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PROJECT REPORT
Submitted by

 Patel Rutvik 166450305543

 Patel Shreyas 166450305545

 Patel Tirth. 166450305546

 Prajapati Nikul. 166450305548

 Rajput Komal. 166450305550

 Savaliya Divyam. 166450305552

IN FULFILLMENT FOR THE AWARD OF THE DEGREE

OF

DIPLOMA

IN

CHEMICAL ENGINEERING.
 PROJECT REPORT

SHREE KJ POLYTECHNIC, BHARUCH

CERTIFICATE

This is to certify that SAVALIYA DIVYAM B., PATEL TIRTH., PATEL SHREYAS.,

PATEL RUTVIK., PRAJAPATI NIKUL., RAJPUT KOMAL.

of Diploma in chemical Engineering have successfully completed the Term-work in the

Subject PROJECT (360501) offered during the academic term 2018-2019.

GUIDE HEAD OF DEPARTMENT

CUMENE 2
 PROJECT REPORT

PREFACE

• 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

more about the chemical equipment.

• 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

were not available .

• 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

existing one requires the use of design report as a preliminary estimate.

• 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

trails were conducted

CUMENE 3
 PROJECT REPORT

ACKNOWLEDGEMENT

We extend our sincere gratitude to our guide Shri K .J. Panchal sir and Head of
department in Chemical Engineering. Shri. T. P. Chowdhury sir in SHREE K. J.
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.

CUMENE 4
 INDEX
SR.no Topic Page no.

From. To.
1 Introduction

1.1 Introduction
1.2 Market analysis
1.3 List manufacturers of cumene
1.4 Properties
1.5 Uses & Application
1.6 Raw materials
1.7 Catalyst used

2 Manufacturing process with flow diagrams.

2.1 Various process of manufacturing

2.2 Selection of most suitable process
2.3 Detail description of selected process
2.4 Process equipment flow diagrams

3 List major equipment & instrumentation

required

3.1 Equipment
3.3 Instrumentation

4 Material balance

4.1 Overall material balance

4.2 Material balance for various equipment

CUMENE 5
 5 Design Basis

5.1 Plant
5.2 Design Plant Size

6 Economic evaluation

6.1 Estimation of capital cost investment

6.2 Estimation of total production cost

7 Utility required

7.1 Utilities

8 Plant location

8.1 Plant location & site selection Schematic

8.2 plant layout

9 Important aspect of safety & pollution

control

9.1 MSDS of Raw Material & Product

9.2 Gas/liquid/solid waste treatment (ETP)

10 Conclusion & Reference

CUMENE 6
CUMENE 7
 Chapter: 1
INTRODUCTION

CUMENE 8
 Chapter: 1

Introduction

Cumene (isopropyl benzene) is an organic compound that is based on an aromatic

hydrocarbon with an aliphatic substitution. It is a constituent of crude oil and refined fuels. It is a

flammable colorless liquid that has a boiling point of 152 °C. Nearly all the cumene that is produced as

a pure compound on an industrial scale is converted to cumene hydroperoxide, which is an intermediate

in the synthesis of other industrially important chemicals, primarily phenol and acetone.

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

compound.

• The cumene molecular have can be visualize as straight chain propylene group have benzene

ring attached at the middle carbon form cumene (C6H5CH(CH3)2

• The cumene production capacity of the world is about 7 million Ton/day distribute over 40

plant. • The catalyst for such a process is phosphoric acid supposed. Silica

Kieselguhr(skpa).

• Only few plants are based on the MONSANTO TECHNOLOGY, which uses aluminum

trichloride (ALCL3) as catalyst .

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

CUMENE 9
Structure.

Fig. 1, 2-dimension structure of cumene. Fig. 2, 3-dimension structure of cumene

CUMENE 10
1.2. PRESENT STATUS AND MARKET ANALYSIS.
Essentially, all world cumene is consumed for the production of phenol and acetone. As a

result, demand for cumene is strongly tied to the phenol market. Trade In cumene accounts for only 4%

of world production. The largest exporter of cumene are the United States & Japan. Taiwan also import

large volume of cumene for phenol production.

As of early 2011, the U.S. cumene market was tight-primarily as a result of a shortage of

feedstock propylene. Schedule plant maintenance by several large cumene manufacturer was also

planned for early to mid 2011. Because of the cumene shortage, phenol and acetone plant operations

rate have been reduced significantly, which in turn has restricted phenol export to Europe and higher

demand region such as Asia & South America.

