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INTRODUCTION

Chapter: 1 INTRODUCTION

CUMENE

1.

INTRODUCTION

Chapter: 1

Introduction

Cumene (isopropyl benzene) is an organic compound that is based on an aromatic hydrocarbon with an aliphatic substitution. It is a constituent of crude oil and refined fuels. It is a flammable colorless liquid that has a boiling point of 152 °C. Nearly all the cumene that is produced as a pure compound on an industrial scale is converted to cumene hydroperoxide, which is an intermediate in the synthesis of other industrially important chemicals, primarily phenol and acetone. •

The alkylation of benzene with propylene gives CUMENE a very important petrochemical C3 compound.

•

The cumene molecular have can be visualize as straight chain propylene group have benzene ring attached at the middle carbon form cumene (C6H5CH(CH3)2

•

The cumene production capacity of the world is about 7 million Ton/day distribute over 40 plant. • The catalyst for such a process is phosphoric acid supposed. Silica Kieselguhr(skpa).

•

Only few plants are based on the MONSANTO TECHNOLOGY, which uses aluminum trichloride (ALCL3) as catalyst.

•

Cumene producers account for approximately 20% of the global demand for benzene.

CUMENE

2.

INTRODUCTION

Structure.

Fig. 1, 2-dimension structure of cumene.

CUMENE

Fig. 2, 3-dimension structure of cumene

3.

INTRODUCTION

1.2. PRESENT STATUS AND MARKET ANALYSIS. Essentially, all world cumene is consumed for the production of phenol and acetone. As a result, demand for cumene is strongly tied to the phenol market. Trade In cumene accounts for only 4% of world production. The largest exporter of cumene are the United States & Japan. Taiwan also import large volume of cumene for phenol production. As of early 2011, the U.S. cumene market was tight-primarily as a result of a shortage of feedstock propylene. Schedule plant maintenance by several large cumene manufacturer was also planned for early to mid 2011. Because of the cumene shortage, phenol and acetone plant operations rate have been reduced significantly, which in turn has restricted phenol export to Europe and higher demand region such as Asia & South America.

Fig. 3, world consumption patterns of cumene

Increased demand for bisphenol A and phenolic resin will result in strong Demand for phenol, particularly in Asia (excluding Japan). As a result, consumption of cumene for phenol is forecast to grow at approximately 8% per year in the region China alone is expected to add a million metric ton of

CUMENE

4.

INTRODUCTION

cumene capacity during stream in 2013) to supply its phenol/ acetone plants that are slated to come on stream during that period. Overall, worldwide cumene consumption for the production of phenol/acetone is forecast to grow at an average annual rate of about 4.5% during 2010–2015.

CUMENE

5.

INTRODUCTION

1.3. LIST PRODUCER OF CUMENE. Table 1, list global cumene manufacturers.

SR. No List of cumene manufacturing industry

1

2

3

4

CUMENE

Herdillia chemicals Ltd. Air India building, 13thfloor,narimanpoint, Bombay400021(Maharashtra) Si group India ltd. Ballarpur road Opp. juinagar railway station Turbhethane, NaviMumbai(Maharashtra) Hindustan organic chemicals Industry, 81,Maharishi karvemarg, Harchandri house, Mumbai (400002) Global polychem LLC. N-2, sector 11, Noida-201301, Uttar Pradesh.

Capacity

2000 TPA

1470 TPA

40000 TPA

10301 TPA

6.

INTRODUCTION

1.3.2 LIST GLOBAL MANUFACTURER Table 2, Global manufacturer of cumene and capacity of cumene

1

Hangzhou Tianlong Co., Ltd Zhejiang, China.

2

A.M. FOOD chemical co., Ltd Shandong, China.

10000 TPA

3

TS CHEMICAL PVT. LTD Texas, American

20000 TPA

4

JLM CHEMICAL .PVT .LTD Blue Island, IL, USA

1120 TPQ

5

EniChem , ENI. CO.LTD. San Donato Milanese, Italy

1980 TPQ

CUMENE

300000 TPA

7.

INTRODUCTION

1.5 PROPERTIES  PHYSICAL PROPERTIES OF CUMEN. •

Color

:- colorless

•

Odor.

:- odorless

•

Molecular weight.

:-

120.19

•

Purity

:-

99%

•

Melting point.

:-

-96.9°C

•

Boiling point.

:-

152.5°C

•

Density

:-

0.862 gm/cc

•

Flash point.

:-

•

Vapor pressure

•

Ignition point.

:-

138°C

•

Freezing point

:-

-96°C

•

Thermal conductivity.

:-

0.124 w×m/k

•

Surface tension.

:-

0.791 N/M

•

Flammable limit in air. :-

:-

39°C 4.5 mmHg at 25°C

lower – 0.9% volume,

:-. Higher – 6.5% volume

CUMENE

•

Toxicity limit.

:-

200 PPM

•

Soluble

:-

Water, and more solvent.

•

Insoluble in.

:-

Alcohol, Ether, Carbon tetrachloride & etc.

8.

INTRODUCTION

 CHEMICAL PROPERTIES OF CUMENE •

Cumene under goes oxidation to give cumene hydroperoxide by means of air or oxygen. C6 H5CH(CH2)2 + O2 = C6H5 (CH3)2COOH.

•

By catalytic actions of dilute sulphuric acid, cumene hydroperoxide is Split into phenol & acetone. C6H5(CH3)2COOH = C6H5OH + CH3COCH3

CUMENE

9.

INTRODUCTION

1.6 USES OF CUMENE

1. Cumene is a natural component of coal tar and crude oil, and also can be used as Blanding component in gasoline. 2. A building-block chemical, almost all cumene approximately 98% of cumene is consumed as a chemical intermediate in the production of phenol & acetone, two chemicals that are widely use plastic . 3. Additional, cumene I’m minor amounts is used as a solvent during the manufacturing of paints, lacquer & enamel. 4. Cumene is also used as a solvent for fats and raisins. 5. Cumene by itself is not generally sold by producers for consumers used. 6. Cumene in minor amounts is used as a thinner for paints, enamels and lacquers and to produce acetophenone, the chemical intermediate dicumylperoxide and isopropyl benzene.

CUMENE

10.

INTRODUCTION

1.7

RAW MATERIALS USED.

Raw materials for cumene manufacturing are; 1.Benzene 2.Propane 3.Propylene.

1.8

CATALYST USED.  QZ-2000™

&

 QZ-2001™ 2000catalyst is a solid, regenerable, zeolite catalyst used to produce cumene ((isopropyl benzene) via alkylation of benzene with QZ_2001 catalyst is based on a proprietary beta zeolite formulation developed by UOP.

CUMENE

11.

MANUFACTURING PROCESS

CHAPTER: 2

MANUFACTURING PROCESSES OF CUMENE WITH FLOW DIAGRAMS

CUMENE.

12.

MANUFACTURING PROCESSES WITH FLOW DIAGRAM

1. Q-MAX™ CUMENE manufacturing process flow diagram.

Fig. 4, Q-MAX™ cumene manufacturing process.

CUMENE

13.

MANUFACTURING PROCESSES WITH FLOW DIAGRAM

2 CD-TECH CUMENE manufacturing process flow diagram.

Fig.5 CD-TECH CUMENE manufacturing process.

CUMENE

14.

MANUFACTURING PROCESSES WITH FLOW DIAGRAM

3. MONSANTO – LUMMUS crest cumene process.

Fig.6, MONSANTO LUMMUS cumene manufacturing process

CUMENE

15.

MANUFACTURING PROCESSES WITH FLOW DIAGRAM

4. UOP cumene manufacturing process.

Fig.7, UOP cumene manufacturing process.

CUMENE

16.

MANUFACTURING PROCESSES WITH FLOW DIAGRAM

5. Badger Cumene Manufacturing Process.

Fig.8, MOBILE BADGER cumene manufacturing process.

CUMENE

17.

MANUFACTURING PROCESSES WITH FLOW DIAGRAM

2.3 SELECTION OF CUMENE MANUFACTURING PROCESS •

Q-MAX ™ Manufacturing process is most convenient process for CUMENE manufacturing

Justification of selection of cumene:•

Product yield is 99.7 weight%.

•

High activity and selective with minimum by product formation.

•

Typical cumene productive yield is 95.5% pure.

•

Extremely tolerant to poison.

•

Proven run-length of up to 5 years.

•

Low catalyst cost .

•

Low in investments as compare to other process.

•

Reduce in solid waste.

•

Corrosion free environment.

CUMENE

18.

MANUFACTURING PROCESSES WITH FLOW DIAGRAM

2.4 Process description on Q-MAX ™ cumene manufacturing process. 1. Raw material propylene and benzene are used for the production of cumene. 2. These are stored in the respective storage tanks of 500MT capacity in the storage yard pumped to the unit by the centrifugal pumps. 3. Benzene pumped to the feed vessel which mixes with the recycled benzene. Benzene stream is pumped through the vaporizer with 25 atmospheric pressure and vaporized to the temperature of 243 , mixed with the propylene which is of same and temperature and pressure of benzene stream. 4. This reactant mixture passed through a fired super heater where reaction temperature 350

is obtained.

