Rev a Nth
Transcript of Rev a Nth
MANUFACTURE OF PHENOL-FORMALDEHYDE RESIN
USING RESOL TYPE
Report submitted in the partial fulfillment of the A project requirement for the award of
the degree of “Bachelor of Technology” in Chemical Engineering
Submitted By
Y.T.REVANTH KUMAR
ROLL NO. 07039
DEPARRMENT OF CHEMICAL OF ENGINEERING
UNIVERSITY COLLEGE OF TECHNOLOGY
OSMANIA UNIVERSITY , HYDERABAD-07.
UNIVERSITY OF COLLEGE OF TECHNOLOGY(AUTONOMOUS) OSMANIA UNIVERSITY,HYDERABAD-500 007
PREPARED A PROJECT REPORT ON
MANUFACTURE OF PHENOL-FORMALDEHYDE USING RESOL TYPE
GENNERAL INSTRUCTIONS
(N.B: THIS SHEET SHOULD BE INCLUDED IN THE ORIGINAL PROJECT REPORT)
1. The report for the allotted project must be handed over to the vice principal ,University
College of Technology,OU,on or before 3 PM ,21April 2011,marketed outside as project
report (report name) and bearing the candidate’s name and hall ticket number.
2. The report may be type written on bond size paper and on sketches and drawings with
dimensions must be Xerox copies of originals.The project is to be submitted in
duplicate.One copy would be returned to the candidate after the examination.
3. The students have to present the statues of their progress in the report preparation to the
supervisor on any day suggested by the supervisor.
4. The project report should be adjusted in the range 40-60 pages.neatness should be taken
into account.
5. Each project report should normally include the following chapters with details indicated
(where ever possible).
6. The material balance and energy balance over each process equipment should be
presented with necessary calculation consolidated in brief followed by tabular
presentations of the balances.
7. Details of calculations (along with formulae,if any) necessary for the design of the
equipment should be shown.All the design specifications of the equipment should be
summarized.
8. All the reference should be indicated in the text with a super script number where ever
applicable in continues order from the beginnings to the end of the report.
It may be noted that the non adherence to any of the items listed above shell lead to loss
of credit in the award of grade.
PRINCIPAL
CERTIFICATE
This is to certify that the project entitled “MANUFACTURE OF PHENOL-
FORMALDEHYDE RESINS” that is being submitted by Mr B.LAXMAN NAIK &
Y.T.REVANTH KUMAR in partial fulfillment for the award of the Bachelor of
Technology in Chemical Engineering at the University College of Technology ,Osmania
University , Hyderabad,is a record of bonafide work carried out by him at OUCT under
my guidance and supervision.
The results embodied in this project have not been submitted to any other university or
institute for award of any degree.
Asst. Prof.P.RAJAM Dr T.Sankarshna
Project guide , Principal,
Department of chemical engineering, College of Technology,
University College of Technology, Osmania University.
Osmania University.
Examiner
ACKNOWLEDGEMENT
I am very much grateful to P.RAJAM,Assistant Professer,Department of Chemical
Engineering ,University College of Technology,Osmania University,Hyderabad, for his
kind help and valuable guidance through out this project work.
I would also like to thank Dr T.Sankarshna,Principal and Head of Department,Chemical
Engineering ,University College of Technology,Osmania University,Hyderabad,for his
kind support he has shown in my project work.
I would also like to thank other staff members of University College of
Technology,Osmania University,Hyderabad, for their kind support in materializing this
project.
B.LAXMAN NAIK
ROLLNO:07016
B.TECH:- 4/4
CHEMICAL ENGINEERING
&
Y.T.REVANTH KUMAR
ROLL NO.:07039
B.TECH:- 4/4
CHEMICAL ENGINEERING
CONTENTS
TITLE PAGE NO.
INTRODUCTION 6-7
DESCRIPTION 8
PHYSICAL PROPERTIES 9
CHEMICAL PROPERTIES 10
METHODS OF PRODUCTION 10
PROCESS DESCRIPTION 11-12
MATERIAL BALANCE 13-15
ENERGY BALANCE 16-17
REACTION KINETICS 18
REACTOR DESIGN 19-24
APPLICATIONS AND EXAMPLES 25-32
COST ESTIMATION 33-36
PLANT LOCATION AND LAY OUT 37-40
HEALTH HAZARDS AND TOXICITY INFORMATION 41-42
FIRST AID AND FIRE FIGHTING MEASURES 43-44
HANDLING AND STORAGE 45-47
BIBLIOGRAPHY 48
INTRODUCTION
On July 13, 1907, Leo H. Baekeland applied for his famous “heat and pressure” patent for the
processing of phenol-formaldehyde resins. This technique made possible the worldwide
application of the first wholly synthetic polymer material (only cellulose derivatives were known
before). Even from his first patent application of February 18, 1907, it was clear that Baekeland,
more than these predecessors, was fully aware of the value of phenolic resins.
Before his involvement with phenolic resins Baekeland had worked on
photographic problems with the same intensity. His success in developing a fast-copying
photographic paper, known throughout the world under the name Velox, gave him the financial
independence, which allowed him to build his own research laboratory in his home in Yonkers,
New York. There, starting in 1905, he devoted his whole time to the investigation of phenolic
resins.
However, the first patent covering phenolic resins (as substitute for hard
rubber) was granted to A. Smith in 1899. A. Von Bayer found in 1872 while studying phenolic
dyes, that phenol reacting with formaldehyde was converted to a colorless resin. He first noticed
that a reddish-brown resinous mass was produced during the reaction of bitter almond oil with
pyrogallic acid. However, nothing was done with this resinous material. Ter Meer, A. Claus and
E. Trainer continued the experiments. Claus and Trainer obtained a resinous material from 2 mol
of phenol and 1 mol of formaldehyde and hydrochloric acid. After the non-converted phenol was
distilled off, a soluble resin was obtained with a MP of 100°C. However, they also could not
think of application for this material and reported disappointedly: “It is not possible to crystallize
this resinous material.”
Phenols and formaldehyde are converted to resinous products in the presence of acidic and
alkaline catalysts. These may be permanently fusible and soluble in organic solvents or heat-
curable depending upon the preparation conditions.
Phenolic resins were already being sold as substitutes for shellac, ebonite, horn and celluloid.
These are colorable, can be mixed with fillers and under the influence of heat shaped in molds
into solid parts.
STRUCTURE:
CHEMICAL IDENTIFICATION:
MOLECULAR FORMULA: C6H5-OH-CH2OH
STRUCTURAL FORMULA: HO-C-CH2-CH2-CH2-CH2-C(=O)-C
Appearance and odour: Odourless,brown in color.
Warning properties: Insufficient information available for evaluation, however, since
the material is odourless and Irritant properties are unreliable, assume warning properties
are poor.