Fig. 3, world consumption patterns of cumene

Increased demand for bisphenol A and phenolic resin will result in strong Demand for phenol,

particularly in Asia (excluding Japan). As a result, consumption of cumene for phenol is forecast to

grow at approximately 8% per year in the region China alone is expected to add a million metric ton of

cumene capacity during stream in 2013) to supply its phenol/ acetone plants that are slated to come on

CUMENE 11
stream during that period. Overall, worldwide cumene consumption for the production of

phenol/acetone is forecast to grow at an average annual rate of about 4.5% during 2010–2015.

1.3. LIST PRODUCER OF CUMENE.

Table 1, list global cumene manufacturers.
SR. List of cumene manufacturing industry Capacity
No

1 Herdillia chemicals Ltd. 2000 TPA

Air India building,
13thfloor,narimanpoint,
Bombay400021(Maharashtra)
2 Si group India ltd. 1470 TPA
Ballarpur road
Opp. juinagar railway station
Turbhethane,
NaviMumbai(Maharashtra)
3 Hindustan organic chemicals Industry, 40000 TPA
81,Maharishi karvemarg,
Harchandri house,
Mumbai (400002)
4 Global polychem LLC. 10301 TPA
N-2, sector 11,
Noida-201301, Uttar Pradesh.

CUMENE 12
1.3.2 LIST GLOBAL MANUFACTURER
Table 2, Global manufacturer of cumene and capacity of cumene
1 Hangzhou Tianlong Co., Ltd Zhejiang, 300000 TPA
China.

2 A.M. FOOD chemical co., Ltd Shandong, 10000 TPA

China.

3 TS CHEMICAL PVT. LTD 20000 TPA

Texas, American

4 JLM CHEMICAL .PVT .LTD 1120 TPQ

Blue Island, IL, USA

5 EniChem , ENI. CO.LTD. San 1980 TPQ

Donato Milanese, Italy

CUMENE 13
1.5 PROPERTIES

 PHYSICAL PROPERTIES OF CUMEN.

• Color :- colorless

• Odor. :- odorless

• Molecular weight. :- 120.19

• Purity :- 99%

• Melting point. :- -96.9°C

• Boiling point. :- 152.5°C

• Density :- 0.862 gm/cc

• Flash point. :- 39°C

• Vapor pressure :- 4.5 mmHg at 25°C

• Ignition point. :- 138°C

• Freezing point :- -96°C

• Thermal conductivity. :- 0.124 w×m/k

• Surface tension. :- 0.791 N/M

• Flammable limit in air. :- lower – 0.9% volume,

:-. Higher – 6.5% volume

• Toxicity limit. :- 200 PPM

• Soluble :- Water, and more solvent.

• Insoluble in. :- Alcohol, Ether, Carbotetrachloride & etc.

CUMENE 14
  CHEMICAL PROPERTIES OF CUMENE

• Cumene under goes oxidation to give cumene hydroperoxide by means of air or oxygen.

C6 H5CH(CH2)2 + O2 = C6H5 (CH3)2COOH.

• By catalytic actions of dilute sulphuric acid, cumene hydroperoxide is Split into phenol

& acetone.

C6H5(CH3)2COOH = C6H5OH + CH3COCH3

1.6 USES OF CUMENE

1. Cumene is a natural component of coal tar and crude oil, and also can be used as Blanding

component in gasoline.

2. A building-block chemical, almost all cumene approximately 98% of cumene is consumed as a

chemical intermediate in the production of phenol & acetone, two chemicals that are widely use

plastic .

3. Additional, cumene I’m minor amounts is used as a solvent during the manufacturing of paints,

lacquer & enamel.

4. Cumene is also used as a solvent for fats and raisins.

5. Cumene by itself is not generally sold by producers for consumers used.

6. Cumene in minor amounts is used as a thinner for paints, enamels and lacquers and to produce

acetophenone, the chemical intermediate dicumylperoxide and isopropyl benzene.

CUMENE 15
1.7 RAW MATERIALS USED.
Raw materials for cumene manufacturing are;

1.Benzene

2.Propane

3.Propylene.

1.8 CATALYST USED.

 QZ-2000™ &

 QZ-2001™

2000catalyst is a solid, regenerable, zeolite catalyst used to produce cumene

((isopropyl benzene) via alkylation of benzene with QZ_2001 catalyst is based

on a proprietary beta zeolite formulation developed by UOP.

CUMENE 16
 Chapter: 2

MANUFACTURING PROCESSES OF CUMENE WITH FLOW

DIAGRAMS.

CUMENE 17
2.1 Various process of manufacturing.

1) Q-max™ Manufacturing process.

2) CD -TECH manufacturing process.

3) Monsanto – Lummus Crest Cumene Process.

4) UOP cumene process .

5) Badger cumene process .

CUMENE 18
CUMENE 19
1) Q-MAX™ CUMENE manufacturing process flow diagram.

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

CUMENE 20
2) CD-TECH CUMENE manufacturing process flow diagram.