5. The vapor mixture is sent to the reactor tube side which is packed with the solid phosphoric acid catalyst supported on the exothermal heat is removed by the pressurized water which is used for steam production and the effluent from the reactor i.e. cumene, p-DIPB, unreacted benzene, propylene and propane with temperature 350

is used as the heating media in the vaporizer

which used for the benzene vaporizing and cooled to 40

in a water cooler, propylene and

propane are separated from the liquid mixture of cumene, p-DIPB, benzene in a separator operating slightly above atmospheric and the pressure is controlled by the vapor control value of the separator, the fuel gas is used as fuel for the furnace also. 6. The liquid mixture is sent to the benzene distillation column which operates at 1 atmospheric pressure, 98.1% of benzene is obtained as the distillate and used as recycle and the bottom liquid mixture is pumped at bubble point to the cumene distillation column where distillate 99.9% cumene and bottom pure p-DIPB is obtained.

CUMENE

19.

MANUFACTURING PROCESSES WITH FLOW DIAGRAM

7. The heat of bottom product p-DIPB is used for preheating the benzene column feed, All the utility as cooling water, electricity, steam from the boiler, pneumatic air is supplied from the utility section. 8. The typical reactor effluent yield contains 94.8 Wt. % cumene and 3.1 Wt. % of diiso propyl benzene. The remaining 2.1 % is primarily heavy aromatics. 9. This high yield of cumene is achieved without of di-iso propyl benzene and is unique to the solid phosphoric acid catalyst process. 10. The cumene product is 99.9 Wt. % pure and the heavy aromatics, which have an octane number of 109, can either be used as high-octane gasoline blending components or combined with additional benzene and sent to a trans alkylation section of the plant where diiso propyl benzene is converted to cumene. 11. The overall yields of cumene for this process are typically 97-98 Wt. % with trans alkylation and 94-96 Wt. % without trans alkylation.

CUMENE

20.

MANUFACTURING PROCESSES WITH FLOW DIAGRAM

2.5 Manufacturing process description of Cumene. A representative Q-Max flow diagram is shown. The alkylation reactor is typically divided into four catalyst beds contained in a single reactor shell. The fresh benzene is routed through the upper midsection of the depolarizer column to remove excess water and then sent to the alkylation reactor via a side draw. The recycle benzene to both the alkylation and trans alkylation reactors comes from the overhead of the benzene column. A mixture of fresh and recycle benzene is charged down flow through the alkylation reactor. The fresh propylene feed is split between the four catalyst beds. An excess of benzene is used to avoid polyalkylation and to help minimize olefin oligomerization. Because the reaction is exothermic, the temperature rise in the reactor is controlled by recycling a portion of the reactor effluent to the reactor inlet, which acts as a heat sink. In addition, the inlet temperature of each downstream bed is reduced to the same temperature as that of the first bed inlet by injecting a portion of cooled reactor effluent between the beds. Effluent from the alkylation reactor is sent to the depolarizer column, which removes any propane and water that may have entered with the propylene feed. The bottoms from the depolarizer column are sent to the benzene column, where excess benzene is collected overhead and recycled. Benzene column bottoms are sent to the cumene column, where the cumene product is recovered overhead. The Cumene column bottom which contains most isopropyl benzene is send to the DIPB stream leaves the column by way of a side cut and is recycled to the Tran alkylation reactor. The DIPB column bottom consist of heavy aromatic by-product, which are normally blended into fuel oil. Steam or hot oil provide the heat for the product, fractionation section. CUMENE

21.

MANUFACTURING PROCESSES WITH FLOW DIAGRAM

A portion of the recycle benzene from the top of the benzene column is combined with the recycle DIPB from the side cut of the DIPB column and sent to the trans alkylation reactor. In the trans alkylation reactor, DIPB and benzene are converted to additional cumene. The effluent from the trans alkylation reactor is then sent to the benzene column. The QZ-2000 catalyst utilized in both the alkylation and trans alkylation reactors is regenerable. At the end of each cycle, the catalyst is typically regenerated ex-situ via a simple carbon burn by a certified regeneration contractor. However, the unit can also be designed for in-situ catalyst regeneration. Mild operating conditions and a corrosion-free process environment permit the use of carbon steel construction and conventional process equipment.

CUMENE

22.

MANUFACTURING PROCESSES WITH FLOW DIAGRAM

2.6 PROCESS FLOW DIAGRAM WITH INSTRUMENTATION AND EQUIPMENT OF QMAX™ PROCESS FOR CUMENE MANUFACTURING

. Fig.9, PFD. of Cumene manufacturing process with all instrumentation and fittings with feed locations, heat exchanger, pumps, coolers etc

CUMENE

23.

LIST MAJOUR EQUIPMENT AND INSTERUMENT

Chapter: 3

LIST MAJOR EQUIPMENT AND INSTRUMENTATION REQUIRED IN MANUFACTURING OF CUMENE

CUMENE

24.

LIST MAJOUR EQUIPMENT AND INSTERUMENT

3.1 MAJOR EQUIPMENT

Major equipment required in Q-MAX ™ CUMENE MANUFACTURING are follow: 1. Alkylation reactors. 2.Trans alkylation reactor 3. Depolarizer column. 4. Benzene column. 5. Cumene column. 6. DIPB column. Other general equipment used in cumene manufacturing process. 1.

Feed drum.

2.

Feed pump.

3.

Feed vaporizer.

4.

Feed heater.

5.

Effluent coolers.

6.

Phase separator.

7.

Condenser.

8.

Reflux pump.

9.

Reboiler.

10. Cumene Reflux drum.

CUMENE

25.

LIST MAJOUR EQUIPMENT AND INSTERUMENT

1. Alkylation reactors. The alkylation reactor is typically divided into four catalyst beds contained in a single reactor shell. The fresh benzene is routed through the upper midsection of the depropanizer column to remove excess water and then sent to the alkylation reactor via a side draw. The recycle benzene to both the alkylation and trans alkylation reactors comes from the overhead of the benzene column.

Fig. 10, Alkylation Reactor of Q-MAX ™ Cumene manufacturing process.

CUMENE

26.

LIST MAJOUR EQUIPMENT AND INSTERUMENT A mixture of fresh and recycle benzene is charged down flow through the alkylation reactor. The fresh propylene feed is split between the four catalyst beds. An excess of benzene is used to avoid polyalkylation and to help minimize olefin oligomerization. Because the reaction is exothermic, the temperature rise in the reactor is controlled by recycling a portion of the reactor effluent to the reactor inlet, which acts as a heat sink. In addition, the inlet temperature of each downstream bed is reduced to the same temperature as that of the first bed inlet by injecting a portion of cooled reactor effluent between the beds. Effluent from the alkylation reactor is sent to the depolarizer column, which removes any propane and water that may have entered with the propylene feed.

2. Trans alkylation reactor. In the trans alkylation reactor, DIPB and benzene are converted to additional cumene. The effluent from the trans alkylation reactor is then sent to the benzene column. The QZ-2000 catalyst utilized in both the alkylation and trans alkylation reactors is regenerable.

At the end of each cycle,

the catalyst is typically regenerated ex-situ via a simple carbon burn by a certified regeneration contractor. However, the unit can also be designed for in-situ catalyst regeneration. Mild operating conditions and a corrosion-free process environment permit the use of carbon-steel construction and conventional process equipment.

CUMENE

27.

LIST MAJOUR EQUIPMENT AND INSTERUMENT

3. Depolarizer Reactors. Depolarizer Reactors is reactors which removes propane, water, and other impurities present in the propylene feed. The depolarizer has a total condenser, partial reboiler, 20 equilibrium stages , and operates at 17 bar. The feed streams, a saturated liquid at 101.6°C, enter at stage 11 at a flow rate of 100Kmol/hr.

Fig. 11, Depolarizer Reactor.

CUMENE

28.

LIST MAJOUR EQUIPMENT AND INSTERUMENT

4. Benzene column. The bottoms from the depolarizer column are sent to the benzene column, where excess benzene is collected overhead and recycled. Benzene column bottoms are sent to the cumene column, where the cumene product is recovered overhead.

Fig. 12, Benzene column.

CUMENE

29.

LIST MAJOUR EQUIPMENT AND INSTERUMENT

5. Cumene Column. Benzene column bottoms are sent to the cumene column, where the cumene product is recovered overhead. The Cumene column bottom which contains most d-isopropyl benzene is send to the DIPB stream leaves the column by way of a side cut and is recycled to the Tran alkylation reactor. The bottom liquid mixture is pumped at bubble point to the cumene distillation column where distillate 99.9% cumene and bottom pure p-DIPB is obtained.

Fig.13, Cumene Column.

CUMENE

30.