Uses and occurrences: PF-resins are usually compression or transfer moulded.They are
used for preparing laminates of papers ,fabrics, etc.The dark colour,however,becomes a
disadvantage for the resin and hence , for applications such as decorative laminates,the
PF resins are used for forming the lower layers.They are used as cast resins , imitation
jewelleries, handles, knobs, electric switches, etc.They are used as adhesive for bonding
plywood and as binding agent for making grinding wheel out of caborandom
particles.presently,phenonlic structural forms are being manufactured which are heat
resistance with high impact strenghthly , atc.The cellular forms may have densities
arranging from 1-20 lb/ft3 . Phenol is used as a basic feedstock for producing numerous
derivatives. The major derivatives and uses are described briefly below. Phenolic resins
are the condensation product of phenol or substituted phenols with an aldehyde, such as
formaldehyde. The largest use for phenolic resins is in adhesives (for plywood), followed
by binders for insulation (fiberglass, mineral wool, etc.), impregnating and laminating
agents (for plastic and wood laminates), and molding compounds and foundry resins.
PHYSICAL PROPERTIES
High-Strength Glass Fiber Reinforced
Relative Density 1.69-2.0 (Kg/m3)
Melting Temperature ( 149-193 0 k)
Thermo set Processing Range (◦F) C:300-380 I:330-390
Molding pressure I-20
Shrinkage 0.001-0.004
Tensile Strength 7000-18000
Compressive Strength 16,000-70,000
Flexural Strength 12,000-60,000
Izod Impact (ft-lb/in) 0.5-18.0
Linear expansion 8-21
Hardness Rockwell E54-101
Flammability V-0
Boiling Point, °C(102 to 107)
Coefficient of Thermal Expansionper .0008
Flash Point °F 112 to 160
Specific gravity 1.69 to 2
Water absorption(%weight increases) 0.12-1.5
0.3 to 1.2(saturated after 24hr)
Specific Heat of Liq cal/gm/°C at 25-40°C 0.55 to 0.5
CHEMICAL PROPERTIES
When phenol reacts with formaldehyde in the presence of alkaline catalyst , methyols
form, is shown in the following reaction
C6H5OH + CH2O C6H5 -OH-CH2OH
(PHENOL) (FORMALDEHYDE) (METHYLOL PHENOL)
Subsequently , methylol-methylol condensation may take place to give resol with an
ether linkage (c-0-c)
C6H5-OH-CH2-OH+C6H5-OH-CH2-OH
RESOL
METHODS OF PRODUCTION:
MANUFACTURE OF PF-RESINS USING RESOL TYPE OF RESIN.
MANUFACTURE OF PF-RESINS USING NOVALAC TYPE OF RESIN.
PROCESS SELECTION:
MANUFACTURE OF PF-RESINS USING RESOL TYPE OF RESIN
PROCESS DESCRIPTION:
For the manufacture of one-stage resins, all the necessary ingredients such as , phenol,
formaldehyde and catalyst are charged into the reaction kettle and a basic condition is
maintained by adding a weak alkali such as CA(OH)2.2H2O or NH4OH.The maolar ratio
of phenol to aldehyde is taken as 1:1.25.The temperature for the reaction is about 1600c.
The reaction that follows is quite fast,the time taken being usually less than one hour.The
reaction products are mostly the di- and tri-methylol phenols having high solubility in
water. To stop the reaction , the mixture is neutralized. The water is then removed by
vaccum distillation and the resin is thickend . Alternatively,the mixture can be dehydrated
by heating under vaccum.But heating should not be carried out for long has this may lead
to premature cross.linking ,accompained by exothermiuc heat evalution.the water-soluble
resin may ,how ever, be taken directly for adhesive or surface coating applications. If a
moulding compound is desired , the reaction mass is dehydrate under vaccum and quickly
discharged from the reaction kettle on to a water-cooled pan where it quickly cools to a
brittle solid.It is then broken up manually , ground and compounded.
Reactants: Phenol to aldehyde 1:1.25 ratio taking in the reaction and 1.5 part of Alkali
metal is adding.
Reaction conditions:
Temperature: 433 K
Pressure : 2 atm
Conversion : 80%
MANUFACTURE OF PF RESIN
MATERIAL BALANCE
Material balance equations involve the law of consevation of mass action.According
to this law , all the mass is conserved.The mass input is equal to the sum of the
mass output from the reactor,amount of material accumulated and the amount of
material generated are consumed.
(NOTE: All the amounts are given in KG)
Basis : 1,000 KG of PF-resin was produced per day.
Material balances can be done for each aquipment/unit individually.
The basic stoichiometric equation be
C6H5OH + CH2O C6H5 -OH-CH2OH
(PHENOL) (FORMALDEHYDE) (METHYLOL PHENOL)
The molecular weights of each compound are:
Compound
Molecular
weight
(g mol)
Phenol(C6H5OH) 94
Formaldehyde(CH2O) 30
Methylol
phenol(C6H5OHCH2O
H)
125
NH4OH 35
MATERIAL BALANCE AT REACTOR:
Reactor
ASSUMPTION:Let the conversion in the reactor be 80%
Compound Entering leaving
C6H5OH 221.5 -
CH2O 272.6250 -
C6H5OHCH2OH - 494.1250
NH4OH 11.75 11.75
TOTAL 505.8750 505.8750
MATERIAL BALANCE:
Material balances can be done for each aquipment/unit individually.
The basic stoichiometric equation be
C6H5-OH-CH2-OH+C6H5-OH-CH2-OH
RESOL
VACUUM DISTILATION:
The complete water is removed and the resin is thickened.
Vacuum distilation
Compound Molecular
weight
Methylo
phenol(C6H5OH-
CH2-OH)
125
Methylol phenol 125
Resol(C6H5OHCH2
-O-CH2-C6H5OH)
232
Amount of feed entering into vacuum distillation =1,011.75 KG
Amount of water removed from distilation = 11.75 KG
Amount of alkali present in distillation =11.75 KG
Total amount leaving = 1,011.75 KG.
ENERGY BALANCE
Energy balance is made based on the first law of thermodynamics.According to first law of
Thermodynamics,energy is conserved.It cannot be produced or destroyed.It can be converte from
one form to other.
The values of specific heats and heat of information are given in the following table.
