INTRODUCTION:-
The word phenol is also used to refer to any compound which contains a six-membered aromatic ring, bonded directly to a hydroxyl group (-OH). In effect, phenols are a class of organic compounds. Phenol, also known as carbolic acid or hydroxybenzene, is a colorless solid or a clear, thick liquid with a characteristically sweet odor. Phenol is derived from the basic raw materials of benzene and propylene. Phenol is the monohydroxy benzene C6H5OH having a characteristic odour and when very dilute, a sweetish taste.
Phenol is toxic and corrosive. In case of accidental contact, the area exposed should be rapidly and thoroughly washed with a mild alkaline solution. Phenol is readily biodegradable. It has a low bio concentration potential, meaning phenol does not accumulate in tissues of living organisms.
Phenol is moderately toxic to aquatic organisms on an acute basis. The most significant products from phenol are phenolic resins, Bisphenol A, Caprolactam and salicylic acid. Phenol has antiseptic properties and was used in the pioneering technique of antiseptic surgery, though the skin irritation caused by continual exposure to phenol eventually led to the substitution of aseptic (germ-free) techniques in surgery. It is also the active ingredient in some oral anesthetics such as Chloraseptic spray. Phenol was also the main ingredient of the Carbolic Smoke Ball, a device sold in London designed to protect the user against influenza and other ailments.
HISTORY:-
Phenol was discovered in the 1650s by German chemist, Johann Rudolf Glauber (1604-1668), who obtained it by condensing coal tar vapors. Little was known of phenol's properties for nearly two hundred years until another German chemist, Friedlieb Ferdinand Runge (1795-1867), isolated phenol in 1834 and named it carbolic acid. In 1843, phenol's modern name was introduced by French chemist, Charles Frederic Gerhardt (1816-1856), who used a different method to prepare the acid. Large-scale manufacture of phenol began during the 1860s. At first, phenol was produced from coal tar, but processes were later developed for manufacturing phenol from petroleum. The compound was first synthesized from benzene in 1867 by French organic chemist, Charles Adolph Wurtz (1817-1884), and August Friedrich Kekule von Stradonitz. The antiseptic properties of phenol were used by Sir Joseph Lister (1827–1912) in his pioneering technique of antiseptic surgery. The Cumene process (Cumene-phenol process, Hock process) was invented by Heinrich Hock in 1944.
The production of synthetic phenol started in India in 1968 with the commissioning of unit of Herdillia Chemicals Ltd at Thane, Maharashtra with an installed capacity of 10,000 tonne per annum. A unit to produce 6,000 tonne per annum of phenol based on chlorobenzene route was established in Durgapur but it had to shut down because of maintenance and corrosion problem. A 40,000 TPA phenol unit of Hindustan Organic Chemical Ltd was commissioned in 1987 at Cochin. With Durgapur unit closed the present installed capacity of two units. HOC and Herdillia amounts to 60,000 tonne per annum. In addition there is another unit of Neyveli Lignite Corporation which recovers phenol from its coal tar distribution unit with an installed capacity of 1,470 TPA.
NAMES
IUPAC NAME Benzenol
Systematic name Phenol
Other names Carbolic acid, Benzenol, Phenylic acid, hydroxyl benzene, phenic acid.
PROPERTIES
Molecular formula C6H5OH
Molecular mass 94.11 g mol−1
Appearance White Crystalline Solid
Melting point 40.5 °C
Boiling point 181.7 °C
Density 1.07 g/cm³
Specific Gravity 1.06 @ 20°C
Solubility in water 8.3 g/100 ml (20 °C)
Acidity (pKa) 9.95
Flash point 79°C
Auto ignition temperature 715°C
Dipole moment 1.7D
Vapour pressure @ 77°F 0.35 mm Hg
Vapour density @ 60°F(air = 1) 3.24
APPLICATION AND USES
The main use of phenol is as a feedstock for phenolic resins, bisphenol A and caprolactam (an intermediate in the production of nylon-6). It is used in the manufacture of many products including insulation materials, adhesives, lacquers, paint, rubber, ink, dyes, illuminating gases, perfumes, soaps and toys. Also used in embalming and research laboratories. It is a product of the decomposition of organic materials, liquid manure, and the atmospheric degradation of benzene.
Phenol has antiseptic properties and was used by Sir Joseph Lister (1827-1912) in is pioneering technique of antiseptic surgery, though the skin irritation caused by continual exposure to phenol eventually led to the substitution of aseptic (germ-free) techniques in surgery. It is also the active ingredient in some oral anesthetics such as Chloraseptic spray. Phenol was also the main ingredient of the Carbolic Smoke Ball, a device sold in London designed to protect the user against influenza and other ailments.
It is found in some commercial disinfectants, antiseptics, lotions and intments. Phenol is active against a wide range of microorganisms, and there are some medical and pharmaceutical applications including topical anaesthetic and ear drops, sclerosing agent. It is also used in the treatment of ingrown nails in the "nail matrix phenolization method". Another medical application of phenol is its use as a neurolytic agent, applied in order to relieve spasms and chronic pain. It is used in dermatology for chemical face peeling.
TYPES OF PHENOL MANUFACTURING PROCESS
There are five types of process to manufacture phenol.The industrially important methods of manufacture of phenol are the following.
Cumene hydroperoxidation process
Rasching process
Toluene two stage oxidation process
Benzene Sulphonation process
Chlorobenzene caustic hydrolysis
CUMENE PER OXIDATION PROCESS:
In this type of process the cumene is first oxidized to produce cumene hydroperoxide. Then it is mixed with H2SO4 as a catalyst. By this cleavage will be separated out.
From this cleavage phenol and acetone will be separated by distillation.
RASCHING PROCESS:
In this process the main raw material is Benzene and Hydrochloric acid. The vapour of benzene and HCl is mixed to form chlorobenzene. This crude chlorobenzene is heated upto 500°C. The crude phenol is separated at this temperature. The crude phenol is distillated and pure phenol is separated.
TOLUENE TWO STAGE OXIDATION PROCESS:
Toluene in liquid phase is oxidized with air in a reactor under 40-70 p.s.i in presence of a soluble cobalt catalyst maintained at 150°c to produce benzoic acid. Then the crude benzoic acid is distillated and the pure benzoic acid is separated. That is transferred to an oxidizer and by oxidizing phenol is produced
BENZENE SULPHONATION PROCESS:
Benzene is can be converted to phenol with the help of inorganic acids and salts; this process is oldest of all the process where phenol is produced by reactants such as cumene and toluene. Benzene is reacted with sulphuric acid to form benzene sulphonic acid at 150 to 170°C. Benzene sulphonic acid is reacted with sodium sulfite to form sodium benzene sulphonate. Sodium benzene sulphonate is fused with sodium hydroxide to form sodium phenoxide. Sulphuric acid and sodium phenoxide are reacted to produce crude phenol and Sodiumsulphite.
CHLOROBENZENE CAUSTIC HYDROLYSIS:
Benzene which is in dry state, reacted with chlorine at the presence of the catalyst iron or anhydrous ferric chloride at about 85°C temperature to form Chlorobenzene in a chlorination tower. Then 10% solution of dilute caustic soda is mixed with Chlorobenzene which is reacted with caustic solution where chlorine present at the benzene ring is reacted with hydrogen and produce water vapors which is removed a tail gas. Phenol is obtained from hydrolysis occurs at the neutralizer where reaction with concentrated hydrochloric acid take place to form phenol and sodium chloride.
METHOD OF PROCESS SELECTED:
The best method to produce phenol is the cumene hydroperoxidation process, because in this process main products produced are phenol and acetone. Acetone is economically good as phenol. The cumene (isopropyl benzene) is easily available. This method is economically feasible.
