Manufacturing of CumeneChapter 1 INTRODUCTION Cumene is the common name for isopropyl benzene, an organic compound that is an aromatic hydrocarbon. It is a constituent of crude oil and refined fuels. It is a flammable colorless liquid that has a boiling point of 152 °C. Nearly all the cumene that is produced as a pure compound on an industrial scale is converted to cumene hydro-peroxide, which is an intermediate in the synthesis of other industrially important chemicals such as phenol and acetone. Cumene (isopropyl benzene) is produced by reacting propylene and benzene over an acid catalyst. Cumene may be used to increase the octane in gasoline, but its primary use is as a feedstock for manufacturing phenol and acetone. The preparation of cumene was first described in 1841 when Gerhardt and Cahours obtained it by distilling cumic acid with lime. The use of aluminium chloride to alkylate benzene was reported by Radziewanowski in 1892. Before the development of the cumene route to phenol and acetone, cumene had been used extensively during World War II as a fuel additive to improve the performance of aircraft piston engines. Like phenol and acetone, α-methylstyrene, diisopropylbenzene, or acetophenone, although these cumene derivative compounds are of considerable commercial importance. Currently, over 80% of all cumene is produced by using zeolite based processes. Early processes using zeolite based catalyst system were developed in the late 1980s.[9] Gharda institute of technology, lavel Page 1 Manufacturing of Cumene Chapter 2 PROPERTIES Cumene is colorless liquid soluble in alcohol, carbon tetra chloride, ether and benzene. It is insoluble in water. 2.1 PHYSICAL PROPERTIES OF CUMENE[8] PROPERTY Molecular weight Boiling Point, °C Freezing point, °C Density, gm/cm3 0°C 20°C 40°C Thermal conductivity, w/m.k 25°C Viscosity, mPa.s (cp) 0°C 20°C 40°C Surface tension, mN/m 20°C Flash point, °C Autoignition temperature, °C 0.791 44 523 1.076 0.791 0.612 0.124 0.8786 0.8169 0.8450 VALUE 120.19 152.39 -96.03 Gharda institute of technology, lavel Page 2 Manufacturing of Cumene Antoine Constants A B C 13.99 3400 207.78 2.2 THERMODYNAMIC PROPERTIES OF CUMENE[8] PROPERTY Relative molar mass Critical temperature, °C Critical pressure, Kpa Critical density, g/cm3 Heat of vapourisation at bp, J/g Heat of vapourisation at 25°C, J/g VALUE 120.2 351.4 3220 0.280 312 367 2.3 CHEMICAL PROPERTIES:[8] 1. Cumene undergoes oxidation t o give cumene hydroperoxide by means of air or Oxygen C6H5CH(CH3)2 + O2 C6H5C(CH3)2OOH Cumene Oxygen Cumene Hydroperoxide 2. By the catalytic action of dilute sulphuric acid, cumene hydroperoxide is split into Phenol and acetone C6H5C(CH3)2OOH C6H5OH + CH3COCH3 Cumene Hydroperoxide Phenol Acetone Gharda institute of technology, lavel Page 3 The largest use for acetone is in solvents although increasing amounts are used to make bisphenol A and methylacrylate. lavel Page 4 . Phenol in its various for maldehyde resins to bond construction materials like plywood and composition board (40% o f the phenol produced) for the bisphenol. The hydroperoxide is then selectively cleaved to Phenol and acetone. The cumene oxidation process for phenol synthesis has been growing in popularity Since the 1960’s and is prominent today. Gharda institute of technology. 4. 5. A employed in making epoxy resins and polycarbonate (30%) and for caprolactum. Cumene in minor amounts is used as a thinner for paints. 7. As feedback for the production of Phenol and its co-product acetone 2.Manufacturing of Cumene Chapter 3 USES Cumene is used[2] 1. Cumene is also used as a solvent for fats and raisins. enamels and lacquers and to produce acetophenone. 6. the starting material for nylon-6 (20%). 3. Minor amounts are used for alkylphenols and pharmaceuticals. Methylstyrene is produced in controlled quantities from the cleavage of cumene Hydroperoxide or it can be made directly by the dehydrogenation o f cumene. The first step of this process is the formation of cumene hydroperoxide. the chemical intermediate dicumylperoxide and diisopropyl benzene. and especially alpha-methyl styrene produced from the downstream phenol units.CH=CH2 Side Reaction C6 H6 + nCH3CH=CH2 C6 H6-n.Manufacturing of Cumene Chapter 4 MANUFACTURING PROCESSES OF CUMENE. 3. 4.1 INTRODUCTION SPA (Solid phosphoric acid) remains a viable catalyst for cumene syenthesis. CD-Cumene process. The temperature is maintained at approximately 250 C by adding cold propane at each stage to absorb heat of reaction. 4. 4. 2.2 CHEMICAL REACTION Main Reaction C6H6 + CH3. acetone. Q-Max process.1.1 LIQUID PHASE ALKYLATION USING PHOSPHORIC ACID [2] 4. lavel Page 5 .1. The SPA catalyst provides an essentially complete conversion of propylene on a one pass basis.1. producers have been given increasing incentives for better cumene product quality of the phenol. Liquid phase alkylation using Aluminium chloride. Into the top of a reactor packed stage wise with H3PO4 impregnated catalyst. which operates at 3-4 MPa and at 200-260 C and pumped at 25 atms. Liquid phase alkylation using Phosphoric acid. 4. There are four types of manufacturing process of cumene. C3H7 . In recent years .3 PROCESS DESCRIPTION Propylene-propane feedstock from refinery off gases from a naphtha steam cracking plant and recycle benzene is mixed with benzene are charged upflow into fixed bed reactor. cumene.(CH)n C6H5.and polycumenes in the remaining Gharda institute of technology. The propanized bottoms are separated into benzene. 1. The reactor effluent is depropanized and the propane split into quench or product streams. 1 wt% diisopropylbenzene (DIPB).Manufacturing of Cumene two stills. The heave aromatics which have research octane no (RON) of about 109 can be either used as high octane gasoline blending components or combined with additional benzene and sent to transalkylation section of the plant where DIPB is converted to cumene.1% is primarily heavy aromatics.9 wt% pure. lavel Page 6 . The remaining 2.8 wt% cumene and 3. This high yield of cumene is achieved without transalkylation of DIPB is the key advantage of SPA catalyst process. A typical reactor effluent stream contain 94. The overall yield of cumene for this process based on benzene and propylene is typically 97-98 wt% if transalkylation is included or 94-96 wt% without transalkylation Gharda institute of technology. The cumene product is 99. Manufacturing of Cumene 4.1. lavel Page 7 .4 PROCESS FLOW DIAGRAM Figure 4.4.a Liquid phase alkylation using phosphoric acid Gharda institute of technology.1. Fresh benzene contains too much water for immediate addition to the reactors.2. The distillation section consist of ethylbenzene unit have been constructed where the catalyst complex is prepared in a separate vessel. Benzene from the base contains less than 10ppm water. having pretreatment section if required. All the reactants and recycle streams are introduced into the reaction zone. The promoter is essential for stabilizing the catalyst complex. The reaction conditions. propylene is dried in a regenerative absorptive drier and fed to de-ethanizer where c2 compounds are distilled.2 PROCESS DESCRIPTIONIf feed treatment is required depending on the quality of feedstock. The benzene is recovered in an absorber containing recycling PAB and the HCl is scrubbed out of the off. After condensation. for only a stable complex will catalyze the reaction. a reactor section and a distillation section.1 INTRODUCTION Aluminium chloride is a preferred alkylating agent for the production of cumene. Liquid propylene in the overheads is vaporized and fed to the reactor.Manufacturing of Cumene 4. there may be provided a pump to recirculate settled complex to the top of the reaction zone and a compressor to recycle propane. Basically the design is same to that described for other processes. The complex is hereby lifted and mixed intimately with the reactants. 4. one containing water and the other containing caustic Gharda institute of technology. Aluminium chloride is added to the top of the reactor and the promoter usually HCl or isopropyl enters with the reactant. which is insoluble in a hydrocarbon. The reaction section usually consists of two or more brick lined vessels partitioned into reaction and settling zones with downstream separators and wash drums. including arrangement for the feeding catalyst and recycle of polyalkylbenzenes for dealkylation are however quite different. benzene and water separate in a decanter.gas in two towers. In addition to the gaseous feed to distribute the catalyst complex. propylene vapours are admitted at the base where catalyst complex. is mixed with recycle benzene and fed to column. Care has to be taken with the reactor off gases which in addition to benzene and other light hydrocarbons contains HCl. lavel Page 8 . tends to settle.2.2 LIQUID PHASE ALKYLATION USING AlCl3 [2] 4. Since agitation is required. The bottoms pass to a propylene column where c4’s and heavier are removed in the base stream. The later operation is conducted in a small column under high vacuum.3 PROCESS FLOW DIAGRAM Gharda institute of technology. The residual gas can be compressed and used as fuel. lavel Page 9 . The material heavier than cumene is not disposed of as fuel.2. 