Compound specific heat(KJ/K.mol.0k)
Phenol 221.75
Formaldehyde 70.14
Methylol phenol 138.23
The basis of stoichiometric equation be
C6H5OH + CH2O C6H5 -OH-CH2OH
(PHENOL) (FORMALDEHYDE) (METHYLOL PHENOL)
Energy balance in the reactor:
heat of reaction at 1600c
Heat input = (m.cp.dt)REACTANTS
=(221.5*2.21*103*(433-298)) + (272.6250*70.14*(433-298))
=92.20 KJ
Heat output = (m.cp.dt)PRODUCTS
= 125*138.23*(433-298) = 92.20 KG
ENERGY BALANCE IN THE VACUUM DISTILATION:
Compound specific heat(KJ/K.mol.0k)
Methylol phenol 138.23
Resin 74.4774
The basis of stoichiometric equation be
C6H5-OH-CH2-OH+C6H5-OH-CH2-OH
RESOL
Energy balance in the vacuum distilation:
heat of reaction at 2000c
Heat input = (m.cp.dt)REACTANTS
= (138.23*125*(473-433))+(138.23*125*(473-433))
= 6.9*105 KG
Heat output = (m.cp.dt)PRODUCTS
= 232*74.47*(437-433)
= 6.9*105 KJ
REACTION KINETICS:
The basis reaction involved in the production of PF resin is
C6H5OH + CH2O C6H5 -OH-CH2OH
(PHENOL) (FORMALDEHYDE) (METHYLOL PHENOL)
The rate kinetics for the above reaction is
-rA=k[C6H5OH] [CH2O]
The value of the rate constant is (k) = 5.6 x 10-4(lit/mol)2/sec
Compound Mass Flow(Kg/hr) Density(Kg/m3) Volumetric Flow
(m3/hr)
C6H5OH 221.5 1350 0.63
CH2O 272.6250 30.943 0.23
TOTAL 0.86
Intial concentration of Phenol (CA0) =221.5/(94x0.86) = 2.74 mol/lit
Intial concentration of Formaldehyde(CB0)=272.5/(30x0.86)=10.56 mol/lit
Therefore, M= CB0/ CA0=3.856
The mean residence time(t) = CA0.XA/(-rA)
= CA0.XA/k. CA03(1-XA)(M-XA)
= 1 hour
mean residence time(t) = volume/volumetric flow rate
Hence volumetric flow rate = 0.86 m3
REACTOR DESIGN
Material of construction:
Stainless steel type 4/4 is reccomended for the process reator etc.The rate of corssion for
stainless steel is low and it is economically satble,has it is cheeper than the other materials.It has
good strenghth of ductility , hence it can be easilt used.For other equipment such as storage tank,
decantor etc mild steel is used certain coating according to process temperature of
compositions.Mild steel is also cheep and easy to fabricate
Composition of properties
1)Stainless steel type 4/4
Chromium 12.5%
Nickle 2.5%
Iron 85%
Yield strenght 60000 psi
Tensile strenghth 98000 psi
Density 7800 Kg/m3
Melting point 2650-27500C
2) Mild steel
Manganese 0.45%
Carbon 0.2%
Silicon 0.25%
Iron 99%
Yield strenghth 38000 psi
Tensile strenghth 65000 psi
Density 7800 Kg/m3
Melting point 27600C
AIM:To deisgn process reactor
TYPE:cylindrical with to hemispherical dished ends with agitation
Materials:stain less steel Chromium 12% Cr
Jacket-Mild steel
Conditions:
Opertaing pressure/design pressure =2 atm
Operating temperature/Design temperature = 1600C
Total volumes of reactants = 0.86 m3
Taking 50% has the safety factor design
Total volume of the reactor=1.5*0.86
= 1.29 m3
Let height of the reactor=1.5*Diameter of reactor
Total volume of the reactor=volume of cylindrical portion+2(volume of hemisphere portion)
V = π/4 * 1.5 D3 + 2 * 4/3* πD3/8*1/2
V = 13/24 πD3
1.29 = 13/24 πD3
D= 0.9117 m
H=1.3675 m
Volume of bottom of hemisphere = 4/3 πD3/8*1/2
= 0.1985 m3
Volume of reactants in the cylindrical portion=volume of reactants – volume of hemisphere
= 0.86 – 0.1985 = 0.6615 m3
Height of cylindrical portion=volume of cylindrical portion/ π/4*D2 = 0.6998 m
Height of liquid from bottom=h+D/2=1.1557 m
Toal height of reactor = 1.1557+0.9117=2.0674 m
Shell thickness:
Operating pressure = 2 atm
Design presuure 10% excess of internal pressure = 2.25 atm=2.32 Kgf/cm2
t=P D/(2fj-p)+CA
From IS CODE standards for stainless steel 4/4 type 1978-1961 ST.18
f=10.5*102 Kgf/cm2
CA= 2mm
D= 91.17 cm
t = 2.32*91.17/(2*10.5*100-2.32)
= 0.1008mm
Assuming safety factor as 50%
t=0.1008*1.5=0.1512 mm
Corrosion allowance=2 mm
Reactor shell thickness (t) = 0.1008+2=2.1008 mm
Therefore,the consider the thickness os the shell as 4mm
Dome end Thickness:
t= P D/(4fj-p)+CA+TA
t=2.32*91.17/(4*10.5*100-2.32) = 0.0504 mm
Assume 50%safety factor then thickness=1.5*0.0504=0.0756mm
CA=2+TA=2.0756mm
Dome end thickness=2.0756+2.5=4.5756
Therefore,we consider Dome end thickness as 5mm
Impeller Design
Assume
Number of baffles = 4
The number of blocks = 6
Typical properties are as follows
(D/Dt) = 1/12 ; (W/Da) = 1/5
(L/Da) = 1/4 ; (J/Dt) = ½.4
Let (Da/Dt) = 1/2
Da=Dia of Impeller
Dt=Dia of reactor
D=length of Impeller
J=baffle spacing width
Dt = 0.9117 m
Da/Dt = 1/2
Da=0.4559 m
D = 0.076 m ; W=0.0912 m
L=0.114m ; J=0.3799m
Height of baffle=2*Dt=2*0.9117=1.8234m
Power consumption
μ = 8.98*10-4Kg/m sec
ρ =114.2 Kg/m3
Let n=60 rpm=1rps
NRe=nDa2 ρ / μ
=1*0.45592*1142.6//8.98*10-4
= 264.45*103 (turbulent)
Therefore , Froude number is neglected
NPO=Pgc/N3Da5 ρ
P = 6*13*0455951142.6 = 135.01 W
REACTOR DESIGN
APPLICATIONS - EXAMPLES
Ablation
Phenolic resin chars when heated to temperatures greater than 480°F (250°C). This process
continues at very high temperatures greater than 1,000°F (>500°C), until the resin completely
converts to amorphous carbon. This characteristic contributes to the unique ablative properties of
phenolic resins. An ablative surface is a heat shield designed to wear away in a controlled
fashion at very high temperatures. Examples are rocket nozzles, rocket blast shields, and
atmospheric reentry shields.
Several aerospace ablative applications specify PLENCO resins.