RAW MATERIALS:
The main raw materials used in the cumene hydroperoxidation are as given by
Cumene
Air
Alkali(NaOH)
Sulphuric acid(H2SO4)
CHEMICAL REACTIONS INVOLVED:
C6H5CH(CH3)+ O2 NaOH C6H5C (CH3)2OOH
(Cumene) (Oxygen) (Cumene hydroperoxide)
C6H5C (CH3)2OOH H2S04 C6H5OH + CH3COCH3
(Cumeneperoxide) (Phenol) (Acetone)
PROCESS DESCRIPTION:
Step 1- Oxidation of cumene to the cumene hydroperoxide:
The cumene is the raw material used in this process. The oxidation of cumene is done by the homoginity of the reaction. The liquid cumene is sent in the oxidizer. Then the compressed air at 5atm is sent and mixed with the liquid cumene. An alkali is added in this process of oxidation, because in cumene impurities like styrene, aniline and sulfer compounds can be present. Those will act as inhibitors during this process. In cumene a small amount of phenol can be present, by adding alkali phenol can be completely removed.
Otherwise it will form acetophenone and 2-phenyl2-proponal. Some acids like formic acid can be neutralized by alkali. Here sodium hydroxide (NaOH) is used as the alkali. The amount of NaOH added is 0.01ppm.
This oxidation is carried out in the presence of nickel as catalyst, because the autocatalytic reaction takes a long time to form cumene hydroperoxide. The process is maintained at the PH of 8.5 to 10.5.It is carried out in a large stainless steel vessels which can withstand the operating temperature and pressure. This oxidation reaction of cumene to cumene hydroperoxide is an exothermic reaction. The temperature maintained in the reactor is 110°C and the pressure maintained is 5atm. The unreacted off gases like oxygen and nitrogen will be sent out from top. The liquid stream of cumene hydroperoxide and unconverted cumene will be sent out. Mostly this outlet stream contains 80% of cumene hydroperoxide and rest is unconverted cumene. The cumene hydroperoxide is explosive when it accumulates. So this product stream will be sent to the next stage after cooling it to 70°C.
Step 2- Splitting the cumene hydroperoxide to cleavage:
The product stream of cumene hydroperoxide is sent next to the acidifier. In this equipment the cumene hydroperoxide is converted. In this conversion the hydroperoxide is a relatively stable compound and at 100°C the induction period of its auto catalytic decomposition is 8hours. So that to achive good phenol selectivity this decomposition should take place catalytically. Here the sulphuric acid(H2S04) is used as a catalyst, because it is also helpful to neutralize the base medium produced in the oxidizer. The amount of sulphuric acid added is 300ppm.
The dissociation of cumene hydroperoxide to cleavage take place in relatively at low temperature at 80°C. So that the temperature maintained in the acidifier is 80°C, and the pressure maintained is 5atm. In this stream the H2S04 is added and there should be the vigorous agitation take place. To minimize the undesirable chain reactions and to avoid the explosion by the hydroperoxide the total stream of cumene hydroperoxide is converted into the cleavage. This decomposition is an exothermic reaction and a lot of heat will be liberated during this reaction. This heat will be removed by the water which is passed in the outer jacket of the acidifier and by controlling the temperature of the vessel is maintained.
At the outlet stream 80% of the cumene hydroperoxide is converted into the cleavage. The rest will be the unconverted cumene hydroperoxide. The cleavage is having the following composition
Phenol = 62%
Acetone = 31%
Cumene = 5 %
α –methyl styrene = 1.4%
Acetophenone = 0.6%
This cleavage and the unconverted cumene hydroperoxide is sent to a gravity separator. In this separator the cleavage will be in the top and the cumene hydroperoxide will be as the bottom layer. The cleavage will be taken out and this will be sent to the wash tower. The unconverted cumene hydroperoxide will be recycled back to the acidifier.
Step 3- Purification of the products:
The cleavage from the separator will be now sent to the wash tower. In the cleavage there will be the acid present in it can cause corrosion to the next distillation columns, so that the acid want to be removed. Here in this tower the cleavage is sent in and the water is sprayed from the top of the column. This water will dissolve the acid present in the cleavage. This acidified wash water will be separated out and the acid free cleavage will be sent to the acetone column.
The cleavage from the wash tower will be sent to the heater where it will be heated upto 90°C and then it will be sent to the atmospheric distillation column. This column is maintained at 90°C at the bottom and 56°C at the top. In this column the acetone vapour will be separated from the top. Then the vapours will be sent to an condenser. In this condenser acetone vapour will be condensed. The residue from the distillation column will be taken out from the bottom then it will be heated upto 95°C. The heated material will be sent to the cumene column.
In this column the cumene is separated in a vaccum distillation column. The vaccum distillation is used in the next three stages, because this cleavage will be stable only upto 150°C, apart from this temperature it will be cracked and it will form cumene and propylene. But the boiling point of the further products will be higher than 150°C. The vaccum pressure maintained cumene column is 150mmHg. In this pressure cumene is separated at 80°C. The cumene vapour is separated from top and it is condensed by a condenser and taken out. This cumene will be recycled and mixed with the feed cumene. The residue from this column will be heated to 110°C and it will be sent to the next vaccum distillation column.
In this column the pressure maintained is 150mmHg and the temperature will be maintained at 110°C. At this temperature α –methyl styrene will be separated from the top of the column and condensed by a condenser. The rest of the residue will be taken out from the bottom of the column and heated to 130°C. This will be sent to the phenol column. In this phenol column the pressure is maintained at 150mmHg and the temperature is maintained at 130°C. at the top of the column the phenol is taken out as vapour and it is condensed using condenser. Then the liquid phenol will be collected and stored. At the bottom of the column the acetophenone will be collected.