LIST MAJOUR EQUIPMENT AND INSTERUMENT

6. DIPB COLUMN. The Cumene column bottom which contains most d-isopropyl benzene is send to the DIPB stream leaves the column by way of a side cut and is recycled to the Tran alkylation reactor. The DIPB column bottom consist of heavy aromatic by-product, which are normally blended into fuel oil. Steam or hot oil provide the heat for the product, fractionation section.

Fig. 14, DIPB Column.

CUMENE

31.

LIST MAJOUR EQUIPMENT AND INSTERUMENT

3.2 Instrumentation Required in Cumene Manufacturing Process. Major instrumentation required in cumene manufacturing process are: 1. Pressure measuring instruments. • •

Diaphragm pressure valve. Border tube pressure gauge

2. Flow measuring devices. •

Turbine flow meter.

•

Vortex flowmeters.

•

Coriolis flowmeter.

3. Temperature measuring devices. •

Electro pyrometer.

•

Helix bimetallic element thermometer.

4. Level measuring instrument. •

Radar level measuring transmitter.

•

Buoyancy level measurement device.

5. Valve control and regulations. 6. Ph measuring instruments.

CUMENE

•

Ph meter.

•

Ph indicator.

32.

MATERIAL BALANCE

Chapter: 4

MATERIAL BALANCE

CUMENE

33.

MATERIAL BALANCE

4.1 Overall Material Balance. Reaction’s in the Alkylation Reactor: C3H6 + C6H6 = C6H5 - C3H7 (Cumene, IPB) C3H6+C6H5-C3H7 = C3H7 –C6H4-C3H7 (di iso propyl benzene; DIPB; C6H4[CH(CH3)2]) Reaction’s in the Trans-Alkylation Reactor: C3H7–C6H4-C3H7+C6H6 2(C6H5-C3H7) Conversion of Propylene in Alkylation reactor: %100 Reactor Conversion for Trans-Alkylation reactor: %50

Basis: Per hour of operation Amount of cumene to be obtained = 1 M ton of cumene per annum. =106/330 tons per day of cumene. = 106/ (330 x 24) tons of cumene per hr. = 126.26 x 103 kg of cumene per hr. = (126.26 x 103)/120.19 kmoles of cumene per hr. = 1050.50 Kgmole/hr.

Assuming 97% conversion and 2% loss. ∴ Cumene required = 1050.50/ .98 =1071.94 Kgmoles/hr. = 128836.32 Kg/hr.

CUMENE

34.

MATERIAL BALANCE Hence 128836.32 kg of cumene is required to be produced per hr. Propylene required =1071.94/.97 = 1105.09 Kgmole = 1105.09 x 42 Kg/hr. of propylene = 46413.78 Kg/hr. of propylene

Assuming benzene required is 25% extra = 1105.09 x 1.25 Kmoles of benzene = 1381.3625 Kgmole/hr. = 107746.27 Kg/hr.

Propane acts as an inert in the whole process. It is used for quenching purpose in the reactor. It does not take part in the chemical reaction. Also, it is inevitably associated with the propylene as an impurity as their molecular weight is very close. We assume propylene to propane ratio as 3:1. Being an inert we are neglecting propane balance in the material balance to avoid complexity.

CUMENE

35.

MATERIAL BALANCE 1.) Material balance around reactor: Propylene = 46413.78 Kg/hr Benzene = 107746.27 Kg/hr Products:

ALKYLATION

Cumene = 128836.32 Kg/hr. Propylene = 1105.09-1071.94

REACTOR

DIPB =33.15 Kmoles/hr. is reacted to give

Benzene required to give DIPB = 33.15/2 kmoles/hr. = 16.575 kmoles/hr. DIPB produced= 16.575 x 162 = 2685.15 Kg/hr. Benzene in product = 1381.3625 – 1071.94 -16.575 = 292.85 kmoles/hr. = 22820.85 kg/hr. Input = 46413.78 + 107746.27 = 154160.05 Kg/hr. Output = 128836.32 + 2685.15 + 22820.85= 154342 Kg/hr. Input = output

CUMENE

36.

MATERIAL BALANCE 2) Depropanising column. Propane column is Depropanising column. Assuming almost all the propane is removed in depropanising column and sent to reactor for quenching. Hence material balance for depropanasing column is not considered.

CUMENE

37.

MATERIAL BALANCE

3.) Distillation column 1: (Benzene column)

Feed, F= Benzene + cumene + DIPB = 154160 Kg/hr XF= 22820.85/154160 = 0.1480

D = Benzene = 15969.41Kg/hr

Benzene Column

W= Cumene + DIPB = 138190 kJ/KG

F=D+W 154160 = D +W F XF = DXD +WX w Taking XF = 0.9999 , XD = 0.05 154160 x 0.1480 = D x 0.9999 +W x 0.05 3023.5 =0.9999 D + (20374 – D) x 0.05 D = 15969.41 Kg/hr. = Benzene

CUMENE

38.

MATERIAL BALANCE W = 154160 – 15969.41 = 138190.5 Kg/hr. = cumene + DIPB Input = 154160 kg/hr. Output = 15969.41 + 138190.5 = 154160 kg/hr. Input = Output

Assuming all the Benzene present in benzene column is recycled to the feed. Hence considering negligible amount of benzene to be part of residue. This will avoid the complexity of multicomponent distillation in Cumene column. Therefore, amount of benzene recycled

= 15969.5 Kg/hr.

Therefore, feed actually given to the system = 154160 + 15969.5 = 170129.5 Kg/hr.

CUMENE

39.

MATERIAL BALANCE 4) Distillation column 3: (Cumene column) . F = Cumene + DIPB = 138190.5 Kg/hr XF = 128836.3/138190.5 = 0.932

Cumene = D = 17065.2Kg/hr CUMENE COLUMN DIPB = W = 371.79Kg/hr = 2%.

F = D +W 138190.6 = D +W FXF = DXD + WXW Taking XD = 0.995 XW = 0.01 138190.5 x 0.932 = D x 0 .995 + W x 0.01 128793.54 = 0.995D + (138190.5 – D) 0.01

D = 129051 kg/hr.

W = 138190.5 – 129 = 9139.5 Kg/hr. Input = 138190.5 Kg/hr. Output = 129051 + 9139.5 = 138190.5 Kg/hr. Input = output

CUMENE

40.

MATERIAL BALANCE Table 4, Overall Material balance of cumene manufacturing flow diagram Chemical

Input

Output

Mol.wt.

Kmol/hr

Kg/hr

Kmol/hr

Kg/hr

Benzene

78

1382.4

107,746.27

204.74

15,969.42

Propylene

42

1105.09

46413.78

0

0

Propane

44

5.9

259.38

5.9

259.3844

Cumene

120

0

0

1075.43

129,051

DIPB

162

0

0

56.42

9139.5

Total

-

-

154,160.05

-

145,371.2

CUMENE

41.

DESIGN BASIS FOR NEW PLANT

Chapter: 5

DESIGN BASIS FOR NEW PLANT.

CUMENE

42.

DESIGN BASIS FOR NEW PLANT

5.1 Design Basis. Capacity, (kmol/h),110

•

Alkylation reactor type catalytic distillation reactor Catalyst, Zeolite -Y Catalyst regeneration frequency, years;2 Catalyst life, years; 6 Temperature °C (top-bottom) 198-249 Pressure, bar14 B/P feed ratio, mole/mole1.64 Conversion, %: 99 Propylene%100 Benzene%55

•

Trans alkylation reactor type: Single catalyst bed Catalyst Zeolite-Y Catalyst life, years6 Temperature °C140-150 Benzene/DIPB feed ratio, mole/mole 5.2 Conversion of DIPB%50 Overall yields, mol% Separations Units:

CUMENE

43.

DESIGN BASIS FOR NEW PLANT

•

Benzene column: Type: Distillation column Purity of Top product: %100Benzene Purity of Bottom Product: %78.5Cumene Operational Condition: Tin:1030C T bottom :1240C Ttop:45 Operational pressure:0.3bar.

•

Cumene column: Type: Distillation column Purity of Top Product: %100Cumene Purity of Bottom Product: %100DIPB, Operational Conditions: Tin:1240C Tbottom:1720C Ttop:1100C Operational pressure :0.3

CUMENE

44.

ECONOMIC EVALUTION

Chapter:- 6

ECONOMIC EVALUATION OF PROJECT

CUMENE

45.

ECONOMIC EVALUTION

6.1 Economic Evaluation of Project. Economic Evaluation Of Project is displayed in four categories following . 1. Total Capital Investment. a) Fixed capital investment. b) Working capital investment. 2. Total production cost. a) Manufacturing cost.  Variable costs.  Plant Overhead costs.  Fixed charges. b) General expenses.  Administrative expenses.  Marketing and sales expenses.  Research and development. 3. Net gross income . 4. Cash flow.

CUMENE

46.

ECONOMIC EVALUTION

• Equipment purchasing cost investment Table.8 Equipment purchasing cost investment

Sr. no.