Abrasives
The variety of abrasive products available in the market is practically endless, as they have to
meet the specific needs of the individual grinding applications and substrates. Applications range
from simple cut off wheels to precision sanding tasks, and involve materials like metal, wood,
minerals, and composites. Generally, there are three groups of abrasive products: bonded, coated,
and non-woven.
Bonded abrasives
Bonded abrasives like grinding wheels are comprised of abrasive particles embedded in a
bonding matrix. While the grit used may be from a wide variety of minerals and abrasive
particles, phenolic resin is the matrix binder of choice. Achieving the optimal combination of
resistance to burst or fracture strength, flexibility and porosity, coupled to the manufacturing
method, requires optimization of the binding resin to the specific application of the wheel in
question. Modification of the blend of phenolic novolac powder, hexa, and liquid resol resin is
usually needed to achieve such optimization. For increased strength, fiberglass reinforcement
inlays are used. These inlays are themselves typically saturated with a special liquid phenolic
resin.
Plastics Engineering Company tailors powdered and liquid resins for bonded abrasives to the
specific needs of the customers and their unique cold forming or hot molding process.
Accelerated cure resins are available as well as dust reduced powdered novolac-hexa products.
PLENCO resins are available as solvent-based flexible phenolic resins for use in fiberglass
reinforcement inlays as well.
Coated Abrasives
Coated abrasives are flexible grinding materials typically available as sheets, discs or belts.
These applications require abrasive grains fixed to the surface of a variety of backings, like paper
or fabric, by special liquid phenolic resin binders. The manufacture of coated abrasives with their
unique properties requires multiple production steps.
PLENCO resins in solvent or aqueous liquid solutions meet the special requirements of this
application.
Non-Woven Abrasives
Household and industrial applications use non-woven abrasives, also called abrasive pads. The
characteristically green pads used for cleaning the dishes are the most publicly visible non-
woven abrasive.
Manufacturers of non-woven abrasive parts typically employ the use of liquid phenolic binders.
PLENCO phenolic resins provide the excellent wetting properties and the short drying times
needed by abrasive pad manufacturers to meet the technical requirements while achieving a high
line speed for improved productivity.
Adhesives
Wood bonding applications such as particleboard or wafer-board have traditionally used
phenolic resin binders. Due to their specific “affinity” for wood and wood fibers, special liquid
phenolic resins may be required for the specialty wood adhesives industry typically in
combination with a polyvinylacetate (PVAc) backbone polymer.
PLENCO liquid phenolic resol resins with low free phenol and low free formaldehyde contents
are available especially for use in adhesive applications. Plastics Engineering Company can also
supply low ash content, soluble solid resol resins, and of course a wide range of novolac resin-
hexa systems.
Carbon
Phenolic resins have an excellent affinity for graphitic and other forms of carbon. Manufacturers
often use the resin simply as a binder and adhesive for their carbon materials. At high
temperature, phenolic resins form a char of amorphous carbon. This means phenolic bonded
carbon materials can be heat treated to yield an all carbon structure. Because of these unique
properties, phenolic resins find application in the manufacture of electrodes, carbon-carbon
composites, carbon seals, and washers.
Phenolic resins are the binder of choice for manufacturing the carbon brushes used in electrical
motors, starters and the like. Depending on the manufacturing process, powdered or liquid
solutions of novolac resin-hexa blends, powdered resol resins, and liquid resol binding systems
provide the desired binding properties.
Several PLENCO phenolic resins meet the requirements demanded by this technically
challenging application.
Coatings
Cured phenolic resins demonstrate exceptional chemical resistance. Railroad cars, storage tanks
and heat transfer equipment are coated using phenolic resins as part of baked phenolic coating
systems.
PLENCO straight phenolic resin systems approved for coating applications are available and the
researchers at Plastics Engineering Company are ready to tailor a resin system to the
requirements of the customer.
Composites
Phenolic resins are the polymer matrix of choice in composite products especially when meeting
high flame, smoke and toxicity (FST) properties. Phenolic resins provide for excellent strength at
elevated temperatures in a variety of environments and are compatible with a multitude of
composite fibers and fillers. Multiple applications benefit by using phenolic resins in the
following composite part manufacturing processes:
Resin Transfer Molding
Pultrusion and Profile Extrusion
Filament Winding
Hand Lay-up
Lightweight and high strength honeycomb structured core materials for aircraft and other
aerospace applications utilize phenolic binding resins, usually in a dipping-saturating process.
The composite manufacturing processes and components vary significantly from product to
product and process to process so that customized PLENCO phenolic resins are the best answer
for our customers to find the optimum process and composite performance.
Felt Bonding
Fiber felt manufacturers use phenolic resins with reclaimed or virgin fibers to produce thermal
and acoustical insulation for the automotive and household appliance industries. Felt
manufacturers achieve optimum rigidity, sound absorption and acoustical insulation performance
by varying the density of the felt product. The versatility of the phenolic resin to affect the part
density mirrors the versatility of substrate fibers used. Phenolic resins provide exceptional
resistance under all environmental conditions.
Specific applications are:
Functional components used in visible areas (e.g., package deck)
Below surface products used for padding and sound absorption (e.g., hood liner)
Rigid parts used as substrate for decorative material
Felt manufacturers achieve specific performance requirements by judicious use of PLENCO
powder resins. Resin formulation provides for good mold release, improved compatibility with
scrim materials, and accelerated cure speeds for production efficiency.
Environmental considerations continue to grow in importance. PLENCO phenolic resins for felt
bonding applications exhibit low emission and odor levels. Low dust level versions of PLENCO
phenolic resins are available also.
Foam
Special phenolic resins in combination with the proper cure catalysts, surfactants and blowing
agents produce foam products. Phenolic foam has a unique set of properties such as excellent fire
and heat resistance and a low smoke and toxicity rating when burned. Proper surfactants produce
closed cell foams with excellent insulating R-values. Other surfactants produce open cell foams
demonstrating unique water absorption properties.
Typical application fields are:
Floral foam (dry and wet foams)
Orthopedic foam (for making foot print casts)
Insulating Foams
PLENCO phenolic resins are widely accepted by the foam industry for their superior
consistency, crucial for the challenging production process.
Foundry
Many technologies are available to foundries for the production of dies for metal castings.
Manufacturers using the shell molding process experience excellent dimensional accuracy,
surface smoothness and high production rates using phenolic resin coated foundry sands. The
shell molding process involves first creating mold cavities and cores by shaping sand coated with
phenolic resin over a not metal form. Removed from the form and assembled, the mold and cores
create the “negative” shape of the desired metal form. Hot metal is poured into the resin-sand
mold and allowed to cool. Once hard, the excess resin-sand material is broken away revealing
the metal part. Some recover the broken away sand for reuse. The careful selection of sand type,
resin characteristics and coating method results in the desired mold and core properties such as
strength, rigidity, flexibility, surface finish, part release and applicability to reuse.