Fig.5 CD-TECH CUMENE manufacturing process.

CUMENE 21
3) MONSANTO – LUMMUS crest cumene process.

Fig.6, MONSANTO LUMMUS cumene manufacturing process

CUMENE 22
4) UOP cumene manufacturing process .

Fig.7, UOP cumene manufacturing process.

CUMENE 23
5) Badger Cumene Manufacturing Process.

Fig.8, MOBILE BADGER cumene manufacturing process.

CUMENE 24
2.3 SELECTION OF CUMENE MANUFACTURING PROCESS

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

manufacturing

Justification of selection of cumene:-

 Product yield is 99.7 weight%.

 High activity and selective with minimum by product formation.

 Typical cumene productive yield is 95.5% pure.

 Extremely tolerant to poison.

 Proven run-length of up to 5 years.

 Low catalyst cost .

 Low in investments as compare to other process.

 Reduce in solid waste.

 Corrosion free environment.

CUMENE 25
 2.4 Process description on Q-MAX ™ cumene manufacturing process.

1. Raw material propylene and benzene are used for the production of cumene.

2. These are stored in the respective storage tanks of 500MT capacity in the storage yard

pumped to the unit by the centrifugal pumps.

3. Benzene pumped to the feed vessel which mixes with the recycled benzene. Benzene stream

is pumped through the vaporizer with 25 atmospheric pressure and vaporized to the

temperature of 243℃, mixed with the propylene which is of same and temperature and

pressure of benzene stream.

4. This reactant mixture passed through a fired super heater where reaction temperature

350℃ is obtained.

5. The vapor mixture is sent to the reactor tube side which is packed with the solid phosphoric

acid catalyst supported on the exothermal heat is removed by the pressurized water which

is used for steam production and the effluent from the reactor i.e. cumene, p-DIPB,

unreacted benzene, propylene and propane with temperature 350℃ is used as the heating

media in the vaporizer which used for the benzene vaporizing and cooled to 40℃ in a water

cooler, propylene and propane are separated from the liquid mixture of cumene, p-DIPB,

benzene in a separator operating slightly above atmospheric and the pressure is controlled

by the vapor control value of the separator, the fuel gas is used as fuel for the furnace also.

6. The liquid mixture is sent to the benzene distillation column which operates at 1

atmospheric pressure, 98.1% of benzene is obtained as the distillate and used as recycle and

the bottom liquid mixture is pumped at bubble point to the cumene distillation column

where distillate

CUMENE 26
 99.9% cumene and bottom pure p-DIPB is obtained.

7. The heat of bottom product p-DIPB is used for preheating the benzene column feed, All the

utility as cooling water, electricity, steam from the boiler, pneumatic air is supplied from the

utility section.

8. The typical reactor effluent yield contains 94.8 Wt. % cumene and 3.1 Wt. % of diiso propyl

benzene. The remaining 2.1 % is primarily heavy aromatics.

9. This high yield of cumene is achieved without of di-iso propyl benzene and is unique to the

solid phosphoric acid catalyst process.

10. The cumene product is 99.9 Wt. % pure and the heavy aromatics, which have an octane

number of 109, can either be used as high-octane gasoline blending components or

combined with additional benzene and sent to a trans alkylation section of the plant where

diiso propyl benzene is converted to cumene.

11. The overall yields of cumene for this process are typically 97-98 Wt. % with trans alkylation

and 94-96 Wt. % without trans alkylation.

CUMENE 27
2.5 Manufacturing process description of Cumene.
A representative Q-Max flow diagram is shown. The alkylation reactor is typically divided

into four catalyst beds contained in a single reactor shell.

The fresh benzene is routed through the upper midsection of the depolarizer

column to remove excess water and then sent to the alkylation reactor via a side draw.

The recycle benzene to both the alkylation and trans alkylation reactors comes from the

overhead of the benzene column.

A mixture of fresh and recycle benzene is charged down flow through the alkylation

reactor. The fresh propylene feed is split between the four catalyst beds. An excess of benzene is used

to avoid polyalkylation and to help minimize olefin oligomerization.

Because the reaction is exothermic, the temperature rise in the reactor is controlled by

recycling a portion of the reactor effluent to the reactor inlet, which acts as a heat sink. In addition, the

inlet temperature of each downstream bed is reduced to the same temperature as that of the first bed

inlet by injecting a portion of cooled reactor effluent between the beds.

Effluent from the alkylation reactor is sent to the depolarizer column, which removes

any propane and water that may have entered with the propylene feed.

The bottoms from the depolarizer column are sent to the benzene column, where excess

benzene is collected overhead and recycled. Benzene column bottoms are sent to the cumene column,

where the cumene product is recovered overhead. The Cumene column bottom which contains most

isopropyl benzene is send to the DIPB stream leaves the column by way of a side cut and is recycled to

the Tran alkylation reactor. The DIPB column bottom consist of heavy aromatic by-product, which are

normally blended into fuel oil. Steam or hot oil provide the heat for the product, fractionation section.