Equipment

Quantity

Cost in INR

MAJOR EQUIPMENT 1

Alkylation Reactor

1

9000035

2

Trans Alkylation Reactor

1

6000322

3

Benzene column

1

7939141

4

Cumene column

1

9201500

5

Depropanizer

1

4500232

6

DIPB column

1

3950023

7

Flash tank

3

2000000

8

Cooler

3

5321500

9

Heater

3

1500000

10

Compressors

1

1200000

11

Reflux drum

3

1500000

12

Reboiler

3

9000000

13

Pumps

6

8736600

14

Valves

8

5488000

15

Storages tanks

4

5000000

INSTRUMENTATION 1

Flow controller

6

500000

2

Flow measuring devices

2

50000

3

Pyrometer

2

15000

4

Level controller

6

70000

5

Level measuring

6

75000

6

Flow measuring device

8

80000

7

Flow controller

8

95600

8

Pressure measuring devices

8

80900

9

Pressure controller

8

120000

10

DCS control system

1

100000

CUMENE

47.

ECONOMIC EVALUTION COST OF ETP 1

Screen units

1

100000

2

Equalizers

1

100000

3

Sedimentation tank

2

200000

4

Dispersion units

1

100000

5

Aeration unit

1

100000

6

Filters

2

200000

7

Sludge thickening units

2

200000

Other cost of spare equipment used in case of failure TOTAL COST EQUIPMENT

CUMENE

15000000/152800000

48.

ECONOMIC EVALUTION

1.TOTAL CAPITAL INVESTMENT COST. Total Capital Investment is sum of fixed capital investment and working capital investment. Fixed Capital Investment. Fixed capital investment in a sum of Direct cost and Indirect cost.

I. Direct Costs: material and labor involved in actual installation of complete facility (7085% of fixed-capital investment) A. Equipment + installation + instrumentation + piping + electrical + insulation + painting (5060% of Fixed-capital investment). 1. Purchased equipment cost (PEC): (15-40% of Fixed-capital investment) Consider purchased equipment cost = Rs. 1.528×10^8 2. Installation, including insulation and painting: (25-55% of purchased equipment cost.) Consider the Installation cost = 40% of Purchased equipment cost = 40% of 1.528×10^8 = 0.40 ×1.528×10^8 = Rs.0.6112×10^8 3. Instrumentation and controls installed: (6-30% of Purchased equipment cost.) Consider the installation cost = 20% of Purchased equipment cost = 20% of ×1.528x10^8 = 0.20 ×1.528×10^8 = Rs. 0.3056×10^8

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49.

ECONOMIC EVALUTION 4. Piping installed: (10-80% of Purchased equipment cost) Consider the piping cost = 40% Purchased equipment cost = 0.40 ×1.528×10^8 = Rs. 0.6112×10^8 5. Electrical, installed: (10-40% of Purchased equipment cost) Consider Electrical cost = 25% of Purchased equipment cost = 25% of 1.528 ×10^8 = 0.25 ×1.528×10^8 = Rs.0.382×10^8

B. Buildings, process and Auxiliary: (10-70% of Purchased equipment cost Consider Buildings, process and auxiliary cost, = 40% of PEC = 40% of 1.528 ×10^8 = 0.40 ×1.528×10^8 = Rs. 0.6112×10^8

C. Service facilities and yard improvements: (40-100% of Purchased equipment cost)

Consider the cost of service facilities and yard improvement, = 60% of PEC = 60% of 1.528 ×10^8 = 0.60 ×1.528×10^8 = Rs. 0.9168×10^8

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ECONOMIC EVALUTION

D. Land: (1-2% of fixed capital investment or 4-8% of Purchased equipment cost) Consider the cost of land = 6% PEC = 6% of 1.528 ×10^8 = 0.06 ×1.528×10^8 = Rs. 0.09168×108 Thus, Direct cost = Rs. 5.058×10^8----- (82.74% of FCI)

II. Indirect costs: expenses which are not directly involved with material and labor of actual installation of complete facility (15-30% of Fixed-capital investment)

A. Engineering and Supervision: (5-30% of direct costs) Consider the cost of engineering and supervision, = 10% of Direct costs = 10% of 5.058 ×10^8 = 0.1× 5.058 ×10^8 = Rs.0.5058×10^8 B. Construction Expense and Contractor’s fee: (6-30% of direct costs) Consider the construction expense and contractor’s fee, = 10% of Direct costs = 10% of 5.058×10^8

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ECONOMIC EVALUTION = 0.1× 5.058 ×10^8 = 0.5058×10^8 C. Contingency: (5-15% of Fixed-capital investment) Consider the contingency cost = 10% of Fixed-capital investment = 12% of 6.113×10^8 = 0.12 × 6.113×10^8 = Rs. 0.7336×10^8 Thus, Indirect Costs = Rs. 1.7452×10^8--- (28.55% of FCI) I. Fixed Capital Investment: Fixed capital investment = Direct costs + Indirect costs = (5.058×108) + (1.7452×108) = Rs. 6.803×108

1) Working Capital: (10-20% of Fixed-capital investment) Consider the Working Capital = 15% of Fixed-capital investment. = 15% of 6.803×10^8 = 0.15 × 6.803×10^8 = Rs. 1.0205×10^8

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ECONOMIC EVALUTION 2) Total Capital Investment (TCI): Total capital investment = Fixed capital investment + Working capital = (6.803×10^8) + (1.0205×10^8) = Rs. 7.8235×10^8 Table. 9 Total capacity cost investment Sr.no Types of costs

Factors of equipment cost

Total cost in ₹ 10 Million

Fixed Capital Investment I.

Direct cost A.

Purchased Equipment cost (PEC)

-

1.528

Equipment installation cost

40% of (PEC)

0.6112

Installation & control

20% of (PEC)

0.3056

Piping costs

40% of (PEC)

0.6112

Electrical costs

25% of (PEC)

0.382

B.

Buildings, Process & Auxiliary cost

40% of (PEC)

0.6112

C.

Service facility &yard improvement.

60% of (PEC)

0.9168

D.

Land

6% of (PEC)

0.09168

Total Direct cost 5.058 II

Indirect costs A.

Engineering & supervision

10% of (Direct cost)

0.5058

B.

Construction expenses

10% of (Direct cost)

0.5058

C.

Contingency

12% of (Direct cost)

0.7336

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53.

ECONOMIC EVALUTION Total indirect costs 1.7452 Total fixed capital investment 6.803 Working capital investment 1.

Working capital investment 15% of fixed capital investment

1.0205

Total Capital Investment Fixed Capital Investment + (6.803×10^8) +

1.

7.8235

Working capital investment (1.0205×10^8)

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ECONOMIC EVALUTION

2. ESTIMATION OF TOTAL PRODUCT COST: I. Manufacturing Cost = Direct production cost + Fixed charges + Plant overhead cost.

A. Fixed Charges: (10-20% total product cost) i. Depreciation: (13% of FCI for machinery and equipment and 2-3% for Building Value for) Consider depreciation = 13% of FCI Depreciation = (0.13×6.803×108) + (0.03×0.6112×108) = Rs. 0.9027×108 ii. Local Taxes: (1-4% of fixed capital investment) Consider the local taxes = 3% of fixed capital investment = 0.03×6.803×108 = Rs. 0.2041×108 iii. Insurances: (0.4-1% of fixed capital investment) Consider the Insurance = 0.7% of fixed capital investment = 0.007×6.803×108 = Rs. 0.0476×108 iv. Rent: (8-12% of value of rented land and buildings) Consider rent = 10% of value of rented land and buildings = 10% of ((0.09168×108) + (0.6112×108)) = Rs. 0.0703x108 Thus, Fixed Charges = Rs. 1.2247×108

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ECONOMIC EVALUTION B. Direct Production Cost: (about 60% of total product cost) Now we have Fixed charges = 10-20% of total product charges – (given) Consider the Fixed charges = 15% of total product cost Total product charge = fixed charges/15% = 1.2247×108/15% = 1.2247×108/0.15 = Rs. 8.1647×108 i.

Raw Materials: (10-50% of total product cost)

Consider the cost of raw materials, = 25% of total product cost Raw material cost = 25% of 8.1647×108 = 0.25×8.1647×108 = Rs. 2.0412×108 ii.

Operating Labor (OL): (10-20% of total product cost) Consider the cost of operating labor, = 12% of total product cost = 12% of 8.1647×108 = 0.12×8.1647×108 = Rs. 0.9797×108

iii. Direct Supervisory and Clerical Labour (DS & CL): (10-25% of OL) Consider the cost for Direct supervisory and clerical labour, = 12% of OL = 12% of 0.9797×108 = 0.12×0.9797×108

= Rs.

0.1176×108

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56.

ECONOMIC EVALUTION iv. Utilities: (10-20% of total product cost) Consider the cost of Utilities, = 12% of total product cost = 12% of 8.1647×108 = 0.12×8.1647×108 = Rs. 0.9797×108 v.