4. is returned to the reactors for transalkylation after removing the heaviest polyalkylbenzenes.Manufacturing of Cumene soda solution. lavel Page 10 .2.a Liqid phase alkylation using Aluminium Chloride Gharda institute of technology.3.Manufacturing of Cumene Fig 4. Benzene column bottom is sent to the cumene column where cumene product is recovered overhead. where the propylene reacts to completion to form mainly cumene. Effluent from the alkylation reactor is sent to the depropanized column. which removes the propane that entered the unit with the propylene feed.3 Q-MAX PROCESS[1. The bottom from the cumene column. Both reactors are fixed bed. Mild operating conditions and a corrosion free process environment permit the use of carbon steel construction and conventional process equipment. The Depropanizer column bottoms is sent to the benzene column where benzene is collected overhead and recycled.1 INTRODUCTION The Q. The typical design cycle length between regenerations is 2years.Manufacturing of Cumene 4. a distillation section. along with any excess water which may have accompanied the feeds.6] 4.Max process is based on liquid phase process. The catalyst in both the alkylation and transalkylation reactors is regenerable.3.3. lavel Page 11 . and a transalkylation reactor. The bottoms from the DIPB column consist of a small stream of heavy aromatic by-product which are normally used as high octane gasoline blending component. but the unit can be designed for somewhat longer cycles if desired.2 PROCESS DESCRIPTION A Q-max unit consists of an alkylation reactor. Ultimate catalyst life is at least three cycle. The Q-Max process produces nearly equilibrium levels of cumene between 85 to 95 mole% and DIPB between 5 and 15 mole%. The alkylation reactor is divided into four catalyst beds contained in a single reactor vessel. Propylene and a mixture of fresh and recycle benzene are charged to the alkylation reactor. Gharda institute of technology.5. containing mostly diisopropylbenzene is sent to the DIPB column where DIPB is recovered and recycled to the transalkylation reactor. The Q-Max process had selected most promising catalyst based on beta zeolite for cumene production. 4. 3. lavel Page 12 .3.3 PROCESS FLOW DIAGRAM Recycle Benzene Benzene Propylene Propane DIPB Cumene Alkylation Reactor Heavies Transalkylation Reactor Benzene Column Cumene Column DIPB Column Depropanizer Figure4.3.Manufacturing of Cumene 4.a : Q-Max process Gharda institute of technology. all zeolite-based processes consist of essentially the same flowsheet configuration.Manufacturing of Cumene 4. Reaction products are continuously removed from the reaction zones by distillation. When refinerygrade propylene is used as a feedstock.4 CD CUMENE PROCESS[1] 4. ZEOLITE CATALYST. is recovered for improved energy efficiency. The alkylation reaction takes place isothermally and at low temperature. The Gharda institute of technology. The catalyst is non corrosive and environmentally friendly. and minimizing fugitive emissions.Cumene process produces ultra high purity cumene using a proprietary zeolite catalyst that is non corrosive and environmentally friendly. 4. All waste heat. The CD-cumene technology can process chemical or refinery grade propylene. Except for the CDTech process. Low operating temperatures result in lower equipment design and operating pressures. enhance product purity and yields. The alkylation reaction is carried out in fixed-bed reactors at temperatures below those used in SPA-based processes. with a much lower capital investment.4. improve safety of operations. CD-cumene process uses a proprietary zeolite catalyst.based processes. lavel Page 13 . The unique catalytic distillation column combines reaction and fractionation in a single unit operation. These factors limit the formation of by-product impurities. It can also use dilute propylene streams with purity as low as 10mol percent. than the environmentally outdated acid. which combines catalytic reaction and distillation in a single column. including the heat of reaction.4. This modern process features higher product yields. which help to decrease capital investment.1 INTRODUCTION The CD. A separate transalkylation reactor converts recycled PIPB and benzene to additional cumene. provided the content of other olefins and related impurities are within specification. the effluent from alkylation is sent to a depropanizer column that removes propane overhead.2 PROCESS DESCRIPTION Cumene is formed by the catalytic alkylation of benzene with propylene. and result in expected reactor run lengths in excess of two years. and PIPB are respectively separated in the overhead of each column.7% to almost stoichiometric. A small stream of heavy aromatics is separated in the bottoms of the PIPB column. with B/P feed ratios between 3 and 5. In addition. depending on the nature of the zeolite employed.97% can be obtained. for example. Benzene. Gharda institute of technology. Like the AlCl3 catalyst. varying from 99. lavel Page 14 . A particular advantage of the zeolite catalysts is that they are regenerable and can be used for several cycles. with PIPB and benzene recycled to the reaction system.Manufacturing of Cumene bottoms of the depropanizer are then mixed with the transalkylation reactor effluent and fed to a series of three distillation columns. Depending on feedstock quality. zeolites are sufficiently active to transalkylate PIPB back to cumene. Product purities as high as 99. Therefore. One limitation of the zeolite technology is potential poisoning of the catalyst by contaminants in the feed. its sulfur content must be closely controlled. carbon steel can be used as the material of construction throughout the plant because of the mild operating conditions and the absence of highly corrosive compounds. product cumene. the waste disposal problems associated with SPA and AlCl3 catalysts are greatly reduced. guard beds or additional feed pretreatment may thus be required. Overall selectivity of benzene to cumene is quite high. If refinerygrade propylene is used. Manufacturing of Cumene 4.3 PROCESS FLOW DIAGRAM Benzene Propane Cumene Propylene Cumene Column Transalkylator PIPB Column PIPB Recycle Heavies Figure : CD.4.Cumene process Gharda institute of technology. lavel Page 15 . b) Cumene product 99. 5. d) Reduces utilities and operating cost. c) PAB may be recycled to the reactor as aluminium chloride has ability to transalkylated PAB in presence of benzene. c) The Q-Max requires minimum pretreatment of feeds.Manufacturing of Cumene Chapter 5 SELECTION OF PROCESS 5.1. b) The expected catalyst cycle is 2-4 years and the catalyst should not need replacement for at least 3 cycles.9 wt% pure. which further minimizes the capital costs. Gharda institute of technology. 5. applicable to conversion of existing cumene plants.4 CD. 5.1 ADVANTAGES 5. lavel Page 16 .2 LIQUID PHASE ALKYLATION USING AlCl3[2] a) Propane in propylene feed is recovered as liquid petroleum gas(LPG) b) By product removal is relatively simple.1.3 Q-MAX PROCESS[1] a) The catalyst in the both alkylation and Transalkylation reactor are regenerable.CUMENE PROCESS[1] a) High selectivity and lower by product formation. reduced plot area. recover all waste heat and heat of reactions. High product yield.1. c) Decrease capital investment. improve safety and operability. b) Lower maintenance cost.1 LIQUID PHASE ALKYLATION USING PHOSPHORIC ACID[2] a) The SPA catalyst provides an essentially complete conversion of propylene on a one pass basis. c) By product removal is relatively simple.1. a) Extends reactor run length over one year without regeneration. its treatment is the major disadvantage of this process. Q-Max Process and CD-Cumene process doesn’t have any disadvantage.Manufacturing of Cumene e) Improves economics – plant can be custom designed to process specific feed stocks including the less expensive feedstock.2 LIQUID PHASE ALKYLATION USING ALUMINIUM CHLORIDE[2]: a) Feed pretreatment is required. c) Reduces utilities and operating costs. improves safety and operability. g) Meets evolving environmental requirements.2 DISADVANTAGES 5. Gharda institute of technology. d) Improves economics.2.2. recovers all waste heat and heat of reaction. h) Catalytic reaction and distillation is done in single column. f) Continuous process. c) The catalyst is not regenerable and must be disposed at the end of each short catalyst cycle. 5.plans can be custom designed to process specific feedstocks including less expensive feedstock. But from this two processes CD-Cumene process is more effective than Q-max process because. b) The presence of HCL in and around the reaction area can be troublesome. sustain high conversion and selectivity. So that we are selecting CD-cumene process of manufacturing of CUMENE. b) The process requires a relatively high benzene propylene molar feed ratio on the order of 7/1 to maintain cumene yield.1 LIQUID PHASE ALKYLATION USING PHOSPHORIC ACID[2]: a) Cumene yield is limited to 95% because of the oligomerization of propylene and the formation of heavy alykalate by-products. lavel Page 17 . b) Decrease capital investment. 5. 093 KJ/mol Gharda institute of technology..20 ∆Hf @298(KJ/mol) 3.4512×10-1T – 1.8243×10-6T3 For Cumene ( ) – {∫ ( ) +∫ ( ) Cp (J/mol k) 217.6078×10-3T2 + 3.1 Calculation of heat of reaction at 443K Hr = ∆Hf298 + ∫ }……………….[4] Cp(cumene) = 124.718 + 3.Manufacturing of Cumene Chapter 6 THERMODYNAMIC FEASIBILITY Table 6.3 137.58 – 34936.93 ∆Gf @298(KJ/mol) 136.3293*10-1T-1.7331×10-3T2 + 2.93 20.392×10-1T – 1.[10] Cp values are.a : Thermodynamic data Component Cumene Propylene Benzene Chemical reaction C3H6 + C6H6 → C9H12 Reaction temperature = 170 6.96 62.92 = 34.8755×10-6T3 Cp(benzene) = −31.2146×10-6T3 Cp(propylene) = 54.6 269.87 Entropy @298(J/mol k) 388.57 266.72 129.24 + 16956.62 + 6.9 + 34002.7331*10-3T2+2.66 298 ∫443 (124.6315×10-3T2 + 3.62+6.42 82.96 115.3043T – 3.2146*10-6T3)dT = 18069. lavel Page 18 .662 + 1. 