“Feasibility Report on the Production of a Cumene Manufacturing

Plant”
Report Submitted in partial fulfilment of the requirement for the degree of
B.Tech.
In
Chemical Engineering

Under the Supervision of

Mr. Azad Singh

By
Rishi Chauhan

To

University School of Chemical Technology

Guru Gobind Singh Indraprastha
University Sector 16-C, Dwarka, New
Delhi -110078
July, 2023
 DECLARATION

This is to certify that the report entitled “Feasibility Report on the production of a Cumene
Manufacturing Plant” which is submitted by me in partial fulfilment of the requirement for the
award of degree B.Tech. in Chemical Engineering to USCT, GGSIP University, Sector 16-C,
Dwarka, New Delhi-110078, comprises only my original work and due acknowledgement has
been made in the text to all other material used.

July 2023

Rishi Chauhan

APPROVED BY: Mr. Azad Singh

Dean

University School of Chemical Technology

i
 CERTIFICATE

This is to certify that the Report entitled “Feasibility Report on the production of a Cumene
Manufacturing Plant” which is submitted by Rishi Chauhan in partial fulfilment of the
requirement for the award of degree B.Tech. in Chemical Engineering to USCT, GGSIP
University, Sector 16-C, Dwarka, New Delhi - 110078 is a record of the candidate’s own work
carried out by him under my/our supervision. The matter embodied in this thesis is original and
has not been submitted for the award of any other degree.

(Mr. Azad Singh)

Date: Supervisor

ii
 ACKNOWLEDGEMENT

I am grateful to be given this opportunity to share my work on “Feasibility Report on the

production of a Cumene Manufacturing Unit” and would like to dedicate this report to my project
supervisor Mr. Azad Singh, professor, USCT, who provided me the benefits of his esteemed
guidance and to whom I would like to express my deepest gratitude for his discerning guidance
and constant support, without which this project would not have been possible.

Finally, I would also like to extend my sincere thanks to Dr. Arinjay Kumar, Dean USCT, for
providing me with this wonderful learning opportunity to gain an insightful experience in
feasibility report preparation.

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 TABLE OF CONTENTS

Declaration i

Certificate ii

Acknowledgement iii

Table of Contents iv

List of Figures vi

List of Tables vi

Abstract vii

Chapter 1: Introduction & Market Analysis 1

1.1 Introduction 1

1.2 Market Report 2

1.2.1 Scope of this Report 2

1.2.2 Growing Usage in Acetone Application 3

1.2.3 China to Dominate the Asia-Pacific Market 4

1.2.4 Competitive Landscape 4

Chapter 2: Process Selection 5

2.1 Properties of cumene 5

2.2 Methods of production of cumene 5

2.2.1 Conventional Process 6

2.2.2 Current Industrial Process 7

2.3 Process Description Design goals and Constraints 8

2.3.1 Overall Process Design Description 9

Chapter 3: Material and Energy Balances 11

3.1 Mass Balance 11

i
3.2 Energy Balance 16

Chapter 4: Sizing and Detailed Design of Major Equipment 20

4.1 Design of Distillation Column 20

4.2 Mechanical Design of Equipment 23

Chapter 5: DWSIM Simulation 28

5.1 Process Flow Diagram 28

5.1.1 Overall Stream Data 29

5.2 Conversion Reactor Unit 29

5.3 Separation Unit 31

5.4 Heating Unit 32

5.5 Recycle Unit 34

Chapter 6: Cost Analysis 35

6.1 Estimation of Capital Investment 35

a. Fixed Capital Investment 39

b. Total Capital Investment 39
c. Total Product Cost 43
d. Gross Income 43
e. Rate of Return 44

Chapter 7: Plant Layout 45

Chapter 8: Waste Treatment 46

8.1 Health and Environmental Consideration 46

8.2 Safety and Hazard Analysis 49

REFERENCE AND BIBLIOGRAPHY 50

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 LIST OF FIGURES

Fig. 1 Cumene market growth

Fig. 2 Cumene manufacturing data using different catalyst
Fig. 3 Friedel-Crafts Reaction of Benzene and Propene to form Cumene
Fig. 4 Structure of p-diisopropyl benzene or DIPB
Fig. 5 PFD of Cumene production process design
Fig. 6 Process flow diagram
Fig. 7 Overall stream material and property data
Fig. 8 Overall stream energy data
Fig. 9 Conversion reactor unit
Fig. 10 Reactor unit material and stream property data
Fig. 11 Conversion reactor property data
Fig. 12 Separation unit
Fig. 13 Separation unit material stream property data
Fig. 14 Heating unit
Fig. 15 Heating unit material stream property data
Fig. 16 Heat exchanger property data
Fig. 17 Benzene recycle unit
Fig. 18 Recycle stream property data
Fig. 19 Plant Layout

LIST OF TABLES

Table 1. Properties of cumene or isopropyl benzene

Table 2. Overall material balance
Table 3. Benzene and cumene feed to vaporizer
Table 4. Bubble point and Dew point calculation for Benzene and Cumene
Table 5. Liquid state heat calculation for the mixture
Table 6. Gas state calculation for the mixture
Table 7. The heat required for raising the reactant feed temperature
Table 8. Vapor-pressure data of cumene - diisopropylbenzene
Table 9. T-xy data for cumene- diisopropylbenzene system
Table 10. Mechanical design of distillation column parameters and properties

v
 ABSTRACT

The aim of this techno-feasibility report is to outline the scope of setting up an isopropyl
benzene, or cumene, production facility by studying and analysing the process flow diagrams,
sizing the major equipment, and performing cost analysis of the process.

The facility employs the use of a preheater and a fired heater to increase the feed temperature to
the reactor. The reactor is a packed bed reactor which employs the use of inert packing and a
catalyst. The product stream is separated using three distillation columns. The first column
separates the impure propane and the recycle stream from the product streams which can be sold.
The second column is to separate the impurities which will be used as a fuel gas from recycle
stream. The third column separates the two major products- cumene and di-isopropyl benzene or
DIPB, into the required purities to sell. The design goal is to produce amount of 150 tons per day
of cumene, with a purity of 99.9 mol%. The propane impurity in the feed propylene can be used
later as fuel gas primarily for the recycle stream, saving the amount of fuel gas needed to be
purchased.

Before the construction can begin, a more detailed analysis and study should be conducted, with
a piping and instrument diagram for the complete process, and vendor-priced equipment. The
proposed model should be significantly profitable with a short payback period and needs to
account for differences in expected and actual costs. Further development and upgradation of this
plant may prove to be a valuable investment for the future.

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 CHAPTER 1

INTRODUCTION & MARKET ANALYSIS

1.1 INTRODUCTION

Isopropyl benzene, or cumene, is a major component in the production of phenol globally.

Cumene is produced by reacting benzene and propylene at high temperatures and pressure
usually over a zeolite (or other) catalyst. This report will investigate the chemical and economic
feasibility of developing a new cumene production process for the synthesis and purification of
cumene with an output goal of 150 tons per day for a minimum of 5 years.

Cumene in the global petrochemical industry is used primarily as a reactant for the production of
phenol. Benzene and propylene, the two reactants used to create cumene, are produced primarily
as a by-product of crude oil refining. Cumene is essential for the downstream production of
important chemicals like bisphenol-A (BPA), polycarbonate resin, and phenolic resins. These
chemicals are used extensively in the construction, packaging, and pharmaceutical industries and
are expected to increase in demand in future.

This process occurs at a temperature of around 250-350 ºC and a pressure of around 30 bar. The
primary (and only) by-product of this reaction as the result of further alkylation of cumene is p-
diisopropyl benzene (DIPB).

While this product can be sold for profit if pure, the desired product for this production plant is
cumene. This process is assumed to be an irreversible reaction due to a relatively nominal rate of
reverse reaction due to the operating temperatures and the catalyst. The catalyst, zeolite, a
crystalline-aluminosilicate composite, is used to increase selectivity for cumene in the market.
Newer exotic composites involving mixtures of zeolites, inorganic oxides, and silanol are making
grounds in providing greater selectivity.

