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Design of Phenol Plant
Design of Phenol Plant
Economics
Design Objective
ABC Corporation is looking for a cost-effective method of attaining 300,000 tons of phenol
per year as a raw material for their downstream resin production. Currently, phenol is
purchased at $0.64 per pound. Cumene, a raw material in phenol production, can be
obtainable internally for $0.60 per pound. Our technical assignment included designing a
phenol plant, estimating the production cost of phenol per pound, and making an
economically feasible decision for ABC Corporation
Process Overview
Capital Costs
Unit
Coolers, $7.6
Misc, $15.1
Oxidation Reactor
Vent
Reactors, $13.4
Waste
Phase
Gas
4%_Oxygen, 96%_Nitrogen
Trace Amounts:
Burning as fuel
Acetone, Cumene,
credit
Carbon Dioxide
Vent to
Atmosphere
Hydrogen
Exchangers, $36.6
Columns, $25.9
Streams of compressed air and pure cumene are fed into oxidation reactors where the
cumene is oxidized to cumene hydro peroxide (CHP) and a by-product di-methyl benzyl
alcohol (DMBA). Cumene in the vent from the reactors is recovered and recycled back into
the process.
Unreacted cumene, CHP and DMBA are then sent to a distillation column where cumene in
the distillate stream is recycled back to the oxidation reactors. In the bottoms, CHP, DMBA,
and any remaining cumene is then sent to a cleavage reactor. CHP is cleaved to form Phenol
and Acetone and DMBA reacts with the sulfuric acid catalyst in the cleavage reactor to form
alpha-methyl styrene (AMS) and water.
Acetone, water, cumene, AMS, and phenol are then sent through a separation train of
distillation columns to isolate each component. Isolated cumene is recycled back into the
oxidation reactors. AMS is hydrogenated back into cumene, which is also recycled back to
the oxidation reactor. The water stream is sent to a wastewater treatment facility. The byproduct acetone is cooled and stored for sale, and the final phenol product is cooled and
sent to the resins plant.
Column T-100
Partial Condenser
Vent
Hydrogenation
Reactor Vent
Cleavage Reactor
Catalyst and
Organic Waste
Column T-104
Bottoms Waste
Compressor, $16.9
Operating Costs
Total: 23
Gas
Trace Amounts:
Nitrogen
Vent to
Atmosphere
2%_Oxygen
Total: 5
Gas
98%_Hydrogen, 2%_Cumene
Trace Amounts:
Burning as fuel
Water, Carbon
Vent to
AMS
credit
Dioxide
Atmosphere
Not Simulated
Solid
Water-Treatment Salts
Bacterial
process
Digestion
Total: 44
Liquid
98%_Water, 2%_Cumene
Trace Amounts:
Acetone
process
BTCF,
$91.4
Reactions
Misc, $2.3
Cleavage Reactor:
-Rapid CHP decomposition causing a
Runaway Exothermic Reaction
Refrigerant,$0.4
Hydrogenation Reactor:
-Flammability of Hydrogen resulting in explosion
Electricity,$3.5
Oxidation Reactor
Cleavage Reactor
(Main Reaction)
(Main Reaction)
(Side Reaction)
(Side Reaction)
Utilities,
$46.7
Raw
Materials
(Cumene &
Hydrogen,
$306
Steam,$36.9
Economic Decision
Final Production Cost of Phenol: $0.73 per pound
Simulation:
Yield of Phenol: 99 %
Benzene
Specifications:
Pressure of oxidation reactor = 80 psia
Temperature of oxidation reactor = 212F
Pressure of cleavage reactor = 14.7 psia
Temperature of oxidation reactor = 176F
Pressure of hydrogenation reactor = 110 psia
Temperature of oxidation reactor = 194F
99.9 % Purity of Acetone
99.99% Purity of Phenol
Various pressures for distillation columns
Phenolic Resins
Naphtha
Cumene
Propylene
Air
Propane
Natural gas
Naphtha
Crude Oil
Phenol
Hydrogen
Air
Water
Crude Oil