PART 08 Rev 0

Deepak Phenolics Ltd. Part 8: Decomposition Rev.
0
200,000 MTA Phenol Plant and Dephenolation October 13, 2017
Dahej, Gujarat, India Project F698
OPERATIONS TRAINING PROGRAM
PART 8: MHP DECOMPOSITION AND DEPHENOLATION
LESSON NO. 1
TIME:
SUBJECT: Process Description
INTRODUCTION: A general description of the processes focusing on the functions of the

methyl-hydroperoxide (MHP) decomposition unit and the Dephenolation
unit in the phenol process, and the chemistry involved.
OBJECTIVES: Upon completion of this lesson, the trainee should be able to:
- Generally describe the MHP decomposition and Dephenolation

processes and state the functions of the units in the phenol
process.
- Identify the equipment in the processes by its name and number.
TRAINING AIDS: - Process Flow Diagram.
- Operating Philosophy Document
REFERENCES: - Process Description: Oxidation and Spent Air System (1.2)

Process Description: Dephenolation (1.8)
Piping and Instrument Diagrams (P&ID):

MHP Decomposer, Product Cooler and Vent Condenser (62-D131)
Dephenolation Feed Tank & Pump (62-D132)
Extraction Column (62-D133)
Solvent Regeneration Drum & Pumps (62-D134)
Dephenolation Solvent Drum & Pumps (62-D135)
This document contains proprietary information of Kellogg Brown & Root LLC. TO BE KEPT CONFIDENTIAL
Page 1of 16
Deepak Phenolics Ltd. Part 8: Decomposition Rev. 0
PRESENTATION OUTLINE: AIDS

1. Using the Operating Philosophy and the Process Flow PFD
Diagram, generally describe the MHP Decomposition and Operating Philosophy
Dephenolation processes. Identify equipment in the units Instructor Notes
by the name and number. Explain the functions of the
equipment in the process.
2. Have the trainees complete Work Sheet #2.
(Match equipment names with equipment numbers.)
Page 2of 16
INSTRUCTOR NOTES
1. Process Description
Process Description: Oxidation and Spent Air System (1.2)
Process Description: Dephenolation (1.8)
2. Process Chemistry for MHP Decomposition
In the MHP Decomposer, MHP is decomposed into formaldehyde, formic acid, methanol,
hydrogen, and water.
The overall chemical reaction for MHP decomposition is:
3. Process Chemistry for Dephenolation
In an acidic solution, the chemical reaction for dephenolation is:
In an alkaline solution, the chemical reaction for dephenolation is:
Page 3of 16
WORK SHEET #1
Match the equipment number with the equipment name.
A. E-2610 1. Dephenolation Feed Tank
B. E-2611 2. Solvent Regeneration Drum
C. T-2620 3. First Stage Solvent Regen Aqueous Pump & Spare
D. C-2622 4. MHP Decomposer
E. V-2630 5. Dephenolation Solvent Drum
F. P-2630A/B 6. Dephenolation Feed Pump & Spare
G. P-2632A/B 7. MHP Effluent Cooler
H. V-2624 8. Extraction Column
I. P-2620 9. Aqueous Dephenolation Circ. Pump & Spare
Page 4of 16
WORK SHEET #2
Answer Key
A. E-2610 1. C Dephenolation Feed Tank
B. E-2611 2. E Solvent Regeneration Drum
C. T-2620 3. F First Stage Solvent Regen Aqueous Pump & Spare
D. C-2622 4. A MHP Decomposer
E. V-2630 5. H Dephenolation Solvent Drum
F. P-2630A/B 6. I Dephenolation Feed Pump & Spare
G. P-2632A/B 7. B MHP Effluent Cooler
H. D-2624 8. D Extraction Column
I. P-2620 9. G Aqueous Dephenolation Circ. Pump & Spare
Page 5of 16
LESSON NO. 2
TIME:
SUBJECT: Phenol Drain Drum and Dephenolation Feed Tank
INTRODUCTION: A general description of Phenol Drain Drum and Dephenolation Feed

Tank, discussing the principles of operations and the functions within the
systems.
OBJECTIVES: Upon completion of this lesson, the trainees should be able to:
- Describe why this equipment is necessary and how they function.
- Identify the auxiliary equipment necessary and how the equipment

operates.
- Describe the instrumentation scheme.
TRAINING AIDS: - Instructors Notes.
- Projector: Process Flow Diagram.
REFERENCES: - Process Description: Dephenolation (1.8)
- Piping and Instrument Diagrams (P&ID):