Maintenance and repairs (M & R): (2-10% of fixed capital investment)

Consider the maintenance and repair cost, = 5% of fixed capital investment = 0.05×6.803×108 = Rs. 0.3402×108 vi. Operating Supplies: (10-20% of M & R or 0.5-1% of FCI) Consider the cost of Operating supplies, = 15% of M & R = 15% of 0.3402×108 = 0.15 ×0.3402×108 = Rs. 0.05103×108 vii. Laboratory Charges: (10-20% of OL) Consider the Laboratory charges, = 15% of OL = 15% of 0.9797×108 = 0.15×0.9797×

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ECONOMIC EVALUTION 108 = Rs. 0.1469×108 viii. Patent and Royalties: (0-6% of total product cost) Consider the cost of Patent and royalties, = 4% of total product cost = 4% of 8.1647×108 = 0.04×8.1647×108 = Rs. 0.3266×108 Direct Production Cost = Rs. 4.983×108 ----- (61% of TPC) C. Plant overhead Costs (50-70% of Operating labour, supervision, and maintenance or 515% of total product cost); includes for the following: general plant upkeep and overhead, payroll overhead, packaging, medical services, safety and protection, restaurants, recreation, salvage, laboratories, and storage facilities. Consider the plant overhead cost, = 60% of OL, DS & CL, and M & R = 60% of ((0.9797×108) + (0.1176×108) + (0.3402×108)) = Rs. 0.8625×108 Thus, Manufacture cost = Direct production cost + Fixed charges + Plant overhead costs. Manufacture cost = (4.983×108) + (6.803×108) + (0.8625×108) Manufacture cost = Rs. 12.6485×108

II. General Expenses = Administrative costs + distribution and selling costs + research and

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ECONOMIC EVALUTION development costs A. Administrative costs:(2-6% of total product cost) Consider the Administrative costs, = 5% of total product cost = 0.05 ×8.1647×108 = Rs. 0.4082×108 B. Distribution and Selling costs: (2-20% of total product cost); includes costs for sales offices, salesmen, shipping, and advertising. Consider the Distribution and selling costs, = 15% of total product cost = 15% of 8.1647×108 = 0.15 ×8.1647×108 = Rs. 1.2247×108 C. Research and Development costs: (about 5% of total product cost) Consider the Research and development costs, = 5% of total product cost = 5% of 8.1647×108 = 0.05 × 8.1647×108 = Rs. 0.4082×108 D. Financing (interest): (0-10% of total capital investment) Consider interest = 5% of total capital investment

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ECONOMIC EVALUTION = 5% of 7.8235×108 = 0.05×7.8235×108 = Rs. 0.3912×108 = Rs. 2.4323×108 2.

Total Product cost = Manufacture cost + General Expenses = (12.6485×10^8) + (2.4323×108) = Rs. 15.0808×108

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ECONOMIC EVALUTION Table.10 Total Production costs of Cumene plant Sr.no

Designation

Factors

Total ₹ in 10 Million

Manufacturing cost A.

Fixed Charges

13% of (TPC)

1.

Depreciation

13%of (FCI)

0.9027

2.

Local taxes

3% of (FCI)

0.2042

3.

Insurance

0.7% of (FCI)

0.0476

4.

Rents

10% of (FCI)

0.0703

Total Fixed cost 1.2247 B.

Direct production costs

60% of (TPC)

1.

Operating labour

12% of (TPC)

0.9797

2.

Raw materials

25% of (TPC)

2.0412

3.

Direct supervisor & Clerical Labour

12% of (OL)

0.1172

4.

Utilities

12% of (TPC)

0.9797

5.

Maintenance & Repairs

5% of (TPC)

0.3402

6.

Operating supply

15% of (mfg.)

0.05103

7.

Labour charges

15% of(OL)

0.1469

8.

Patent & royalty

4%of (TPC)

0.3266

Total Direct production costs 4.983 C.

Plant Overhead cost

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60%of OL, DS, mfg.

0.8625

61.

ECONOMIC EVALUTION Total plant Over head cost 0.862 Total Manufacturing cost 12.6485 General Expenses A

Administrative cost

5% of (TPC)

0.4082

B

Distribution & selling cost

15% of (TPC)

1.2247

C

Research & Development

15% of (TPC)

0.4082

D

Finance

5%of (TPC)

0.3912

Total General expenses 2.4323 Total Production costs

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15.0808

62.

ECONOMIC EVALUTION 3.

Gross Earnings/Income:

Wholesale Selling Price of cumene per kg = Rs.53 Total Income = Selling price × Quantity of product manufactured = 53 x 30000000 = Rs. 15.9×108 Gross income = Total Income – Total capital investment = (15.9×108) – (8.1647×108) = Rs. 7.7353×108 Let the Tax rate be 45% (common) Net Profit = Gross income - Taxes = Gross income× (1- Tax rate) = 7.7353 x 108 (1-0.45) = Rs. 4.2544×108 Net profit margin = (net profit/ annual income) *100 = (4.2544*108/15.9*108)/100 =26.756% Payback period = FCI/(net profit) = 6.803*10^8/4.2544*108 = 1.6. Rate of return = net profit* 100/ (total capital investment) = 4.2544*108*100 / 7.8235*108 = 54.38 %

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ECONOMIC EVALUTION

4. Cash Flow :

Fig. 15, Discounted cash flow of project.

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64.

UTILITY REQIIRED IN CUMENE MANUFACTURING

Chapter. 7

UTILITY REQUIRED IN CUMENE MANUFACTURING

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65.

UTILITY REQIIRED IN CUMENE MANUFACTURING

7.1 Utilities. The word utilities are not generally used for the ancillary services needed in the operation of any production process. These services will normally be supplied from a central site facility, and will include: (1) Electricity. (2) Steam for process heating. (3) Cooling water. (4) Water for general use. (5) Demineralized water. (6) Compressed air. (7) Inert gas supplies. (8) Refrigeration. (9) Effluent disposal facilities.

Electricity: . The power required for electrochemical processes, motor drives, lighting, and general use maybe generated on site, but will more usually be purchased from the local supply company. The voltage at which the supply is taken or generated will depend on the demand. For a large site the supply will be taken at a very high voltage, typically 11,000 or 33,000 V. Transformers will be used to step down the supply voltage to the voltages used on the site. In the United Kingdom a three phase 415V system is used for general industrial purposes, and 240V single phase for lighting and other low power requirements. If several large motors is used, a supply at an intermediate high voltage will also be provided, typically 6000 or 11,000V.

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UTILITY REQIIRED IN CUMENE MANUFACTURING Steam: The steam for heating is usually generated in water tube boilers using the most

economical

fuel level available. The process temperatures required can usually be obtained with low temperature steam typically 2.5 bar and steam distributed at a relatively low pressure, typically around 8 bar (100 psig). Higher steam pressures, or proprietary heat transfer fluids, such as dowtherm will be needed for high process temperatures.

Combined Heat and Power (Co-generation): The energy costs on a large site can be reduced if the electrical power required is generated on the site and the exhaust steam from the turbines used for process heating. The overall thermal efficiency of such systems can be in the range 70-80 %, compared with the 30-40 % obtained from a conventional power station, where the heat in the exhaust steam is wasted in the condenser. Whether a combined heat and power system scheme is worth considering for a particular site will depend on the size of the site, the cost of fuel, the balance between the power and heating demands, and particularly on the availability of and cost of, stand by supplies and the price paid for any surplus power electricity generated.

Cooling Water: Natural and forced draft cooling towers are generally used to provide the cooling water required in a site; unless water can be drawn from a convenient river or lake in sufficient quantity.

Water for General Use:

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67.

UTILITY REQIIRED IN CUMENE MANUFACTURING The water required for general purposes on a site will usually be taken from the local mains supply, unless a cheaper source of suitable quantity water is available from a river, lake or well. Demineralized Water: Demineralized water from which all the minerals have been removed by ion exchange, is used where pure water is needed for process use, and as boiler feed water. Mixed and multiple bed ion exchange units are used, one resin converting the cations to hydrogen and the other removing the acid radicals. Water with less than one ppm of dissolved solids can be produced.

Refrigeration: It will be needed for processes that require temperatures below those that can be economically obtained with cooling water. For temperatures down to around 10 o C chilled water can be used. For lower temperatures, down to -30oC, salt brines are used to distribute the “refrigeration” round the site from a central refrigeration machine.

Compressed Air: It will be needed for general use, and for the pneumatic controllers that are usually used for chemical process plant control.

Inert Gases: Where large quantities of inert gas are required for the inert blanketing of tanks and for purging is usually supplied from a central facility. Nitrogen is normally used and is manufactured on site in an air liquefaction plant, or purchased as liquid in tankers.

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68.

PLANT LOCATION AND SITE SELECTION

Chapter:8

Plant locations, Plant layout & site selection.

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69.

PLANT LOCATION AND SITE SELECTION

8.1 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

factors to be considered are: 1.

Location with respect to the marketing area

2.

Raw material supply.

3.

Transport facilities.

4.

Availability of labor.

5.

Availability of utilities: water, fuel, power.

6.

Availability of suitable land.

7.

Environmental impact, and effluent disposal.

8.

Local community considerations.

9.

Climate.

10.