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1.2 Market Report

The cumene market is projected to register a CAGR of over 4% during the forecast period (2021-
2026). The COVID-19 pandemic affected various chemical and industrial activities and
negatively impacted the demand for cumene. The automotive industry also faced a decline in
production and sales due to the pandemic situation and thus affected the cumene market.

In the medium term, the major factors which drive the cumene market include the increasing use
of acetone as a solvent and an increasing demand for phenol from the plastic industry. On the flip
side market growth is expected to be significantly hindered. Asia-Pacific is expected to dominate
the global market for cumene.

Additionally, the market is expected to register the highest CAGR during the forecast period
2014-2025.

Fig 1. Cumene market growth

1.2.1 Scope of this Report

Cumene (isopropyl benzene) is an aliphatic-substituted aromatic hydrocarbon. Crude oil and

refined fuels all contain it. It is a colourless, flammable liquid with a boiling point of 152°C. The
cumene market is segmented by manufacturing process, application, and geography. By
manufacturing process, the market is segmented into aluminium chloride catalyst, solid

2
phosphoric acid (SPA) catalyst, and zeolite catalyst. By application, the market is segmented into
phenol, acetone, paints and enamels, high-octane aviation fuels, and other applications.

Fig 2. Cumene manufacturing data using different catalysts

1.2.2 Growing Usage of Acetone Application

1. A major fraction of global acetone production is used as a by-product of phenol production,

which involves the use of cumene. The demand for acetone is driven primarily by its use as a
solvent in products, such as lacquers and finishes, nail polish removers, and adhesives.

2. Acetone is used in a wide range of applications, such as MMA-manufacturing methyl

methacrylate and BPA, and as a solvent in the cosmetics and pharmaceutical industries.

3. The pharmaceutical industry is continuously expanding, increasing the demand for acetone,
thus, driving the cumene market. At the end of 2019, the global pharmaceutical market had
been valued at USD 1,250.4 billion as the market grew at a rapid pace in 2020 due to the
COVID-19 outbreak.

4. Due to the increase in demand for acetone globally and the setting up of new phenol/acetone
production facilities, the cumene market is expected to witness a high growth rate during the
forecast period.

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1.2.3 China to Dominate the Asia-Pacific Market

● In Asia-Pacific, China is the largest economy in terms of GDP. In 2019, the country witnessed
about ~6.1% growth in its GDP, despite facing trade disturbances due to its trade war with the
United States. At present, the Chinese economy had been hit severely by the COVID-19
pandemic. According to the projections of the International Monetary Fund (IMF), the
Chinese GDP growth has registered a 1.9% in 2020, due to the COVID-19 pandemic. It is
expected to recover and reach 8.2% by the end of 2021.

● Additionally, cumene is also used as a thinner for paints, enamels, and lacquers. This is
increasing the demand for cumene further in the region.

● China is the leading producer and consumer of paints and coatings across the world. At
present, China has more than 10,000 paint companies and produces the majority of the
coatings in Asia-Pacific. Regional producers occupy more than half of the share in the
domestic paints market.

● However, the country's steps toward recovery from COVID-19, along with fruitful
investments expected to be witnessed soon, are likely to act as driving factors for the cumene
market during the forecast period.

1.2.4 Competitive Landscape

The global cumene market is fragmented in nature, with extreme competition among market
players to increase their share in the market studied. Some of the key players in the market
include Cepsa, INEOS, Kumho P&B Chemicals Inc., Dow, and Koch Industries Inc., among
others.

INEOS is set to build a cumene manufacturing plant in Germany with its best technology. The
plant has a capacity of 750,000 metric tons per year of cumene.

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 CHAPTER 2 PROCESS SELECTION

2.1 Properties of Cumene:

Property Description
1. Molecular Weight 120.19
2. Melting Point -96.0℃

3. Boiling Point 152.4

4. Density 0.8618 g/cm3 at 20℃
5. Refractive Index 1.4915 at 20℃; 1.489 at 25℃
6. Solubility Insoluble in water; Miscible
in acetone benzene, ethanol, ether.
7. Flash Point 39℃
8. Ignition Point 138℃
9. Toxic Limit Concentration 250 ppm
10. Reactivity Combustible, not compatible with
oxidizers, nitic acid and sulphuric acid.

Table 1: Properties of Cumene or Isopropyl Benzene

2.2 Method of Production of Cumene:

Cumene, or isopropyl benzene, become an important intermediate product in the 1950s since the
discovery of its smooth conversion into phenol and acetone via the Hock process, which became
a widely utilised industrial process. In 1995, more than 8.0 x l06 tonnes per year of the world
production capacity was attributed to cumene, with the figures of 2.7 x 106 tonnes per year in the
USA, 2.4 x 106 tonnes per year in Western Europe and 0.88 x 106 tonnes per year in Japan.

5
2.2.1 Conventional Process:

Cumene is exclusively manufactured by the Friedel-Crafts alkylation of benzene with propene. In

the most important industrialized countries, about 7-8% of the total propene consumption is
attributed to the propene used for the production of cumene.

Fig 3. Friedel-Craft reaction of Benzene and Propane to form Cumene

Main reaction:

Side reaction:

Fig 4. Structure of p-diisopropyl benzene or DIPB

Conventionally, cumene was produced by the alkylation of benzene with propylene over an acid
catalyst. The reaction takes place either in the liquid or gas phase. As in the ethylation of
benzene, Friedel-Crafts systems or proton donors are used as catalysts. Reaction conditions for
the alkylation with propene are generally milder than with ethylene since propene is more easily
protonated.

6
After distillation, cumene is obtained is usually of purity of more than 99.5%. Process
improvements to increase the cumene yield include using highly propylated products via
downstream trans-alkylation.

The majority of the currently operating processes use the UOP route. More recent process
developments concern the use of zeolite catalysts (e.g., ABB Lummus Crest/Nova, Enichem,
etc.), which have the advantages of a noncorrosive system without the release of acidic catalyst
components. In addition, yields of nearly 100% can be attained, thereby increasing the capacity
of the plant. Cumene is used almost exclusively for the manufacture of phenol by the Hock
process. Cumene-containing alkylation products of benzene are employed to improve the octane
rating of motor gasoline.

There are some inherent problems associated with conventional acid catalysts. Disadvantages of
using solid phosphoric acid (SPA) Process:

● Lower Activity

● Catalyst non-regenerability

● Unloading of spent catalyst from the reactor is difficult

● Significant yield of DIPB

Disadvantages of using Aluminium chloride as catalyst

● High corrosion

● Environmental hazard

● Washing step for catalyst removal

2.2.2. Current Industrial Process

Cumene is an important chemical in the present industrial world and its uses are steadily
increasing. The process followed for the production of cumene is the catalytic alkylation of
benzene with propylene and nowadays zeolite-based catalysts are used in place of the normal
acid-based catalysts due to added advantages. The cumene production process has been greatly

7
studied and the reaction mechanism and the reaction kinetics have been specified by many
researchers. Both experimental, as well as computer-based simulation and optimization studies,
have been carried out by various researchers.

2.3 Process Description Goals and Design

The main basis of this project is to use the new catalyst properties to develop a reactor and
subsequent support systems to produce 150 tons of cumene per day of a 99.5 mol% cumene
product for a 15-year plant lifetime with 2 years of construction.

The input of benzene is assumed to be pure, while the input of propylene has a 5 mol% impurity
of propane.

Fig 5. PFD of Cumene production process

As a by-product, DIPB can be sold if purity is greater than 98 mol%. The production goal
translates to an approximate reactor output of 104 kmol/hr of cumene. Every aspect of the
reactor, separation systems, and other units were designed to reach this output goal while
minimizing costs, reducing environmental impact, complying with common industry “good

8
practice” standards. These standards are incorporated throughout the design process and are
explained in detail in subsequent sections.