CUMENE 28
 A portion of the recycle benzene from the top of the benzene column is combined with the

recycle DIPB from the side cut of the DIPB column and sent to the trans alkylation reactor.

In the trans alkylation reactor, DIPB and benzene are converted to additional cumene. The

effluent from the trans alkylation reactor is then sent to the benzene column. The QZ-2000 catalyst

utilized in both the alkylation and trans alkylation reactors is regenerable.

At the end of each cycle, the catalyst is typically regenerated ex-situ via a simple carbon burn

by a certified regeneration contractor. However, the unit can also be designed for in-situ catalyst

regeneration.

Mild operating conditions and a corrosion-free process environment permit the use of

carbonsteel construction and conventional process equipment.

CUMENE 29
2.4 PROCESS FLOW DIAGRAM WITH INSTRUMENTATION AND EQUIPMENT OF Q-
MAX™ PROCESS FOR CUMENE MANUFACTURING

. Fig.9, PFD. of Cumene manufacturing process with all instrumentation and fittings with feed

locations, heat exchanger, pumps, coolers etc

CUMENE 30
 Chapter: - 3

LIST MAJOR EQUIPMENT AND INSTRUMENTATION REQUIRED

IN MANUFACTURING OF CUMENE

CUMENE 31
.

CUMENE 32
 3.1 MAJOR EQUIPMENT

Major equipment required in Q-MAX ™ CUMENE MANUFACTURING are follow: -

1. Alkylation reactors. 2.

Trans alkylation reactor

3. Depolarizer column.

4. Benzene column.

5. Cumene column.

6. DIPB column.

Other general equipment used in cumene manufacturing process.

1. Feed drum.

2. Feed pump.

3. Feed vaporizer.

4. Feed heater.

5. Effluent coolers.

6. Phase separator.

7. Condenser.

8. Reflux pump.

9. Reboiler.

10. Cumene Reflux drum.

CUMENE 33
 1. Alkylation reactors.

The alkylation reactor is typically divided into four catalyst beds contained in a single reactor

shell. The fresh benzene is routed through the upper midsection of the depropanizer column to remove

excess water and then sent to the alkylation reactor via a side draw. The recycle benzene to both the

alkylation and trans alkylation reactors comes from the overhead of the benzene column.

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

CUMENE 34
 A mixture of fresh and recycle benzene is charged down flow through the alkylation

reactor. The fresh propylene feed is split between the four catalyst beds. An excess of benzene is used

to avoid polyalkylation and to help minimize olefin oligomerization.

Because the reaction is exothermic, the temperature rise in the reactor is controlled by

recycling a portion of the reactor effluent to the reactor inlet, which acts as a heat sink. In addition, the

inlet temperature of each downstream bed is reduced to the same temperature as that of the first bed

inlet by injecting a portion of cooled reactor effluent between the beds.

Effluent from the alkylation reactor is sent to the depolarizer column, which removes

any propane and water that may have entered with the propylene feed.

2. Trans alkylation reactor.

In the trans alkylation reactor, DIPB and benzene are converted to additional cumene. The

effluent from the trans alkylation reactor is then sent to the benzene column. The QZ-2000 catalyst

utilized in both the alkylation and trans alkylation reactors is regenerable. At the end of each cycle,

the catalyst is typically regenerated ex-situ via a simple carbon burn by a certified regeneration

contractor. However, the unit can also be designed for in-situ catalyst regeneration. Mild operating

conditions and a corrosion-free process environment permit the use of carbon-steel construction and

conventional process equipment.

CUMENE 35
 3. Depolarizer Reactors.

Depolarizer Reactors is reactors which removes propane, water, and other impurities present

in the propylene feed. The depolarizer has a total condenser, partial reboiler, 20 equilibrium stages , and

operates at 17 bar. The feed streams, a saturated liquid at 101.6°C, enter at stage 11 at a flow rate of

100Kmol/hr.

Fig. 11, Depolarizer Reactor.

CUMENE 36
 4. Benzene column.

The bottoms from the depolarizer column are sent to the benzene column, where excess

benzene is collected overhead and recycled. Benzene column bottoms are sent to the cumene

column, where the cumene product is recovered overhead.

Fig. 12, Benzene column.

CUMENE 37
 5. Cumene Column.

Benzene column bottoms are sent to the cumene column, where the cumene product is

recovered overhead. The Cumene column bottom which contains most d-isopropyl benzene is send to

the DIPB stream leaves the column by way of a side cut and is recycled to the Tran alkylation reactor.