Plastics Engineering Company provides phenolic novolac sand coating resins in pastille form,
for consistent melting and coating, efficient transport, and low dust. Resin formulations make use
of proprietary accelerants, plasticizers or release agents to achieve a wide range of properties.
These additives together with a customized phenol level, melt point, and hexa amount achieve
optimal performance for each foundry’s requirements, like a low peel to improve release from
the hot metal former. The PLENCO product range includes resins for core sands, mold sands,
and recyclable sand.
Friction
Phenolic thermoset resin is the choice for composite friction materials: the pads, blocks, linings,
discs and adhesives used in brake & clutch systems that create retarding or holding forces with
application against a moving part. The inherently heat resistant phenolic resin carbonizes and
chars at extreme service temperatures, it does not melt and smear like other polymer matrices.
This property results in restored friction properties when the material cools and “recovers” from
hard braking.
Formulas for phenolic composite friction materials are combinations of friction and wear-
controlling agents, reinforcing fibers and inert fillers blended with un-cured phenolic resin in an
amount necessary to bond the other ingredients in place with sufficient strength and resiliency
when finished. Judicious selection of the types and amounts of raw materials used allows for the
optimization of performance with cost and consistency. Formulas for basic friction applications
may contain 5 to 10 different ingredients while specialized material formulas may include a
score or two of raw materials. Only one type of bonding resin is typically used. The effect of that
one binder on the final composite’s properties depends on the total formulation and
manufacturing method however. That is, no single type of resin product works optimally with all
friction formulas or applications.
The salient step in the manufacture of phenolic composite friction materials is the molding and
initial curing of the composite under heat and pressure. This molding step typically involves
pressing a uniform blend of ingredients in a shaped mold preheated to 280° - 400°F (140° –
200°C) from one to three tons of pressure per square inch. The phenolic resin melts and flows
during the molding operation to coat and then secure the other ingredients when the resin cross-
links or “cures” to an infusible state. The resin’s performance during the hot molding step is
most important to assuring an efficient manufacturing process. Friction material manufacturers
select the type and amount of binder resin product used as a complement to the envisioned
manufacturing process, its compatibility with other raw materials, environmental concerns and
the expected service requirements.
To this end, Plastics Engineering Company is uniquely suited to assist friction material designers
with a number of liquid and solid novolac (2-stage) and resol (1-stage) phenolic resins
demonstrating a wide variety of flow and cure character combinations. The resins can be custom
formulated with cure accelerating or performance enhancing additives. PLENCO resins are
suitable for all types of brake and clutch uses, including pads for lawn & garden equipment and
automotive brakes, blocks for on and off road trucks, and linings for industrial, oil field and
marine friction applications.
Proppants (Frac Sand)
Oil and natural gas producers improve well yields using hydraulic fracturing fluids containing
round specialty sands coated with phenolic resin. The industry refers to these sands as proppant
or frac sands. The hydraulic fracturing fluid containing the proppant sand is pumped into the well
effectively pressurizing the borehole and fracturing the surrounding rock. The fluid fills the
nascent fissures and the resin-coated sand works as a prop to keep the fissure from sealing on
release of pressure. Round sand is used to provide a porous medium through which the oil and
gas can easily flow.
Proprietary proppant sands made with PLENCO resins continually improve petroleum yields
every day.
Refractory
High carbon yield, wear resistance, and excellent particle wetting and bonding properties make
phenolic resins ideal for refractory products. There are two general categories of refractory
products: shaped and unshaped. Hydraulically pressed refractory bricks, slide gates, shrouds,
nozzles, and crucibles are examples of shaped products. Examples of unshaped products are tap-
hole compounds, tundish liners and ramming mixes used in steel making. Plastics Engineering
Company provides phenolic refractory resins as liquids in a variety of solvents, including water
based systems. Manufacturers may also choose from a wide range of novolac-hexa powder resin
products.
Some companies combine phenolic resins with temperature resistant ceramic fibers in a vacuum
forming process to manufacture riser sleeves, ladles, and hot toppings. This application typically
uses novolac-hexa powder resins with low emission levels. Non-hexa cured PLENCO resins are
available for this application to reduce ammonia and formaldehyde emissions.
Rubber
Tires and technical rubber goods use straight phenolic novolac resins as reinforcing agents.
PLENCO novolac resin pastilles are the preferred choice for a manufacturer who compounds the
resin into the rubber for superior mix consistency and reduced dusting when compared to using
powders or resin in flaked form. Special effort assures consistent pastille size and shape to meet
the requirements of the automated dosing systems used by the industry. PLENCO phenolic
novolac pastille resins are available in a variety of softening point and emission level versions.
Some rubber applications require phenolic novolac-hexa powder resin products in combination
with the rubber compound. Plastics Engineering Company provides novolac-hexa with
customized flow and the hexa curing agent level specific to each application.
COST ESTIMATION
ESTIMATION OF MANUFACTURING COST:
Factors affecting the cost of manufacturing:
Direct manufacturing costs: These costs represent operating expenses that vary with production
rate. When product demand drops, productin rate is reduced below the design capacity. At this
lower we would expect a reduction in the factors making up the direct manufacturing costs.
These costs are proportional to the production rate. These costs include cost of raw materials
(CRM), waste treatment (CWT), utilities(CUT), operating labor (COL), direct supervisory and clerical
labor, maintenance & repairs, operating supplies, laboratory charges and patents and royalties.
Fixed manufacturing costs: These costs are independent of changes in production rate. They
include property taxes, insurance and depreciation that are charged at constant rates even when
the plant is not in operation.
General expenses: These costs represent an overhead burden that is necessary to carry out
business functions. They include management, sales, financing and research functions. General
expenses seldom vary with production level. However items such as research and development
and distribution and selling costs may decrease if extended periods of low production levels
occur.
