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Phenol Production Process Design Team 10 – Tiffany Robinson, Daniel Harrell, Dillian Beechler Organizational Problem ABC Corporation’s resins production unit wants to carry out a study estimate of a plant to produce phenol as a raw material at a cheaper cost than the current market price of $0.64/lb. The production rate of concern is 190,000 metric tons per year. Basic Flow Diagram and Process Background The phenol production process is based on the oxidation and cleavage of cumene. Oxidation of Cumene (Hock process) [1] : C 6 H 5 CH CH 32 +O 2 →C 6 H 5 C CH 32 OOH C 6 H 5 CH CH 32 + 1 2 O 2 → CH 32 C 6 H 3 CH 2 OH Cleavage reactions to produce phenol and acetone/AMS by-products [1] : CH 32 C 6 H 3 CH 2 OH → C 6 H 4 C 2 H 3 CH 3 +H 2 O C 6 H 5 C CH 32 OOH → C 6 H 5 OH + CH 3 COCH 3 AMS and acetone are by-products of the reactions that are sold for credit. In addition to the credit received from by-products, there is also fuel credit obtained from the vent in the process. Finally, water is the only waste in the process and will be sent to a wastewater treatment facility. HYSYS Process Flow Diagram The process is comprised of six main steps that include the following: • Cumene oxidation to hydroperoxide • Cumene hydroperoxide concentration • Cumene hydroperoxide decomposition/cleavage • Cleavage effluent neutralization • Product fractionation/purification • Effluent treatment Key Economic Results Process Economics Capital Investment Summary Equipment Installed Cost Utilities Cost Summary Economic Conclusions The production cost for the design process exceeds the current market price of $0.64/lb of phenol and makes the implementation of the design impractical. Unless new alternative methods or adjustments to optimize the process are determined, executing the process design is not economically viable. Therefore, it is not recommended that this design be implemented. Safety Considerations Major Hazards • Oxygen concentration in oxidation reactor • CHP distillation column reboiler • Cleavage reactor General Safety • Training • Proper PPE • Protective systems and alarms • Routine inspection and monitoring of process Environmental Considerations Environmental pollution is a major concern for all industrial plants, such as the phenol production plant. Proper disposal is imperative for maintaining the wellbeing of the surrounding environment. For the phenol production process the streams of concern are: • Vent from 2nd stage separator • Vent from partial condenser • Wastewater from acetone-water separation train References [1] Ullman’s Encyclopedia of Industrial Chemistry, 5th ed., 1985. [2] The Essential Chemical Industry: Online. 2015. Via http://www.essentialchemicalindustry.org/chemicals/phenol.html [3] Perry, R. H., & Green, D. W. (2008). Perry's chemical engineers' handbook. New York: McGraw-Hill. Table 2-2. [4] University, Safety Officer in Physical Chemistry at Oxford (2005). "Safety (MSDS) data for cumene hydroperoxide". Retrieved 2015-03-13. [5] Richard J. Lewis, Richard J. Lewis (Sr.), Hazardous chemicals desk reference, Publisher Wiley-Interscience, 2008, ISBN 0- 470-18024-2, ISBN 978-0-470-18024-2, 1953 pages [6] "Cumene". National Institute for Occupational Safety and Health (NIOSH). 4 December 2014. Retrieved 24 February 2015. Total cost per pound of product $0.857/lb Total Capital Investment (TCI) $183 MM Total annual operating costs $299 MM/yr Component Hazards Toxicity/Dangers Acetone Flammable, harmful if swallowed or contacted with skin, irritant Cumene Flammable, toxic, harmful if swallowed or contacted with skin, irritant, carcinogen, hazardous to environment AMS Flammable, toxic, harmful if swallowed or contacted with skin, irritant, hazardous to environment CHP Oxidizing, toxic, corrosive, harmful if swallowed or contacted with skin, irritant, hazardous to environment Phenol Combustible, corrosive, harmful if swallowed or contacted with skin, irritant