The bottom liquid mixture is pumped at bubble point to the cumene distillation column where

distillate 99.9% cumene and bottom pure p-DIPB is obtained.

Fig.13, Cumene Column.

CUMENE 38
 6. DIPB COLUMN.

The Cumene column bottom which contains most d-isopropyl benzene is send to the DIPB

stream leaves the column by way of a side cut and is recycled to the Tran alkylation reactor. The DIPB

column bottom consist of heavy aromatic by-product, which are normally blended into fuel oil. Steam

or hot oil provide the heat for the product, fractionation section.

Fig. 14, DIPB Column.

CUMENE 39
 3.2 Instrumentation Required in Cumene Manufacturing Process.
Major instrumentation required in cumene manufacturing process are: -

1. Pressure measuring instruments.

 Diaphragm pressure valve.

 Border tube pressure gauge

2. Flow measuring devices.

• Turbine flow meter.

• Vortex flowmeters.

• Coriolis flowmeter.

3. Temperature measuring devices.

• Electro pyrometer.

• Helix bimetallic element thermometer.

4. Level measuring instrument.

• Radar level measuring transmitter.

• Buoyancy level measurement device.

5. Valve control and regulations.

6. Ph measuring instruments.

• Ph meter.

• Ph indicator.

CUMENE 40
 Chapter :- 4

MATERIAL BALANCE

CUMENE 41
4.1 Overall Material Balance.

Reaction’s in the Alkylation Reactor:

C3H6 + C6H6 = C6H5 - C3H7 (Cumene, IPB)

C3H6+C6H5-C3H7 = C3H7 –C6H4-C3H7

(diisopropylbenzene; DIPB; C6H4[CH(CH3)2])

Reaction’s in the Trans-Alkylation Reactor:

C3H7–C6H4-C3H7+C6H6 2(C6H5-C3H7)

Conversion of Propylene in Alkylation reactor: %100

Reactor Conversion for Trans-Alkylation reactor: %50

Basis: Per hour of operation

Amount of cumene to be obtained = 1 M ton of cumene per annum.

=106/330 tons per day of cumene.

= 106/ (330 x 24) tons of cumene per hr.

= 126.26 x 103 kg of cumene per hr.

= (126.26 x 103)/120.19 kmoles of cumene per hr.

= 1050.50 Kgmole/hr.

Assuming 97% conversion and 2% loss.

∴ Cumene required = 1050.50/ .98

=1071.94 Kgmoles/hr.

= 128836.32 Kg/hr.

CUMENE 42
 Hence 128836.32 kg of cumene is required to be produced per hr.

Propylene required =1071.94/.97

= 1105.09 Kgmole

= 1105.09 x 42 Kg/hr. of propylene

= 46413.78 Kg/hr. of propylene

Assuming benzene required is 25% extra

= 1105.09 x 1.25 Kmoles of benzene

= 1381.3625 Kgmole/hr.

= 107746.27 Kg/hr.

Propane acts as an inert in the whole process. It is used for quenching purpose in the reactor. It

does not take part in the chemical reaction. Also, It is inevitably associated with the propylene

as an impurity as their molecular weight is very close.

We assume propylene to propane ratio as 3:1.

Being an inert we are neglecting propane balance in the material balance to avoid complexity

CUMENE 43
 1.) Material balance around reactor:

Propylene = 46413.78 Kg/hr

Benzene = 107746.27 Kg/hr

Products:
ALKYLATION
Cumene = 128836.32 Kg/hr
REACTOR
Propylene = 1105.09-1071.94
DIPB =33.15 Kmoles/hr is reacted to give

Benzene required to give DIPB

= 33.15/2 kmoles/hr

= 16.575 kmoles/hr

DIPB produced= 16.575 x 162

= 2685.15 Kg/hr

Benzene in product = 1381.3625 – 1071.94 -16.575

= 292.85 kmoles/hr

= 22820.85 kg/hr

Input = 46413.78 + 107746.27 = 154160.05 Kg/hr

Output = 128836.32 + 2685.15 + 22820.85= 154342 Kg/hr

Input = output

CUMENE 44
 2) Depropanising column.

Assuming almost all the propane is removed in depropanising column and sent to reactor for

quenching. Hence material balance for depropanasing column is not considered.

