Professional Documents
Culture Documents
Latest Edited 6.2 PDF
Latest Edited 6.2 PDF
Latest Edited 6.2 PDF
CUMENE
PROJECT REPORT
Submitted by
OF
DIPLOMA
IN
CHEMICAL ENGINEERING.
SHREE KJ POLYTECHNIC, BHARUCH
CERTIFICATE
This is to certify that SAVALIYA DIVYAM B., PATEL TIRTH., PATEL SHREYAS.,
successfully completed the Term-work in the Subject PROJECT (360501) offered during the academic
term 2018-2019.
• Teaching is the important knowledge, but training develops habits. It assures that technical skills cannot be
perfect without practical training. Hence, the practical training is grate valuable for engineering student the
actual aim of in plant training is to get all operation and process which are carried out in the industries and
• Practical makes a man perfect in practical training a person deals with many technical problems. In real
operation and process another aim of I plant training is to learn industrial management and discipline.
• This project describes the manufacture of “ISOPROPYL ALCOHOL” is prepared fulfillment in chemical
engineering. It is purely academic in nature though attempts have been made to incorporate faculty data
available from journals, books and other sources. Reasonable assumption have been made for data those
• This report includes the information based on theoretical backgrounds. So this report cannot applicable to
industrial scale to tally . but for actual setting up of a new chemical plant and expansion or revision of
• The report provides preliminary information and gives an idea and in sign into the process design aspects.
• The report also includes safety consideration, instrumentation, and process control. The reference section at
the end lists the source of information. A detailed market surveys and plant set up design factor has to be
studied before setting up a plant end. A number of pilot trials should be conducted before starting. No such
We extend our sincere gratitude to our guide Shri K .J Panchal sir and Head of
department in Chemical Engineering Prof. Shri. sir in SHREE KJ
POLYTECHNIC, BHARUCH for sharing his knowledge and resources and also for his
availability.
We are also thankful to Shri K.J . Panchal sir our project group guider in Chemical
Engineering Department.
For extending his help in the course, we are also thanks to all the authors and
editors of various reference books, research paper that helped us through his report.
From. To.
1 Introduction
1.1 Introduction
1.2 Structural formula
1.3 Market analysis
1.4 List manufacturers of cumene
1.5 Properties
1.6 Uses & Application
1.7 Raw materials
1.8 Catalyst used
3.1 Equipment
3.3 Instrumentation
4 Material balance
6 Plant location
7 Economic evaluation
8.1 Safety
8.2 Pollution
10 Conclusion
11 Preference
Chapter 1
INTRODUCTION
1.1 INTRODUCTION
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
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
• The cumene production capacity of the world is about 7 million Ton/day distribute over 40 plant.
Kieselguhr(skpa).
• Only few plants are based on the MONSANTO TECHNOLOGY, which uses aluminum
• Cumene producers account for approximately 20% of the global demand for benzene.
1.2 STRUCTURE
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
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
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 capacity during stream in 2013) to supply its phenol/ acetone plants that are slated to come on
stream during that period. Overall, world wide cumene consumption for the production of
phenol/acetone is forecast to grow at an average annual rate of about 4.5% during 2010–2015.
• Color :- colorless
• Odour. :- odourless
• Purity :- 99%
oxygen.
✓ C6H5CH(CH3)2 + O2 = C6H5(CH3)2COOH.
• By catalytic actions of dilute sulphuric acid, cumene hydroperoxide is Split into phenol
& acetone.
1. Cumene is a natural component of coal tar and crude oil, and also can be used as Blanding
component in gasoline.
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,
➢ 1.Benzene
➢ 2.Propane
➢ 3.Propylene.
➢ QZ-2000™
&
➢ QZ-2001™
manufacturing.
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
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 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
utility as cooling water, electricity, steam from the boiler, pneumatic air are supplied from the
utility section.
8. The typical reactor effluent yield contains 94.8 Wt. % cumene and 3.1 Wt. % of diiso propyl
9. This high yield of cumene is achieved without of diiso propyl benzene and is unique to the
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
11. The overall yields of cumene for this process are typically 97-98 Wt. % with trans alkylation
A representative Q-Max flow diagram is shown. The alkylation reactor is typically divided
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
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
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
Effluent from the alkylation reactor is sent to the depropanizer column, which
removes any propane and water that may have entered with the propylene feed.