Phenol Drain Drum & Pump (62-D101)
Page 6of 16
PRESENTATION OUTLINE:
1. Describe the Phenol Drain Drum and the Dephenolation Feed Tank.
2. Describe the principles of operations.
Page 7of 16
INSTRUCTOR NOTES
1. Process Description: Dephenolation (1.8)
2. Operating Principles
Phenol Drain Drum
The Phenol Drain Drum Pumps may be operated manually or automatically; individually or
simultaneously.
Dephenolation Feed Tank Operating Principles
The dephenolation feed pump provides (1) feed to the Dephenolation unit, and (2) continuous
recirculation for the Dephenolation Feed Tank.
The feed tank level must be allowed to fluctuate, with a constant flow to the extraction steps
being highly preferred over a constant inventory in the feed tank.
Page 8of 16
LESSON NO. 3
TIME:
SUBJECT: Dephenolation
INTRODUCTION: A general description of Dephenolation, discussing the principles of

operations and the functions within the system.
- Describe why these equipment are necessary and how they

function.

operates.
- Projector: Process Flow Diagram
- Projector: Extraction Column Internals
REFERENCES: - Process Description: Dephenolation (1.8)

Solvent Regeneration Drum & Pumps (62-D134)
Dephenolation Solvent Drum & Pumps (62-D135)
Page 9of 16
1. Describe the Dephenolation unit and its auxiliary equipment.
3. Have the Trainees complete Work Sheet # 1

(Refresher Questions - Home Work)
Page 10of 16
INSTRUCTOR NOTES
1. Process Description: Dephenolation (1.8)
The system used to remove phenol from aqueous waste streams is a solvent extraction method.
In acidic solution, phenol exists as its molecular form; in alkaline solution, it exists as sodium
phenate form. Phenol may thus be extracted into organic solvent or alkaline solution depending
upon the solution pH.
The equipment configuration is relatively simple: aqueous waste streams are collected in the
Dephenolation Feed Tank; the pH of the mixture is lowered to 6 to 8; phenol is extracted from the
aqueous phase by a solvent in a countercurrent Extraction Column. The phenol is then
extracted from the solvent by reaction with caustic to form sodium phenate, which is returned to
the Neutralizer in the phenol unit as an aqueous solution. Solvent mass flow to the extraction
column is normally around two times the waste water mass flow. Net aqueous from the plant is
discharged to the offsite waste water treatment facilities.
The water from the Dephenolation Feed Tank is fed on preset flow control, to the Extractor feed
pH control system (static mixer) where it is mixed with sulfuric acid to maintain the pH at a 4.5 to
5.0. This serves to "spring" phenol from sodium phenate, and also assures that phenol is present
only in its molecular form, vs. existing as a salt such as sodium phenate.
The pH adjusted water is fed to the top of the Extraction Column, where it flows countercurrent to
the organic solvent recycled from the Dephenolation Solvent Drum; fresh solvent, from the Crude
AMS Surge Tank, is added as makeup. Most of the phenol is extracted from the water into the
organic phase. The phenol free (NML 40 wt.ppm) water is purged to the offsite waste water
treatment bio-pond on Extractor interface level control, while the organic phase overflows to the
Solvent Regeneration Drum on back pressure control. The extraction Column back pressure
(~2.0 to 2.5 kg/cm2g) is set to provide sufficient head to transfer the waste water to OSBL waste
water treatment facilities.
The Solvent Regeneration Drum contains a strong aqueous solution of sodium hydroxide and
sodium phenate as the heavier liquid phase, where phenol is removed from the organic phase
and is contained by the aqueous phase as sodium phenate.
A purge of aqueous phase, equivalent to the amount of phenol gained in the first extraction
drum, is removed upstream of the mixing point and is recycled to the Neutralizer. The purge
quantity is on flow control cascaded by the interface level.
A fresh 30 wt% caustic is injected into the circulating aqueous phase to maintain its "absorption"
capacity. The organic phase overflows the second stage of the Solvent Regeneration Drum to
the Dephenolation Solvent Drum where it is water washed to remove any residual sodium. The
regenerated and water washed solvent is recycled back to the Extraction Column on flow ratio
control with the incoming phenolic water, and a slip stream purged to the Crude AMS Caustic
Wash Drum, to maintain a constant solvent inventory in the Dephenolation unit. The organic
purge rate is on flow control cascaded by liquid level in the drum.
3. Extraction Column Datasheet

Page 11of 16
WORKSHEET #1
(Home Work)
1. What is the purpose of the Dephenolation unit?
2. Why is it essential to lower the pH of the phenolic water prior to extraction?
3. Why is the water wash step necessary?
4. What are the operating conditions for the Dephenolation unit?
Extraction Column Pressure: _______
pH of extraction Column Feed: _______
Ratio of Solvent to Phenolic water in Extraction Column: _______
Ratio of Regeneration feed to recycle aqueous solution in P250-D-2630: _______
Page 12of 16
PART VIII: MHP DECOMPOSITION AND DEPHENOLATION
LESSON NO. 4
TIME:
SUBJECT: MHP Decomposition
INTRODUCTION: A general description of MHP Decomposition, discussing the principles of

operations and the functions within the system.
- Describe why these pieces of equipment are necessary and how

they function.

operates.
- Projector: Process Flow Diagram.
REFERENCES: - Process Description: Oxidation and Spent Air System (1.2)

MHP Decomposer, Product Cooler and Vent Condenser (62-D131)
Page 13of 16
1. Describe the MHP Decomposition system.
3. Have the Trainees complete Work Sheet # 1