Political and strategic considerations.

1.

Marketing Area:

For materials that are produced in bulk quantities such as cement, mineral acids and fertilizers where the cost of the product per ton is relatively low and the cost of transport a significant fraction of the sales price, the plant should be located close to the primary market. This consideration will be less important for low volume production, high-priced products, such as pharmaceuticals.

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PLANT LOCATION AND SITE SELECTION

2. Raw Materials: The availability and price of suitable raw materials will often determine the plant location. Plant producing bulk chemicals are best located close to the source of the major raw material: where this is also close to the marketing area.

3. Transport: The transport of materials & products to & from the plant will be an overriding consideration in site selection. If practicable, site should be selected that is close to at least two major forms of transport road, rail, waterway (canal or river) or a sea port. Road transport is being increasingly efficient for the movement of personnel &essential equipment & supplies & the proximity of the site airport should be considered.

4.Availability of labor: Labour will be needed for construction of the plant & its operation. Skilled construction workers will usually be brought in from outside the site area, but there should be an adequate pool of unskilled labour available locally; & labour suitable for training to operate the plant. Skilled tradesmen will be needed for plant maintenance. Local trade union customs & restrictive practices will have to be considered when assessing the availability & suitability of the local labour for recruitment & training.

5.Utilities (Services) Chemical processes invariably require large quantities of water for cooling & general process use, & the plant must be located near a source of water of suitable quantity. Process water may be drawn from a river, from wells, or purchased from a local authority. At some sites the cooling water required can be taken from a river or lake, or from the sea; at other locations cooling tower will be needed. Electrical

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71.

PLANT LOCATION AND SITE SELECTION

power will be needed at all

sites. Electrochemical processes that require large quantities of power; for

example, aluminum smelters need to be located close to a cheap source of power. A competitive priced fuel must be available on site for steam & power generation.

6.Environment impact, & disposal: All industrial processes produce waste products & full consideration must be given to the difficulties & cost of their disposal. The disposal of toxic & harmful effluents will be . covered by local regulations & the appropriate authorities must be consulted during the initial site survey to determine the standards that must be met. An environmental impact assessment should be made for each new project or major modification or addition to an existing process.

7.Local community considerations: The proposed plant must fit in with & be acceptable to the local community. Full consideration must be given to the safe location of the plant so that it does not impose a significant additional risk to the community. On a new site, the local community must be able to provide adequate facilities for the plant personnel: school, banks, housing & recreational & cultural facilities

8.Land (site selection) Sufficient suitable land must be available for the proposed plant & for future expansion. The land should ideally be flat, well drained & have suitable load bearing characteristics. A full site evaluation should be made to determine the need of piling or other special formations.

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PLANT LOCATION AND SITE SELECTION

9.Climate: Adverse climate conditions at a site will increase cost. Abnormally low temperatures will require the provision of additional insulation & special heating for equipment & pipe runs. Stronger structures will be needed at locations subject to high winds (cyclone hurricane areas) or earthquakes.

10.Political & Strategic Considerations: Capital grants tax concessions & other inducements are often given by the government to direct renew investments to preferred locations, such as areas of high unemployment. The availability of such grants can be the overriding consideration in site selection.

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PLANT LOCATION AND SITE SELECTION

8.2 plant layout The economic construction & efficient operation of a process unit will depend on how well he plant & equipment specified on the process flow-sheet is laid out. The principal factors to be considered are: 1. Economic consideration: construction & operating cost 2. The process requirements 3. Convenience of operation 4. Convenience of maintenance 5. Safety 6. Modular construction

1. Costs: The cost of construction can be minimized by adopting a layout that gives the shortest run of connecting pipe between equipment & the least amount of structural steel work. However, this will not necessarily be the best arrangement for operation & maintenance. Process Requirements: An example of the need to consider process considerations is the need to clavate the base of columns to provide the necessary net positive suction head to a pump or the operating head for a thermosyphon reboiler. 2. Process Requirements: 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. Enough working space and head room must be provided to allow easy access to equipment.

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PLANT LOCATION AND SITE SELECTION

3.Maintenance: Heat exchangers need to be cited so that the tube bundles can be easily withdrawn for cleaning and tube replacement. Vessels that require frequent replacement of catalyst or packing should be located on the outside of buildings. Equipment that requires dismantling for maintenance, such as compressors and large pumps, should be placed under cover. 4.Safety: Blast walls maybe needed to isolate potentially hazardous equipment and confine the effects of an explosion. At least two escape routes for operators must be provided from each level in the process buildings. 5.Plant Expansion: Equipment’s 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 services pipes over-sized to allow for future requirements. 6.Modular Constructions: In recent years there has been a move to assemble sections of plant at the plant manufacturers site. These modules will include the equipment, structural steel, piping and instrumentation. The modules are then transported to the plant site, by road or sea.

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PLANT LOCATION AND SITE SELECTION

8.3 Plant layout.

Fig. 12, Plant layout.

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IMPORTANT ASPACT OF SAFETY & POLLUTION

CHAPTER. 9

IMPORTANT ASPECT OF SAFETY AND POLLUTION

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IMPORTANT ASPACT OF SAFETY & POLLUTION

9.1 MSDS of Raw materials and product. HAZARDS IDENTIFICATION Inhalation Breathing high concentrations may be harmful. Mist or vapor can irritate the throat and lungs. Breathing this material may cause central nervous system depression with symptoms including nausea, headache, dizziness, fatigue, drowsiness, or unconsciousness. Eye Contact This material can cause eye irritation with tearing, redness, or a stinging or burning feeling. Further, it can cause swelling of the eyes with blurred vision. Effects may become more serious with repeated or prolonged contact. Skin Contact May cause mild skin irritation with redness and/or an itching or burning feeling. Effects may become more serious with repeated or prolonged contact. It is likely that some components of this material are able to pass into the body through the skin and may cause similar effects as from breathing or swallowing it. Ingestion – Swallowing this material may be harmful. Swallowing this material may cause stomach or intestinal upset with pain, nausea, and/or diarrhea. This material can get into the lungs during swallowing or vomiting. Small amounts in the lungs can cause lung damage, possibly leading to chronic lung dysfunction or death. Swallowing this material may cause effects. Chronic Health Effects Summary Secondary effects of ingestion and subsequent aspiration into the lungs may cause pneumatically (lung cavity) formation and chronic lung dysfunction.

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IMPORTANT ASPACT OF SAFETY & POLLUTION Conditions Aggravated by Exposure Disorders of the following organs or organ systems that may be aggravated by significant exposure to this material or its components include: Skin, Respiratory System, Central Nervous System (CNS). Target Organs – May cause damage to the following organs: kidneys, liver, mucous membranes, spleen, upper respiratory tract, skin, adrenal, central nervous system (CNS), eye, lens or cornea. Carcinogenic Potential – This product is not known to contain any components at concentrations above 0.1% which are considered carcinogenic by OSHA, IARC or NTP.

1. FIRST AID MEASURES Take proper precautions to ensure your own health and safety before attempting rescue or providing first aid. Inhalation – Move victim to fresh air. If victim is not breathing, immediately begin rescue breathing. If breathing is difficult, 100 percent humidified oxygen should be administered by a qualified individual. Seek medical attention immediately. Keep the affected individual warm and at rest. Eye Contact – Check for and remove contact lenses. Flush eyes with cool, clean, low-pressure water for at least 15 minutes while occasionally lifting and lowering eyelids. Do not use eye ointment unless directed to by a physician. Seek medical attention if excessive tearing, irritation, or pain persists.

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IMPORTANT ASPACT OF SAFETY & POLLUTION Skin Contact – Remove contaminated shoes and clothing. Flush affected area with large amounts of water. If skin surface is damaged, apply a clean dressing and seek medical attention. Do not use ointments. If skin surface is not damaged, clean affected area thoroughly with mild soap and water. Seek medical attention if tissue appears damaged or if pain or irritation persists. Ingestion – Do not induce vomiting. If spontaneous vomiting is about to occur, place victim’s head below knees. If victim is drowsy or unconscious, place on the left side with head down. Never give anything by mouth to a person who is not fully conscious. Do not leave victim unattended. Seek medical attention immediately.

2. FIRE FIGHTING MEASURES NFPA Flammability Classification - NFPA Class-IC flammable liquid. Flash Point - Closed cup: 36°C (96°F). (Pesky-Martens.) Lower Flammable Limit - AP 0.9 % Upper Flammable Limit - AP 6.5 % Auto ignition Temperature - 424°C (795°F) Hazardous Combustion Products - Carbon dioxide, carbon monoxide, smoke, fumes, and/or unburned hydrocarbons. Special Properties – This material releases vapors at or below ambient temperatures. When mixed with air in certain proportions and exposed to an ignition source, its vapor can cause a flash fire. Use only with adequate ventilation. Vapors are heavier than air and may travel long distances along the ground to an ignition

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IMPORTANT ASPACT OF SAFETY & POLLUTION source and flash back. A vapor and air mixture can create an explosion hazard in confined spaces such as sewers. If container is not properly cooled, it can rupture in the heat of a fire.