2.3.1. Overall Process Design Description

The final cumene process design is shown as a PFD in Figure 5. At the start of the process, a feed
carrying benzene, propane, and propylene enters the plant from the storage facility. The recycle
stream intersects the feed stream at a check valve. Upon mixing the Feed and Recycle streams,
the mixture enters the first pump. The pump increases the pressure of the stream from 1 bar to
nearly 40 bar so that the mixture is at suitable operating pressure. The pump also increases the
temperature to close to 33°C in the stream. The stream exits the pump and enters the first of two
heating units. The first is a preheater for the reactor feed stream, which also acts as a condenser
for the reactor exit stream. The streams run countercurrent, to allow a high heat transfer over the
length of the reactor. The mixture stream then exits the preheater at a new temperature of
approximately 200°C and enters the fired heater, while the other stream exits the exchanger at
180°C. The fired heater raises the stream to reactor conditions, to close to 377°C and 40 bar. The
pressure drop over both heat exchangers is 0.5 bar. The stream then exits the fired heater and
enters the reactor. The reactor feed contains large quantities of propylene and benzene, and
smaller quantities of propane and cumene, from the feed impurity and the recycle stream,
respectively. The stream leaving the reactor contains a roughly 86.9 mol % cumene. It also
contains small amounts of benzene, and DIPB, and propane impurity. All of the propylene was
consumed in the reactor. The stream exits as a vapour at a temperature of about 370-372°C and
39 bar. The stream then enters an expansion valve. This valve lowers the pressure of the stream to
nearly 6 bar for a pressure drop of almost 33 bar while decreasing the temperature to 330-332°C.
The stream then exits the valve and enters the preheater as the hot shell-side fluid. This allows
energy already in the system to be used to preheat the feed stream while condensing the reactor
outlet stream. This cools the stream to an exit temperature of about 180°C. The stream exits the
preheater and enters the first distillation tower which is designed so that benzene is the light key,
and cumene the heavy key. This separation allows for a small column for the distillate to separate
the recycle, and a secondary large column to separate the DIPB. The distillate of this column,
contains roughly 55 mol% benzene, 43 mol% propane and a small amount of cumene impurity
and it then enters a heat exchanger to prepare the stream for the

9
second tower. This heat exchanger lowers the stream temperature from 130-135°C to 80°C while
operating at 5-6 bar. The stream leaves the heat exchanger as a liquid and enters the second
distillation tower. This tower is designed to remove the propane from the recycle stream. The
distillate stream, Propane, exits the column with around 75-80 mol% propane and the remaining
molar flow consisting of benzene. The stream exits at a pressure of about 6 bar and a temperature
of 90-92°C. The bottom stream of the distillation column is the Recycle stream which contains
95-96 mol% benzene with the remaining molar flow consisting of cumene. This stream exits at 6-
7 bar and 150-153°C and is transported back to the start to add into the initial Feed stream. The
bottom stream of the distillation tower exits the reactor at 235-240°C. It contains about 96 mol%
cumene, 2.8-3 mol% DIPB, and the remaining molar flow is made up of benzene. This stream
then enters a heat exchanger to lower the temperature. The heat exchanger lowers the temperature
from 235-240°C to close to 200°C in the stream. The stream is then ready to enter the third
distillation tower, which separates cumene and the remaining benzene from DIPB. The distillate
stream exits at a purity of almost 99.5 mol% cumene with an impurity of 0.40-0.45 mol%
benzene and 0.05 mol% DIPB. This stream exits at 235-240°C and 6-7 bar. The bottoms stream
exits at 300-305°C and 6-7 bar with a purity of 98.6 mol% DIPB with an impurity of 1.4 mol%
cumene. Both of these purities reach the requirements needed for the sale of the products.

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 CHAPTER 3

MATERIAL AND ENERGY BALANCE

3.1 Mass Balance

Material balance is an exact accounting of all materials that enters, leaves accumulates or
depleted in an industrial process or a particular process equipment in a given time interval of
operation. The material balance, when done properly, gives an estimate of the material
requirement and products formed during a process. All material balance calculations are based on
the principle of conservation of mass, which states that matter can neither be created nor be
destroyed, but they may undergo physical or chemical changes.

The law of conservation of mass states that the total mass of various components involved
remains constant during a unit process.

Thus any unit process,

Rate of mass input = Rate of mass output + Rate of mass accumulation.

For steady state operation where accumulation is constant,

Rate of mass input = Rate of mass output.

ASSUMED DATA:

● Conversion is 99% propylene

● Product molar selectivity cumene to p-DIPB is 31:1.

● Propylene feed is 95% pure and the rest of propane.

● Benzene is about >99.9% purity.

● Molar feed ratio od benzene to propylene is 2:1.

● Top product of benzene column is 98.1% benzene and1.9% cumene.

● Top product of the cumene separation column is 99.9 mole% cumene.

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● Bottom product of the cumene separation column is 100 mole % p-DIPB.

Let propane be the reactant which does not participate in the reaction, it is used as a fuel.

And assuming our plant runs 12 hours per day then according to these assumptions, we can
proceed further.

BASIS: (150 ton)/(12 hr) of cumene

12.5 tons/hr of cumene

12500 kg/hr of cumene

(12500 kg/hr) / 120.19 = 104 Kmol/hr of cumene

Primary reaction:

CH2-CH2-CH2 + C6H6 ――――→ C6H5-C3H7

(propylene) (benzene) (cumene)

1 Kmol of benzene = 1 Kmol of propylene = 1Kmol of a cumene

Side reaction:

CH2-CH2-CH2(propylene) + C9H12(cumene) ―――――→ C3H7-C6H4-C3H7 (p-DIPB)

1Kmol of benzene = 2 Kmol of propylene =1 Kmol of cumene

Propylene used for the cumene and DIPB:

So for cumene, propylene required is 104 kmol/hr

Selectivity is 31: 1 of cumene to DIPB, i.e., catalyst converts propylene and benzene to the ratio
of 31 moles of cumene and 1-mole DIPB.

Conversion of propylene is 99%

Let X Kmol of DIPB formed

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Then, cumene formed is 31X

31 X = 104

X = 3.35

Hence, p-DIPB formed is 3.35 kmol/hr.

Now,

PROPYLENE BALANCE:

Propylene required for cumene = 104.16 kmol

Propylene required for DIPB = 2х3.35 = 6.7 kmol

Total propylene required = 110.86 kmol

We are given that the conversion of propylene is 99%. So,

Propylene in feed = 110.86 / 0.99 = 112 kmol

Propylene unreacted = 112- 110.86 = 1.14 kmol

PROPANE PRESENT:

Total propylene present = 110.7 Kmol

Since 95% is pure propylene and the rest is propane. So,

Total feed = 112.007/0.95 = 117.902 Kmol

So, propane in the feed will be = 117.902- 112.007 = 5.89 Kmol

2. BENZENE BALANCE:

Benzene required for cumene = 104 kmol

Benzene required for DIPB = 3.35

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Total Benzene required = 104 + 3.35 = 107.35 kmol

We have: benzene to propylene feed ratio is 2:1.

Benzene if feed = 2x110.7 = 221.78 kmol

Unreacted Benzene = 221.7 – 107.35 = 114.35 kmol.

FEED VESSEL:

Fresh feed = 107.36 kmol

Recycle feed = 114.35 kmol

Mixed feed = 107.36+ 114.35 = 221.71 kmol

BALANCE AROUND REACTOR:

Feed = mixed benzene feed + propylene feed

Feed = 221.71 + 118.8 = 340.5 kmol

SEPARATOR:

Bottom = 223.987 Kmol

Top = propylene + propane

Feed = top + bottom (feed would be reactor outlet 231 Kmol)

Top = 231- 223.987 = 7.01 Kmol

BENZENE DISTILLATION COLUMN:

Feed = 223.987 kmol

We are given that the top product(distillate) contains 98.1% of benzene.