CUMENE 45
 3.) Distillation column 1: (Benzene column)

Feed,

F= Benzene + cumene + DIPB = 154160 Kg/hr

XF= 22820.85/154160 = 0.1480

D = Benzene = 15969.41Kg/hr

Benzene
BENZENE COLUMN

Column W= Cumene + DIPB = 138190 kJ/KG

F=D+W

154160 = D +W

F XF = DXD +WX w

Taking XF = 0.9999

, XD = 0.05

154160 x 0.1480 = D x 0.9999 +W x 0.05

3023.5 =0.9999 D + (20374 – D) x 0.05

D = 15969.41 Kg/hr

= Benzene

W = 154160 – 15969.41

= 138190.5 Kg/hr

CUMENE 46
 = cumene + DIPB

Input = 154160 kg/hr

Output = 15969.41 + 138190.5

= 154160 kg/hr

Input = Output

Assuming all the Benzene present in benzene column is recycled to the feed . Hence considering

negligible amount of benzene to be part of residue. This will avoid the complexity of multicomponent

distillation in Cumene column.

Therefore amount of benzene recycled = 15969.5 Kg/hr.

Therefore feed actually given to the system = 154160 + 15969.5

= 170129.5 Kg/hr.

CUMENE 47
4.).Distillation column 3: (Cumene column) .

F = Cumene + DIPB = 138190.5 Kg/hr

XF = 128836.3/138190.5 = 0.932

Cumene = D = 17065.2Kg/hr

CUMENE COLUMN

DIPB = W = 371.79Kg/hr = 2%.

F = D +W

138190.6 = D +W

FXF = DXD + WXW

Taking XD = 0.995

XW = 0.01

138190.5 x 0.932 = D x 0 .995 + W x 0.01

128793.54 = 0.995D + (138190.5 – D) 0.01

D = 129051 kg/hr

W = 138190.5 – 129 = 9139.5 Kg/hr

Input = 138190.5 Kg/hr

Output = 129051 + 9139.5

= 138190.5 Kg/hr.

Input = output

CUMENE 48
Table 4, Overall Material balance of cumene manufacturing flow diagram

Chemical Input Output

Mol.wt. Kmol/hr Kg/hr Kmol/hr Kg/hr

Benzene 78 1382.4 107,746.27 204.74 15,969.42
Propylene 42 1105.09 46413.78 0 0
Propane 44 5.9 259.38 5.9 259.3844
Cumene 120 0 0 1075.43 129,051
DIPB 162 0 0 56.42 9139.5

Total - - 154,160.05 - 145,371.2

CUMENE 49
 Chapter: 5

DESIGN BASIS FOR NEW PLANT.

CUMENE 50
5.1 Design Basis.
Capacity,(kmol/h),110

• Alkylation reactor type catalytic distillation reactor

Catalyst, Zeolite -Y

Catalystregenerationfrequency,years2

Catalystlife,years6

Temperature,°C (top-bottom) 198-249

Pressure,bar14

B/P feed ratio, mole/mole1.64

Conversion,%:

Propylene%100

Benzene%55

• Trans alkylation reactor type: Single catalyst bed

Catalyst Zeolite-Y

Catalystlife,years6

Temperature,°C140-150

Benzene/DIPB feed ratio, mole/mole 5.2

ConversionofDIPB,%50

Overall yields, mol%

Separations Units:

CUMENE 51
 • Benzene column:

Type :Distillation column

Purity of Top product :%100Benzene

Purity of Bottom Product :%78.5Cumene

Operational Conditions :Tin:1030C Tbottom :1240C Ttop:45

Operational pressure:0.3bar.

• Cumene column:

Type :Distillation column

Purity of Top Product :%100Cumene

Purity of Bottom Product :%100DIPB,

Operational Conditions :Tin:1240C Tbottom:1720C Ttop:1100C

Operational pressure :0.3

CUMENE 52
 Chapter no 6

ECONOMIC EVALUATION OF PROJECT

CUMENE 53
6.1 Economic Evaluation Of Project.
Economic Evaluation Of Project is displayed in four categories following .

1. Total Capital Investment.

a) Fixed capital investment.

b) Working capital investment.

2. Total production cost.

a) Manufacturing cost.

 Variable costs.

 Plant Overhead costs.

 Fixed charges.

b) General expenses.

 Administrative expenses.

 Marketing and sales expenses.

 Research and development.

3. Net gross income .

4. Cash flow.

CUMENE 54
• Equipment purchasing cost investment

Table.8 Equipment purchasing cost investment

Sr. no. Equipment Quantity Cost in INR
MAJOR EQUIPMENT
1 Alkylation Reactor 1 9000035
2 Trans Alkylation Reactor 1 6000322
3 Benzene column 1 7939141
4 Cumene column 1 9201500
5 Depropanizer 1 4500232
6 DIPB column 1 3950023
7 Flash tank 3 2000000
8 Cooler 3 5321500
9 Heater 3 1500000
10 Compressors 1 1200000
11 Reflux drum 3 1500000
12 Reboiler 3 9000000
13 Pumps 6 8736600
14 Valves 8 5488000
15 Storages tanks 4 5000000
INSTRUMENTATION
1 Flow controller 6 500000
2 Flow measuring devices 2 50000
3 Pyrometer 2 15000
4 Level controller 6 70000
5 Level measuring 6 75000
6 Flow measuring device 8 80000
7 Flow controller 8 95600
8 Pressure measuring devices 8 80900
9 Pressure controller 8 120000
10 DCS control system 1 100000
COST OF ETP
1 Screen units 1 100000
2 Equalizers 1 100000
3 Sedimentation tank 2 200000
4 Dispersion units 1 100000
5 Aeration unit 1 100000
6 Filters 2 200000
7 Sludge thickening units 2 200000
Other cost of spare equipment used in case of failure 15000000/-
TOTAL COST EQUIPMENT 152800000