MATERIAL BALANCE
BASIS: 1000kgs production of phenol
Overall reactions:
Oxidation of cumene:
C6H5CH(CH3) + O2 NaOH C6H5C (CH3)2OOH
(120) (32) (152)
Decomposition of cumene hydroperoxide:
C6H5C (CH3)2OOH H2S04 C6H5OH + CH3COCH3
(152) (94) (58)
Molecular weights of components:
Cumene(isopropyl benzene)= 120 kg moles
Cumene hydroperoxide = 152 kg moles
Oxygen = 32 kg moles
Phenol = 94 kg moles
Acetone = 58 kg moles
Mass of inlet of cumene and oxygen = 120+32=152 kg moles
Mass of outlet of phenol and acetone = 94+52= 152 kg moles
INLET =OUTLET
OXIDIZER:
Feed:
Cumene = 1650 kgs
Required oxygen = 440 kgs
1 kg of air contains 0.23 kgs of O2
X kgs of air contains 440 kgs of O2
Amount of air supplied = 1913 kgs of air
25% excess air supplied = 478 kgs of air
Actual amount of air supplied = 2319 kgs of air
NaOH Off gases
OXIDIZER
Cumene cumene hydroperoxide
Air Cumene
COMPONENTS INLET kgs/hr OUTLET kgs/hr
Cumene 1650 418
Air 2391 ---
Cumene hydroperoxide --- 1672
Off gases --- 1951
Total 4041 4041
ACIDIFIER:
H2SO4
ACIDIFIER
Cumene hydroperoxide cleavage
Cumene Cumene hydroperoxide
COMPONENTS INLET kgs/hr OUTLET kgs/hr
Cumene hydroperoxide 1672 418.1
Cumene 418 ---
Clevage --- 1672.4
H2SO4 0.5 ---
Total 2090.5 2090.5
SEPERATOR:
Cleavage
SEPERATOR
Cleavage
Cumene hydroperoxide
Cumene hydroperoxide
COMPONENTS INLET kgs/hr OUTLET kgs/hr
Cumene hydroperoxide 1672.4 418.1
Carryover Clevage --- 41.8
Clevage 418.1 1630.6
Total 2090.5 2090.5
WASH TOWER:
Water
WASH TOWER
Cleavage Acid free cleavage
Acidified wash water
COMPONENTS INLET kgs/hr OUTLET kgs/hr
Cleavage 1630.6 ---
Water 24 ---
Acid free clevage --- 1625.6
Acidified wash water --- 29
Total 1654.6 1654.6
ACETONE COLUMN:
Acetone
ACETONE COLUMN
Carryover cleavage
Cleavage
Residue
Carryover acetone
COMPONENTS INLET kgs/hr OUTLET kgs/hr
OVERHEAD BOTTOM
Cleavage 1625.6 --- ---
Acetone --- 498.8 ---
Carryover cleavage --- 5 ---
Carryover acetone in residue --- --- 5
Residue --- --- 1116.8
Total
1625.6
503.8
1121.8
1625.6
CUMENE COLUMN:
Cumene
CUMENE COLUMN
Carryover acetone
Feed
Residue
COMPONENTS INLET kgs/hr OUTLET kgs/hr
OVERHEAD BOTTOM
Feed 1121.8 --- ---
Cumene --- 81.3 ---
Carryover acetone in cumene --- 5
Residue --- --- 1035.5
Total
1121.8
86.3
1035.5
1121.8
α - METHYL STYRENE COLUMN:
α - methyl styrene
α - METHYL
STYRENE COLUMN
Feed
Residue
COMPONENTS INLET kgs/hr OUTLET kgs/hr
OVERHEAD BOTTOM
Feed 1035.5 --- ---
α - methyl styrene --- 22.8 ---
Residue --- --- 1012.7
Total
1035.5
22.8
1012.7
1035.5
PHENOL COLUMN:
Phenol
PHENOL COLUMN
Carryover acetophenone
Feed
Acetophenone
COMPONENTS INLET kgs/hr OUTLET kgs/hr
OVERHEAD BOTTOM
Feed 1012.7 --- ---
Phenol --- 1002.9 ---
Carryover acetophenone --- 3.8 ---
Acetophenone --- --- 5
Total
1012.7
1006.7
5
1012.7
The amount product phenol = 1006.7 kgs/hr
Purity of the product phenol = 99.6%
ENERGY BALANCE
OXIDIZER:
Inlet heat@ 70°C:
Cumene @ 30°C
Mass1 = 1650kgs
Cp1 = 0.415 kcal/kg °C
ΔT1 = (30-25) = 5
Q1 =m1× Cp1 × ΔT1
Q1 = 1650×0.415×5
Q1 =3423.8 kcal
Q1 =14331.2 KJ.
Air @ 30°C
Mass2 =2391 kgs
Cp2 = 1.005 KJ/kg°C
ΔT2 = (30-25) = 5°C
Q2 = m2×Cp2 ×ΔT2
Q2 = 2391×1.005×5
Q2 = 12014.8 KJ
Total heat inlet Q= Q1+ Q2= 14331.2 + 12014.8
Q = 26346.1 KJ
Outlet heat@ 110°C:
Cumene hydro peroxide @ 110°C
Mass1 = 1672 kgs
Cp1 = 0.450 kcal/kg°C
ΔT1 = (110-25) = 85°C
Q1 = m1 × Cp1× ΔT1
Q1 = 1672×0.450×85
Q1 = 63954kcal
Q1 = 267698.7 KJ
Cumene @ 110°C
Mass2 =418 kgs
Cp2 = 0.455kcal/kg°C
ΔT2 = (110-25) =85°C
Q2 = m2×Cp2 ×ΔT2
Q2 =418×0.455×85
Q2 =16166.2 kcal
Q2 =67668.3 KJ
Off gases @ 110°C
Oxygen
Mass3 =110 kgs
Cp3 =0.936 KJ/kg°C
ΔT3 = (110-25) =85°C
Q3 = m3×Cp3 ×ΔT3
Q3 =110×0.936×85
Q3 =9004 KJ
Nitrogen
Mass4 =1841 kgs
Cp4 =1.035 KJ/kg°C
ΔT4 = (110-25) =85°C
Q4 = m4×Cp4 ×ΔT4
Q4 =1841×1.035×85
Q4 =161961.9 KJ
Total heat outlet Q= Q1+ Q2+ Q3+ Q4
Q=267698.7 +67668.3 +9004+161961.9
Q= 506332.9 KJ
Heat of reaction of cumene hydroperoxide = 736 KJ/kg
For 1672 kgs of cumene hydroperoxide = 736×1672
= 1230592
COMPONENTS INLET HEAT KJ OUTLET HEAT KJ
Cumene 14331.2 67668.3
Air 12014.8 ---
Heat of reaction of
Cumene hydroperoxide 1230592 ---
Cumene hydroperoxide --- 267698.7
Off gases --- 170965.9
Heat removed by water --- 750605.1
Total 1256938 1256938
Heat content of reactant + heat of reaction = heat content of product + heat loss
26346.1+1230592 = 506332.9+750605.1
1256938KJ=1256938KJ
COOLER:
Inlet heat @ 110°C:
Heat taken by cumene hydroperoxide =267698.7 KJ
Heat taken by cumene = 67668.3KJ
Total heat inlet = 335367 KJ
Outlet heat @70°C:
Cumene hydroperoxide@ 70°C:
Mass1 = 1672 kgs
Cp1 = 0.450 kcal/kg°C
ΔT1 = (70-25) =45°C
Q1 = m1 × Cp1× ΔT1
Q1 = 1672×0.450×45
Q1 = 33858 kcal
Q1 = 141722.8 KJ
Cumene @ 70°C:
Mass2 =418 kgs
Cp2 = 0.435kcal/kg°C
ΔT2 = (70-25) =45°C
Q2 = m2×Cp2 ×ΔT2
Q2 =418×0.435×45
Q2 =8182.4 kcal
Q2 =34249.6 KJ
Total heat inlet Q= Q1+ Q2= 141722.8+34249.6
Q= 175972.4 KJ
COMPONENTS INLET HEAT KJ OUTLET HEAT KJ
Cumene hydroperoxide 267698.7 141722.8
Cumene 67668.3 34249.6
Heat removed by water --- 159394.6
Total 335367 335367
ACIDIFIER:
Inlet heat @ 70°C:
Heat taken by cumene hydroperoxide =141722.8KJ
Heat taken by cumene = 34249.6KJ
Total heat inlet in product Q1 = 175972.4 KJ
H2SO4 @ 30°C:
Mass2 = 0.5kgs
Cp2 = 1.44KJ/kg °C
ΔT2 = 45°C
Q2 =m2 × Cp2 × ΔT2
Q2 = 0.5×1.44×45
Q2 =32.4 KJ
Total heat inlet Q = Q1+Q2 = 175972.4+32.4 =176004.8KJ
Outlet heat @ 80°C:
Mass of cleavage = 1672.4 kgs
COMPONENTS MASS kgs SPECFIC HEAT KJ/Kg°C
Phenol 1036.9 2.29
Acetone 518.4 1.481
Cumene 83.6 1.842
α - methyl styrene 23.5 1.406