The equation used to evaluate the cost of manufacture using these costs is given by,
Cost of manufacture (COM) = Direct manufacturing costs (DMC) + Fixed manufacturing costs
(FMC) + General expenses (GE). - IV
Multiplying factors used for estimating different manufacturing costs are:
Direct supervisory and clerical labor - 0.18 COL
Maintenance and repairs - 0.06 FCI
Operating supplies - 0.009 FCI
Laboratory charges - 0.15 COL
Patents and royalties - 0.03 COM
Depreciation - 0.1 FCI
Local taxes and insurance - 0.032 FCI
Plant overhead costs - 0.708 COL + 0.036 FCI
Administrative costs - 0.177 COL + 0.009 FCI
Distribution and selling costs - 0.11 COM
Research and development - 0.05 COM
Where COL is cost of operating labor, FCI is fixed capital investment and COM is cost of
manufacturing By adding all these costs, equation - IV becomes
COM = 0.304 FCI + 2.73 COL + 1.23 (CUT + CWT + CRM ) - V
Estimation of cost of raw materials (CRM):
Cost of the propylene and benzene assumed are Rs 35 /kg and Rs. 20 /kg
As per the material balance calculations, consumption of phenol and formaldehyde are 4965.374
kg/ hr and 8338.294 kg/hr respectively
Assuming that plant operates 340 days a year, yearly raw material cost is calculated as,
CRM = 4965.374*24*340*35 + 8338.294*24*340*20
= Rs. 2787080395
Estimation of cost of operating labor (COL):
Operator requirements for various equipment is taken from table 3.3 of reference 2 of
bibliography Equipment in the plant, operator requirement per equipment is tabulated in the table
(operator requirement for process equipment)
Equipment
type
Operator requirement
per equipment per shift
No of
equipments in
the plant
Operator
requirement per
shift
Air plant 1 1 1
Boiler 1 2 2
Cooling
towers1 2 2
DM plant 0.5 1 0.5
Power
generator0.5 2 1
Sub station 0.5 1 0.5
Incinerator 2 1 2
Effluent
treatment
plant
2 1 2
Water
treatment2 1 2
Furnace 0.5 1 0.5
Heat
exchangers0.1 7 0.7
Tower 0.35 2 0.7
Reactor 0.5 1 0.5
Total operator requirement per shift 15.4
Assuming that single operator works on the average 49 weeks a year, five 8 hour shifts a
week, number of operators needed to be employed is 4.5 ( with reference to section 3.2 of
reference 2 of bibliography) .
Total no of operators = 15.4*4.5 = 69.3
Assuming that cost to company of operator, Rs. 250000 per annum
Cost of operating labor, COL = 69.3*250000
= Rs. 17325000
Estimation of total cost of manufacturing (COM):
Assuming that the cost of utilities, CUT is Rs. 200000000 and cost of waste water
treatment, CWT is Rs. 100000000.
Total cost of manufacturing is calculated by the equation - V
COM = 0.304*1174480906 + 2.73*17325000 + 1.23*(200000000 + 100000000 +
2787080395)
= Rs 4693448332
ESTIMATION PRODUCT COST:
Capacity of plant is 300 metric ton/day
As assumed in the previous section, plant operates 340 days a year.
Yearly production of plant = 300*340
= 102000 t/year
= 102000000 Kg/year
Assuming that the cost of cumene is Rs 50/kg
Total product cost = Rs. 5100000000
ESTIMATION RATE OF RETURN AND PAYBACK PERIOD:
Profit per year = cost of product – cost of manufacturing (COM)
= 5100000000 – 4693448332
= Rs. 406551668
Net profit after tax, assuming tax to be 25%
= 406551668 (1-0.25)
= Rs. 304913751
Rate of return = net profit * 100/ fixed capital investment
= 304913751*100/1174480906
= 25.96 %
Pay back period = 1/rate of return= 1/25.96= 3.85 years.
PLANT LOCATION AND LAYOUT
PLANT LOCATION AND SITE SELECTION The location of the plant can have a crucial effect on the profitability of a project, and the scope
for future expansion. Many factors must be considered when selecting a suitable site. The other
considerations are as follows:
Location, with respect to the marketing area
Raw material Supply
Transport facilities
Availability of labor
Availability of utilities: water, fuel, power
Environmental impact, and effluent disposal
Local community considerations.
Climate
Availability of suitable land
Political and strategic considerations
The major raw materials for cumene plant are propylene and benzene. Cumene plants are almost
always located near acetone and phenol plants, due to the difficulties of storage and
transportation of cumene. One more significant factor in plant location is the availability of
propylene. In view of its risk in handling and transportation of propylene they are located very
close to refineries. This factor minimizes the cost of transportation even. The most optimum
location would be in a petrochemical industrial area where there is requirement for acetone and
phenol.
SITE LAYOUT
The process units and ancillary buildings should be laid out to give the most economical flow of
materials and personnel around the site. Hazardous processes must be located at a safe distance
from other buildings. Consideration must be given to the future expansion of the site. The
ancillary buildings and services required on a site, in addition to the main processing units
include
Storage for raw materials and products; tank firms and warehouses
Maintenance workshops
Stores, for maintenance and operating supplies
Laboratories for process control
Fire stations and other emergency services
Utilities: steam boilers, compressed air, power generation, refrigeration, transformer stations
Effluent disposal plant
Offices for general administration
Canteens and other amenity buildings, such as medical centres
Car parks
When roughing out the preliminary site layout, the process units will normally be sited first and
arranged to give a smooth flow of materials through the various processing steps from raw
material to product storage. Process units are normally spaced at least 30m apart. Principal
ancillary buildings then be arranged so as to minimize the time spent by personnel in traveling
between buildings. Administration offices and labs in which a relatively large no of people will
be working, should be located well away from potentially hazardous processes. Control rooms
will normally be located adjacent to the processing units, but with potentially hazardous
processes may have to be sited at a safer distance. The siting of the main process units will
determine the layout of the plant roads, pipe alleys and drains. Utility buildings should be sited to
give the most economical run of pipes to and from the process units. Cooling towers should be
sited so that under the prevailing wind the plume of condensate spray drifts away from the plant
area and adjacent properties. Main storage areas should be placed between the loading and
unloading facilities and the process units they serve. Storage tanks containing hazardous
materials should be sited at least 70m from the site boundary. Typical plot plan is shown in the
fig.7.2.1
PLANT LAYOUT
A plant layout is that arrangement of major equipments, supporting system and utilities, so that such
operation is performed at the point of greatest convenience. Plant Layout is placing of the right equipment,
coupled with right method, in the right place to permit the processing of a product in most effective manner
through the shortest possible distance in the least shortest possible time.
The importance of a good layout is better pronounced in operating effective, such as economics
in the cost of materials handling, minimization of production delays and avoiding of bottlenecks
etc., one of the preliminary task of a good layout is the selection of a proper site. A schematic
plant layout of the cumene plant is shown in Figure attached at the end of the report. The
parameters considered to arrive at the plant layout are: Economic considerations, Process
Requirements, Operation & Maintenance requirements, Safety, Fire suppression system and
Expansion.
Economic considerations
Construction and operating costs can be minimized by adopting a layout that gives the shortest
run of connecting pipe between equipment and the least amount of structural steel work.
Although this is will not necessarily be the best arrangement for operation and maintenance, cost
considerations can be compromised up to some extent to give optimum cost plant for safe
arrangement and convenient maintenance.