Let.s assume all the benzene is collected at the top only. Then,

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BENZENE BALANCE:

F*xf = D*xd

223.987 x 0.51= Dx0.981

So, D (top product) = 116.4 kmol

Hence, Cumene present in the top product will be = 114.4x 0.019 = 2.21 kmol

Bottom product of the benzene distillation column will be:

Bottom = Feed – Top

Bottom = 223.987 – 116.4 = 107.5 kmol

CUMENE DISTILLATION COLUMN:

Feed = 107.5 kmol

We are given that the top product(distillate) contains 99.9 mol% cumene and 100 mol% DIPB at
the bottom.

So, CUMENE BALANCE :

F*xf = D*xd

107.5 x 0.968 = D x 0.999

D (top product) = 104.16 kmol of cumene

Bottom product = Feed – Top product

Bottom = 107.5 – 104.16 = 3.35 kmol of DIPB .

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OVERALL PLANT MATERIAL BALANCE :

INPUT OUTPUT
Mol wt. Kmol/hr Kg/hr Kmol/hr Kg/hr
BENZENE 78 221.7 17292.26 114.35 8919.3
PROPYLENE 42 112.007 4704.29 1.119 47
PROPANE 44 5.89 259.16 5.8 255.2
CUMENE 120 0 0 104.16 12499.2
DIPB 162 0 0 3.35 544.32
TOTAL 339.59 22255.71 228.77 22265.02

Table 2: Overall material balance

YIELD:

We know that:

Yield = moles of product formed / moles of reactant fed

As 1 mol of cumene is produced by 1 mol of propylene so the stoichiometric coefficient is 1.

Moles of cumene produced = 104.16 kmol

Moles of reactant fed = 110.8 kmol

So, the yield of cumene is :

Yield = 104.16 / 110.8

= 94% .

3.2 Energy Balance

Benzene feed vaporizer

The stream of mixed feed of benzene and cumene is feed to the vaporizer with 40℃ at 25 atm.

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 Component Mol. weight kmol Kg Mole fraction Mass fraction

BENZENE 78 221.7742 17298.39 0.990101 0.984851

CUMENET 120 2.217 266.088 0.009899 0.015149

TOTAL 223.9916 17564.48 1 1

Table 3: Benzene and cumene feed to the vaporizer

The bubble point and dew point of the mixture are found by using Antoine equation, the vapor
pressure is calculated at various temperatures to find the saturated temperature.

Pi xi P yi = pixi/P yi P yi P/pi
BENZENE 2587.637 0.99 2533.125 1.011305 2507.794 0.969144
CUMENE 660.4975 0.01 2533.125 0.002607 25.33125 0.038352
TOTAL 1.013912 1.007496

Table 4: Bubble point and Dew point calculation for benzene and cumene mixture

Where P is the total pressure

Pi is the vapour pressure at 243℃. So, at 516 k the mixed feed will be vaporized.

Heat required for vaporize =313 int 516(C dT) + latent heat

Latent heat of benzene = 23,773.63 kJ/kmole

Latent heat of cumene = 30919.2 kJ/kmole

Average heat capacity of benzene = 161.46 kJ/kmole k

Average heat capacity of cumene = 246.92 kJ/kmole k

Enthalpy of benzene = Cp ∆T + λ = 161.46 x 203 + 23,773.63 = 56,550.01 kJ/Kmole

Enthalpy of cumene = 246.92 x 203+ 30919.2 = 81043.96 kJ/Kmole

Heat required for the mixed feed = 0.99 x 56550.01+0.1 x 81043.96 = 64088.89 kJ/Kmole
= 64088.89 X 223.9 = 14349502 kJ = 14349.502 MJ/h

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Propylene feed vaporizer:

Propylene and propane fed from the tank with 25℃ at 25.33 bar.

The stream is vaporized and heat to the temperature 243℃ and mixed with benzene feed.
Bubbling point and dew point of the mixture is about 62.5℃.
Latent heat of propylene = 17229.4 kJ / h
Latent heat of propane = 17611.41 kJ / h
The average heat capacity of liquid propylene =123.51
And propane=125.48
The average heat capacity of gaseous propylene = 82.86 and propane=97.48.

Liquid State:

Propylene Propane

Cp 123.51 125.48

ΔT 37.5 37.5

Q (kJ/h) 4631.625 4705.5

Table 5: Liquid state heat calculation for the mixture

Gas State:

Propylene Propane

Cp 82.86 97.483

ΔT 180.5 180.5

Q (kJ/h) 14956.23 17595.6815

Table 6: Gas state heat calculation for the mixture

Heat required for propylene:

17229.46+4631.625+14956.23 = 21861.08 kJ/h

1
Heat required for propane:
17611.39+4705.5+17595.075 = 39912.57 kJ/h
Heat required for the feed = 117.9 (21861.08 X 0.95 + 39912.57 X 0.05) = 2683.83 MJ/h
Fired heater:

The heat required for raising the temperature reactant feed to 350 ℃
Inlet ℃ = 243
Outlet ℃ = 350

Comp Kmole/H Heat Capacity Constants Of Gas Mixture

n A B C D E
C 3 H6 112.0071 31.298 7.24x10-2 1.95x10-4 -2.16x10-7 6.30x10-11

C 3 H8 5.8951 28.277 1.16x10-1 1.96x10-4 -2.33x10-7 6.87x10-11

C 6 H6 221.7742 -31.368 4.75x10-1 -3.11x10-4 8.52x10-8 -5.05x10-12

C9H12 2.21274 10.149 5.11x10-1 -1.77x10-5 -2.26x10-7 8.80x10-11

nA nB nC nD nE

3.51x103 8.11 2.18x10-2 -2.42x10-5 7.05x10-9

1.67x102 6.84x10-1 1.16x10-3 -1.37x10-6 4.05x10-10

-6.96x103 1.05x102 -6.91x10-2 1.89x10-5 -1.12x10-9

2.25x101 1.13 -3.92x10-5 -5.00x10-7 1.95x10-10

Cp= -3.26x103 1.15x102 -4.61x10-2 -7.14x10-6 6.53x10-9

ΔT = 107 31725.5 9508697.667 2879866400 8.8098x1011

CpAT= - 349019.239 3.65x106 -4.39x105 -2.06x104 5.76x103

𝚺CpAT= 2.85x106 kJ/h

Table 7: The heat required for raising the temperature reactant feed to 350℃

1
 CHAPTER 4

SIZING AND DETAILED DESIGN OF MAJOR EQUIPMENTS

4.1 Design of Distillation Column

Terminology:

Some of the terms used in the following calculation are defined here as follows:

F = Flow rate of Feed, Kg/day.

D = Molar flow rate of Distillate, Kg/day.

W = Molar flow rate of Residue, Kg/day.

xf = mole fraction of cumene in feed.

yd = mole fraction of cumene in Distillate.

xw = mole fraction of cumene in Residue.

Mf = Average Molecular weight of Feed, Kg/kmol

Md = Average Molecular weight of Distillate, Kg/kmol

Mw = Average Molecular weight of Residue, Kg/kmol

Rm = Minimum Reflux ratio

R = Actual Reflux ratio

L = Molar flow rate of Liquid in the Enriching Section, kmol/hr

G = Molar flow rate of Vapor in the Enriching Section, kmol/hr

L = Molar flow rate of Liquid in Stripping Section, kmol/hr

G = Molar flow rate of Vapor in Stripping section, kmol/hr

q = Thermal condition of Feed

ρL = Density of Liquid, kg/m3 .

ρV = Density of Vapor, kg/m3 .

2
qL = Volumetric flow rate of Liquid, m3 /s
qV = Volumetric flow rate of Vapor, m3 /s

µL = Viscosity of Liquid, cP.