Acetophenone 10.2 1.97
Q1=((1036.9×2.29)+( 518.4×1.481)+( 83.6×1.842)+( 23.5×1.406)+( 10.2×1.97)) ×(80-25)
Q1= 184069.8 KJ
Cumene hydroperoxide@ 80°C:
Mass2 = 418.1kgs
Cp2 = 0.450kcal/kg °C
ΔT2 = (80-25)=55°C
Q2 =m2 × Cp2 × ΔT2
Q2 = 418.1×0.450×55
Q2 =10348 kcal/kg°C
Q2 = 43314.6KJ
Total heat outlet Q = Q1+Q2 = 184069.8 +43314.6=227384.4KJ
Heat of reaction of cleavage = 2983 KJ/kg
For 1672.4 kgs of cleavage =2983×1672.4 = 4988769.2
COMPONENTS INLET HEAT KJ OUTLET HEAT KJ
Cumene hydroperoxide 141722.8 43314.6
Cumene 34249.6 ---
H2SO4 32.4 ---
Heat of reaction of cleavage 4988769.2 ---
cleavage --- 184069.8
Heat removed by water --- 4937386
Total 5164774 5164774
SEPERATOR:
Inlet heat @80°C:
Heat in cumene hydroperoxide =43314.6KJ
Heat in cumene = 184069.8KJ
Total heat inlet = 227384.4 KJ
Outlet heat @80°C:
Heat in cumene hydroperoxide =43314.6KJ
Heat in cleavage = 184069.8KJ
Total heat outlet = 227384.4 KJ
WASH TOWER:
Inlet heat @80°C:
Mass of Cleavage =1630.6
COMPONENTS MASS kgs SPECFIC HEAT KJ/Kg°C
Phenol 1011 2.29
Acetone 505.5 1.481
Cumene 81.5 1.842
α - methyl styrene 22.8 1.406
Acetophenone 9.8 1.97
Q1=((1011×2.29)+( 505.5×1.481)+( 81.5×1.842)+( 22.8×1.406)+( 9.8×1.97)) ×(80-25)
Q1= 179592.7KJ
Water @ 30°C
Mass2 = 24kgs
Cp2 = 4.18KJ/kg °C
ΔT2 = (30-25) =5°C
Q2 =m2 × Cp2 × ΔT2
Q2 = 24×4.18×5
Q2 = 501.6 KJ
Total heat outlet Q = Q1+Q2 =179592.7+501.6 =180094.3KJ
Outlet heat @75°C:
Acid free cleavage = 1625.6 kgs
COMPONENTS MASS kgs SPECFIC HEAT KJ/Kg°C
Phenol 1007.8 2.29
Acetone 503.8 1.462
Cumene 81.3 1.821
α - methyl styrene 22.8 1.367
Acetophenone 9.8 1.97
Q1=((1007.8×2.29)+( 503.8×1.462)+( 81.3×1.821)+( 22.8×1.367)+( 9.8×1.97)) ×(75-25)
Q1=162146.9KJ
Acidified wash water @ 40°C
Mass = 24kgs
Cp = 4.18KJ/kg °C
ΔT = (40-25) =15°C
Q2 =m2 × Cp2 × ΔT2
Q2 = 24×4.18×15
Q2 = 1504.8 KJ
Heat taken by carryover cleavageQ3=16442.6KJ
Total heat outlet Q= Q1+Q2+ Q3= 162146.9+1504.8+16442.6 = 180094.3
COMPONENTS INLET HEAT KJ OUTLET HEAT KJ
Cleavage 179592.7 ---
Water 501.6 ---
Acid free cleavage --- 162146.9
Acidified wash water --- 1504.8
Carryover cleavage --- 16442.6
Total 180094.3 180094.3
HEATER:
Inlet heat @75°C:
Cleavage
Mass of cleavage = 1625.6 kgs
COMPONENTS MASS kgs SPECFIC HEAT KJ/Kg°C
Phenol 1007.8 2.29
Acetone 503.8 1.462
Cumene 81.3 1.821
α - methyl styrene 22.8 1.367
Acetophenone 9.8 1.97
Q=((1007.8×2.29)+( 503.8×1.462)+( 81.3×1.821)+( 22.8×1.367)+( 9.8×1.97)) ×(75-25)
Q=162146.9KJ
Outlet heat @90°C:
Mass of cleavage = 1625.6 kgs
COMPONENTS MASS kgs SPECFIC HEAT KJ/Kg°C
Phenol 1007.8 2.32
Acetone 503.8 1.509
Cumene 81.3 1.863
α - methyl styrene 22.8 1.445
Acetophenone 9.8 1.97
Q=((1007.8×2.32)+( 503.8×1.509)+( 81.3×1.863)+( 22.8×1.445)+( 9.8×1.97)) ×(90-25)
Q=214512.2KJ
COMPONENTS INLET HEAT KJ OUTLET HEAT KJ
Cleavage 162146.9 214512.2
Heat added by steam 52366.3 ---
Total 214512.2 214512.2
ACETONE COLUMN:
Inlet heat @90°C:
Mass of cleavage =1625.6 kgs
COMPONENTS MASS kgs SPECFIC HEAT KJ/Kg°C
Phenol 1007.8 2.32
Acetone 503.8 1.509
Cumene 81.3 1.863
α - methyl styrene 22.8 1.445
Acetophenone 9.8 1.97
Q=((1007.8×2.32)+( 503.8×1.509)+( 81.3×1.863)+( 22.8×1.445)+( 9.8×1.97)) ×(90-25)
Q=214512.2KJ
Outlet heat:
Acetone vapours @ 56°C
Mass1 = 498.8 kgs
λ1 = 212.3KJ/kg
Q1 = m1× λ1
Q1 =498.8×212.3
Q1 =105895.2 KJ
Cleavage vapours @ 56°C
Mass2 = 5 kgs
Q2 = 549.8 KJ
Total heat outlet as vapour = 105895.2+549.8=106445KJ
Bottom residue @90°C
Mass of residue= 116.8 kgs
COMPONENTS MASS kgs SPECFIC HEAT KJ/Kg°C
Phenol 1004.8 2.32
Cumene 81.3 1.863
α - methyl styrene 22.8 1.445
Acetophenone 9.8 1.97
Q3=((1004.8×2.32)+( 81.3×1.863)+( 22.8×1.445)+( 9.8×1.97)) ×(90-55)
Q3= 107756.8KJ
Carryover acetone @90°C
Mass4 = 5kgs
Cp4 = 1.509KJ/kg °C
ΔT4 = (90-25) =65°C
Q4 =m4 × Cp4 × ΔT4
Q4 = 5×1.509×65
Q4 = 490.4KJ
Total heat outlet Q = Q1+Q2+ Q3+ Q4
Q =105895.2+549.8+107756.8+490.4
Q = 214512.2KJ
COMPONENTS INLET HEAT KJ OUTLET HEAT KJ
Cleavage 214512.2 ---
Vapour acetone --- 105895.2
Vapour cleavage --- 549.8
Bottom residue --- 107756.8
Carryover acetone in residue --- 490.4
Total 214512.2 214512.2
OVERHEAD ACETONE CONDENSER:
Inlet heat @ 56°C:
Acetone vapours @ 56°C
Mass1 = 498.8 kgs
λ1 = 212.3KJ/kg
Q1 = m1× λ1
Q1 =498.8×212.3
Q1 =105895.2 KJ
Cleavage vapours @ 56°C
Mass2 = 5 kgs
Q2 = 549.8 KJ
Total heat inlet as vapour Q = Q1+Q2
Q= 105895.2+549.8=106445KJ
Outlet heat@50°C:
Acetone
Mass1 =498.8kgs
Cp1 =1.397 KJ/kg°C
ΔT1 = (50-25) =25°C
Q1 = m1×Cp1 ×ΔT1
Q1 =498.8×1.397 ×25
Q1 =17083.9 KJ
Heat produced by clevage Q2=207.8KJ
Total heat outlet Q = Q1+Q2
Q =17083.9+207.8
Q = 17371.7 KJ
COMPONENTS INLET HEAT KJ OUTLET HEAT KJ
Vapour acetone 105895.2 ---
Vapour cleavage 549.8 ---
Heat removed by water --- 89073.3
Condensed acetone --- 17083.9
Condensed cleavage --- 207.8
Total 106445 106445
HEATER:
Inlet heat @90°C:
Mass of residue= 116.8 kgs
COMPONENTS MASS kgs SPECFIC HEAT KJ/Kg°C
Phenol 1004.8 2.32
Cumene 81.3 1.863
α - methyl styrene 22.8 1.445
Acetophenone 9.8 1.97
Q1=((1004.8×2.32)+( 81.3×1.863)+( 22.8×1.445)+( 9.8×1.97)) ×(90-25)
Q1= 197421.2KJ
Acetone
Mass2 =5kgs
Cp2 =1.509 KJ/kg°C
ΔT2 = (90-25) =65°C
Q2 = m2×Cp2 ×ΔT2
Q2 =5×1.509 ×65
Q2 =490.4 KJ
Total heat inlet Q = Q1+Q2
Q =197421.2+490.4 =197911.6 KJ
Outlet heat @95°C:
Mass of residue= 116.8 kgs
COMPONENTS MASS kgs SPECFIC HEAT KJ/Kg°C
Phenol 1004.8 2.32
Cumene 81.3 1.863
α - methyl styrene 22.8 1.445
Acetophenone 9.8 1.97
Q1=((1004.8×2.32)+( 81.3×1.863)+( 22.8×1.445)+( 9.8×1.97)) ×(95-25)
Q1=212607.5 KJ
Acetone
Mass2 =5kgs