CUMENE 55
 1.TOTAL CAPITAL INVESTMENT COST.

Total Capital Investment is sum of fixed capital investment and working capital investment.

Fixed Capital Investment.

Fixed capital investment in a sum of Direct cost and Indirect cost.

I. Direct Costs: material and labour involved in actual installation of complete facility (70-85% of

fixed-capital investment)

A. Equipment + installation + instrumentation + piping + electrical + insulation + painting

(5060% of Fixed-capital investment).

1. Purchased equipment cost (PEC): (15-40% of Fixed-capital investment)

Consider purchased equipment cost = Rs. 1.528×10^8

2. Installation, including insulation and painting: (25-55% of purchased equipment cost.)

Consider the Installation cost = 40% of Purchased equipment cost

= 40% of 1.528×10^8

= 0.40 ×1.528×10^8

= Rs.0.6112×10^8

3. Instrumentation and controls, installed: (6-30% of Purchased equipment cost.)

Consider the installation cost = 20% of Purchased equipment cost

= 20% of ×1.528x10^8

= 0.20 ×1.528×10^8

= Rs. 0.3056×10^8

4. Piping installed: (10-80% of Purchased equipment cost) Consider the piping cost = 40%

Purchased equipment cost

CUMENE 56
 = 0.40 ×1.528×10^8

= Rs. 0.6112×10^8

5. Electrical, installed: (10-40% of Purchased equipment cost) Consider Electrical cost =

25% of Purchased equipment cost

= 25% of 1.528 ×10^8

= 0.25 ×1.528×10^8

= Rs.0.382×10^8

B. Buildings, process and Auxiliary: (10-70% of Purchased equipment cost

Consider Buildings, process and auxiliary cost,

= 40% of PEC

= 40% of 1.528 ×10^8

= 0.40 ×1.528×10^8

= Rs. 0.6112×10^8

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

Consider the cost of service facilities and yard improvement,

= 60% of PEC

= 60% of 1.528 ×10^8

= 0.60 ×1.528×10^8

= Rs. 0.9168×10^8

D. Land: (1-2% of fixed capital investment or 4-8% of Purchased equipment cost)

Consider the cost of land = 6% PEC

= 6% of 1.528 ×10^8

CUMENE 57
 = 0.06 ×1.528×10^8

= Rs. 0.09168×10^8

Thus, Direct cost = Rs. 5.058×10^8----- (82.74% of FCI)

II. Indirect costs: expenses which are not directly involved with material and labour of actual

installation of complete facility (15-30% of Fixed-capital investment)

A. Engineering and Supervision: (5-30% of direct costs)

Consider the cost of engineering and supervision,

= 10% of Direct costs

= 10% of 5.058 ×10^8

= 0.1× 5.058 ×10^8

= Rs.0.5058×10^8

B. Construction Expense and Contractor’s fee: (6-30% of direct costs)

Consider the construction expense and contractor’s fee,

= 10% of Direct costs

= 10% of 5.058×10^8

= 0.1× 5.058 ×10^8

= 0.5058×10^8

C. Contingency: (5-15% of Fixed-capital investment)

Consider the contingency cost = 10% of Fixed-capital investment

= 12% of 6.113×10^8

CUMENE 58
 = 0.12 × 6.113×10^8

= Rs. 0.7336×10^8 Thus,

Indirect Costs = Rs. 1.7452×10^8--- (28.55% of FCI)

I. Fixed Capital Investment:

Fixed capital investment = Direct costs + Indirect costs

= (5.058×108) + (1.7452×108)

= Rs. 6.803×108

1) Working Capital: (10-20% of Fixed-capital investment)

Consider the Working Capital = 15% of Fixed-capital investment.

