Introduction

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:

1 CSTR: 78.5 m3 at 60oC at 1 atm 1 PFR: 4.98 m3 at 120oC at 6 bar of pressure

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

General Design Settings

Conversion of 60% of CHP fixed in CSTR for good control of heat released, PFR to decompose remain CHP

PFR Reactions: All CSTR reactions with decomposition of DCP

Reactions assumed to take place simultaneously and in reactor only

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

Acid concentration as 150ppm, similar to ILLA operating conditions

Volumes of CSTR: 650, 1100 and 1450 m3 and PFR: 312 m3

Too large hence high cost and maintenance

Agitation in large CSTR would be high safety concern

Options Available (Recommended)

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

Configuration proposed by Sifniades et al. (US Patent 4,358,618)

Isothermal gives high conversion per unit energy supplied Simpler to operate isothermal than adiabatic reactor AMS dimers and cumylphenol generated reduced by 2 stage reaction CSTR at 78.5 m3 and PFR at 4.98 m3 More economical

Recommended Process
CSTR (1st Stage)

PFR (2nd 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

Recommended Process - PFD

Meets The Requirements

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

78.5m3 at design pressure of 1.1 atm

Diameter of 3.68 m and height of 7.36 m

SS 316 Thickness, =
.

= 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

1 Pitched blade impeller with 6 Blades

Flat blades set at 45 angles, for simultaneous axial and radial flow
Height above floor = 1.23 m Length of Blade = 0.31 m

Width of Blade = 0.25 m

Impeller Speed = 77.6 rpm Assuming 85 % efficiency, Actual Power = 17.9 hp

Mechanical Design of PFR

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

0.1wt% Acid 0.05wt% Acid

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

Main reactions: Decomposition of CHP and DCP

Flowrate / (kg/hr)

Molar Flow vs PFR Length

50000 45000 40000 35000 30000 25000 20000

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

Conversion Ratio Optimisation

Percentage of CHP conversion was varied for CSTR and PFR

CSTR
n (%)

CSTR
e

PFR
(%)

PFR

CHP conversion has to take place mostly at CSTR

Despite decrease in PFR size, increase in CSTR volume is drastic More capital invested in CSTR volume increase than savings from PFR volume decrease CHP conversion for CSTR was fixed as 60%

Conversio Volum Conversion Volume

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

Double Pipe Heat Exchanger

Most Uo

economical choice, simple to operate and maintain as 750 Wm-2K-1 (Richard Coulson)

Cooling

water in @ 25C and out @40C

a bend of 12ft CSTR HE-100
20653 26.8 PFR HE-101 14916 87.3

Assuming

Heat released (kW) Tlm (C)

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

1 CSTR of size 78.5 m3 at 60oC at 1 atm

Bare Module: Purchase: Bare Module: Purchase:

SGD 527 000.00 SGD 186 000.00 SGD 182 000.08 SGD 88 000.00

1 PFR of size 4.98 m3 at 120oC at 6 bar

Upon optimisation, total bare module cost was SGD 2,746,000.00.