Cp2 =1.510 KJ/kg°C
ΔT2 = (95-25) =70°C
Q2 = m2×Cp2 ×ΔT2
Q2 =5×1.510×70
Q2 =528.5 KJ
Total heat outlet Q = Q1+Q2 =212607.5+528.5=213136KJ
COMPONENTS INLET HEAT KJ OUTLET HEAT KJ
Residue 197421.2 212607.5
Carryover acetone 490.4 528.5
Heat added by steam 15224.4 ---
Total 213136 213136
CUMENE COLUMN:
Inlet heat @95°C:
Mass of feed= 116.8 kgs
COMPONENTS MASS kgs SPECFIC HEAT KJ/Kg°C
Phenol 1004.8 2.32
Cumene 81.3 1.863
α - methyl styrene 22.8 1.445
Acetophenone 9.8 1.97
Q1=((1004.8×2.32)+( 81.3×1.863)+( 22.8×1.445)+( 9.8×1.97)) ×(95-25)
Q1=212607.5 KJ
Acetone
Mass2 =5kgs
Cp2 =1.510 KJ/kg°C
ΔT2 = (95-25) =70°C
Q2 = m2×Cp2 ×ΔT2
Q2 =5×1.510×70
Q2 =528.5 KJ
Total heat inlet Q = Q1+Q2 =212607.5+528.5=213136KJ
Outlet heat:
Cumene vapours @ 90°C
Mass = 81.3 kgs
λ = 343.9KJ/kg
Q1 = m1× λ1
Q1 =81.3×343.9
Q1 =27959.1 KJ
Acetone vapours @ 90°C
Mass = 5 kgs
λ = 212.3KJ/kg
Q2 = m2× λ2
Q2 = 1061.5 KJ
Residue @ 95°C
Mass = 1035.5 kgs
COMPONENTS MASS kgs SPECFIC HEAT KJ/Kg°C
Phenol 1004.8 2.32
α - methyl styrene 22.8 1.445
Acetophenone 9.8 1.97
Q3= ((1004.8×2.32) + (22.8×1.445) + (9.8×1.97)) × (95-25)
Q3=184115.4 KJ
Total heat outlet Q = Q1+Q2+Q3=27959.1+1061.5+184115.4 =213136KJ
COMPONENTS INLET HEAT KJ OUTLET HEAT KJ
feed 212607.5 ---
Vapour cumene --- 27959.1
Vapour acetone --- 1061.5
Bottom residue --- 184115.4
Carryover acetone in feed 528.5 ---
Total 213136 213136
CUMENE VAPOUR CONDENSER:
Inlet heat:
Cumene vapours @ 90°C
Mass = 81.3 kgs
λ = 343.9KJ/kg
Q1 = m1× λ1
Q1 =81.3×343.9
Q1 =27959.1 KJ
Acetone vapours @ 90°C
Mass = 5 kgs
λ = 212.3KJ/kg
Q2 = m2× λ2
Q2 = 1061.5 KJ
Total heat inlet Q = Q1+Q2 = 27959.1+1061.5 =29020.6 KJ
Outlet heat@80°C:
Cumene
Mass1 =81.3 kgs
Cp1 =1.842 KJ/kg°C
ΔT1 = (80-25) =55°C
Q1 = m1×Cp1 ×ΔT1
Q1 =81.3 ×1.842 ×55
Q1 =8236.5 KJ
Acetone
Mass2 =5kgs
Cp2 =1.509 KJ/kg°C
ΔT2 = (80-25) =55°C
Q2 = m1×Cp1 ×ΔT1
Q2 =5×1.509 ×55
Q2 =414.9 KJ
Total heat outlet Q = Q1+Q2 =8236.5+414.9=8651.4 KJ
COMPONENTS INLET HEAT KJ OUTLET HEAT KJ
Vapour cumene 27959.1 ---
Vapour acetone 1061.5 ---
Heat removed by water --- 20369.2
Condensed cumene --- 8236.5
Condensed acetone --- 414.9
Total 29020.6 29020.6
HEATER:
Inlet heat @ 95°C:
Mass=1035.5 kgs
COMPONENTS MASS kgs SPECFIC HEAT KJ/Kg°C
Phenol 1004.8 2.32
α - methyl styrene 22.8 1.445
Acetophenone 9.8 1.97
Q= ((1004.8×2.32) + (22.8×1.445) + (9.8×1.97)) × (95-25)
Q=184115.4 KJ
Outlet heat @ 110°C:
Mass=1035.5 kgs
COMPONENTS MASS kgs SPECFIC HEAT KJ/Kg°C
Phenol 1004.8 2.32
α - methyl styrene 22.8 1.523
Acetophenone 9.8 1.97
Q= ((1004.8×2.32) + (22.8×1.445) + (9.8×1.97)) × (110-25)
Q=252275.8 KJ
COMPONENTS INLET HEAT KJ OUTLET HEAT KJ
Residue 184115.4 252275.8
Heat added by steam 68160.4 ---
Total 252275.8 252275.8
α - METHYL STYRENE COLUMN:
Inlet heat @ 110°C:
Mass=1035.5 kgs
COMPONENTS MASS kgs SPECFIC HEAT KJ/Kg°C
Phenol 1004.8 2.32
α - methyl styrene 22.8 1.523
Acetophenone 9.8 1.97
Q= ((1004.8×2.32) + (22.8×1.445) + (9.8×1.97)) × (110-25)
Q=252275.8 KJ
Outlet heat :
α - methyl styrene vapours @ 100°C
Mass = 22.8 kgs
λ = 449.1KJ/kg
Q1 = m1× λ1
Q1 =22.8×449.1
Q1 =10239.7 KJ
Residue @110°C
Mass =1012.7kgs
COMPONENTS MASS kgs SPECFIC HEAT KJ/Kg°C
Phenol 1002.9 2.32
Acetophenone 9.8 1.97
Q2= ((1002.9×2.32) + (9.8×1.97)) × (110-25)
Q2=242036.1 KJ
Total heat outlet Q = Q1+Q2 =10239.7+24203.1=252275.8 KJ
COMPONENTS INLET HEAT KJ OUTLET HEAT KJ
feed 252275.8 ---
Vapour α - methyl styrene 10239.7
Bottom residue --- 242036.1
Total 252275.8 252275.8
α - METHYL STYRENE CONDENSER:
Inlet heat:
α - methyl styrene vapours @ 100°C
Mass = 22.8 kgs
λ = 449.1KJ/kg
Q = m× λ
Q =22.8×449.1
Q =10239.7 KJ
Outlet heat:
α - methyl styrene condensed @ 95°C
Mass = 22.8 kgs
Cp =1.445 KJ/kg°C
ΔT = (95-25) =70°C
Q = m1×Cp1 ×ΔT1
Q =22.8×1.445 ×70
Q =2306.2 KJ
COMPONENTS INLET HEAT KJ OUTLET HEAT KJ
Vapour α - methyl styrene 10239.7 ---
Heat removed by water --- 7933.5
Condensed α - methyl styrene --- 2306.2
Total 10239.7 10239.7
HEATER:
Inlet @110°C
Mass =1012.7kgs
COMPONENTS MASS kgs SPECFIC HEAT KJ/Kg°C
Phenol 1002.9 2.32
Acetophenone 9.8 1.97
Q= ((1002.9×2.32) + (9.8×1.97)) × (110-25)
Q=242036.1 KJ
Outlet @130°C
Mass =1012.7kgs
COMPONENTS MASS kgs SPECFIC HEAT KJ/Kg°C
Phenol 1002.9 2.32
Acetophenone 9.8 1.97
Q= ((1002.9×2.32) + (9.8×1.97)) × (130-25)
Q=298985.8 KJ
COMPONENTS INLET HEAT KJ OUTLET HEAT KJ
Residue 242036.1 298985.8
Heat added by steam 56949.7 ---
Total 298985.8 298985.8
PHENOL COLUMN:
Inlet @130°C
Mass =1012.7kgs
COMPONENTS MASS kgs SPECFIC HEAT KJ/Kg°C
Phenol 1002.9 2.32
Acetophenone 9.8 1.97
Q= ((1002.9×2.32) + (9.8×1.97)) × (130-25)
Q=298985.8 KJ
Outlet heat
Phenol vapours @ 120°C
Mass1 = 1002.9 kgs
λ1 = 296.7KJ/kg
Q1 = m1× λ1
Q1 =1002.9×296.7
Q1 =297510.4 KJ
Acetophenone vapours @ 120°C
Mass2 = 3.8 kgs
λ2 = 116.1KJ/kg
Q2 = m2× λ2
Q2 =3.8×116.7
Q2 =441.2 KJ
Bottom acetophenone @130°C
Mass = 5kgs
Cp = 1.97KJ/kg°C
ΔT = (130-25) =105°C
Q3 = 1034.3 KJ
Total heat outlet Q= Q1+Q2+ Q3= 297510.4 9+441.2 +1034.3 = 298985.88KJ
COMPONENTS INLET HEAT KJ OUTLET HEAT KJ
feed 298985.8 ---
Vapour phenol --- 297510.4
Vapour Acetophenone --- 441.2
Acetophenone --- 1034.3
Total 298985.8 298985.88
PHENOL VAPOUR CONDENSER:
Inlet heat
Phenol vapours @ 120°C
Mass1 = 1002.9 kgs
λ1 = 296.7KJ/kg
Q1 = m1× λ1
Q1 =1002.9×296.7
Q1 =297510.4 KJ
Acetophenone vapours @ 120°C
Mass2 = 3.8 kgs
λ2 = 116.1KJ/kg
Q2 = m2× λ2
Q2 =3.8×116.7
Q2 =441.2 KJ
Total heat outlet Q= Q1+Q2=297510.4+441.2 =297951.6KJ
Inlet heat@ 100°C
Mass=1006.7 kgs
COMPONENTS MASS kgs SPECFIC HEAT KJ/Kg°C
Phenol 1002.9 2.32