The bottoms from the depropanizer 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 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.
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
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-
Figure 7, PFD. of Cumene manufacturing process with all instrumentation and fittings with feed
of Cumene
.
1. Alkylation reactors.
3. Depropanizer column.
4. Benzene column.
5. Cumen column.
6. DIPB column.
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.
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.
The fresh propylene feed is split between the four catalyst beds. An excess of benzene is used to avoid
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
Effluent from the alkylation reactor is sent to the depropanizer column, which
removes any propane and water that may have entered with the propylene feed.
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.
3. Depropanizer Reactors.
Depropanizer Reactors is reactors which removes propane, water, and other impurities
present in the propylene feed. The depropanizer 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.
The bottoms from the depropanizer column are sent to the benzene column, where excess
benzene is collected overhead and recycled. Benzene column bottoms are sent to the 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
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.
• Vortex flowmeters.
• Coriolis flowmeter.
• Electro pyrometer.
6. Ph measuring instruments.
• Ph meter.
• Ph indicator.
Chapter :- 4
MATERIAL BALANCE
4.1 Overall Material Balance.
C3H7–C6H4-C3H7+C6H6 2(C6H5-C3H7)
= 1050.50 Kgmole/hr
=1071.94 Kgmoles/hr
= 128836.32 Kg/hr
= 1105.09 Kgmole
= 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
Being an inert we are neglecting propane balance in the material balance to avoid complexity.
1.) Material balance around reactor :
Products:
Propylene = 1105.09-1071.94
Reactor
= 33.15/2 kmoles/hr
= 16.575 kmoles/hr
= 2685.15 Kg/hr
= 292.85 kmoles/hr
= 22820.85 kg/hr
Input = output
2) Depropanising column.
Assuming almost all the propane is removed in depropanising column and sent to reactor for
Feed,
D = Benzene = 15969.41Kg/hr
Column
F=D+W
154160 = D +W
F XF = DXD +WX w
Taking XF = 0.9999
, XD = 0.05
D = 15969.41 Kg/hr
= Benzene
W = 154160 – 15969.41
= 138190.5 Kg/hr
= cumene + DIPB
= 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
= 170129.5 Kg/hr.
4.).Distillation column 3: (Cumene column) .
XF = 128836.3/138190.5 = 0.932
Cumene = D = 17065.2Kg/hr
Column
F = D +W
138190.6 = D +W
Taking XD = 0.995
XW = 0.01
D = 129051 kg/hr
= 138190.5 Kg/hr.
Input = output
Table 4, Overall Material balance of cumene manufacturing flow diagram
Capacity,(kmol/h),110
Catalyst, Zeolite -Y
Catalystregenerationfrequency,years2
Catalystlife,years6
Pressure,bar14
Conversion,%:
Propylene%100
Benzene%55
Catalyst Zeolite-Y
Catalystlife,years6
Temperature,°C140-150
ConversionofDIPB,%50
Separations Units:
• Benzene column:
Operational pressure:0.3bar.
• Cumene column:
Utilities:
The word utilities is 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.
(8) Refrigeration.
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 a number of large motors is used, a supply at an intermediate high voltage will also be
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
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.
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
Compressed Air:
It will be needed for general use, and for the pneumatic controllers that are usually used for
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
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:
3. Transport facilities.
4. Availability of labour.
9. Climate.
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.
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
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
4. Availability of labour:
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
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 power will be needed at all sites. Electrochemical processes that
require large quantities of power; for example, aluminium 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.
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
Type equation here.coverd 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.
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.
9. Climate:
Adverse climate conditions at a site will increase cost. Abnormally low temperatures will require
the provisition 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.
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
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:
3. Convenience of operation
4. Convenience of maintenance
5. Safety
6. Future expansion
7. 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 take into account process considerations is the need to clevate the
base of columns to provide the necessary net positive suction head to a pump or the operating
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. Sufficient working space and head room must be provided to allow easy access to
equipment.
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
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:
Equipments 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
6. Modular Constructions:
In resent 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