(Refresher Questions - Home Work)
Page 14of 16
INSTRUCTOR NOTES
1. Process Description: Oxidation and Spent Air System (1.2)
Methyl-hydroperoxide (MHP) contained in the spent caustic stream from the oxidation area is
toxic to bio-treatment microorganism. Therefore, MHP is destroyed by thermal decomposition
prior to being sent to offsite. MHP is quite stable in strong acids, but decomposes in alkaline
solution.
Spent caustic, pumped from the Recycle Cumene Wash Drum by interface level cascaded to
flow control, is combined with aqueous purge from the Spent Air Separator and fed to the
Decomposer, where it is heated to 130 °C at 2.4 kg/cm2g and held at a pH greater than 11.5 in
the decomposer.
In the decomposer, MHP decomposes into formaldehyde, formic acid, methanol, hydrogen, and
water. Gases evolved are sent to incinerator on back pressure control after condensing out any
residual organics in the MHP Vent Condenser. The liquid effluent from the MHP Decomposer, is
removed on level control, cooled and sent to the Dephenolation Feed Tank.
Page 15of 16
WORKSHEET #1
(Home Work)
1. What is the purpose of MHP Decomposition Unit?
2. Why is high pH of the feed to MHP decomposition important?
3. What are the expected operating conditions of the MHP Decomposer?
Pressure: ________
Temperature: ________
Page 16of 16

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Deepak Phenolics Ltd. Part 8: Decomposition Rev.

OPERATIONS TRAINING PROGRAM

PART 8: MHP DECOMPOSITION AND DEPHENOLATION

SUBJECT: Process Description

INTRODUCTION: A general description of the processes focusing on the functions of the

- Generally describe the MHP decomposition and Dephenolation

- Identify the equipment in the processes by its name and number.

TRAINING AIDS: - Process Flow Diagram.

- Operating Philosophy Document

REFERENCES: - Process Description: Oxidation and Spent Air System (1.2)

Piping and Instrument Diagrams (P&ID):

PRESENTATION OUTLINE: AIDS

Process Description: Oxidation and Spent Air System (1.2)

Process Description: Dephenolation (1.8)

2. Process Chemistry for MHP Decomposition

The overall chemical reaction for MHP decomposition is:

3. Process Chemistry for Dephenolation

In an acidic solution, the chemical reaction for dephenolation is:

In an alkaline solution, the chemical reaction for dephenolation is:

Match the equipment number with the equipment name.

A. E-2610 1. Dephenolation Feed Tank

B. E-2611 2. Solvent Regeneration Drum

C. T-2620 3. First Stage Solvent Regen Aqueous Pump & Spare

D. C-2622 4. MHP Decomposer

E. V-2630 5. Dephenolation Solvent Drum

F. P-2630A/B 6. Dephenolation Feed Pump & Spare

G. P-2632A/B 7. MHP Effluent Cooler

H. V-2624 8. Extraction Column

I. P-2620 9. Aqueous Dephenolation Circ. Pump & Spare

A. E-2610 1. C Dephenolation Feed Tank

B. E-2611 2. E Solvent Regeneration Drum

C. T-2620 3. F First Stage Solvent Regen Aqueous Pump & Spare

D. C-2622 4. A MHP Decomposer

E. V-2630 5. H Dephenolation Solvent Drum

F. P-2630A/B 6. I Dephenolation Feed Pump & Spare

G. P-2632A/B 7. B MHP Effluent Cooler

H. D-2624 8. D Extraction Column

I. P-2620 9. G Aqueous Dephenolation Circ. Pump & Spare

OPERATIONS TRAINING PROGRAM

PART 8: MHP DECOMPOSITION AND DEPHENOLATION

SUBJECT: Phenol Drain Drum and Dephenolation Feed Tank

INTRODUCTION: A general description of Phenol Drain Drum and Dephenolation Feed

- Describe why this equipment is necessary and how they function.

- Identify the auxiliary equipment necessary and how the equipment

- Describe the instrumentation scheme.

TRAINING AIDS: - Instructors Notes.

- Projector: Process Flow Diagram.

REFERENCES: - Process Description: Dephenolation (1.8)

- Piping and Instrument Diagrams (P&ID):

2. Describe the principles of operations.

1. Process Description: Dephenolation (1.8)

Phenol Drain Drum

Dephenolation Feed Tank Operating Principles

OPERATIONS TRAINING PROGRAM

PART 8: MHP DECOMPOSITION AND DEPHENOLATION

INTRODUCTION: A general description of Dephenolation, discussing the principles of

- Describe why these equipment are necessary and how they

- Identify the auxiliary equipment necessary and how the equipment

- Describe the instrumentation scheme.

TRAINING AIDS: - Instructors Notes.

- Projector: Process Flow Diagram

- Projector: Extraction Column Internals

REFERENCES: - Process Description: Dephenolation (1.8)

- Piping and Instrument Diagrams (P&ID):