Acetophenone 3.8 1.97
Q= ((1002.9×2.32) + (3.8×1.97)) × (100-25)
Q=212674.8 KJ
COMPONENTS INLET HEAT KJ OUTLET HEAT KJ
Vapour phenol 297510.4 ---
Vapour acetophenone 441.2
Heat removed by water --- 85276.8
Condensed phenol & acetophenone --- 212674.8
Total 297951.6 297951.6
EQUIPMENT DESIGN
ACIDIFIER
Temperature = 80
Pressure = 5atm
Material = stainless steel
COMPONENT MASS
(kgs) DENSITY
(kg/m3) VOLUME
(m3)
Cumene
hydroperoxide 1672 1020 1.6
Cumene 418 860 0.49
H2SO4 0.5 3720 0.0003
Total 2090.5 3720 2.0903
Volume of the acidifier:
Volume of the acidifier = 2.09m3
Actual volume of acidifier = volume of reactor×1.6
= 2.09×1.6
Actual volume of acidifier = 3.34 m3
Length and diameter of acidifier:
Assume L/D ratio = 1.5
L = 1.5D
Volume of the acidifier = Π×D2L/4
Volume of acidifier = Π×D2 (1.5D)/4
3.34 = Π×D2 (1.5D)/4
D3 = 2.84
Diameter of the acidifier = 1.42 m3
L = 1.5D
L = 1.5×1.42
Length of the acidifier = 2.13 m
Area of the acidifier:
Area of the acidifier = Π×D2/4
= Π× (1.42)2 / 4
Area of the acidifier = 1.58 m2
Thickness of the shell:
Thickness of the shell = ( Pi×Di/(2FJ-Pi) )+ corrosion allowance
1 atm = 101325 N/m2
5 atm = 506625 N/m2
Design pressure (Pi) = 1.05×506625
= 531956.25 N/m2
Maximum allowable stress = 160×106
Joint efficiency = 85%
Thickness of shell =((531956.25×1.42) / ((2×160×106×1.85) - 531956.25))+(20×10-4)
Thickness of shell = 4.78×10-3 m
Design of head:
For torispherical head
t = ((Pi×Rc×Cs)/(2FJ+Pi(Cs-0.2))+corrosion allowance
Rc = crown radius = dia of shell
Rk = knuckle radius = 6% of shell dia
= 0.06× 1.42
= 0.0852 m
Cs = stress factor = ¼ (3+(Rc/Rk))
= ¼(3+(1.42/0.0852))
= 4.92
t =(531956.25 ×1.42×4.92)/ ((2×160×106×1.85) - 531956.25(4.92×0.2))+(20×10-4)
t =3.354×10-3m
Diameter of agitator:
Da =0.8× diameter of shell
=0.8×1.42
=1.136 m
Baffle width & height:
Baffle width = 1.42/12
= 0.118 m
Baffle height = height of cylindrical shell = 2.13m
Power required in acidifier = 1KW/m3
P = 2.01 KW
P = 2010 W
P = 5×p×n3×Da5
n3 = 2010 / (5×833.9×1.1365)
n3 = 0.2548
n = 0.6339 rps
n = 39 rpm
DESIGN SUMMARY:
Actual volume of acidifier = 3.34 m3
Diameter of the acidifier = 1.42 m
Length of the acidifier = 2.13 m
Area of the acidifier = 1.58m2
Thickness of the shell = 4.78×10-3m
Design of head = 3.354×10-3m
Diameter of agitator = 1.136 m
Baffle width = 0.118 m
Baffle height = 2.13 m
Revolution of agitator = 39 revolution/ min
ACIDIFIER
DISTILLATION COLUMN
Material balance:
F=D+B
1625.6Kgs=503.8Kgs+1121.8Kgs
Solute balance:
Fxf =Dxd + Bxb
COMPONENTS MASS
(kgs) MOLECULAR WEIGHT
(Kg/kg moles) MOLES IN (kgmoles)
Phenol 1007.8 94 10.72
Acetone 503.8 58 8.69
α –methyl styrene 22.8 118 0.19
Cumene 81.3 120 0.68
Acetophenone 9.8 120 0.08
Total moles=20.36
Feed
Xf=Moles of acetone/total moles
=8.69/20.36
Xf=0.426
Distillate
Xd =acetone/cleavage
=8.6/0.24
Xf =0.97
Bottom
Xb=acetone/cleavage
=0.086/95.69
Xb=4.3×10-3
Column height:
Pitch=450mm
P=0.45m
Height of distillation column= (N-1)p+2p
Assume η=60to65%
In this case η=65%
Actual number of plates =N-1/η
=14-1/0.65
=20
Column height = (N-1) p+2p
= (20-1)0.45+2(0.45)
=9.45m
Column diameter:
Top
Flv=Lw/Vw ×√
Assume top temperature of acetone=56.5
T=329.5k
Density of liquid (329.5K)=784.6Kg/m3
=13.5Kmol/m3
Density of vapour =P/RT
=1/0.0823×329.5
=0.0369Kmol/m3
Bottom
Cleavage composition;
COMPOSITION MOLES
(Kgs) MOLECULAR WEIGHT
(Kg/kgmoles) MOLES
(Kmol)
Phenol 1004.8 94 10.7
Cumene 81.3 120 0.7
α –Methyl styrene 22.8 118 0.19
Acetophenone 9.8 120 0.08
Total 11.67
Density of liquid=x1 1+x22+x33+........+xnn
= (0.92×1070)+(0.06×860)+(0.016×1030)+(0.006×191)
=1053.7Kg/m3
l=90.3Kmol/m3
Flv=Lw/Vw ×√
T=363K
Density of liquid (363K )=1053.7Kg/m3
=90.3Kmol/m3
Density of vapour =P/RT
=1/0.0823×363
=0.0335Kmol/m3
F =B+D
F =1625.6Kg
B =1116.8+5
=1121.8Kg
D =498.8+5
=503.8Kg
V =D(R+1)
=503.8(3.5+1)
V =2267.1Kgmol/hr
L/D=R
=503.8×3.5
=1763.3Kgmol/hr
Flooding velocity:
Top
Flv=Lw/Vw ×√
=1763.3/2267.1×√0.0369/13.5
Flv=0.0408
Bottom
Slope = Lw/Vw
=0.05/0.03
=1.7
Flv =1.7×√
=1.7√0.0335/90.3
Flv =0.0327
Top
uf (Top) =K×√
From graph;
(Flooding velocity Vs K)
K=0.082
uf =0.082×√(13.5-0.0369)/0.0369
uf (Top)=1.5662m/sec
Bottom;
uf =K√(
K=0.08√ (90.3-0.0335)/0.0335
uf (Bottom)=4.1527m/sec
Design velocity:
Design velocity is 65% of flooding velocity
Top
Design velocity uD=1.5662×0.65
=1.0180m/sec
Design velocity uD=4.1527×0.65
=2.6992m/sec
Area of the column:
Top
Volumetric flow rate=Mass flow rate/Density
=2267.1/0.0369
=61439m3/hr
V=17.1m3/sec
Net area=Volumetric flow rate/Velocity
=17.1/1.018
=16.8m2
Base area=16.8/ (1-0.12)
=19.1m2
Bottom
Mass flow rate at bottom=B(R+1)
=1121.8× (3.5+1)
=5048.1
Volumetric flow rate= Mass flow rate/Density
=5048.1/0.0335
=150689.5m3/hr
V=41.9m3/sec
Net area=Volumetric flow rate/Velocity
=41.9/2.6992
=15.52m2
Base area=15.52/ (1-0.12)
=17.6m2
Diameter of the column
Top
Column diameter=√ (19.1×4)/
=4.9m
Bottom
Column diameter=√ (17.6×4)/
=4.7m
DESIGN SUMMARY
Number of theoretical plates required =14 plates
Total Column height =9.45m
Top column area =19.1m2
Bottom column area =17.6m2
Top column diameter =4.9m
Bottom column diameter =4.7m
Design velocity at top =1.018m/sec
Design velocity at bottom =2.699m/sec
PLANT LOCATION
Plant location plays an important role in determining the sources of a process plant. Plant location refers to the various parameters, which governs the operation of the plant. The following are the major parameters which have to be carefully considered.
Raw material:
The raw materials must be available without any interruption to the reach of the plant. It can cause urgent shut down or reducing the production when there is a lack of raw material. This must be considered to be important.
Availability of power:
The electricity source must be available to the plant, because it is the prime source for the process plants. This electricity is used in agitated vessels, pumps, compressors and etc. continuous and uninterrupted power supply is essential for the continuous operation of the plant.
Water:
Water is an essential material majorly used in the process plants and it is necessary to the labours. The water can be used for cleaning the equipments and plant. The water is also used in the wash towers, coolers and condensers. In the plant location the ground water source should be available. Water should also available in neighborhood at low cost.
Transport facility:
The raw material and the products want to be transported in and out of the plant. So that the road transport facilities should be good and easily available. If the harbor is nearby mean’s, its best to easy shipping.
Skilled labours and their facilities:
The plant must require skilled labours. They should know about the process and they want the knowledge of the safe working and hard working. They want to be available at nearby location.
Those labours must get their facilities like bus transportation, hospitals, canteens and shelter at nearby to the plant.
Markets:
It is essential that the plant must be closed to the market or else, unreasonable amount will be spending for transporting the products to the market.
Climate condition:
Climate and environment affect the operational efficiency of workers; excess cold may cause tiredness, fatigue or disease among the workers. Decreased humidity and climate temperature is high can cause dehydration to the employees while working. So that, plant must be located in such a place where the climate is conductive to efficient operation of the plant.
Plant sewage and waste disposal:
The primary source of sewage and waste in a process plants are sanitary waste, process drains and surface drainage. The sewage system is designed to conduct these to disposal without logged with solid or filled with dangerous concentration of explosive gases.
Local community consideration:
The process plant must fit in with and be acceptable to the local community. 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. On a new site, the local community must be able to provide adequate facilities for the plant personnel like school, banks, housing and faculties.
MATERIAL HANDLING AND SAFTEY
HAZARDS IDENTIFICATION
Potential Acute Health Effects:
Very hazardous in case of skin contact (irritant), of eye contact (irritant), of ingestion, . Hazardous in case of skin contact (corrosive, sensitizer, permeator), of eye contact (corrosive). Slightly hazardous in case of inhalation (lung sensitizer). Liquid or spray mist may produce tissue damage particularly on mucous membranes of eyes, mouth and respiratory tract. Skin contact may produce burns. Inhalation of the spray mist may produce severe irritation of respiratory tract, characterized by coughing, choking, or shortness of breath. Severe over-exposure can result in death. Inflammation of the eye is characterizedby redness, watering, and itching. Skin inflammation is characterized by itching, scaling, reddening, or, occasionally, blistering.
Potential Chronic Health Effects:
The substance maybe toxic to kidneys, liver, central nervous system (CNS). Repeated or prolonged exposure to the substance can produce target organs damage. Repeated or prolonged contact with spray mist may produce chronic eye irritation and severe skin irritation.Repeated or prolonged exposure to spray mist may produce respiratory tract irritation leading to frequent attacks of bronchial infection. Repeated exposure to a highly toxic material may produce general deterioration of health by an accumulation in one or many human organs.
FIRST AID MEASURES
Eye Contact:
Check for and remove any contact lenses. In case of contact, immediately flush eyes with plenty of water for at least 15minutes. Cold water may be used. Get medical attention immediately.
Skin Contact:
In case of contact, immediately flush skin with plenty of water for at least 15 minutes while removing contaminated clothing and shoes. Cover the irritated skin with an emollient. Cold water may be used. Wash clothing before reuse. Thoroughly clean shoes before reuse. Get medical attention immediately.
Serious Skin Contact:
Wash with a disinfectant soap and cover the contaminated skin with an anti-bacterial cream. Seek immediate medical attention.
Inhalation:
If inhaled, remove to fresh air. If not breathing, give artificial respiration. If breathing is difficult, give oxygen. Get medical attention immediately.
Serious Inhalation:
Evacuate the victim to a safe area as soon as possible. Loosen tight clothing such as a collar, tie, belt or waistband. If breathing is difficult, administer oxygen. If the victim is not breathing, perform mouth-to-mouth resuscitation. Seek medical attention.
Ingestion:
If swallowed, do not induce vomiting unless directed to do so by medical personnel. Never give anything by mouth to an unconscious person. Loosen tight clothing such as a collar, tie, belt or waistband. Get medical attention immediately.
FIRE AND EXPLOSION DATA
Flammability of the Product:
May be combustible at high temperature.