TL = Temperature of Liquid, K.

TV= Temperature of Vapor, K.

PRELIMINARY CALCULATIONS:

Vapor-pressure data of cumene-Diispropylbenzene:

1/T (℃) 2.35 2.3 2.25 2.2 2.15 2.10

PA(mm Hg) 760 943 1211.9 1480.2 1998.1 2440.6

PB(mm Hg) 190.56 257.2 314.1 403.4 518 760

LnPA(mm Hg) 6.63 6.85 7.1 7.3 7.6 7.8

LnPB(mm Hg) 5.25 5.55 5.75 6 6.25 6.63

Table 8 : Vapor-pressure data of cumene-Diispropylbenzene

T-xy data for cumene – Diispropylbenzene system:

T (℃) 152.4 160 170 180 190 202

XA 1 0.733 0.496 0.331 0.163 0

YA 1 0.909 0.791 0.644 0.429 0

Table 9: T-xy data for cumene – Diispropylbenzene system

Vapour-pressure data from Perry’s Chemical Engineers handbook 6th edition pg2-52.

Splitting the feed into two towers of equal capacity as the feed rate of the distillation tower is too high.
The production rate in our case is almost ten times more than the normal production rate.

2
[We discover from the material balance equation that if XF, XD, and XW are maintained, then on
halving the feed rate, both distillate and residue are also halved in value.]

Fmolar = (0.932 x 13819.05)/120.19 + (0.068 x 13819.05)/162 = 107.52 kmol/hr

Mfeed = 3819.05/107.52 = 128.5 Kg/kmol

Taking feed as saturated liquid, q=1

So,
Slope of q-line = q/(q-1) = ∞ .
Therefore q-line is vertical.

Now,

R = 1.4 x 0.38 = 0.532

L = RD =0.532 x 104.16 = 55.41 Kmoles/hr

G = (R+1) D = 1.532 x 104.16 = 159.57 Kmoles/hr

L = L+qF = 55.41 + 1x107.52 = 162.91 Kmoles/hr

G = G+(q-1) F= 160.17 Kmoles/hr

From the X-Y diagram, XD/(Rm+1) = 0.72

Hence Rm =0.38

Assuming a reflux ratio of 1.4 times the Rm value we get (By using McCabe Thiele method):

2
 McCabe Theile Diagram

Now,
From the diagram we have the following data for the distillation column:

Total number of stages including reboiler = 9.

Therefore, actual number of stages in the tower = 8

Number of stages in the enriching section = 2

Number of stages in the stripping section = 6.

4.2 Mechanical Design of Equipment

Shell:

Diameter (Di) = 1.99 m

Working/Operating Pressure = 1.0329 kg/cm2

Design pressure = 1.1× (OP)=1.1×1.0329 = 1.1362 kg/cm2

2
Working temperature = 441 K

Design temperature = 457.8 K

Shell material - IS: 2002-1962 Grade I Plain Carbon steel

Table 10: Mechanical design of distillation column parameters and properties

HEAD-TORISHPERICAL DISHED HEAD:

Material - IS: 2002-1962 Grade I Plain Carbon steel

Allowable tensile stress = 950 kg/cm2

SUPPORT SKIRT:

Height of support 1 m Material - Carbon Steel

SHELL MINIMUM THICKNESS:

Considering it as an internal pressure vessel:

The thickness will be given as :

ts = ((P×Di)/ ((2×ft×J)- P)) + C

where,
ts is the thickness of the shell in mm

2
P is the internal design pressure in kg/cm2

Di = diameter of shell in mm

ft = permissible/allowable tensile stress in kg/cm2

C = Corrosion allowance, mm

J = Joint factor(J= 85% = 0.85)

Considering double welded butt joint with backing strip

Thus, ts = ((1.1362×1990)/ ((2×950×0.85)-1.1362)) + 3 = 4.556 mm.

Head Design- Shallow dished and Torispherical head:

Thickness of head is given by:

th = (P×Rc×W) / (2×f×J)
where,

P =internal design pressure, kg/cm2

Rc = crown radius = diameter of shell, mm=1990mm

W=stress intensification factor or stress concentration factor for torispherical head

W= ¼ × (3 + (Rc/Rk) 0.5)

Rk = knuckle radius, which is at least 6% of crown radius in m

So, Rk = 6% × Rc = 0.06×1990 = 119.4 mm
Substituting the values in the above equation, we get:
W= ¼ × (3 + (Rc/Rk) 0.5) = ¼ × (3 + (1/0.06)0.5) = 1.7706 mm

th = (1.1362×1990×1.7706)/ (2×950×0.85) = 2.7538 mm.

DESIGN OF SUPPORT:

SKIRT SUPPORT:

The cylindrical shell of the skirt is made to withstand the combined stresses brought on by the dead
weight of the vessel, wind load, and seismic load. The skirt's uniform thickness is made to endure the
highest levels of compressive or tensile loads.

Data available to us are:

2
(i) Diameter =1990 mm.

(ii) Height = 4500 mm = 4.5 m

(iii) Weight of vessel, attachment =5745.7 kg.

(iv) Diameter of skirt (straight) = 1990 mm

(v) Height of skirt = 1.0 m

(vi) Wind pressure = 122.06 kg/m2

Stresses due to dead Weight:

fd = ∑W/ (π *Dok* tsk)

fd = stress,

∑W = dead weight of vessel contents and attachments

Dok = outside diameter of skirt,

tsk = thickness of skirt,

fd = 5745.7/ (π ×199.6× tsk) = 91.6/ tsk kg/cm2

Stress due to wind load:

The stress is givem by:

Pw = k×p1×h1×Do

p1 = wind pressure for the lower part of vessel,

k = coefficient depending on the shape factor = 0.7 for cylindrical vessel.

Do = outside diameter of vessel,

The bending moment due to wind at the base of the vessel is given by:

Mw = Pw ×H/2

fwb = Mw/Z = 4 ×Mw ×(Dok) 2 ×tsk 37

Z- Modulus of section of skirt cross-section

Pw = 0.7×122.06×1.0×1.99 = 765.13 kg

2
Mw = Pw ×H/2 = 765.13×4.5/2 = 1721.5 kgm

Substituting the values we get,

fwb = 8.2/tsk kg/cm2

Design of skirt bearing plate:

Assume both circle diameter = skirt diameter + 32.5 =199+ 32.5 = 231.5 cm

Compressive stress between Bearing plate and concrete foundation:

A = area of contact between the bearing plate and foundation

Z = Section Modulus of area,

Mw = the bending moment due to wind,

fc = (5745.7×4)/ (231.52 -1992 )) + (0.7×122.06×3×42.32 )/ (2× (231.54 -914 )/ (32×231.5)) = 0.133

+0.138 fc=0.271kg/cm2 . Which is less than the permissible value for concrete.

Maximum bending moment in bearing plate

Stress: f = (6×0.271× 16.252 )/ (2 ×Tb2 ) = 214.68/tB2

Permissible stress in bending is 1000 kg/cm2. Thus, tB2 = 214.68/1000 => tB = 0.463 cm.

Therefore, a bolted chair has to be used.

Anchor Bolts:

Minimum weight of Vessel = Wmin = 3000 kg. (Assumed value)

fc,min = (Wmin/A) - (Mw/Z)

= [(4×3000) × (231.52 – 1992 ))] - (0.7× 122.06× 3 ×42.32 )/ (2× (231.54 – 1994 )/ (32×231.5))

= 0.273 – 0.415 = - 0.142 kg/cm2

Since fc is negative, the vessel skirt must be anchored to the concrete foundation by anchor bolts.

Pbolts = fc(min)A/n

Assuming there are 20 bolts,

Pbolts = (0.142/20) × (((231.52-1992 ))/4) = 78.01 kg.