89 + 29282.093 – 23.71 – 32888.662 + 1.6315*10-3T2 + 3.065KJ/mol Heat of formation at 298K ∆Hf298 = ∑ ∆Hf(product) − ∑ ∆Hf(reactant)………………[10] = ∆Hf(cumene) – [∆Hf(propylene) +∆Hf(benzene) ] = 3.260 KJ/mol For Benzene 298 ∫353(-31.21 + 30.25 – 72726.1.42KJ/mol Heat of reaction at 443K ∆Hr443 = −99.93 – (20.11 + 18540.23 = 23.16 + 29674.42 + 82. Gharda institute of technology.6078*10-3T2 + 3.3043T – 3.75 = −4590.4512*10-1T .8243*10-6T3)dT +30.75 = 22.Manufacturing of Cumene For Propylene 443 298∫ (54.652KJ/mol Heat of reaction is negative.260 – 22.99 + 70070.718 + 3. lavel Page 19 .93) = −99.065 = −110. so the reaction is exothermic.42 + 34.8755*10-6T3)dT = 7934. 2 Calculation of Entropy S443 = S298 +∫ ( ) …………………….20 – 12.22×10-8 = 275.334J/mol For Benzene S443 = 269.[11] = S298 + α ln(T2/T1) + β(T2− T1) – γ{ [1/(T2)2] – [1/(T1)2] } For Cumene S443 = 388.55 +18.Manufacturing of Cumene 6.04 − 1×10-8 = 338.694 +50.6 +54.6 +21.4512×10-1(443−298) + 1.57 + 124.6078×10-3× [ (1/4432) – (1/2982) ] = 269.56J/mol Gharda institute of technology.57 +49.7331×10-3× [ (1/4432) –(1/2982) ] = 388.20 – 31.3043×10^-1(443−298) + 3.6315×10-3× [ (1/4432) – (1/2982) ] = 266. lavel Page 20 .912 – 2.662 ln(443/298) + 1.621 ln(443/298) + 6..3293(443−298) +1.74 – 1.711J/mol For propylene S443 = 266.401 + 917.718 ln(443/298) + 3.068×10-8 = 1355. 12 ( ) Gharda institute of technology.334 +275...27KJ/mol Gibb’s free energy is negative. 6.Manufacturing of Cumene Entropy of reaction at 443k ∆S443 = ∑ S(product) − ∑ S(reactant) ……………………[11] = 1355.652 – [443×(741.4 Calculation of equilibrium constant ∆G = −RT ln(Kp) ………………………………. lavel Page 21 .817×10-3)] = −439.817J/mol = 741... [10] Kp = = = 1..3 calculation of Gibb’s free energy ∆G = ∆H − T∆S ……………………………………[11] = −110.56) =741. so the reaction is feasible.711 – (338.817×10-3 KJ/mol 6. Assuming 300 working days.9 * 346.33 = 17.67 – 329.67 kmol/hr Benzene to propylene feed ratio is 4:1. Hence 90% of cumene get converted into cumene and 5% propylene get reacted with cumene to form PIPB. lavel Page 22 .67 kg/hr = 346.1000 ton/ day cumene production = 41666.33 kmol/hr Unreacted propylene = 346.34 kmol/hr Benzene reacted = 0. Propylene fed = 346.Manufacturing of Cumene Chapter 7 MATERIAL BALANCE Plant capacity 300.67 = 329.000 ton / year.67 kmol/hr ReactionMain reaction: C3H6 + C6H6 → C9H12 Side reaction: C9H12 + C3H6 → C6H4( CH (CH3)2)2 Assuming 95% conversion is possible in reactor-1. Basis.67 = 312 kmol/hr Gharda institute of technology.95 * 346. Benzene fed = 1400 kmol/hr Propylene reacted = 0. 33 kmol/hr DIPB produced = 0.67 kmol/hr Cumene produced in finishing reactor = 0.67 = 17. lavel Page 23 .33 Gharda institute of technology.67 = 17.428 = 31757.05 * 346.05 * 346.75 kmol/hr Cumene produced = 312kmol/hr But 5% of propylene reacts with the cumene and produce PIPB (it contains DIPB and little amount of TIPB) Cumene produced = 312 – 0.95 * propylene feed * heat of reaction = 0.75 + 312 = 1344.67 * 96.75 – 312 = 1032.98 * 17.95 * 346.7 Benzene reacted with DIPB to produce cumene = 0.67 = 294.75 kmol/hr Unreacted benzene = 1344.26) / (30.33 kmol/hr From given. Hence heat evolved in CD-column is = 0.26 kJ Benzene evaporated = (total heat evolved) / (latent heat of benzene) = (31757.05 * 346.75) = 1032. Selectivity of propylene to cumene = 81.75 kmol Benzene fed into CD-column = benzene evaporated in CD-column + benzene reacted = 1032.Manufacturing of Cumene Since the reaction is exothermic. 3466 kmol/hr Material balance of cumene column: cumene 346.9834 Kmol/hr DIPB 17.31 Kmol/hr Cumene + DIPB 346.33 + 16.33 Kmol/hr DIPB 17. lavel Page 24 .33 Kmol/hr Heavy ends 0.Manufacturing of Cumene = 16.98 kmol/hr Net amount cumene produced = 312 + 17.3466 Kmol/hr Gharda institute of technology.31 Kmol/hr + 17.98 = 346.33 Kmol/hr Material balance of DIPB column: DIPB 16.31kmol/hr PIPB produced = 0.02 * 17.33 = 0. 33 kmol/hr Gharda institute of technology. lavel Page 25 .9834 Kmol/hr +16.9834Kmol/hr Benzene + PIPB 16.33 kmol/hr cumene = 17.9834Kmol/hr Material balance for finishing reactor: Benzene = 17.33 kmol/hr propylene = 17.Manufacturing of Cumene Material balance of transalkylation reactor: Cumene 16. Assuming 300 working day .7703E-5 1.149 31.298 -31.9481E-4 -3.2449E-1 4. The heat given out when 1mol propylene reacted is the heat of reaction = 96.98 kJ/hr This amount of heat is taken out of reaction zone by evaporation of benzene.5237E-8 Energy balance on CD-column – Benzene propylene unreacted benzene + propylene cumene + PIPB Cumene synthesis is exothermic reaction.368 B 5. Basis = 1000 ton of cumene per day = 346.428 kJ Hence total heat given out = 33393.67 kmol/hr Cp values data: Component Cumene Propylene Benzene A 10. Condenser load = 33393. lavel Page 26 .Manufacturing of Cumene Chapter 8 ENERGY BALANCE Plant capacity is 300. Hence heat taken out in condenser is.98 kJ/hr Gharda institute of technology.1138E-1 7.1137E-4 D -2. This vapour phase benzene is then cooled and bring to liquid phase.7460E-1 C -1.000 ton / year.1582E-7 8.2612E-7 -2. 96 * (35-170) = 10200. Heat load on reboiler = mCp∆T = [346.33 * 382.42 * (170-152)] = 1477.67 * 217.63 * 103 kJ/hr Gharda institute of technology. This mixture is heated to near about 170 C to distill out cumene from the PIPB column. lavel Page 27 .67 * 217. Load on condenser = mCp(35-170) = 346.Manufacturing of Cumene Energy balance on cumene column – : Cumene Cumene + DIPB DIPB The cumene with PIPB comes out from CD-column at 152 C.96 * 103 kJ/hr The cumene is cooled to liquid phase.96 * (170-152)] + [17. The net heat given out from the reaction = 96.33 * 382.35 * 102 kJ/hr Energy balance on transalkylation reactorCumene Benzene + PIPB In this unit producing cumene from DIPB and benzene. lavel Page 28 .33 = 1671.Manufacturing of Cumene Energy balance on PIPB column- DIPB DIPB Heavy ends PIPB comes out from cumene column is separated in DIPB and heavier ends.09 kJ/hr Gharda institute of technology. Reboiler load = 17. for this separation mixture is heated to 200 c.09 kJ/hr Condenser load = 1671.428 * 17.42 * (200-170) = 1988. Since reaction is exothermic. 166 - Mol fraction 0.13 927.34 1022.721 0.0465 Vapor pressure data Log p = A. lavel Page 29 . 2.00166 pi 31627.926 0.0122 Mol fraction 0.24 Propylene Benzene Cumene DIPB Total Mol..42 1.Manufacturing of Cumene Chapter 9 DESIGN OF MULTICOMPONENT DISTILLATION COLUMN Assume 99% benzene is separated as a overhead & 99.33 372.75 346.31 17. Fraction 0. 4.98 0.33 344. Propylene lighter than light key Benzene light key Cumene heavy key PIPB heavier than heavy key Material balance Component Feed Moles 17.09 xi = yi/ki 0.999 Top temperature = 870C Gharda institute of technology.33 1413.245 0.B/(T+C) Calculation of top temperature Component Propylene Benzene Cumene yi 0.98 0.34 1032.73 Distllate Mol 17.58 17.0277 0.0166 0.000968 0.68 96.018 0.732 Bottom Mol 10.5% cumene is separated as bottom product In our case 1.0166 0. 3.15 1 0.98 0.31 ki 17.0123 0. 993 Bottom temp = 152 0 C Nmin = = ( ( ) ( ) )( ) = 3.0277 0. lavel Page 30 . of bottom. of bottom.67 45881. + = 87 + (152-87) = 108. + (temp.67 Component Vapour pressure at 108.30 185.17 8.4 7.97 2865.67 Minimum reflux ratio Lower pinch temperature = column top temp.188 yi = kixi 0.0 0.66 409.temp of top) = 87 + (152-87) = 130.0 0.0465 Pi 4521.Manufacturing of Cumene Calculation of bottom temperature Component Propylene Benzene Cumene Xi 0.86 209.8334 0.18 733.0 0.008742 0.9 0.33 64840.temp of top) Propylene Benzene Cumene DIPB 219.11 ki 5.926 0.26 αi αavg (temp.150411 0.34 38.186 158.14 1684.05 1.0 1.91 Αi Vapour pressure at 130.01 89.2 Gharda institute of technology.43 0.51 1.53 7.33 Upper pinch temperature = column top temp.218 186. S 10. θ lies between.099492 -0.354 0.1 -0.2 2 1.367 = (0.238/1.H.36) = 0.421 …………for all component.2 = (0. lavel Page 31 . αB < θ < αA αA = 7.238 Assume.5 R = 1.S – R. Gharda institute of technology.5 R Rmin = 0.001355 0.H.000508 0.58 2.00244 0.51 αB = 1 1 < θ < 7.51 Trial and error method Θ 7 5 1.Manufacturing of Cumene The minimum reflux ratio can be calculated by underwood’s method RRmin + 1 = =1–q The feed line is a saturated liquid at its boiling point.423 R.000358 0.238) = 0. By trial and error method.00187 ∆= L.749 0.74 0.238 = 0. = 1.356 0.579642 2.S 10. so q = 1.H.5 * 0.264 L.36/1.S 0.H. 08 vfl = 1. Erbar – Maddox correlation ( = 0.9.38 N= = 9. lavel Page 32 .85 × 1.21 m/s. fig.45m from fig 9.Manufacturing of Cumene From.4. ρ = 2.42 = 1. Assuming 85% flooding condition Vfl = 0.66 = 10 Assuming 50 % efficiency of stages Theoretical no of stages = = 20 vs ) The Principal factor that determine the tower diameter is the gas ( vapour) velocity.5 Where Vfl = flooding velocity of gas ( vapour ) K = constant ρl . It is the flooding condition that fixes the upper limit of gas ( vapour) velocity. ρv = density of liquid & vapour respectively here .7 Kg/ m3 ρ = 862 Kg/ m3 Assuming plate spacing 0. The flooding velocity is given by vfl = ( )0. Gharda institute of technology.42 m/s.1 K = 0. An = At – Ad = At – 0.68 m2 Column diameter Dt = √ =√ = 2.Manufacturing of Cumene Maximum flow rate Vmax = = 8. lavel Page 33 .88 m2.91 m Gharda institute of technology.88At At = = 6.12At = 0.36 m/s Net area required = An = = = 5. Manufacturing of Cumene LIQUID FLOW PATTERN: Liquid flow pattern is determined by two parameters 1. Maximum liquid flowrate 2. Column diameter Here , Lmax = = 0.0238 m3/s Hole area, Ah = 10% of active area Aa = At – 2Ad = 6.68 – 2 × 0.80 = 5.08 m2 Ah = 0.10 × 5.08 = 0.508 m2 Weir length = 0.77 × Dt = 0.77 × 2.91 = 2.24 m Let’s take Hole diameter = 7 mm Plate thickness= 5 mm Gharda institute of technology, lavel Page 34 Manufacturing of Cumene PLATE DESIGN: Column diameter = 2.91 m