Design ObjectiveABC Corporation is looking for a cost-effective method of attaining 300,000 tons of phenolper year as a raw material for their downstream resin production. Currently, phenol ispurchased at $0.64 per pound. Cumene, a raw material in phenol production, can beobtainable internally for $0.60 per pound. Our technical assignment included designing aphenol plant, estimating the production cost of phenol per pound, and making aneconomically feasible decision for ABC Corporation

Process OverviewStreams of compressed air and pure cumene are fed into oxidation reactors where thecumene is oxidized to cumene hydro peroxide (CHP) and a by-product di-methyl benzylalcohol (DMBA). Cumene in the vent from the reactors is recovered and recycled back intothe process.Unreacted cumene, CHP and DMBA are then sent to a distillation column where cumene inthe distillate stream is recycled back to the oxidation reactors. In the bottoms, CHP, DMBA,and any remaining cumene is then sent to a cleavage reactor. CHP is cleaved to form Phenoland Acetone and DMBA reacts with the sulfuric acid catalyst in the cleavage reactor to formalpha-methyl styrene (AMS) and water.Acetone, water, cumene, AMS, and phenol are then sent through a separation train ofdistillation columns to isolate each component. Isolated cumene is recycled back into theoxidation reactors. AMS is hydrogenated back into cumene, which is also recycled back tothe oxidation reactor. The water stream is sent to a wastewater treatment facility. The by-product acetone is cooled and stored for sale, and the final phenol product is cooled andsent to the resins plant.

ReactionsOxidation Reactor Cleavage Reactor(Main Reaction) (Main Reaction)

(Side Reaction) (Side Reaction)

Hydrogenation Reactor

Simulation:Yield of Phenol: 99 %

Specifications:• Pressure of oxidation reactor = 80 psia• Temperature of oxidation reactor = 212°F• Pressure of cleavage reactor = 14.7 psia• Temperature of oxidation reactor = 176°F• Pressure of hydrogenation reactor = 110 psia• Temperature of oxidation reactor = 194°F• 99.9 % Purity of Acetone• 99.99% Purity of Phenol• Various pressures for distillation columns

EconomicsCapital CostsTotal Capital Investment (TCI): $271 MM

Operating CostsTotal Annual Operating Costs: $483 MM/year

Economic DecisionFinal Production Cost of Phenol: $0.73 per pound

CHEAPER to BUY Phenol

Health & Environment

Continuous Process Emissions:

Major Safety Considerations

Cleavage Reactor: Hydrogenation Reactor:-Rapid CHP decomposition causing a -Flammability of Hydrogen resulting in explosionRunaway Exothermic Reaction

Minor Safety ConsiderationsOxidation Air Compressor:-Compressed Air Temperature below 600 °F to prevent auto ignition of cumene

High Pressure Steam Reboiler:-600 psi steam used in AMS/Phenol Distillation Column Reboiler

Oxidation Reactor Vent Composition:-Oxidation reactor vent LOC with cumene is less than 6 mol %

Commercial Uses and Supply Chain of PhenolPhenol is used in various products:

• Epoxy Resins – paint coatings• Polycarbonate plastics – CDs and domestic electrical appliances• Nylon and Polyamide plastics – carpets, nets, and clothing• Antioxidant in rubber manufacture• Intermediate to herbicides and insecticides• Manufacture of surfactants, detergents, and emulsifiers• Precursor to pharmaceuticals – aspirin and chloraseptic

ABC Corporation’s Phenol Production Plant:

Design and Economic Evaluation for 300,000 tons/yrGroup 21: Laura Bertrand, Brandon Burns, Amiel Kirtikar, Brandon Lorentz

Raw Materials

(Cumene & Hydrogen,

$306

Misc,$38.6 BTCF,

$91.4

Utilities, $46.7

Production Costs, MM$/year

Coolers, $7.6

Exchangers, $36.6

Compressor, $16.9Reactors, $13.4

Columns, $25.9

Misc, $15.1

Total Installed Equipment Cost, MM $

Steam,$36.9

Electricity,$3.5

Refrigerant,$0.4

Cooling Water,$3.7Misc, $2.3

Utility Costs, MM$/year

Waste Waste Flow and Composition Treatment

Unit Phase (lbmol/hr) (mole %) Treatment Emission DisposalOxidation Reactor Total: 4080 Trace Amounts: Burning as fuel Carbon Dioxide Vent to

Vent Gas 4%_Oxygen, 96%_Nitrogen Acetone, Cumene, credit Atmosphere

Hydrogen

Column T-100 Total: 23 Trace Amounts: Nitrogen Vent to

Partial Condenser Gas 86%_Nitrogen, 12%_Cumene, Phenol, Acetone _ Atmosphere

Vent 2%_Oxygen

Hydrogenation Total: 5 Trace Amounts: Burning as fuel Water, Carbon Vent to

Reactor Vent Gas 98%_Hydrogen, 2%_Cumene AMS credit Dioxide Atmosphere

Cleavage Reactor Not Simulated Water-Treatment Salts Bacterial

Catalyst and Solid Aqueous Sulfuric and Organic process Digestion

Organic Waste Acid Salts with Sodium Phenolate

Column T-104 Total: 44 Trace Amounts: Water-Treatment Cooling Water

Bottoms Waste Liquid 98%_Water, 2%_Cumene Acetone process _

Phenolic Resins Phenol

Cumene

Benzene Naphtha Crude Oil

Propylene

Propane Natural gasAir

Hydrogen

Naphtha Crude Oil

Air

Water