2
 CHAPTER 5: DWSIM SIMULATION

Overview:

Fresh feed streams of benzene and mixture streams enter the process as liquids. Feed streams after
being mixed are fed to the vaporizer. It is pre-heated in two heat exchangers. The first recovers heat
from the hot reactor effluent and the second adds additional heat to bring the reactor inlet temperature.
Then the stream enters a tubular reactor which leaves as reactor effluent and is cooled through feed-
effluent heat exchanger.

The reactor effluent is further cooled down using a condenser and sent to a flash drum by reducing the
pressure through a pressure reduction valve. The gas stream obtained from the tank is used as fuel and
the liquid stream is fed to first distillation column. In the first column, benzene is obtained as distillate
in the top which is recycled back to the reactor. The stream obtained as bottoms is fed to another
distillation column. In the second column cumene of higher purity is obtained as distillate and p-
diisopropylbenzene is obtained in the bottoms.

5.1 Process Flow Diagram :

Fig 6: Process Flow Diagram

2
5.1.1 Overall Stream Data

Fig 7: Overall Streams Material and Property Data

Fig 8: : Overall Streams Energy Data

5.2 Conversion Reactor Unit

The reactants will be fresh propylene (96% propylene, and 4% propane) and an excess of fresh and
recycled benzene. These two will enter the reactor at an inlet temperature between 150 to 200℃ , and
the pressure should be high enough to keep the liquid state inside the reactor.

Two reactions will take place inside this reactor:

C3H6 + C6H6 □ C9H12 (1)

C3H6 + C9H12 □ C12H18 (2)

The first reaction (production of cumene) is the desired, while the other is the unwanted side reaction
(production of diisopropylbenzene). In this reactor the conversion of propylene is almost complete
conversion, which means that the effluents from this reactor will be mainly consisted of benzene,
cumene, DIPB, and propane.
2
Fig 9: Conversion Reactor Unit Fig10: Reactor Unit Material Streams Property Data

Fig 11: Conversion Reactor Property Data

3
5.3 Separation Unit

This separation unit is going to receive the effluents from the conversion reactor, and it will nearly
separate all the propane as an overhead product. At the same time, the bottom (mainly cumene, DIPB,
and benzene) will be moved to the benzene column. This separation column will receive the mixed
stream from the condenser. In the second dilation column the stream will be mainly consisted of
benzene, cumene, and some DIPB. This column will separate the benzene in the overhead and will
recycle it to the two reactors. The bottom (cumene, and DIPB) will go to the cumene column. In the
third separation column the cumene will be separated as an overhead product (purity needed is at least
99.4%), while DIPB is the bottoms product.

Fig 12: : Separation Unit

3
 Fig 13: Separation Unit Material Streams Property Data

5.4 Heating Unit:

MSTR-006 exits the pump and enters the first of two heat exchangers, HE-014 is a preheater for the
reactor feed stream, while also acting as a condenser for the reactor exit stream. The streams run
countercurrent, to allow for a higher heat transfer over the length of the reactor. MSTR-013 exits HE-
014 at a new temperature of 211°C and enters HEAT015, while MSTR-012 exits the exchanger at
180°C. HEAT-015 is a fired heater, with a steady state heat duty of 1434 kW. The fired heater raises
the stream to reactor conditions, of 377°C and 40 bar. The pressure drop over both heat exchangers is
0.5 bar. MSTR-01 then exits HEAT-015 and enters the reactor.

Fig 14: Heating Unit

3
Fig 15: Heating Unit Material Streams Property Data

Fig 16: Heat Exchanger Property Data

3
5.5 Recycle Stream :
At the start of the process, a feed carrying benzene, propane, and propylene enters the plant from the
storage facility. A recycle stream (REC-037) with benzene intersects the feed stream.

Fig 17: Benzene Recycle Unit

Fig 18: : Recycle Stream Property Data

3
 CHAPTER 6: COST ANALYSIS

The most important aspect of plant process design is the economics behind the plant’s construction
and the future value. It is the process of calculating the potential earnings from a project and
subtracting the total cost associated with completing it. It predicts the profit gained from a project and
compares the project cost to its estimated financial benefits.

The Capital investment for the 150 TPD cumene plant was estimated to be 200 crores in the year
2002-2003.

The CHEMICAL ENGINEERING PLANT COST INDEX are :

CI in 2002 : 402
CI in 2022 : 813
So,
Present cost of the plant will be = original cost*(present cost index/past cost index)

= 200 x 107 *(813/402)

= 404.47 x 107

Thus, Present Cost of the Plant = ₹ 404.47 x 107

6.1 Estimation of Capital Investment

1. Direct Cost:

It includes all the expenses that are directly attributed to the production of specific goods or services.
(60-80% of fixed capital Investment ) .

1.1 Equipment + installation + instrumentation + piping + electrical:

(50-60% of fixed capital Investment)

a. Purchased Equipment Cost(PEC) : (15-40% of FCI)

Let’s consider it 25%. So,

PEC = 25% x 404.47 x 107

= 0.25 x 404.47 x 107

= ₹ 101.12 x 107

3
b. Installation Cost (includes insulation and painting) : (25-55% of purchased equipment cost).

Let’s consider it 40% . So,

Installation = 40% of PEC

= 0.40 x 101.12x107

= ₹ 40.45 x107

c. Instrumentation and control : (6-30% of PEC)

Let’s consider it 15%. So,

= 15% of PEC

= 0.15 x 101.12 x107

= ₹ 15.17 x 107

d. Piping Installed : (10-20% of PEC)

Let’s consider it 15%. So,

= 15% of PEC

= 0.15 x 101.12 x 107

= ₹ 15.17 x 107

e. Electrical Installations : (10-20% of PEC)

Lets consider it 20%. So,

= 20% of PEC

= 0.20 x 101.12 x107

= ₹ 20.224 x107

1.2. Buildings, process and auxiliary : (10-60% of Purchased equipment cost)

Let’s consider it 15%. So,

= 15% of PEC

= 0.15 x 101.12 x 107

= ₹ 15.17 x 107

3
1.3. Service Facilities : (10-20% of the purchased equipment cost)

Let’s consider it 10%. So,

= 10% of PEC

= 0.10 x 101.12 x107

= ₹ 10.112 x107

1.4. Yard improvements: (10-15% of the purchased equipment cost)

Let’s consider it 10%. So,

= 10% of PEC

= 0.10 x 101.12 x 107

= ₹ 10.112 x 107

1.5. Land cost : (1-2% of FCI or 4-8% of PEC)

Let’s consider it 1% of FCI. So,

= 1% of FCI

= 0.01 x 404.47 x 107

= ₹ 4.04 x107

Therefore, the direct cost will be:

Direct Cost = Sum of all the above parameters that are calculated.
So,

Direct Cost = (101.12 + 40.45 + 15.17 + 20.224 + 15.17 + 10.112 + 10.112) x 107

Direct Cost = ₹ 227.528 x 107

2. Indirect Cost:

It includes all the expenses that are not directly attributed to the production of specific goods or
services. (15-30% of fixed capital Investment).