Column cross section , At = 6.68 m2 Weir Height : Since column operating at pressure above atmospheric pressure, hw = 50 mm Plate thickness = 5 mm CROSS CHECK:( FOR PLATE DIMENSIONS) Maximum Liquid rate = 23.12 kg/s Assuming turndown ratio at 70% of maximum liquid flowrate , so that minimum liquid flowrate = *23.12 =16.184 kg/s. The height of liquid crest over the segmental weir: (how)max = 0.70 ( )(2/3) = 36 mm of clear liquid (how)min = 0.75 ( )(2/3) = 30 mm of clear liquid At minimum flowrate, dh hw + how = 50+30=80 mm Gharda institute of technology, lavel Page 35 Manufacturing of Cumene from fig 9.2, Kw = 30.2 therefore minimum vapour velocity, vmin = √ ( ( ( ( )) )) vmin = √ = 7.20 m/s But actual vapour velocity = = = 9.92 m/s. Thus the minimum operating velocity (9.92 m/s) lies well above the weep point (i.e. when vapour velocity = 7.20 m/s) Therefore our design is safe from operating point of view Plate pressure drop : The total plate pressure drop is given by, ht = hd + hl + hr dry plate drop hd = K1+ K2 (vgh)2 ( ) for sieve plate , K1=0, K2= Gharda institute of technology, lavel Page 36 hr = = = 14 mm of clear liquid The total pressure drop ht = hd + hl + hr = 3. Cv= 0.42 mm of clear liquid Gharda institute of technology. lavel Page 37 .42 mm of clear liquid Pressure drop due to staric liquid head.3.42 + 86 + 14 = 103. hl = hw + how = 50+36 = 86 mm of clear liquid Residual head.85*10-3 ( ) ( ) = 3.765 Velocity through holes Vgh = hd = 50.9.Manufacturing of Cumene Discharge coefficient Cv is determined as follows. From fig. 24 m Aap = Area under the downcomer apron = 0.166*( now. lavel Page 38 . Hdc = ht + hw + how + hda Head loss in the downcomer due to liquid flow under the downcomer apron : hda = 0.Manufacturing of Cumene Downcomer area backup : Backup in downcomer is given by.04 * 2.0896 m2 Since Aap < Ad we take Ad as Am hda = 0.42+ 50 +36 + 1.166 ( )2 ) = 1.54 mm of clear liquid Gharda institute of technology.12 = 190.24 = 0.12 mm of clear liquid Hdc = 103. Aap = hap*lw Hap= height of lower edge of the apron above the tray = hw – 10 = 50 – 10 =40 mm Lw = 2. lavel Page 39 . Residence time : Τr = = = 5.5] + 0. ( ( ) ) ( ) Since hdc < 0.Manufacturing of Cumene Check : To avoid flooding : Hdc < Now . Gharda institute of technology. Total height of tower = [no of plates * tray spacing] + clearance at top + clearance at bottom = [20 * 0.so there will be no flooding at specified operating condition that means tray spacing is acceptable.5 = 10 m So the design is satisfactory.5 + 0.250m .68 s. 85 4. Permissible tensile stress.757 = 3.19 mm Head thickness : for safety we use hemispherical head at top & bottom of distillation column. Joint efficiency facor . 1. Corrosion allowance. C = 1. lavel Page 40 .1 * 2. The head thickness is given by . th = th = th = 23 mm – Gharda institute of technology. J = 0.1 * operating pressure = 1.0327 N/mm2 2.5 mm Shell thickness is given by.91 m 5. f = 95 N/mm2 ( MOC= CARBON STEEL) 3. Design Pressure. Di =2.Manufacturing of Cumene SHELL THICKNESS : For thickness of shell of distillation column we required following data. Inner diameter. P = 1. ts= ts = ts = 57. Manufacturing of Cumene Gharda institute of technology. lavel Page 41 . Manufacturing of Cumene Gharda institute of technology. lavel Page 42 . Manufacturing of Cumene Gharda institute of technology. lavel Page 43 . Manufacturing of Cumene Gharda institute of technology. lavel Page 44 . 6 = 23. Direct Costs: material and labour involved in actual installation of complete facility (70-85% of fixed-capital investment) a) Equipment + installation + instrumentation + piping + electrical + insulation + painting (5060% of Fixed-capital investment) 1.) Consider the Installation cost Gharda institute of technology.113×108 Estimation of Capital Investment Cost: I.23. 6.113×108 = Rs.055 x 108) × (539. lavel = 40% of Purchased equipment cost Page 45 .055 x 108 Chemical Engineering Plant Cost Index: Cost index in 1990 = 357.528×108 2.6 = Rs.25 × 6.4.1/357. Purchased equipment cost (PEC): (15-40% of Fixed-capital investment) Consider purchased equipment cost = 25% of Fixed-capital investment PEC = 25% of 6.1 Thus. 6.6) = Rs. Installation.4 x 107(1000/400)0.113×108 Fixed Capital Cost (FCI) = Rs.Manufacturing of Cumene Chapter 10 COST ESTIMATION Cost of cumene plant of capacity 400 TPD in 1990 is Rs. Present cost of Plant = (original cost) × (present cost index)/(past cost index) = (4.113×108 = 0.6 Cost index in 2010 = 539. including insulation and painting: (25-55% of purchased equipment cost.4×107 Therefore cost of 1000 TPD in 1990 is: C1 = C2 (Q1/Q2)0. 1. Electrical.20 ×1.528×108 = Rs.6112×108 Gharda institute of technology. installed: (6-30% of Purchased equipment cost.6112×108 3.0. 0.25 ×1.) Consider the installation cost = 20% of Purchased equipment cost = 20% of ×1. Piping installed: (10-80% of Purchased equipment cost) Consider the piping cost = 40% Purchased equipment cost = 0.0. Instrumentation and controls. Buildings. = 40% of PEC = 40% of 1.40 ×1.528 ×108 = 0.528×108 = Rs.6112×108 5. 0. installed: (10-40% of Purchased equipment cost) Consider Electrical cost = 25% of Purchased equipment cost = 25% of 1.528x108 = 0.382×108 B. lavel Page 46 . process and auxiliary cost.3056×108 4.528×108 = 0.Manufacturing of Cumene = 40% of 1.528×108 = Rs. 0. process and Auxiliary: (10-70% of Purchased equipment cost Consider Buildings.528 ×108 = 0.528×108 = Rs.40 ×1.40 ×1.528×108 = Rs. 0. Construction Expense and Contractor’s fee: (6-30% of direct costs) Consider the construction expense and contractor’s fee.1× 5. Engineering and Supervision: (5-30% of direct costs) Consider the cost of engineering and supervision.058 ×108 = 0.058×108 = 0. = 10% of Direct costs = 10% of 5.9168×108 D.1× 5.528 ×108 = 0.058 ×108 Gharda institute of technology.Manufacturing of Cumene C. lavel Page 47 .528×108 = Rs. Direct cost = Rs.528 ×108 = 0. 0. = 10% of Direct costs = 10% of 5.058×108 ----. Land: (1-2% of fixed capital investment or 4-8% of Purchased equipment cost) Consider the cost of land = 6% PEC = 6% of 1.058 ×108 = Rs. 5. = 60% of PEC = 60% of 1.5058×108 B.09168×108 Thus.60 ×1.74% of FCI) II.0.06 ×1. Service facilities and yard improvements: (40-100% of Purchased equipment cost) Consider the cost of service facilities and yard improvement.(82.528×108 = Rs. Indirect costs: expenses which are not directly involved with material and labour of actual installation of complete facility (15-30% of Fixed-capital investment) A. 803×108 = Rs. lavel Page 48 . Fixed Capital Investment: Fixed capital investment = Direct costs + Indirect costs = (5. Fixed Charges: (10-20% total product cost) i.Manufacturing of Cumene = 0.0205×108) = Rs.113×108 = 0.803×108 = 0. 1.7452×108) = Rs. Manufacturing Cost = Direct production cost + Fixed charges + Plant overhead cost.55% of FCI) III. Depreciation: (13% of FCI for machinery and equipment and 2-3% for Building Value for) Consider depreciation = 13% of FCI Gharda institute of technology.113×108 = Rs. = 15% of 6.8235×108 Estimation of Total Product cost: I.058×108) + (1. A.12 × 6. Working Capital: (10-20% of Fixed-capital investment) Consider the Working Capital = 15% of Fixed-capital investment. 0. Indirect Costs = Rs.7336×108 Thus.(28.7452×108 --. Total Capital Investment (TCI): Total capital investment = Fixed capital investment + Working capital = (6.5058×108 C. 1.803×108 IV. 6.0205×108 V.15 × 6. 7.803×108) + (1. Contingency: (5-15% of Fixed-capital investment) Consider the contingency cost = 10% of Fixed-capital investment = 12% of 6. 4-1% of fixed capital investment) Consider the Insurance = 0. Direct Production Cost: (about 60% of total product cost) Now we have Fixed charges = 10-20% of total product charges – (given) Consider the Fixed charges = 15% of total product cost Total product charge = fixed charges/15% = 1. Raw Materials: (10-50% of total product cost) Consider the cost of raw materials.803×108 = Rs. Rent: (8-12% of value of rented land and buildings) Consider rent = 10% of value of rented land and buildings = 10% of ((0.803×108) + (0.09168×108) + (0. = 25% of total product cost Gharda institute of technology. 0.03×6.2247×108 B.6112×108)) = Rs. Insurances: (0.007×6.803×108 = Rs.0703x108 Thus. 1. 8. 0.03×0.2247×108/0.2247×108/15% = 1.6112×108) = Rs.15 = Rs.9027×108 ii. Fixed Charges = Rs.Manufacturing of Cumene Depreciation = (0.0476×108 iv. lavel Page 49 .1647×108 i.13×6. 0. 0.2041×108 iii. Local Taxes: (1-4% of fixed capital investment) Consider the local taxes = 3% of fixed capital investment = 0.7% of fixed capital investment = 0. 1647×108 = 0.9797×108 = Rs. = 12% of total product cost = 12% of 8. 0. lavel Page 50 .25×8.1647×108 = 0.9797×108 = 0. 0. = 12% of OL = 12% of 0.1647×108 = Rs.1647×108 = Rs. 2.12×8. 0.0412×108 ii. Maintenance and repairs (M & R): (2-10% of fixed capital investment) Consider the maintenance and repair cost.12×0. = 12% of total product cost = 12% of 8.Manufacturing of Cumene Raw material cost = 25% of 8.1647×108 = 0.9797×108 v. Utilities: (10-20% of total product cost) Consider the cost of Utilities.9797×108 iii. Direct Supervisory and Clerical Labour (DS & CL): (10-25% of OL) Consider the cost for Direct supervisory and clerical labour.1176×108 iv.12×8.1647×108 = Rs. = 5% of fixed capital investment Gharda institute of technology. Operating Labour (OL): (10-20% of total product cost) Consider the cost of operating labour. 3402×108 = Rs.15 ×0. laboratories. Plant overhead Costs (50-70% of Operating labour. lavel Page 51 . safety and protection. 0. salvage. = 15% of M & R = 15% of 0.3402×108 = 0. 4. medical services. and storage facilities. recreation.15×0. 