1. Site Selection: The facility should be located in an area with access to a reliable and sustainable supply of waste feedstock, as well as transportation infrastructure to ship the products.
2. Waste Feedstock Preparation: The waste should be sorted and pre-treated to remove any non-combustible components and moisture to reduce impurities and optimize the syngas production process.
3. Gasification/Pyrolysis/Plasma Process Design: The feedstock should be converted into syngas through a gasification, pyrolysis or plasma process with high efficiency and minimal emissions, and ensure stable and consistent syngas production.
4. Syngas Cleaning: The syngas should be treated to remove impurities such as sulfur, halides, ash and other particulate matter before entering methanol synthesis process.
5. Methanol Synthesis: The syngas is converted into methanol through an optimized synthesis process using catalysts with high activity, high selectivity, and long lifetimes.
6. Propylene and Acrylic Acid Production: The methanol is then converted into propylene and acrylic acid through optimized chemical reaction and catalyst formulation.
7. Butyl Acrylate Production: Butyl acrylate is produced by reacting acrylic acid with butanol in a hydrocarbon solvent, with strict control of reaction conditions.
8. Process Safety and Control: Process safety and control should be carefully considered to ensure safe, reliable, and consistent production. Safety measures like fire protection systems, leak detection, and emergency shutdown systems should be implemented and monitored.
9. Environmental Considerations: Environmental impact assessments and waste management plans should be developed to minimize the environmental footprint of the facility. Emission controls, waste treatment systems, and energy management programs should also be implemented.
10. Economic Feasibility: The facility should be designed to be economically feasible through an optimized design, reliable equipment sourcing and efficient operation with high product yields, high process efficiency and minimal waste. The revenue generated from product sales should outweigh the investment and operating costs.
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