3
(a) Engineering and Supervision: (5-30% of direct cost)

Let’s consider it 20%. So,

= 20% of Direct cost

= 0.20 x 227.528 x107

= ₹ 45.505 x 107

(b) Construction Expenses: (10% of Direct cost)

= 0.10 x 227.528 x 107

= ₹ 22.752 x 107

(c) Contractor’s Fees :( 2-7% of Direct Cost)

Let’s consider it 4%. So,

= 4% of Direct Cost

= 0.04 x 227.528 x 107

= ₹ 9.101 x 107

(d) Contingency : (5-15 % of Direct Cost)

Let’s consider it 10%. So,

= 10% of Direct cost

= 0.1 x 227.528 x 107

= ₹ 22.752 x 107

Therefore the indirect cost will be :

Indirect Cost = 45.505 x 107 + 22.752 x 107 + 9.101 x 107 + 22.752 x 107

Indirect Cost = ₹ 100.11 x 107

3
3. Fixed Capital Investment :

FCI = Direct cost + Indirect Cost

FCI = (227.528 X107) + (100.11 x 107)

FCI = ₹ 327.638 x 107

4. Working Capital : (10-20% of Fixed Capital Investment)

Let’s consider it 15%. So,

Working Capital = 15% of FCI

WCI = 0.15 x 327.638 x 107

WCI = ₹ 49.145 X107

5. Total Capital Investment :

TCI = FCI + WCI

TCI = (327.638 x 107) + (49.145 x 107 )

TCI = ₹ 376.738 x 107

6.2 ESTIMATION OF TOTAL PRODUCT COST

Manufacturing cost = Fixed charges + Direct production cost + Plant overhead cost

1. Fixed Charges : (10-20% of total production cost)

(a) Depreciation: It depends on the life period, salvage value and method of calculation
(about 10% of FCI for machinery, equipment )
so,

Depreciation = 10% of FCI

= 0.10 x 327.638 x 107

= Rs. 32.763 x107

3
(b) Local Taxes : (1-4 % of FCI)
Let’s consider it 3%. So,

= 0.03 x 327.638 x 107

= ₹ 9.829 x 107

(c) Insurance : (0.1-1% of FCI)

Let’s consider it 0.6 %. So,

= 0.6% of FCI

= 0.006 x 327.638 x 107

= ₹ 1.965 x107

Thus, the fixed charges will be

Fixed charges = 32.763 x 107 + 9.829 x 107 + 1.965 x107

Fixed Charges = Rs 44.557 x107

2. Direct Cost : (60% of the Total Product

Cost) Total product cost = (Fixed charges/ 15%)

Fixed charges = 10-20% of Total Product Cost

let’s consider it 15%. So,

Total Product charge = (44.557 x 107) / 0.15

Total Product Charge = Rs 297.046 x 107

(a) Raw Material : (10-50% of the Total product cost)

Let’s consider it 30%. So,

= 0.3x 297.046 x 107

= ₹ 89.114 x 107

(b) Operating Labour Cost : (10-20% of total product cost)

Let’s consider it 15%. So,

= 0.15 x 297.046 x 107

= ₹ 44.556 x 107
4
(c) Direct supervision and clerical labour (DS & CL) : (10-25% of Total product cost)

Let’s consider it 15%. So,

= 0.15 x 297.046 x 107

= ₹ 44.556 x 107

(d) Utilities cost : (10-20% of the total product cost)

Let’s consider it 10%. So,

= 0.10 x 297.046 x 107

= ₹ 29.70 x 107

(e) Maintenance and Repair (M & R) : (2-10% of FCI)

Let’s consider it 5%. So,

= 0.05 x 327.638 x 107

= ₹ 16.381 x 107

(f) Operating Supplies : (10-20% of M&R or 0.5-1% of FCI)

Let’s consider it 15% of M&R. So,

= 0.15 x 16.381 x 107

= ₹ 2.457 x 107

(g) Laboratory Charges : (10-20% of TPC)

Let’s consider it 15%, So,

= 15% of TPC => 0.15 x 297.046 x 107

= ₹ 44.55 x 107

(h) Patents and Royalties : (0-6% of TPC )

Let’s consider it 4%. So,

= 4% of TPC => 0.04 x 297.046 x 107

= ₹ 11.88 x 107

4
Therefore, the Total Direct Product Cost will be:

TPC = ( 89.114 + 44.556 + 44.556 + 29.70 + 16.381 + 2.457 + 44.55 + 11.88 ) x 107

TPC = ₹ 283.194 x 107.

3. Plant Overhead Costs: (50-70% of Operating Labour, supervision, maintainance or 5-15%

of TPC)

It includes following: general plant upkeep and overhead, payroll overhead, packaging, medical
services, safety and protection, restaurants, recreation, salvage, laboratories and storage facilities.

Lets consider it 60% of OL, DS&CL and M&R.

= 0.6 x (44.556 x 107 + 44.556 x 107 + 16.381 x 107 )

Plant Overhead Cost = Rs 63.295 x107

Thus, Manufacturer cost = Direct production cost + Fixed Charges + Plant Overhead Cost

= 283.194 x 107+ 44.557 x 107 + 63.295 x 107

= ₹ 391.046 x 107

Now,
The General Expenses = Administration cost + Distribution and selling costs + Research and
development cost

(a) Administration cost : (40-60% of TPC)

Let’s consider it 50% of Operating Labour cost, So,

= 0.5 x 44.556 x 107

= ₹ 22.27 x 107

(b) Distribution and Selling cost : (2-20% of TPC) (It includes the cost of sales offices, salesmen and
advertising)

Let’s consider the Cost of Distribution and Selling Costs = 10% of TPC

= 0.1 x 283.194 x 107

= ₹ 28.31 x 107
4
(c) Research and Development cost : (3% of TPC)
= 0.03 x 283.194 x 107
= ₹ 8.495 x 107

Thus, General Expenses = 22.27 x 107 + 28.31 x 107 + 8.495 x 107

= ₹ 59.075 x 107

4. Total Product Cost:

Total Product Cost = Manufacture Cost + General expenses

= 391.046 x 107 + 59.075 x 107

= ₹ 450.121 x 107

Estimation of cost of production :

= Annual production cost / Annual production

= (450.121 x 107)/ 1500000
= ₹ 300.08
Now
,

1. Gross Earnings/ Income :

Selling price of cumene = ₹ 330

Amount of sales = 330 x 15000000

= ₹ 4.95 x 109

Marketing cost (3% revenue) = 0.03 x 4.95 x 109

= ₹ 0.148 x 109

Net selling income = 4.95 x 109 - 0.148 x 109

= ₹ 4.80 x 109

4
Gross Income = Selling Income - Manufacturing cost

= 4.80 x 109 - 3.91 x 109

= ₹ 0.89 x 109

If Corporate taxes (50% of the revenue)

= 0.50 x 0.89 x 109

= ₹ 0.445 x 109
So,
The Net profit of the plant per annum = ₹ 4.45 x 108

Payout Period :

= Total Fixed Capital / Total net profit

= 3276380000/ 445000000

= 7.36 years

Rate of Return : (ROR)

ROR =( Net profit / Total Capital Investment) x100

ROR =( 890000000/ 3767380000) x 100

ROR = 23.62%

4
 CHAPTER 7: PLANT LAYOUT

Fig 19 : Plant Layout

In the above figure, the plant layout is shown in a certain distribution that helps and contribute in
making the plant more efficient, easier to handle, and safer. The parking has its own gate for the
employees only. Next to the parking area, the busses station to take the employees to anywhere in the
whole plant in studied and well planned and designed roads to save energy and time which will lead to
a better productivity. Moreover, the security is next to the parking and the main gate and
administration building to make it easier for the both, the employees and the visitors to reach the
security. The plant area is in place where there is a possibility of expansion area in the future. The
trucks gate was placed next to the stores and far away from the employees’ route.

4
 CHAPTER 8 : WASTE TREATMENT

8.1 Health and Environmental Considerations :

The environment and the health of the workforce are considered in the design of every chemical
process, and this is also true for the process used to produce cumene. Any plant's design must take into
account the workers' safety from chemical exposure. Cumene, DIPB, benzene, propane, propylene,
and water are among the substances used in this cumene synthesis method. All of these compounds are
subjected to a variety of high and low temperatures and pressures at various times throughout the
process. While propane and propylene are in the gaseous form at room temperature and pressure,
benzoene, cumene, and DIPB are liquids with considerable volatility. As a result, these substances are
classified as volatile organic compounds (VOCs) and are subject to legal restrictions aimed at reducing
their output from chemical plants.