0.9797×108 = Rs. Gharda institute of technology.803×108 = Rs. Patent and Royalties: (0-6% of total product cost) Consider the cost of Patent and royalties. 0. includes for the following: general plant upkeep and overhead.1647×108 = Rs.05103×108 vii.3266×108 Direct Production Cost = Rs. Laboratory Charges: (10-20% of OL) Consider the Laboratory charges. = 4% of total product cost = 4% of 8.983×108 ----. 0.9797×108 = 0.1647×108 = 0. restaurants.(61% of TPC) C. packaging.Manufacturing of Cumene = 0. Operating Supplies: (10-20% of M & R or 0. supervision.5-1% of FCI) Consider the cost of Operating supplies. and maintenance or 5-15% of total product cost).05×6.3402×108 vi. = 15% of OL = 15% of 0. payroll overhead.1469×108 viii.04×8. DS & CL. Administrative costs:(2-6% of total product cost) Consider the Administrative costs .1647×108 = 0. Research and Development costs: (about 5% of total product cost) Consider the Research and development costs.3402×108)) = Rs.4082×108 B.2247×108 C. General Expenses = Administrative costs + distribution and selling costs + research and development costs A.8625×108) Manufacture cost = Rs. Distribution and Selling costs: (2-20% of total product cost). lavel Page 52 . = 60% of OL. and M & R = 60% of ((0.1647×108 = Rs.1647×108 Gharda institute of technology.9797×108) + (0. Consider the Distribution and selling costs. 1. = 15% of total product cost = 15% of 8. 0.05 ×8.803×108) + (0.1647×108 = Rs. salesmen.Manufacture cost = Direct production cost + Fixed charges + Plant overhead costs.Manufacturing of Cumene Consider the plant overhead cost.15 ×8. and advertising.1176×108) + (0.6485×108 II. shipping. 0. = 5% of total product cost = 0. 12.983×108) + (6.8625×108 Thus. includes costs for sales offices. Manufacture cost = (4. = 5% of total product cost = 5% of 8. 9×108) – (8.4323×108 IV. 7. Financing (interest): (0-10% of total capital investment) Consider interest = 5% of total capital investment = 5% of 7. 0.3912×108 = Rs.9×108 Gross income = Total Income – Total capital investment = (15. 0. 2. 15.Manufacturing of Cumene = 0. Total Product cost = Manufacture cost + General Expenses = (12. lavel Page 53 .1647×108) = Rs.Taxes = Gross income× (1.4082×108 D.05 × 8.8235×108 = 0.1647×108 = Rs.8235×108 = Rs.05×7. 4.53 Total Income = Selling price × Quantity of product manufactured = 53 x 30000000 = Rs.6485×108) + (2.0808×108 V. 15.45) = Rs.7353×108 Let the Tax rate be 45% (common) Net Profit = Gross income .2544×108 Gharda institute of technology.Tax rate) = 7.7353 x 108(1-0.4323×108) = Rs. Gross Earnings/Income: Wholesale Selling Price of cumene per kg = Rs. 6.38 % Gharda institute of technology. lavel Page 54 .2544*108 = 1. Rate of return = net profit* 100/(total capital investment) = 4.2544*108*100 / 7.803*108/4.8235*108 = 54.Manufacturing of Cumene Pay back period = FCI/(net profit) = 6. & acid gases neutralized. or using electrostatic precipitators. (5) The visual impact. Aqueous Waste: The principal factors which determine the nature of an aqueous industrial effluent and on which strict controls will be placed by the responsible authority are: (1) pH. other than aqueous effluents will usually be flammable and can be disposed of by burning in suitable designed incinerators. Considerations must be given to: (1) All emissions to land. lavel Page 55 . The gases leaving an incinerator may be scrubbed. Waste Management: Waste arises mainly as by products or unused reactants from the process.specification product produced through mis-operation. (2) Waste management. Gaseous Waste: Gaseous effluents which contain toxic or noxious substances will need treatment before discharge into the atmosphere. water. Gaseous pollutants can be removed by absorbtion or adsorbtion. Flammable gases can be burnt. (3) Smells. (3) Toxicity. Gharda institute of technology. (6) Any other nuisances. or as off.Manufacturing of Cumene Chapter 12 ENVIRONMENTAL AND HAZOP STUDY Environmental Considerations: Vigilance is required in both the design and operation of process plant to ensure that legal standards are met and that no harm is done to the environment. Finely dispersed solids can be removed by scrubbing. air. (2) Suspended solid. (7) The environmental friendliness of the products. Liquid Waste: The waste liquids from a chemical process. (4) Biological oxygen demand. (4) Noise. it can cause swelling of the eyes with blurred vision. the surroundings.1 MATERIAL SAFETY DATA SHEET 11. drowsiness.1. The oxygen concentration on water course must be maintained at a level sufficient to support aquatic life. can be painted to blend in with. Breathing this material may cause central nervous system depression with symptoms including nausea. Mist or vapor can irritate the throat and lungs. lavel Page 56 .1 HAZARDS IDENTIFICATION Inhalation Breathing high concentrations may be harmful. It is measured by a standard BOD test. Earth banks and screens of trees can be used to reduce the noise level perceived outside the site. Landscaping and screening by belts of trees can also help improve the overall appearance of the site. redness. Depressant properties yes. Noise: It can cause a serious nuisance in the neighbourhood of a process plant. Medical examination for workers required in some countries Other precautions as for all aromatics. Skin effects primary irritant. as far as practicable. Eye Contact This material can cause eye irritation with tearing. Skin Contact - Gharda institute of technology.Manufacturing of Cumene The pH can be adjusted by the addition of acid or alkali. Absorption through skin slowly absorbed. or unconsciousness. 11. or even contrast with. Lime is frequently used to neutralize acidic effluents. Noisy equipment should. fatigue. or a stinging or burning feeling. Suspended solids can be removed by settling. Narcotic properties yes. Visual Impact: Large equipments such as storage tanks. For some effluents it will be possible to reduce the toxicity to acceptable level by dilution. Other effluents will need chemical treatment. using clarifiers. dizziness. Effects may become more serious with repeated or prolonged contact. headache. Toxicological data: The toxicological data for a cumene plant is usually supposed to have the following values on the various environmental parameters as given below: Threshold limit value 50 ppm. Further. be sited well away from the site boundary. immediately begin rescue breathing. Keep the affected individual warm and at rest. It is likely that some components of this material are able to pass into the body through the skin and may cause similar effects as from breathing or swallowing it. Chronic Health Effects Summary Secondary effects of ingestion and subsequent aspiration into the lungs may cause pneumatocele (lung cavity) formation and chronic lung dysfunction. IARC or NTP. Swallowing this material may cause effects. possibly leading to chronic lung dysfunction or death. Ingestion Swallowing this material may be harmful. Target Organs – May cause damage to the following organs: kidneys. upper respiratory tract. Conditions Aggravated by Exposure Disorders of the following organs or organ systems that may be aggravated by significant exposure to this material or its components include: Skin. adrenal. Small amounts in the lungs can cause lung damage.2 FIRST AID MEASURES Take proper precautions to ensure your own health and safety before attempting rescue or providing first aid.1% which are considered carcinogenic by OSHA. Carcinogenic Potential – This product is not known to contain any components at concentrations above 0. If victim is not breathing. If breathing is difficult. 11. Inhalation – Move victim to fresh air. This material can get into the lungs during swallowing or vomiting. Swallowing this material may cause stomach or intestinal upset with pain. liver. lens or cornea. Central Nervous System (CNS). central nervous system (CNS). mucous membranes. and/or diarrhea. spleen. eye. Seek medical attention immediately. Gharda institute of technology.Manufacturing of Cumene May cause mild skin irritation with redness and/or an itching or burning feeling. 100 percent humidified oxygen should be administered by a qualified individual. skin. lavel Page 57 . nausea.1. Respiratory System. Effects may become more serious with repeated or prolonged contact. Do not use eye ointment unless directed to by a physician. Ingestion – Do not induce vomiting. If skin surface is damaged. Use only with adequate ventilation. Flush eyes with cool. fumes. low-pressure water for at least 15 minutes while occasionally lifting and lowering eyelids. Seek medical attention immediately. Do not leave victim unattended. or pain persists. 