Products of Combustion:
These products are carbon oxides (CO, CO2).
Fire Hazards in Presence of Various Substances:
Flammable in presence of open flames and sparks, of heat. Non-flammable in presence of shocks, of oxidizing materials, of reducing materials, of combustible materials, of organic materials, of metals, of acids, of alkalis.
Explosion Hazards in Presence of Various Substances:
Non-explosive in presence of open flames and sparks, of shocks.
Fire Fighting Media and Instructions:
SMALL FIRE: Use DRY chemical powder.
LARGE FIRE: Use water spray, fog or foam. Do not use water jet.
Special Remarks on Explosion Hazards:
Phenol + sodium nitrite causes explosion on heating.
Peroxydisulfuric acid + phenol causes explosion.
ACCIDENTAL RELEASE MEASURES
Small Spill:
Dilute with water and mop up, or absorb with an inert dry material and place in an appropriate waste disposal container.
Large Spill:
Corrosive liquid. Poisonous liquid. Stop leak if without risk. Absorb with DRY earth, sand or other non-combustible material. Do not get water inside container. Do not touch spilled material. Use water spray curtain to divert vapor drift. Use water spray to reduce vapors. Prevent entry into sewers, basements or confined areas; dike if needed. Eliminate all ignition sources. Callfor assistance on disposal. Be careful that the product is not present at a concentration level above TLV. Check TLV on the MSDS and with local authorities.
HANDLING AND STORAGE
Precautions:
Keep away from heat. Keep away from sources of ignition. Empty containers pose a fire risk; evaporate the residue under a fume hood. Ground all equipment containing material. Do not ingest. Do not breathe gas/fumes/ vapor/spray. Never add water to this product. In case of insufficient ventilation, wear suitable respiratory equipment. If ingested, seek medical advice immediately and show the container or the label. Avoid contact with skin and eyes. Keep away from incompatibles such as oxidizing agents, metals, acids, alkalis.
Storage:
Keep container tightly closed. Keep container in a cool, well-ventilated area. For short term storage keep refrigerated. Do not store above 8°C (46.4°F). For long term storage before the seal is broken, keep frozen at -20 deg. C (-4 deg. F) or below. Sensitive to light. Store in light-resistant containers.
EXPOSURE CONTROLS/PERSONAL PROTECTION
Engineering Controls:
Provide exhaust ventilation or other engineering controls to keep the airborne concentrations of vapors below their respective threshold limit value. Ensure that eyewash stations and safety showers are proximal to the work-station location.
Personal Protection:
Face shield. Full suit. Vapor respirator. Be sure to use an approved/certified respirator or equivalent. Gloves. Boots.
Personal Protection in Case of a Large Spill:
Splash goggles. Full suit. Vapor respirator. Boots. Gloves. A self contained breathing apparatus should be used to avoid inhalation of the product. Suggested protective clothing might not be sufficient; consult a specialist BEFORE handling this product.
ECOLOGICAL INFORMATION
Products of Biodegradation:
Possibly hazardous short term degradation products are not likely. However, long term degradation products may arise.
Toxicity of the Products of Biodegradation:
The products of degradation are less toxic than the product itself.
DISPOSAL CONSIDERATIONS
Waste Disposal:
Waste must be disposed of in accordance with federal, state and local environmental control regulations.
RAW MATRIAL COST IN LACS:
Raw material cost Quantity per day Price per kg
(Rs) Total cost
(Rs)
Cumene(isopropyl benzene) 39600 34 1346400
EMPLOYEE COST:
S.NO Employee Number Salary/month
(Rs)
Total salary/month
(Rs)
1 General manager 1 45000 50000
2 Deputy manager 1 40000 60000
3 Plant manager 1 35000 60000
4 Engineer 6 20000 60000
5 Operator 12 10000 96000
6
7
Total Administrator
Labours 10
30 6000
5000 70000
180000
586000
PARTICULARS OF BUILDING (Rs in Lacs):
Administration Block 60
Power house 10
Security office 2
Canteen 2
Health and saftey 6
Parking 1
Rest room 6
E.T.P plant 30
Total 117
COST OF PROJECT AND MEANS OF FINANCE:
COST OF PROJECT IN LACS:
1 Land and development 70
2 Building 117
3 Plant and machinery 127
4 Margin for working capital 260
5 Preliminary and preoperative expenses 230
6 Provision for contingencies 250
Total 1054
MEANS OF FINANCE:
Share capital 654
Team loan 400
Total 1054
COST OF EQUIPMENT (Rs in lacs):
Equipment No of Equipment Cost
Oxidation tower 1 12
acidifier 1 6
Separator 1 6
Wash tower 1 4
Distillation columns 3 48
Heat exchangers 10 15
Boiler 1 8
Storage tanks 3 24
Water storage 1 4
PROJECTION OF PERFORMANCE AND PROFITABILITY (Rs. In Lacs):
YEAR I II III IV V
Production, Tons 4550 5460.6 6825.7 7280 7735.8
% Capacity 50 60 75 80 85
Sales 4200 5260 6525 7030 7535
COST OF PRODUCTION:
Raw material 1696.22 2035.44 2543.95 2713.17 2882.98
Power and fuel 15 16.5 19 20 21
Direct labour 68 71 75 77 79
Consumable store 12 15 19 22 24
Repairs and Maintenance 6.5 8.0 9.5 10.5 11.5
Other expenses 10 12 15 17 18
Depreciation, buildings 7 10 13 15 16
Depreciation, working capital 5 7 10 12 14
SUB TOTAL 1819.72 2174.92 2636.95 2886.67 3066.18
Interest, team loan 40 35 30 25 20
Interest, working capital 20 35 45 55 70
Selling expenses 35 40 43 45 48
Over head expenses 30 35 39 42 44
TOTAL 1934.72 2309.63 2790.95 3053.67 3248.48
Profit before tax 494.71 733.98 983.26 1012.83 1109.96
Taxes, 35% of PBT 173.14 256.89 344.14 354.49 388.49
Net profit 321.57 477.08 639.12 658.34 721.47
Dividend 16.62 20.65 21.56 22.03 22.21
BREAK EVEN ANALYSIS:
Yearly production = 9100000 Kg
Selling price
Acetone = Rs 70 per kg
Phenol = Rs 39 per kg
Cost of raw materials = Rs34 per Kg
Contribution = Rs21
Breakeven point = fixed cost / contribution
= 31400000 /21
= 1495238.09
Break even percentage = (BET * 100) / yearly production
= (1495238.09/ 9100000) × 100
= 16.43%.
CONCLUSION:
This project has been attempt in understanding the fundamentals of chemical engineering and its application in chemical manufacturing industries. The product phenol has variety of applications like feed for resins, nylon industries and in medical field. In this project attention is given to the manufacturing of phenol from cumene. All the principles learnt during the course of study like stoichiometry, chemical technology, chemical reaction engineering, mass transfer, heat transfer and economics have been applied and a suitable material balance, energy balance, design, plant layout and cost have been computed. Hence it can be concluded that this project will definitely pave the way in increased the profit of chemical industries.
REFERENCES:
Dryden’s outlines of chemical technology
Shreve’s chemical process industries, Austin, McGraw Hill book company, Singapore, 5th Edition (1984).
Robert H.Perry and Don. W. Green, Perry’s Chemical Engineers Hand Book, Seventh Edition (1997), McGraw-Hill international Edition.
Warren L. McCabe, Julian C. Smith, Pater Harriot (2001) ‘Unit Operations Of Chemical Engineering’, Fifth Edition.
Donald Q. Kern, ‘Process Heat Transfer’, Tata McGraw publications limited.
Robert E. Tribal, ‘Mass Transfer Operation’, ‘McGraw Publication Limited’, Third Edition.
B.I.Bhatt and S.M.Vora (1996) “ Stochiometry” Mcgraw-Hill Publications Limited,Third Edition
