We were tasked with exploring a retrofit of an existing dimethyl carbonate (DMC) direct synthesis plant in Peculiar Missouri. The retrofit design must keep the required production rate of 15 million kg/operating year with a 99.5 mol% DMC purity specification. The goals for this project were to model the current and retrofit processes and evaluate the economic viability and environmental impact of the retrofit design.

Direct synthesis of DMC from Carbon Dioxide and Methonal allows for the opportunity of using this reaction for Carbon Dioxide Utilization. Thermodynamic limitations and the formation of an azeotrope between DMC and methanol limit the industrial viability with current direct synthesis technology.

Therefore for this project, we explored direct synthesis of DMC with the hydration reaction of ethylene oxide to improve the favorability of DMC formation while maintaining profitability, lowering energy consumption and adhering to process safety.

Considering a 20 year plant life, our proposed retrofit design maintained the required production rate becoming profitable in year 5, the second year of production. Considering environmental impact, the net carbon emissions from the current and proposed plant were 39.11 and -3.55 million kg of carbon dioxide per year respectively resulting in net negative carbon emissions. This environmentally friendly and profitable design can be used to combat climate change through carbon sequestration working towards solving the National Academy of Engineering's grand challenges .