11. smoke.Manufacturing of Cumene Eye Contact – Check for and remove contact lenses.Closed cup: 36°C (96°F). clean affected area thoroughly with mild soap and water. its vapor can cause a flash fire.) Lower Flammable Limit . If skin surface is not damaged.3 FIRE FIGHTING MEASURES NFPA Flammability Classification .Carbon dioxide. Never give anything by mouth to a person who is not fully conscious.AP 0. If spontaneous vomiting is about to occur. Seek medical attention if excessive tearing. place victim’s head below knees. Vapors are heavier than air and may travel long distances along the ground to an ignition source and flash back. Special Properties – This material releases vapors at or below ambient temperatures. carbon monoxide. place on the left side with head down. apply a clean dressing and seek medical attention. If victim is drowsy or unconscious. clean.5 % Autoignition Temperature . lavel Page 58 . irritation. When mixed with air in certain proportions and exposed to an ignition source. it can rupture in the heat of a fire. Seek medical attention if tissue appears damaged or if pain or irritation persists. Gharda institute of technology.1. If container is not properly cooled. and/or unburned hydrocarbons. A vapor and air mixture can create an explosion hazard in confined spaces such as sewers. Flash Point .NFPA Class-IC flammable liquid. Skin Contact – Remove contaminated shoes and clothing.9 % Upper Flammable Limit . Do not use ointments.AP 6. Flush affected area with large amounts of water.424°C (795°F) Hazardous Combustion Products . (Pensky-Martens. or water spray.4 ACCIDENTAL RELEASE MEASURES Flammable Liquid! Release causes an immediate fire or explosion hazard.1. other drainage systems. Water mist or spray may be used to reduce or disperse vapors. water fog. Notify appropriate authorities of potential fire and explosion hazard if liquid enter sewers or waterways. and natural waterways. Do not touch or walk through spilled material. This material will float on water and its run-off may create an explosion or fire hazard.Manufacturing of Cumene Extinguishing Media – SMALL FIRE: Use dry chemicals. or confined areas. water fog. Cover pooling liquid with foam. Withdraw immediately from the area if there is a rising sound from a venting safety device or discoloration of vessels. or other non-combustible material and transfer to appropriate waste containers. or inert gas (nitrogen). However. Evacuate all nonessential personnel from immediate area and establish a "regulated zone" with site control and security. autoignition or explosion. Do not use a solid stream of water directly on the fire as the water may spread the fire to a larger area. Water fog and spray are effective in cooling containers and adjacent structures. basements. Remove spillage immediately from hard. Verify that responders are properly Gharda institute of technology. Eliminate all ignition sources. LARGE FIRE: Use foam. smooth walking areas. For large spills. Containers can build pressure if exposed to radiant heat. sewers. Stop the leak if it can done without risk. 11.Prevent spilled material from entering waterways. storm drains. Absorb or cover with dry earth. A vapor-suppressing foam may be used to reduce vapors. Use clean. carbon dioxide. Dike far ahead of a liquid spill to ensure complete collection. Protection of Fire fighters – Firefighters must use full bunker gear including NIOSH-approved positive pressure selfcontained breathing apparatus to protect against potential hazardous combustion or decomposition products and oxygen deficiencies. it may not prevent ignition in closed spaces. sand. Be aware that burning liquid will float on water. Water can be used to cool the external walls of vessels to prevent excessive pressure. water can cause frothing and/or may not extinguish the fire. tanks. Evacuate area and fight the fire from a maximum distance or use unmanned hose holders or monitor nozzles. secure the area and control access. non-sparking tools to collect absorbed material. but. All equipment used when handling this material must be grounded. Prevent spilled material from entering sewers. lavel Page 59 . foam. or pipelines. cool adjacent containers with flooding quantities of water until well after the fire is out. Always confirm that receiving container is properly grounded. Drain and purge equipment. in natural environments. as necessary. In an urban area. Follow proper entry procedures. Carefully review operations that may increase the risks associated with static electricity such as tank and container filling.Manufacturing of Cumene HAZWOPER-trained and wearing appropriate respiratory equipment and fire-resistant protective clothing during cleanup operations. Wash exposed skin thoroughly with soap and water after handling. efforts to mitigate the hazards of an electrostatic discharge may include. tank cleaning. or any other potential ignition sources. Place into appropriate waste containers for later disposal. Use only with adequate ventilation and personal protection. agitation. Comply with all applicable local.1. Non-equilibrium conditions may increase the fire hazard associated with this product. Pick up freeliquid for recycle and/or disposal if it can be accomplished safely with explosion-proof equipment. Do not breathe vapor. Collect any excess material with absorbant pads. Gharda institute of technology. Avoid contact with oxidizing agents. cleanup on advice from specialists. lavel Page 60 . In addition to bonding and grounding. sparks. Bonding and grounding alone may be inadequate to eliminate fire and explosion hazards associated with electrostatic charges. Prevent contact with food and tobacco products.5 HANDLING AND STORAGE Handling A spill or leak can cause an immediate fire or explosion hazard. to remove material residues. Always bond receiving containers to the fill pipe before and during loading. When performing repairs and maintenance on contaminated equipment. sand. keep unnecessary persons away from the area. cleanup spill as soon as possible. Do not take internally. and clothing. Eliminate all potential ignition sources. skin. Use gloves constructed of impervious materials and protective clothing if direct contact is anticipated. sampling. Keep containers closed and do not handle or store near heat. filtering. A static spark discharge can ignite accumulated vapors particularly during dry weather conditions. gauging. or other inert non-combustible absorbent materials. but are not limited to. mixing. 11. Avoid contact with eyes. Use appropriate respiratory protection when concentrations exceed any established occupational exposure level Promptly remove contaminated clothing.146 prior to entering confined spaces such as tanks or pits. loading. Never siphon by mouth. A static electrical charge can accumulate when this material is flowing through pipes. etc. nozzles or filters and when it is agitated. state and federal laws and regulations. including compliance with 29 CFR 1910. All electrical equipment should comply with the National Electrical Code.Manufacturing of Cumene ventilation. discharging or other handling operations. Lightning. and Stray Currents"). Additional information regarding the design and control of hazards associated with the handling and storage of flammable and combustible liquids may be found in professional and industrial documents including. Vapor may be ignited by static discharge. Storage Keep container tightly closed. reconditioning. Do not expose product containers to flames. Store only in approved containers. sparks. braze solder. 11. Do not store at elevated temperatures or in direct sunlight. Head spaces in tanks and other containers may contain a mixture of air and vapor in the flammable range. lavel Page 61 . Gharda institute of technology. including bonding and grounding.6 EXPOSURE CONTROLS AND PERSONAL PROTECTION Engineering Controls Provide ventilation or other engineering controls to keep the airborne concentrations of vapor or mists below the applicable workplace exposure limits indicated below. cut. Store in a cool. or grind on containers. NFPA 77 ("Recommended Practice on Static Electricity") and the American Petroleum Institute (API) Recommended Practice 2003. Do not fill any portable container in or on a vehicle. the National Fire Protection Association (NFPA) publications NFPA 30 ("Flammable and Combustible Liquid Code"). well-ventilated area. weld. Empty containers may contain material residues which can ignite with explosive force. Product container is not designed for elevated pressure. state and local authorities before reusing. reclaiming. Always keep nozzle in contact with the container throughout the loading process.1. recycling or disposing of empty containers or waste residues of this product. Storage area must meet OSHA requirements and applicable fire codes. but not limited to. Consult appropriate federal. Protect containers against physical damage. dry. inerting and/or reduction of transfer velocities. drill. Do not store with oxidizing agents. Observe label precautions. heat or other potential ignition sources. (“Protection Against Ignitions Arising Out of Static. Do not use compressed air for filling. Dissipation of electrostatic charges may be improved with the use of conductivity additives when used with other mitigation efforts. An emergency eye wash station and safety shower should be located near the work-station. Do not pressurize. 