Propane, which acts as an inert in this reaction, is an impurity present in the benzene feed in this
chemical process.
The rest of the propane entering the process is distilled off and utilized as a fuel gas to decrease waste
and energy utilization. Propane is not poisonous at low levels, but a high level of propane exposure
(>0.1%) can affect the central nervous system of our bodies. Propane is hard to detect if a leak occurs
since it is a colorless and odourless gas. Drowsiness and loss of consciousness are indicators of
propane toxicity. Propane being heavier than air, will remain close to the ground in the gaseous state.
At a lower flammability limit (LFL) of 2.1% in air and an upper flammability limit (UFL) of 10% in
air, propane is quite a highly flammable gas. If propane is used as a fuel gas, then the possibility of an
environmental leakage is increased. However, propane lacks reactive functional groups and therefore
can be deemed as a safe compound to be released in gaseous form. Propane has a half-life of 14 days
in the atmosphere. Leakage of propane into the water can result in its complete vaporization within a
matter of a few hours.

Propylene has been used mainly as a reactant in this process. It is in most noteworthy amounts before
the reactor, yet isn't found in any stream downstream from the reactor. 54 Propylene has physical
properties similar to those of propane. The health effects of propylene are similar but not as severe as
propane in the case of CNS depression. Asphyxia, however, is still a possibility at high concentrations

4
due to reduced oxygen concentrations. Propylene like propane is an odourless and colourless gas and
is heavier than air. Propylene has LFL and UFL as 2% and 11.1%, respectively. Propylene has a
negligible impact on the environment and can be volatile in water leakage, with a half-life of 26 days
in the atmosphere.

Benzene is yet another reactant in the process of cumene production. Benzene is present in almost all
the streams in this process since it is being recycled. It is heavier than both propane and propylene,
exists as a liquid with comparable volatility at room temperature. Benzene in the liquid state is
colourless but with a sweet odour and is somewhat soluble in water. Benzene toxicity has a wide range
of serious health effects. High exposure to gaseous benzene may lead to acute CNS depression along
with irregular cardiac rhythm leading to ventricular fibrillation or even asphyxia. Ingestion of benzene
may lead to intestinal irritability resulting in vomit. Long term exposure to benzene can also lead to
bone marrow damage resulting in haematological difficulties such as leukaemia and can also be a
potential immunosuppressant. Benzene is highly flammable with the LFL and UFL values at 1.2% and
7.8%, respectively. When released into the atmosphere, benzene may form some ozone compounds
(however at relatively low levels) and has a half-life of 17 days. Benzene can also affect animals if
leaked into soil or water, due to its toxicity leading to reproductive problems.

Cumene is the primary product to be produced in this facility. The highest concentrations of Cumene
is mainly found in the reactor after the reaction and downstream of the separation processes. Cumene
is a volatile liquid, insoluble in water at room temperature. In a gaseous state, cumene may act as a
CNS depressant. At continued cumene exposure, there have been indications of abnormal cardiac
rhythms. There are reportedly not a lot of long term effects of cumene, due to its ready metabolization
in the body. However, a few long term effects are shown in workers indicating altered levels of
bilirubin and liver enzymes, inducing probable hepatic damage along with bone marrow and
haematological damage similar to that found in benzene. Cumene may cause slight irritation to the
eyes 55 and the skin. Cumene has LFL and UFL values of 0.9% and 6.5%, respectively and is
therefore flammable. In the atmosphere, cumene has a half-life of roughly 1.5 hours and does not
appear to affect ozone levels and therefore has limited to no effect on the environment.

The only by-product produced in this process is P-Diisopropylbenzene (DIPB) but its quantity is not
much high relative to cumene and can be found in high concentrations downstream during the

4
separation process. DIPB exists as a volatile liquid at normal conditions and is insoluble in water.
DIPB has similar effects on humans like the other compounds in this process e.g. it acts as a CNS
depressant at high concentration levels. Lower level exposure may lead to irritations on the skin and
affect the respiratory tract. At continued cumene exposure, there have been indications of abnormal
cardiac rhythms. There are reportedly not a lot of long term effects of cumene, due to its ready
metabolization in the body. However, a few long term effects are shown in workers indicating altered
levels of bilirubin and liver enzymes, inducing probable hepatic damage along with bone marrow and
haematological damage similar to that found in benzene. DIPB is a flammable liquid with an LFL and
UFL of 0.8% and 6.5%, respectively. DIPB does not show any indication of harm towards
environmental life. DIPB also volatilizes in water and is a VOC with a half-life of 30 days. This
process attempts also attempts to minimalize environmental impacts as the result of carbon emissions
from energy usage, and waste prevention. The separation flow process, for instance, was designed in a
specific order to significantly reduce the size and utility requirements for one of the columns. The
design of a heat exchanger that uses two existing streams (reactor outflow and feed stream) in the
process to exchange energy between the two also lowers required energy consumption into the
process. This internal conservation of energy within the process not only lowers utility costs for the
plant but also reduces the potential environmental impact of the chemical production industry as a
whole. Additionally, all products formed from this process are either sold or recycled. The cumene and
DIPB products are moved into the petrochemical plant for further processing. The benzene stream is
recycled back into the reactor to save costs from new benzene input. Finally, the propane distilled off
from the process is used as a fuel gas, further reducing the utility requirements of the plant. Overall, 56
this process produces no chemical waste and makes great use of internal energy to reduce the
environmental impact into the 21st century and beyond.
The high pressure and temperature streams coming into and out of the reactor are the process's main
areas of health and safety concern. If a leak were to develop during the process, all byproducts and
reactants would ignite. None of the used products, reactants, or coolants are hazardous or detrimental
to humans when used directly. This report will include a general review of operational risk for each
piece of equipment. The safety of persons using the equipment will be carefully considered when
developing the reactor and separators. Any waste produced during this process is anticipated to be
used as fuel for a fired heater even though the reactants and products employed can be hazardous to
the ozone layer.

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8.2 Safety an Hazard Analysis :
We must take safety and hazard analysis into account. Even though the design takes many of the issues
raised by the What-If analysis into account, care must still be taken to ensure that the process is secure
and efficient.
The following are some of the major safety analysis that are to be kept in mind and to be implemented
in the plant :

1. What if the feed temperature is higher or lower than specified?

➔ Proper personal protection equipment (PPE) should be provided to the employees and all the
workers in the plant which includes gloves and leg covering so that the are safe from any burns
from outside the pipe.

2. What if the flow from the top to the condenser is more or less than specified?

➔ Any extra liquid generated during high flow will be stored in the vessel after the condenser or made
available for use during low flow. To avoid overfilling, there is a level alarm provided.

3. What if the reflux pump goes down?

➔ The control panel automatically will switch the other pump on, preventing a pressure build-up.
Pumps can also be manually turned on from the control room to allow for pump repairs.

4. What if the flow from the bottoms is higher or lower than specified?

➔ In order to prevent too much or too little water from passing through the reboiler, a flowmeter is
attached to a control valve. This will lessen pressure-related problems.

5. What if the reboiler is heating the stream too much or too little?

➔ A temperature indicator is connected to a flow control valve on the hot side of the reboiler.

6. What if the sample port leaks while taking a sample?

➔ Personal Protection Equipment (PPE) is required in the plant at all times and includes safety
glasses. Additional PPE for taking a sample includes a full face mask.

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 REFERENCES

1. Dutta, B. Principles of mass transfer and separation processes

2. Cumene Process - Wikipedia
3. Cumene Market Analysis - Plant Capacity, Production, Operating Efficiency, Demand &
Supply, End-User Industries, Sales Channel, Regional Demand, Foreign Trade, Company
Share, 2015-2032.
4. Mordorintelligence.com. 2021. Cumene Market | 2021 - 26 | Industry Share, Size, Growth -
Mordor Intelligence. [online] Available at:
https://www.mordorintelligence.com/industry-reports/cumene-market
5. Plant Design and Economics for Chemical Engineering by Peter ,M.s and Timmerhaus