Operation and Process Requirements
The location of certain equipments is based on the process requirement. For example to elevate
the base of columns to provide the necessary net positive suction head to a pump. Equipment that
needs to have frequent operator attention should be located convenient to the control room.
Valves, sample points and instruments should be located at convenient positions and heights.
Sufficient working space and headroom must be provided to allow easy access to equipment. All
plant areas shall be suitably illuminated as operation is planned as a three shift continuous
operation. Piping routings should be made for easy access and maintenance. The power cable
and instrumentation cables should be connected in separate trays with power cable tray above the
instrumentation cable.
Maintenance
Heat exchangers need to be sited so that the tube bundles can easily be removed. Equipment that
requires dismantling for maintenance, such as compressors and large pumps, should be placed
under cover. Vessels that require frequent replacement of catalyst should be located on the
outside of buildings.
Safety
Blast walls are needed to isolate potentially hazardous equipment, and confine the effect of an
explosion. At least two escape routes for operators must be provided from each level in process
buildings, as emergency exits.
Fire Suppression System
A Fire suppression system should be provided in order to suppress the Fire and keep the plant
equipments and workers in safe. Firewater main ring with hoses for tall buildings are required for
fighting advanced fires. Reliable fire water supply and reliable power supply like class III / class
II are required for critical (emergency) loads. The lay out should be planned keeping in view of
relative fire hazards and their separation from each other.
Plant Expansion
Equipment should be located so that it can be conveniently tied in with any future expansion of
the process. Space should be left on pipe alleys for future needs, and service pipes over-sized to
allow for future requirements.
HEALTH HAZARDS AND TOXICITY INFORMATION:
National Fire Protection Association Ratings
Health: 3 Flammability: 2 Reactivity: 0
Acute Effects
The consequences of exposure to phenol can be severe. Phenol is highly toxic and corrosive by
all routes of exposure, and overexposure can cause severe injuries and death. However, it can
be handled safely by knowledgeable, trained personnel using appropriate equipment.
Skin
Phenol exposure occurs most often through skin contact. It can cause second or third degree
chemical burns while being rapidly absorbed through the skin. Overexposure can lead to central
nervous system effects such as excitability, dizziness, loss of balance and coordination,
confusion, unconsciousness, shock, convulsion and death. Respiratory problems as well as
kidney and liver damage, are also signs of overexposure. Overexposure can be fatal if contact is
long enough and occurs over a large enough area of the body. Liquid exposure to 15 to 20% of
the body can lead to death. It is important to know that phenol acts as an anesthetic. This means
that skin contact may be very painful at first, but shortly the skin will become numb and the pain
will subside. Just because the pain goes away, it does not mean the phenol has been completely
removed.Please review the MSDS for additional information.
Inhalation
Inhalation of vapors or mists can be severely irritating to the upper respiratory tract, and can
result in damage to the respiratory tract and the lungs. Signs and symptoms of overexposure can
include coughing, choking, runny nose, pain or burning sensation, difficulty breathing and sore
throat. Similar to the effects resulting from skin contact, overexposure can cause kidney and liver
damage, central nervous system effects, shock, convulsions and possibly even death, if exposure
is long enough and the airborne concentrations are high enough.
Eyes
Phenol vapors or mists can be severely irritating to the eyes. Direct contact of phenol with the
eyes can cause severe burns and permanent corneal damage which could result in blindness.
Symptoms of overexposure include, severe pain, redness, swelling and photophobia (intolerance
of light).
Ingestion
Phenol is highly toxic when swallowed. It is absorbed rapidly into the system and can cause the
effects mentioned above, such as kidney and liver damage, shock, convulsions and possibly even
death, if the amount swallowed is large enough. As little as one (1) gram of phenol swallowed by
an adult has resulted in death.
Chronic Effects
Chronic phenol poisoning in industry is rare. Symptoms include vomiting, difficulty swallowing,
loss of appetite, dermatitis, dark urine, discolored skin, general weakness, loss of body weight,
enlarged liver and kidney damage.
Cancer
Phenol was tested by the National Cancer Institute (NCI) in a 2 year cancer bioassay and found
not to be a carcinogen. No organization or regulatory agency classifies phenol as a carcinogen.
FIRST AID:
Employees working in an area where contact with phenol is possible must be trained and
knowledgeable in appropriate first aid procedures. Immediate first aid treatment is critical to
minimize effects. Deluge-type safety showers with quick-opening valves should be immediately
accessible in all working areas, and all personnel should be familiar with their location and
operation.Safety showers should be supplied with tempered water. If the safety shower is in a
remote area, it is suggested that the shower be alarmed and tied into a central monitoring facility.
Moderate pressure water hoses and eye wash fountains should also be located strategically
within work areas.
Skin Contact
Immediately flush with large volumes of water while removing contaminated clothing. Continue
to thoroughly wash with water for at least 20 minutes after clothing is removed. If phenol has
contaminated the face or head, the victim should wear goggles in the shower to prevent phenol
from entering the eyes. Phenol acts as an anesthetic. Just because the pain following initial
contact subsides, it does not mean that all of the phenol has been removed. It is important to
continue to flush the exposed area for the full 20 minutes.After the emergency shower, the
affected area(s) of the patient should be swabbed with cotton soaked in polyethylene glycol
(PEG) 400 for a minimum of 10 to 20 minutes. After treatment with PEG, the patient should be
transported to an emergency medical facility for further treatment.Dispose of all contaminated
clothing, particularly leather items, because it can retain phenol and potentially cause re-
exposure if worn again.
Note: PEG 400 solution should be available in work areas in case of emergencies. This mixture
is available commercially.
Eye Contact
Flush with large amounts of water for at least 20 minutes, separating and lifting the upper and
lower eyelids occasionally. Get medical attention immediately.
Inhalation
If phenol vapors are inhaled, remove the person from the area immediately and get to fresh air
If a person has difficulty breathing, or if breathing has stopped, administer artificial respiration
(mouth-to-mouth) or oxygen as appropriate. Obtain assistance and call for medical help.
Ingestion
If phenol is swallowed, immediately call a physician. Wipe excessive material from mouth and
lip area. Transport person to hospital emergency facility immediately. DO NOT induce vomiting.
Give 1-2 glasses of milk or water if person is conscious and alert. Never give anything by mouth
to an unconscious person.
FIRE FIGHTING
Carbon dioxide and dry chemical extinguishers should be used for small fires. For larger fires,
universal or PSL foams are most effective. If water is used, run-off should be contained to
prevent the entrance of phenolic water into sewers and waterways. The run-off water should be
collected for proper disposal. Any escape of phenol or phenolic water must be reported promptly
to local authorities so that drinking water intakes can be closed and intakes to sewage plants can
be blocked or bypassed. Be careful not to splash personnel with water containing phenol because
it can cause chemical burns and toxic effects. Firefighters should wear a self-contained breathing
apparatus (SCBA).