134). Wear long-sleeved fire-retardant garments (e. Hand Protection Avoid skin contact. Use heavy duty gloves constructed of chemical resistant materials such as Viton® or heavy nitrile rubber. Do not use gasoline. Protection factors vary depending upon the type of respirator used.. If product comes in contact with clothing. Wash hands with plenty of mild soap and water before eating. Eye Protection Safety glasses equipped with side shields are recommended as minimum protection in industrial settings. lavel Page 62 A suitable emergency eye wash Odor is an . splashing.Manufacturing of Cumene Personal Protective Equipment Personal protective equipment should be selected based upon the conditions under which this material is used. Chemical goggles should be worn during transfer operations or when there is a likelihood of misting. smoking. or spraying of this material. Nomex®) while working with flammable and combustible liquids. inadequate warning for hazardous conditions. Body Protection Avoid skin contact. use a NIOSH-approved organic vapor respirator if adequate protection is provided. kerosene. A hazard assessment of the work area for PPE requirements should be conducted by a qualified professional pursuant to OSHA regulations. Promptly remove and discard contaminated leather goods. Respirators should be used in accordance with OSHA requirements (29 CFR 1910. immediately remove soaked clothing and shower. drinking. solvents or harsh abrasives as skin cleaners. water and safety shower should be located near the work station. use of toilet facilities or leaving work. Respiratory Protection For known vapor concentrations above the occupational exposure guidelines (see below). This may include an apron. additional PPE may be required. The following pictograms represent the minimum requirements for personal protective equipment. For certain operations. Additional chemical-resistant protective gear may be required if splashing or spraying conditions exist. Gharda institute of technology. General Comments Use of this material in spaces without adequate ventilation may result in generation of hazardous levels of combustion products and/or inadequate oxygen levels forbreathing. boots and additional facial protection.g. Normally stable but may form peroxides when stored for prolonged time periods in contact with air. 10.10 DISPOSAL CONSIDERATIONS Hazard characteristic and regulatory waste stream classification can change with product use. Accordingly. treatment and/or disposal methodologies for spent materials and residues at the time of disposition. and oxidizers. Materials Incompatibility -Strong acids. Environmental Fate .Keep away from heat. State and/or local Forms peroxides with Gharda institute of technology. storage and disposal of waste material must be conducted in accordance with RCRA regulations (see 40 CFR 260 through 40 CFR 271). Transportation.8 TOXICOLOGICAL INFORMATION Toxicity Data – Effects from Acute Exposure: Overexposure to cumene may cause upper respiratory tract irritation and severe CNS depression. Effects from Prolonged or Repeated Exposure: High-level exposure to cumene vapors significantly increases renal tubule adenoma in male rats.66.1. This product is potentially toxic to freshwater and saltwater ecosystems.This product will normally float on water. alkalies. transportation.7 STABILITY AND REACTIVITY Chemical Stability . Conditions to Avoid . Aquatic toxicity values are expected to be in the range of 1 .1. lavel Page 63 . 10. 10. Components will evaporate rapidly.10 mg/l based upon data from components and similar products. The log Kow value for this product is 3.9 ECOLOGICAL INFORMATION Ecotoxicity .LC50 (fish): 1..10 mg/l. Cumene is regulated by US EPA as a listed hazardous waste (U055). If discarded. it is the responsibility of the user to determine the proper storage. treatment. Furthermore this exposure is associated with increased alveolar/broncheolar adenoma and carcinoma in mice and with increased hepatocellular carcinoma in female mice. prolonged storage.1.Manufacturing of Cumene 10.1. sparks and flame. At this time the relevance of these finds to human health are not clear. This material may be harmful to aquatic organisms and may cause long term adverse effects in the aquatic environment. lavel Page 64 . Gharda institute of technology.Manufacturing of Cumene regulations may be more restrictive. Contact the RCRA/Superfund Hotline at (800) 424-9346 or your regional US EPA office for guidance concerning case specific disposal issues. and effluent disposal. 6. 3. This consideration will be less important for low volume production. and is suitable for long-distance transport of bulk chemicals. waterway (canal or river) or a sea port. 5. high-priced products. Availability of suitable land. Location with respect to the marketing area 2. Local community considerations. site should be selected that is close to at least two major forms of transport road. 7. Availability of labour. Raw material supply. Political and strategic considerations. Plant producing bulk chemicals are best located close to the source of the major raw material: where this is also close to the marketing area. Raw Materials: The availability and price of suitable raw materials will often determine the plant location. lavel Page 65 . Many factors must be considered when selecting a suitable site. Transport facilities. 8. Environmental impact.power. 9. The factors to be considered are: 1. rail. 4. Marketing Area: For materials that are produced in bulk quantities such as cement. Air transport is convenient & Gharda institute of technology.Manufacturing of Cumene Chapter 11 PLANT LOCATION AND LAYOUT Plant location and site selection: The location of the plant can have a crucial effect on the profitability of a project and the scope for future expansion. Climate. Availability of utilities: water. If practicable. Road transport is being increasingly used. 10. such as pharmaceuticals. Transport: The transport of materials & products to & from the plant will be an overriding consideration in site selection. the plant should be located close to the primary market. mineral acids and fertilizers where the cost of the product per ton is relatively low and the cost of transport a significant fraction of the sales price.fuel. Skilled construction workers will usually be brought in from outside the site area. banks. at other locations cooling tower will be needed. from wells. the local community must be able to provide adequate facilities for the plant personnel: school. Utilities(Services) Chemical processes invariably require large quantities of water for cooling & general process use . for example. Process water may be drawn from a river. & labour suitable for training to operate the plant. Local trade union customs & restrictive practices will have to be considered when assessing the availability & suitability of the local labour for recruitment & training. Electrochemical processes that require large quantities of power. but there should be an adequate pool of unskilled labour available locally . housing & recreational & cultural facilities. An environmental impact assessment should be made for each new project or major modification or addition to an existing process. The disposal of toxic & harmful effluents will be coverd by local regulations & the appropriate authorities must be consulted during the initial site survey to determine the standards that must be met. aluminium smelters need to be located close to a cheap source of power. Full consideration must be given to the safe location of the plant so that it does not impose a significant additional risk to the community. Skilled tradesmen will be needed for plant maintenance. Gharda institute of technology. or from the sea.Manufacturing of Cumene efficient for the movement of personnel &essential equipment & supplies & the proximity of the site airport should be considered. lavel Page 66 . At some sites the cooling water required can be taken from a river or lake . A competitive priced fuel must be available on site for steam & power generation.& disposal: All industrial processes produce waste products & full consideration must be given to the difficulties & cost of their disposal. Local community considerations: The proposed plant must fit in with & be acceptable to the local community. or purchased from a local authority. Electrical power will be needed at all sites. Environment impact. Availibility of labour: Labour will be needed for construction of the plant & its operation. & the plant must be located near a source of water of suitable quantity. On a new site. 2. Canteens & other amenity buildings. such as medical centers. such as areas of high unemployment. power generation . transformer stations. the process units will normally be sited first & arranged to give a smooth flow of materials through the various processing steps. The availability of such grants can be the overriding consideration in site selection. 8. Climate: Adverse climate conditions at a site will increase cost. Political & Stratergic Considerations: Capital grants tax concessions & other inducements are often given by the government to direct renew investments to preferred locations. Abnormally low temperatures will require the provisition of additional insulation & special heating for equipment & pipe runs. The ancillary buildings & services required on a site. Utilities: steam boilers. refrigeration. Site Layout: The process units & ancillary buildings should be laid out to give the most economical Flow of materials & personnel around the site. 1. lavel Page 67 . compressed air. Car parks When roughing out the preliminary site layout. A full site evaluation should be made to determine the need of piling or other special formations. Stronger structures will be needed at locations subject to high winds (cyclone hurricane areas) or earthquakes. Offices for general administration. 6. 10. 9. Maintenance workshops. well drained & have suitable load bearing characteristics. 4. Fire stations & other emergency services.Manufacturing of Cumene Land (site selection) Sufficient suitable land must be available for the proposed plant & for future expansion. The land should ideally be flat. Laboratories for process control 5. Consideration must also be given to the future expansion of the site. 7. Hazardous processes must be located at a safe distance from other buildings. 