Extinguishing Media – SMALL FIRE: Use dry chemicals, carbon dioxide, foam, water fog, or inert gas (nitrogen). LARGE FIRE: Use foam, water fog, or water spray. Water fog and spray are effective in cooling containers and adjacent structures. However, water can cause frothing and/or may not extinguish the fire. Water can be used to cool the external walls of vessels to prevent excessive pressure, auto ignition or explosion. Do not use a solid stream of water directly on the fire as the water may spread the fire to a larger area. Protection of Fire fighters – Firefighters must use full bunker gear including NIOSH-approved positive pressure selfcontained breathing apparatus to protect against potential hazardous combustion or decomposition products and oxygen deficiencies. Evacuate area and fight the fire from a maximum distance or use unmanned hose holders or monitor nozzles. Cover pooling liquid with foam. Containers can build pressure if exposed to radiant heat; cool adjacent containers with flooding quantities of water until well after the fire is out. Withdraw immediately from the area if there is a rising sound from a venting safety device or discoloration of vessels, tanks, or pipelines. Be aware that burning liquid will float on water. Notify appropriate authorities of potential fire and explosion hazard if liquid enter sewers or waterways.

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IMPORTANT ASPACT OF SAFETY & POLLUTION

3. ACCIDENTAL RELEASE MEASURES Flammable Liquid! Release causes an immediate fire or explosion hazard. Evacuate all nonessential personnel from immediate area and establish a "regulated zone" with site control and security. A vapor-suppressing foam may be used to reduce vapors. Eliminate all ignition sources. All equipment used when handling this material must be grounded. Stop the leak if it can do without risk. Do not touch or walk through spilled material. Remove spillage immediately from hard, smooth walking areas. Prevent spilled material from entering waterways, sewers, basements, or confined areas. Absorb or cover with dry earth, sand, or other non-combustible material and transfer to appropriate waste containers. Use clean, non-sparking tools to collect Absorbed material. For large spills, secure the area and control access. Prevent spilled material from entering sewers, storm drains, other drainage systems, and natural waterways. Dike far ahead of a liquid spill to ensure complete collection. Water mist or spray may be used to reduce or disperse vapors; but, it may not prevent ignition in closed spaces. This material will float on water and its run-off may create an explosion or fire hazard. Verify that responders are properly HAZWOPER-trained and wearing appropriate respiratory equipment and fire-resistant protective clothing during cleanup operations. In an urban area, cleanup spill as soon as possible; in natural environments, cleanup on advice from specialists. Pick up freeliquid for recycle and/or disposal if it can be accomplished safely with explosion-proof equipment. Collect any excess material with absorbent pads, sand, or other inert non-combustible absorbent materials. Place into appropriate waste containers for later disposal. Comply with all applicable local, state and federal laws and regulations.

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IMPORTANT ASPACT OF SAFETY & POLLUTION

4. HANDLING AND STORAGE Handling A spill or leak can cause an immediate fire or explosion hazard. Keep containers closed and do not handle or store near heat, sparks, or any other potential ignition sources. Avoid contact with oxidizing agents. Do not breathe vapor. Use only with adequate ventilation and personal protection. Never siphon by mouth. Avoid contact with eyes, skin, and clothing. Prevent contact with food and tobacco products. Do not take internally. When performing repairs and maintenance on contaminated equipment, keep unnecessary persons away from the area. Eliminate all potential ignition sources. Drain and purge equipment, as necessary, to remove material residues. Follow proper entry procedures, including compliance with 29 CFR 1910.146 prior to entering confined spaces such as tanks or pits. Use gloves constructed of impervious materials and protective clothing if direct contact is anticipated. Use appropriate respiratory protection when concentrations exceed any established occupational exposure level Promptly remove contaminated clothing. Wash exposed skin thoroughly with soap and water after handling. Non-equilibrium conditions may increase the fire hazard associated with this product. A static electrical charge can accumulate when this material is flowing through pipes, nozzles or filters and when it is agitated. A static spark discharge can ignite accumulated vapors particularly during dry weather conditions. Always bond receiving containers to the fill pipe before and during loading. Always confirm that receiving container is properly grounded. Bonding and grounding alone may be inadequate to eliminate fire and explosion hazards associated with electrostatic charges. Carefully review operations that may increase the risks associated with static electricity such as tank and container filling, tank cleaning, sampling, gauging, loading, filtering, mixing, agitation, etc. In addition to bonding and grounding, efforts to mitigate the hazards of an electrostatic discharge may include, but are not limited to, ventilation, inserting and/or reduction of transfer velocities. Dissipation of electrostatic charges may be improved with the use of conductivity

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IMPORTANT ASPACT OF SAFETY & POLLUTION additives when used with other mitigation efforts, including bonding and grounding. Always keep nozzle in contact with the container throughout the loading process. Do not fill any portable container in or on a vehicle. Do not use compressed air for filling, discharging or other handling operations. Product container is not designed for elevated pressure. Do not pressurize, cut, weld, braze solder, drill, or grind on containers. Do not expose product containers to flames, sparks, heat or other potential ignition sources. Empty containers may contain material residues which can ignite with explosive force. Observe label precautions. Storage Keep container tightly closed. Store in a cool, dry, well-ventilated area. Store only in approved containers. Do not store with oxidizing agents. Do not store at elevated temperatures or in direct sunlight. Protect containers against physical damage. Head spaces in tanks and other containers may contain a mixture of air and vapor in the flammable range. Vapor may be ignited by static discharge. Storage area must meet OSHA requirements and applicable fire codes. Additional information regarding the design and control of hazards associated with the handling and storage of flammable and combustible liquids may be found in professional and industrial documents including, but not limited to, the National Fire Protection Association (NFPA) publications NFPA 30 ("Flammable and Combustible Liquid Code"), NFPA 77 ("Recommended Practice on Static Electricity") and the American Petroleum Institute (API) Recommended Practice 2003, (“Protection Against Ignitions Arising Out of Static, Lightning, and Stray Currents"). Consult appropriate federal, state and local authorities before reusing, reconditioning, reclaiming, recycling or disposing of empty containers or waste residues of this product.

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IMPORTANT ASPACT OF SAFETY & POLLUTION

5. EXPOSURE CONTROLS AND PERSONAL PROTECTION Engineering Controls Provide ventilation or other engineering controls to keep the airborne concentrations of vapor or mists below the applicable workplace exposure limits indicated below. All electrical equipment should comply with the National Electrical Code. An emergency eye wash station and safety shower should be located near the work-station. Personal Protective Equipment Personal protective equipment should be selected based upon the conditions under which this material is used. A hazard assessment of the work area for PPE requirements should be conducted by a qualified professional pursuant to OSHA regulations. The following pictograms represent the minimum requirements for personal protective equipment. For certain operations, additional PPE may be required. Eye Protection Safety glasses equipped with side shields are recommended as minimum protection in industrial settings. Chemical goggles should be worn during transfer operations or when there is a likelihood of misting, splashing, or spraying of this material. A suitable emergency eye wash water and safety shower should be located near the work station. Hand Protection Avoid skin contact. Use heavy duty gloves constructed of chemical resistant materials such as Viton® or heavy nitrile rubber. Wash hands with plenty of mild soap and water before eating, drinking, smoking, use of toilet facilities or leaving work. Do not use gasoline, kerosene, solvents or harsh abrasives as skin cleaners. Body Protection Avoid skin contact. Wear long-sleeved fire-retardant garments (e.g., Nomex®) while working with flammable and combustible liquids. Additional chemical-resistant protective gear may be required

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IMPORTANT ASPACT OF SAFETY & POLLUTION if splashing or spraying conditions exist. This may include an apron, boots and additional facial protection. If product meets clothing, immediately remove soaked clothing and shower.

Promptly remove and discard contaminated leather goods. Respiratory Protection For known vapor concentrations above the occupational exposure guidelines (see below), use a NIOSH-approved organic vapor respirator if adequate protection is provided. Protection factors vary depending upon the type of respirator used. Respirators should be used in accordance with OSHA requirements (29 CFR 1910.134). General Comments Use of this material in spaces without adequate ventilation may result in generation of hazardous levels of combustion products and/or inadequate oxygen levels for breathing. Odor is an inadequate warning for hazardous conditions

6. STABILITY AND REACTIVITY Chemical Stability - Normally stable but may form peroxides when stored for prolonged time periods in contact with air. Conditions to Avoid - Keep away from heat, sparks and flame. Forms peroxides with prolonged storage. Materials Incompatibility -Strong acids, alkalis, and oxidizers.

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IMPORTANT ASPACT OF SAFETY & POLLUTION

7. TOXICOLOGICAL INFORMATION

Toxicity Data – Effects from Acute Exposure: Overexposure to cumene may cause upper respiratory tract irritation and severe CNS depression. Effects from Prolonged or Repeated Exposure: High-level exposure to cumene vapors significantly increases renal tubule adenoma in male rats. Furthermore, this exposure is associated with increased alveolar/bronchiolar adenoma and carcinoma in mice and with increased hepatocellular carcinoma in female mice. Currently the relevance of these finds to human health are not clear.

