a continuous polymerization reactor, molten Nylon is produced and then processed by an extruder and additional mechanical processing equipment to dry the Nylon granules. The production of Nylon granules was chosen instead of Nylon filaments. This is due to the versatility of the Nylon granules to be further processed into different lengths and thicknesses based on the customers' specific needs.

The net present value of the project was calculated to be $12,916,000 with a discounted cash flow rate of return (DCFROR) of 30.4%. The DCFROR is greater than the hurdle rate of 15% which makes this project economically attractive. The payback period is 4.11 years for a ten year project life.

This process has some safety concerns based on the polymerization reactor and components involved in the process, but these risks will be controlled. Cooling jackets, alarms, and other emergency procedures will be implemented to ensure the safety of everyone involved with the plant and the surrounding community.