3. Storages for raw materials & products: tank farms & warehouses. in addition to the main processing units will include. Effluent disposal plant . from raw Gharda institute of technology. Stores for maintenance & operating supplies. greater spacing may be needed for hazardous processes. The main storage area should be placed between the loading & unloading facilities & the process units they serve.Manufacturing of Cumene material to final product storage. They should be arranged so as to minimize the time spent by personnel in travelling between buildings. Storage tanks containing hazardous materials should be sited at least 70m from the site boundary. Control rooms will normally be located be located adjacent to the processing units. The principal factors to be considered are: 1. However this will not necessarily be the best arrangement for operation & maintainance. Administration offices & laboratories. Modular construction Costs: The cost of construction can be minimised by adopting a layout that gives the shortest run of connecting pipe between equipment & the least amount of structural steel work. lavel Page 68 . The sitting of the main process units will determine the layout of the plant roads. Safety 6. should be located well away from potentially hazardous processes. Cooling towers should be sited so that under the prevailing wind the plume of condensate spray drifts away from the plant area & adjacent properties. Access roads will be needed to each building for construction & for operation & maintenance. in which a relatively large number of people will be working. Gharda institute of technology. Plant Layout: The economic construction & efficient operation of a process unit will depend on how well he plant & equipment specified on the process flow-sheet is laid out. but with potentially hazardous processes may have to be sited at a safer distance. Convenience of maintenance 5. Economic consideration: construction & operating cost 2. The process requirements 3. Process units are normally spaced at least 30m apart. pipe alleys & drains. Convenience of operation 4. Utility buildings should be sited to give the most economical run of pipes to & from the process units. Future expansion 7. The location of the principal ancillary buildings should then be decided. Sufficient working space and head room must be provided to allow easy access to equipments. piping and instrumentation. Modular Constructions: In resent years there has been a move to assemble sections of plant at the plant manufacturers site. Gharda institute of technology. and services pipes over-sized to allow for future requirements. and confine the effects of an explosion. and instruments should be located at convienient positions and heights. At least two escape routes for operators must be provided from each level in the process buildings. Space should be left on pipe alleys for future needs. Operator: Equipment that needs to have frequent operator attention should be located convenient to the control room. Equipment that requires dismantling for maintainnace. The modules are then transported to the plant site. Plant Expansion: Equipments should be located so that it can be conveniently tied in with any future expansion of the process. Maintainance: Heat exchangers need to be cited so that the tube bundles can be easily withdrawn for cleaning and tube replacement. The advantage of modular construction are : (1) Improved quality control (2) Reduced construction cost (3) Less need for skilled labour on site. lavel Page 69 . Vessels that require frequent replacement of catalyst or packing should be located on the outside of buildings. such as compressors and large pumps.Manufacturing of Cumene Process Requirements: An example of the need to take into account process considerations is the need to clevate the base of columns to provide the necessary net positive suction head to a pump or the operating head for a thermosyphon reboiler. Safety: Blast walls maybe needed to isolate potentially hazardous equipment. structural steel. Valves. should be placed under cover.sample points. by road or sea. These modules will include the equipment. (4) Less need for a skilled personal on overseas sites. The power required for electrochemical processes. (3) Cooling water. motor drives. The voltage at which the supply is taken or generated will depend on the demand. (4) Water for general use. For a large site the supply will be taken at a very high voltage. (3) More flanged connections. These services will normally be supplied from a central site facility. In the United Kingdom a three phase 415V system is used for general industrial purposes. (6) Compressed air. (7) Inert gas supplies. Transformers will be used to step down the supply voltage to the voltages used on the site. The process temperatures required can usually be obtained with low temperature steam typically 2.5 bar and steam distributed at a relatively low pressure. a supply at an intermediate high voltage will also be provided. and will include: (1) Electricity.000 or 33. lavel Page 70 . (8) Refrigeration. typically 6000 or 11. Electricity: .Manufacturing of Cumene Some of the disadvantages are: (1) Higher design costs. (2) Steam for process heating.000V Steam: The steam for heating is usually generated in water tube boilers using the most economical fuel level available. Utilities: The word utilities is not generally used for the ancillary services needed in the operation of any production process. (9) Effluent disposal facilities. lighting.000 V. and 240V single phase for lighting and other low power requirements. If a number of large motors is used. and general use maybe generated on site. typically 11. (5) Demineralised water. (2) More structural steel work. typically around 8 bar Gharda institute of technology. but will more usually be purchased from the local supply company. (4) Possible problems with assembly on site. Demineralised Water: Demineralised water from which all the minerals have been removed by ion exchange. The overall thermal efficiency of such systems can be in the range 70-80 %. Combined Heat and Power (Co-generation): The energy costs on a large site can be reduced if the electrical power required is generated on the site and the exhaust steam from the turbines used for process heating. Water for General Use: The water required for general purposes on a site will usually be taken from the local mains supply. down to -30oC. unless a cheaper source of suitable quantity water is available from a river. For temperatures down to around 10 o C chilled water can be used. such as dowtherm will be needed for high process temperatures. Mixed and multiple bed ion exchange units are used.Manufacturing of Cumene (100 psig). Cooling Water: Natural and forced draft cooling towers are generally used to provide the cooling water required in a site. Compressed Air: It will be needed for general use. and as boiler feed water. or proprietary heat transfer fluids. and for the pneumatic controllers that are usually used for chemical process plant control. compared with the 30-40 % obtained from a conventional power station. Higher steam pressures. unless water can be drawn from a convinient river or lake in sufficient quantity. one resin converting the cations to hydrogen and the other removing the acid radicals. Water with less than one ppm of dissolved solids can be produced. lavel Page 71 . Refrigeration: It will be needed for processes that require temperatures below those that can be economically obtained with cooling water. lake or well. the balance between the power and heating demands. the cost of fuel. where the heat in the exhaust steam is wasted in the condenser. Gharda institute of technology. salt brines are used to distribute the “refrigeration” round the site from a central refrigeration machine. Whether a combined heat and power system scheme is worth considering for a particular site will depend on the size of the site. is used where pure water is needed for process use. stand by supplies and the price paid for any surplus power electricity generated. For lower temperatures. and particularly on the availability of and cost of. or purchased as liquid in tankers. lavel Page 72 . Nitrogen is normally used and is manufactured on site in an air liquefaction plant. SITE LAYOUT Gharda institute of technology. Effluent Disposal: Facilities will be required at all sites for the disposal of waste materials without creating a public nuisance.Manufacturing of Cumene Inert Gases: Where large quantities of inert gas are required for the inert blanketing of tanks and for purging is usually supplied from a central facility. lavel Page 73 . Building Gate 1 Green Belt Centre Security Office Parking Area Gharda institute of technology. Section Tank Farm Wind Space for future Main Control expansion Room Power Station Plant Utilities Main unit Workshop R & D centre Canteen Medical Admin.Manufacturing of Cumene Product Dispatch Gate 2 E.P.T. Rao. S M Vora.. McGraw Hill. “Petrochemical Production Process” – SBS Publisher εt Distributors Pvt. 33-52 Gharda institute of technology. 8. 4th Ed. USA. 11. 6. USA. V. 7. Kirk Othmer Encyclopedia Of Chemical Technology(2005). Himmelblau D. Basic principles and calculations in chemical engineering.Taylor & Francis Publisher.C. 12..Brayford.G. “ Chemical Engineers Handbook” 5. Y.”Shreve’s Chemical Process Industries”5th Ed. 10.V.McGraw Hill International Edition. Ullmman’s Encyclopedia Of Industrial Chemistry(1985). 9. 1989. Sun G Gyu Lee. pp 3. Austin. Fifth edition. D. 14 (1982). Volume 10. Prentice-Hall.Manufacturing of Cumene Chapter 13 REFERENCE 1.” in Encyclopedia of Chemical Processing and Design. Navid Naderpour . Vol. 5th Ed.-1 4.-2. PERRY & CHILTON. 2.Wiley Critical Content. 639120 .T... “Petroleum Technology” .Vol. 2005. Universities Press(India) Private Limited.Ltd. Chemical Engineering Thermodynamics(2005).J. “Encyclopedia of Chemical Processing”. Volume 12. Stoichiometry. Dryden’s outline of chemical technology for 21st Century. B I Bhatt. “Cumene.. lavel Page 74 .