8. ECOLOGICAL INFORMATION Eco toxicity - LC50 (fish): 1- 10 mg/l. This product is potentially toxic to freshwater and salt water ecosystems. Environmental Fate - This product will normally float on water. Components will evaporate rapidly. Aquatic toxicity values are expected to be in the range of 1 - 10 mg/l based upon data from components and similar products. This material may be harmful to aquatic organisms and may cause long term adverse effects in the aquatic environment. The log Kow value for this product is 3.66.

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IMPORTANT ASPACT OF SAFETY & POLLUTION

9. DISPOSAL CONSIDERATIONS Hazard characteristic and regulatory waste stream classification can change with product use. Accordingly, it is the responsibility of the user to determine the proper storage, transportation, treatment and/or disposal methodologies for spent materials and residues at the time of disposition. If discarded, Cumene is regulated by US EPA as a listed hazardous waste (U055). Transportation, Treatment storage and disposal of waste materials must be conducted in accordance with RCRA regulations (see 40 CFR 260 through 40 CFR 271). State and/or local regulations may be more restrictive. Contact the RCRA/Superfund Hotline at your regional US EPA office for guidance concerning case specific disposal issue.

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IMPORTANT ASPACT OF SAFETY & POLLUTION

9.2 Gaseous/Liquid/Solid Waste Treatment. Gaseous, liquid and solid waste is treated in Effluent treatment plant..

EFFLUENT TREATMENT PROCESS.

Fig.15, Cumene Effluent treatment process.

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IMPORTANT ASPACT OF SAFETY & POLLUTION

1. Screen chamber: Remove relatively large solids to avoid abrasion of mechanical equipment’s and clogging of hydraulic system. •

Screening is the filtration process for the separation of coarse particles from influent.

•

Stainless steel net with varying pore size can be utilized.

•

Screens are cleaned regularly to avoid clogging.

2. Collection tank: The collection tank collects the effluent water from the screening chamber, stores and then pumps it to the equalization tank.

3. Equalization tank: •

The effluents do not have similar concentrations at all the time; the pH will vary

•

time to timetan Effluents are stored from 8 to 12 hours in the equalization tank resulting in a homogenous mixing of effluents and helping in neutralization.

•

It eliminates shock loading on the subsequent treatment system.

•

Continuous mixing also eliminates settling of solids within the equalization tank.

•

Reduces SS, TSS.

•

Equalization makes the waste water homogenous.

•

Retention time depends upon the capacity of treatment plant. (Generally 8-16 hours)

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IMPORTANT ASPACT OF SAFETY & POLLUTION

4. Flash mixer: Coagulants were added to the effluents: 1. Lime: (800-1000 ppm) To correct the pH up to 8-9 2. Alum: (200-300 ppm) To remove color 3. Poly electrolyte: (0.2 ppm) To settle the suspended matters & reduce SS, TSS. The addition of the above chemicals by efficient rapid mixing facilitates homogeneous combination of flocculates to produce microflows. 5. Clarriflocculator: In the clarriflocculator the water is circulated continuously by the stirrer. •

Overflowed water is taken out to the aeration tank.

•

The solid particles are settled down, and collected separately and dried; this reduces SS, TSS.

•

Flocculation provides slow mixing that leads to the formation of macro flocs, which then settles out in the clarifier zone.

•

The settled solids i.e. primary sludge is pumped into sludge drying beds.

6. Aeration tank: •

The water is passed like a thin film over the different arrangements like staircase shape.

•

Dosing of Urea and DAP is done.

•

Water gets direct contact with the air to dissolve the oxygen into water.

•

BOD & COD values of water is reduced up to 90%

•

. Function of aeration is oxidation by blowing air.

•

Aerobic bacteria are used to stabilize and remove organic material presents in waste.

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IMPORTANT ASPACT OF SAFETY & POLLUTION 7. Clarifier: •

The clarifier collects the biological sludge.

•

The overflowed water is called as treated effluent and disposed out.

•

The outlet water quality is checked to be within the accepted limit as delineated in the norms of the Bureau of Indian standards.

•

Through pipelines, the treated water is disposed into the environment river water barren land, etc.

8. Sludge thickener: •

The inlet water consists of 60% water + 40% solids.

•

The effluent is passed through the centrifuge.

•

Due to centrifugal action, the solids and liquids are separated.

•

The sludge thickener reduces the water content in the effluent to 40% water + 60% solids.

•

The effluent is then reprocessed, and the sludge collected at the bottom.

•

Here sludge is dried and discharged.

•

Partial amount of sludge is returned to the aeration tank from thickening unit through recycle tank called return sludge tank and disperse tank.

9. Drying beds: Primary and secondary sludge is dried on the drying be

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REFRENCE & CONCLUSION

Chapter: 10

REFERENCE & CONCLUSION

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REFRENCE & CONCLUSION

10.1. Conclusion. • • • • • • • • • •

As the first step preliminary analysis was carried out based on the properties and application of cumene and various processes used in its manufacture. Cumene is used as a feed to produce phenol its co-product acetone. Cumene oxidation process for phenol synthesis has been growing in popularity since the 1960 and prominent today. The first steeps of this process are the formation of cumene hydroperoxide. The hydroperoxide is then selectively cleaved to phenol and acetone We have focused on alkylation of benzene to produce cumene process in this project and carried out literature survey. The process has many advantages over its alternative processes with benchmarking parameters of economic consideration i.e. profitable and economically. Viable at the same time environment aspect and impact of pollution. Machinery equipment and raw material are easily available along with skill and unskilled labors are available. Cumene is nonhazardous material and safety parameters are easily complied with. The effluent treatment can be carried out with in pollution control board norms. Hence it is a and ecofriendly process.

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REFRENCE & CONCLUSION

10.2. REFERENCE. • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

K. Wisemen, H.-J. Arpe Industrial Organic Chemistry fourth, Completely, Revised Edition http//www.cdtech.com/indexset.html. http://www.businesswire.com/news/home/20110921005269/en/BadgerLicensingProvideCumeneBPA-Licenses-LG http://www.sbioinformatics.com/design_thesis/Cumene/Cumene_Properties http://www.dequi.eel.usp.br/~barcza/Fenol%20UOP.pdf http://www.primaryinfo.com/projects/cumene.html http://www.icis.com/v2/companies/9146114/polimeri-europa.html) Alkylation of aromatics with ethylene and propylene: recent developments in commercial processes Thomas F. Degnan Jr. , Corrissmithh, Chaya R. Venkat) Introduction to Zeolite Science and Practice, page853 http://ip.com/IPCOM/000217241 http://www.icis.com/Articles/1994/04/04/35102/kelloggdow-detail-new-route-to-cumene.html Chemical process technology Jacob A. Moulijn Michiel Makeee Annelies Van Diepen page/279-281 http://www.icis.com/Articles/1997/12/08/51748/mobilbadger-make-the-most-ofcataystuse.html http://www.icis.com/v2/companies/9146114/polimeri-europa.html www.Lummus.CBI.com Petrochemical Production Processes Nauid Naderpour page/77-78 Chemical process technology Jacob A. Moulijn Michiel Makeee Annelies Van Diepen http://www.surechem.org/index.php?Action=document&docId=267794&db=EPA&tab=desc& l ang=&db_query=0%3A%3A0%3A%3A0%3A&markupType=all “Energy Efficient Catalytic Reaction and Production of Cumene”, Russell L. Jarek, Steven M. hornbergg, Stacia Barrow, Daniel E. Trudell, and Tina M. Neroff. (Ullmans Encyclopedia of Chemical Technology, Wiley-VCH, Weinheim, Germany,2003) http://www.cbi.com/images/uploads/tech_sheets/MTBE_Sheet_R-3.pdf Advances in process technology through catalytic distillation, Gary R. Gilder, Kerry Rock, Tim McGuirk, 12141Wick Chester, Houston, TX,USA77079 Economic Design and Controllability Evaluation of Alternative Processes for Cumene Manufacture, Vivek Gera, Sankalp Agarwal and Nitin Kaistha, 2010. www.encyclopedia.co.in. www.wekipedia.org www.technicaltopic.com www.ask.com www.siteselectioncriteria.com 6-Peters, M.S. and K.D. Timmer Haus," Plant Design and Economics for Chemical Engineers", 4thEdition McGraw Hill, NewYork,1991.

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REFRENCE & CONCLUSION

• •

Cumene, Ullman’s encyclopedia of industrial chemistry,2002. Agency for toxic substances and disease from petrochemicals. 4770 Buford highway Ne Atlanta, GA30341888232-6348

• • • •

Indian Oil Corporation Ltd. Upendramishra 9896.99503 Outline of chemical technology, Dryden’s, Gopala rao. Pollution control effluent treatments. s. rao. Unit operation of chemical engineering McCabe and smith Instrumentation, Kirkand Rimboi.

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