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Details of design of cleavage unit of Phenol and Acetone producing plant Cleavage reaction: Breakdown of cumene hydroperoxide (CHP) into phenol and acetone Highly exothermic hence most challenging and vital part of entire plant Proposed design:
Introduction
Kinetics from Chen et al and V. Zakoshansky Input contents contained 80wt% CHP Effluent stream from PFR would have Phenol: Acetone: Cumene ratio of 1.62:1:0.2 (mass) All CHP reacted before sent for purification Acid concentration at 0.1wt% of CSTR input stream Costing calculations based on 3rd edition of Product and Process Design Principles by Seider W.D., J.D. Seader and D.R. Lewin Bare module cost estimated as S$ 2,746,100.00 and purchase cost as S$ 1,572,000.00
Conversion of 60% of CHP fixed in CSTR for good control of heat released, PFR to decompose remain CHP
Differences in Simulation
Absence of kinetic data of formation and decomposition of dicumyl peroxide (DCP) Complex kinetics of DCP breakdown was simplified 40% of DMPC from cumene oxidation converted to DCP prior input to cleavage reactor CSTR Hypothetical component: Sodium Phenate (NaPh) for neutralisation of H2SO4 Simulated neutraliser gave endothermic value but should be exothermic Simulation with Sodium Hydroxide (NaOH) for realisable energy produced
Options Available
3 CSTRs and 1 PFR in series CSTRs: 50oC at 1 atmospheric pressure and PFR: 110oC at 5 bar
1 CSTR at 60oC ,pressure of 1 atm and 1 PFR at 120oC of 6 bar in series 0.1wt% of acid catalyst for safety
Recommended Process
CSTR (1st Stage)
Isothermal since adiabatic produces outlet temperature of b.p. higher than of acetone PFR could not be used as size would be too large for heat controlling
120oC and pressurised to 6 bar Heated to maximise dehydration of DMPC to AMS High pressure to ensure acetone does not evaporate
Complete decomposition of CHP Maximized production of AMS Utilizes NaPh produced in downstream for neutralization to produce more phenol End Yield: 582 kmol/h of cumene to 472 kmol/h of phenol and 474 kmol/h of acetone Required: 350,000 tonnes of phenol/ year at product purity of 99.2% Produced: 355 512 tonnes/yr
CSTR Features
= 0.0194 mm
12mm wall thickness with corrosion allowance (ASME BPV) 4 baffles of height 5.9m and width 0.37 m Shaft diameter = 0.49 cm Tori-spherical head
CSTR Features
Flat blades set at 45 angles, for simultaneous axial and radial flow
Height above floor = 1.23 m Length of Blade = 0.31 m
Total Volume as 4.98m3 at 6.6 bar Length of 8.00 m and diameter of 0.89 m Ideal PFR has turbulent flow for mixing in radial direction and reduce axial mixing Re = 105516, flow is turbulent hence baffles not required Material of construction: SS 316 since contents are same as CSTR Thickness of PFR with corrosion allowance is 3.61 mm
Optimisation of CSTR
% Conversion of CHP
Acid content of 0.1wt% gives lowest volume Curves approach plateau after 60% of CHP generally Bigger size gives slight increase in conversion Most economical size of 78.5m3
Acid Concentrations
80 70 60 50 40 30 20 10 0 0 100 200
0.075wt% Acid
Tank Volume/ m3
Optimisation of CSTR
% Conversion of CHP
Lowest temperature profile requires volume higher than 200m3 for 60% CHP conversion Highest temperature gives least reactor volume but unsuitable as acetone vapour forms Most suitable is 60oC
Vessel Temperature
90 80 70 60 50 40 30
50 DegC 60DegC
20
10 0 0 50 100 150 200
70DegC
Tank Volume/ m3
Optimisation of PFR
Sized according to length by Adjust module All peroxides exhaust at 8m Iterations gave PFR volume of 4.98m3
CHP Acetone
15000
10000 5000 0
Phenol
DCP
5 Reactor Length
CSTR
n (%)
CSTR
e
PFR
(%)
PFR
0 to 60
0 to 65 0 to 70
77.49
99.39 131.2
60 to 100
35 to 100 30 to 100
4.97
4.43 3.67
economical choice, simple to operate and maintain as 750 Wm-2K-1 (Richard Coulson)
Cooling
Assuming
Area (m2)
Length required (m) No of lengths Cooling water flow (kgs1)
1027.5
11550 3158 327.8
227.8
2561 700 236.8
Conclusion
SGD 527 000.00 SGD 186 000.00 SGD 182 000.08 SGD 88 000.00