HANDLING AND STORAGE:
Engineering Controls
Local exhaust ventilation should be used to capture and remove phenol vapors. Good ventilation
should be provided in all working areas.
Personal Protective Equipment
A comprehensive industrial hygiene plan reduces the likelihood of unnecessary exposure to
phenol and other chemicals in the industrial environment. This includes a ready supply of gloves
and other protective wear for employees working with phenol and atmospheric monitoring in
areas where exposure is possible.Personal protective equipment must be used to prevent direct
skin and eye contact and to reduce the potential for inhalation exposure. Employees can be
protected against skin contact by using gloves and other garments made from polyvinyl chloride
(PVC), neoprene or natural rubber. The eyes and face should be protected with splash goggles, a
full face shield or a full face respirator.The need for a respirator and respirator selection depends
upon the airborne concentrations of phenol in the workplace. When concentrations of phenol are
greater than 5 ppm, but less than 50 ppm, a half-mask organic vapor cartridge respirator should
be worn. When dust and/or mists are present, a particulate prefilter must also be used. A full-face
respirator with the same cartridge is suitable for concentrations up to 250 ppm phenol. For
concentrations greater than 250 ppm, an air supplied respirator must be worn. Firefighters should
wear a self-contained breathing apparatus (SCBA). When respirators are used at a facility, the
employer is responsible for implementing a respiratory protection program (OSHA 1910.134).
As with any type of personal protective device an employee may use, safe practices and habits
are crucial to successful implementation. Therefore, a thorough education program should be in
place to properly train employees in the safe use of personal protective equipment. A personal
protective device used incorrectly will not afford the protection for which it was
designed.Anumber of factors will determine the proper course of action in the event of a spill or
leak of phenol.The most important factor to consider is whether available personnel have the
ability to properly handlethe spill based on the size and location of the spill. A responsible
individual should determine if materialsand information are available to enable them to safely
and effectively deal with a spill situation. In preparation for accidental spills, it is advisable to
have written procedures and personnel trained to deal with such emergencies. There are a few
important things to remember when dealing with a phenol spill:Because of phenol’s hazard
classification, preventing environmental releases is of the utmost importance. The reportable
quantity for phenol is 1,000 pounds. This means that if 1,000 pounds or more of phenol are
released to the environment in any 24 hour period, it must be reported to the National Response
Center immediately (phone 1-800-424-8802). Additional notification of state and local agencies
may be necessary; see “Regulatory Issues: Emergency Release Notification” section.When faced
with a phenol spill, first ensure the safety of personnel. If it is determined that an environmental
release is taking place, spill control procedures should be implemented.Determine if phenol is
still leaking and if it can safely be prevented from leaking further, i.e., by closing a valve or
shutting off a pump. Since phenol freezes at about 106°F, some leaks may be stopped by freezing
the area of the leak. Once it has been determined that either the leak has been stopped or it is
impossible to do so, action must be taken to prevent the spill from spreading any further. Spills
should be contained with booms or earthen dikes and allowed to solidify.To avoid water
pollution, water should not be used to flush or clean the area. Any release of phenol or phenolic
water to a waterway or to a storm sewer must be reported promptly to local authorities so that
downstream drinking water intakes can be closed. If phenolic water enters a process sewer
notification should be made to the associated wastewater treatment operations so that protective
measures can be implemented such as bypassing to storage or blocking intakes to the treatment
plant. Phenol is miscible in water to a concentration of 8% by weight, at which point undissolved
phenol will sink.
DOT Regulatory Shipping Information
Phenol is classified by the U.S. Department of Transportation (DOT) as a Class 6.1
(poisonous) material. When shipping via all modes of transportation, shipments must be
documented, packaged, labeled, marked, placarded, loaded and unloaded in accordance
with the applicable DOT Regulations. Title 49, Code of Federal Regulations contains the
regulations for shipping hazardous materials via air, highway, rail, and water, except bulk water
shipments, which are regulated by Titles 33 and 46, Code of Federal Regulations.
Storage
Molten phenol discolors quickly when in contact with iron or copper. The higher the
temperature, the more rapid the discoloration. To minimize discoloration store phenol at
temperatures below 60°C (140°F). The choice of construction materials for storing phenol
depends on color requirements in conjunction with the end use. Preservation of color
of high purity phenol is best accomplished in vessels constructed of stainless steel
or lined carbon steel. Glass, nickel, baked phenolic resins and two part inorganic zinc
silicate such as Plasite 1002/1010 are suitable materials for linings. When the color of
phenol is not important, vessels of ordinary carbon steel serve satisfactorily, because
phenol has no appreciable corrosive activity on mild steel at the temperatures usually
encountered in transportation and storage. Hot phenol readily attacks metals such as
copper, aluminum, magnesium, lead, and zinc. Therefore, these metals and their alloys
are not recommended for use in molten phenol storage tanks where the metal is in direct
contact with the phenol. Constant circulation through external steam-heat exchangers is
the preferred method to maintain phenol in a liquid state while in storage. This minimizes
the chance of moisture contamination due to leaks, facilitates tank cleaning, and avoids
local overheating, which increases color degradation. All lines that are isolated after any
transfer should be blown clear with nitrogen or an acceptable inert gas to prevent damage
due to expansion. All transfer lines should be heat traced and insulated.
Sampling Phenol in Shipping Containers
Proper Personnel Protective Equipment (PPE) should be worn when sampling phenol.
Samples of phenol may be taken through the manway opening of a shipping container by
means of a bottle placed in a stainless steel holder and suspended by a light stainless steel
chain. Before taking a sample for testing, the bottle should be rinsed with the phenol to be
sampled, and quickly closed to minimize moisture pickup and other contamination. An
ordinary three-gallon pail may be used to collect the sampling bottle, bottle holder and
chain as they are withdrawn, dripping, from the tank.
Transfers from Shipping Containers and Storage Tanks
Phenol can be transferred by pumping, pressure, or gravity. Centrifugal and turbine-type
pumps are used in transfer operations. Pipelines carrying phenol should be heat traced
and insulated to keep the chemical in a liquid state to avoid plugging lines. Steam tracing
is the most common means of heating; insulation is also recommended. Phenol should not
remain stagnant in steam traced lines to avoid color formation.
BIBLIOGRAPHY
Reference’s Books
Out lines of polymer science and technology
Advances in polymer science and technology
Robert H.perry and Don W, “Perry’s chemical engineers’ HAND BOOK”,
Mc.Graw hill publications.
Websites
1. www.google.com
2. www.wikipedia.com
3. www.Ethesis list.com
4. www.Patent online.com
5. www.sunocochem.com