= 15% of 6.803×10^8

= 0.15 × 6.803×10^8

= Rs. 1.0205×10^8

2) Total Capital Investment (TCI):

Total capital investment = Fixed capital investment + Working capital

= (6.803×10^8) + (1.0205×10^8)

= Rs. 7.8235×10^8

CUMENE 59
 Table. 9 Total capacity cost investment

Sr.no Types of costs Factors of equipment cost Total cost in ₹ 10

Million

Fixed Capital Investment

I. Direct cost

A. Purchased Equipment cost (PEC) - 1.528

Equipment installation cost 40% of (PEC) 0.6112

Installation & control 20% of (PEC) 0.3056

Piping costs 40% of (PEC) 0.6112

Electrical costs 25% of (PEC) 0.382

B. Buildings, Process & Auxiliary cost 40% of (PEC) 0.6112

C. Service facility &yard improvement. 60% of (PEC) 0.9168

D. Land 6% of (PEC) 0.09168

Total Direct cost 5.058

II Indirect costs

A. Engineering & supervision 10% of (Direct cost) 0.5058

B. Construction expenses 10% of (Direct cost) 0.5058

C. Contingency 12% of (Direct cost) 0.7336

Total indirect costs 1.7452

Total fixed capital investment 6.803

Working capital investment

1. Working capital investment 15% of fixed capital 1.0205

investment

Total Capital Investment

1. Fixed Capital Investment + (6.803×10^8) + 7.8235

Working capital investment (1.0205×10^8)

CUMENE 60
 2. ESTIMATION OF TOTAL PRODUCT COST:
I. Manufacturing Cost = Direct production cost + Fixed charges + Plant overhead cost.

A. Fixed Charges: (10-20% total product cost)

i. Depreciation: (13% of FCI for machinery and equipment and 2-3% for Building Value for)

Consider depreciation = 13% of FCI

Depreciation = (0.13×6.803×108) + (0.03×0.6112×108)

= Rs. 0.9027×108

ii. Local Taxes: (1-4% of fixed capital investment)

Consider the local taxes = 3% of fixed capital investment

= 0.03×6.803×10^8

= Rs. 0.2041×10^8

iii. Insurances: (0.4-1% of fixed capital investment)

Consider the Insurance = 0.7% of fixed capital investment

= 0.007×6.803×10^8

= Rs. 0.0476×10^8

iv. Rent: (8-12% of value of rented land and buildings)

Consider rent = 10% of value of rented land and buildings

= 10% of ((0.09168×10^8) + (0.6112×10^8))

= Rs. 0.0703x10^8

Thus, Fixed Charges = Rs. 1.2247×10^8

B. Direct Production Cost: (about 60% of total product cost)

Now we have Fixed charges = 10-20% of total product charges – (given)

CUMENE 61
Consider the Fixed charges = 15% of total product cost

Total product charge = fixed charges/15%

= 1.2247×108/15%

= 1.2247×108/0.15

= Rs. 8.1647×10^8

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

Consider the cost of raw materials, = 25% of total product cost

Raw material cost = 25% of 8.1647×10^8

= 0.25×8.1647×10^8

= Rs. 2.0412×10^8

ii. Operating Labour (OL): (10-20% of total product cost)

Consider the cost of operating labour,

= 12% of total product cost

= 12% of 8.1647×10^8

= 0.12×8.1647×10^8

= Rs. 0.9797×10^8

iii. Direct Supervisory and Clerical Labour (DS & CL): (10-25% of OL)

Consider the cost for Direct supervisory and clerical labour,

= 12% of OL

= 12% of 0.9797×10^8

= 0.12×0.9797×10^8

= Rs. 0.1176×10^8

CUMENE 62
iv. Utilities: (10-20% of total product cost)

Consider the cost of Utilities,

= 12% of total product cost

= 12% of 8.1647×10^8

= 0.12×8.1647×10^8

= Rs. 0.9797×10^8

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

Consider the maintenance and repair cost,

= 5% of fixed capital investment

= 0.05×6.803×10^8

= Rs. 0.3402×10^8

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

Consider the cost of Operating supplies,

= 15% of M & R

= 15% of 0.3402×10^8

= 0.15 ×0.3402×10^8

= Rs. 0.05103×10^8

vii. Laboratory Charges: (10-20% of OL)

Consider the Laboratory charges,

= 15% of OL

= 15% of 0.9797×10^8

= 0.15×0.9797×10^8

CUMENE 63
 = Rs. 0.1469×10^8

viii. Patent and Royalties: (0-6% of total product cost)

Consider the cost of Patent and royalties,

= 4% of total product cost

= 4% of 8.1647×10^8

= 0.04×8.1647×10^8

= Rs. 0.3266×10^8

Direct Production Cost = Rs. 4.983×108 ----- (61% of TPC)

C. Plant overhead Costs (50-70% of Operating labour, supervision, and maintenance or 5-15% of

total product cost); includes for the following: general plant upkeep and overhead, payroll overhead,

packaging, medical services, safety and protection, restaurants, recreation, salvage, laboratories, and

storage facilities.

Consider the plant overhead cost,

= 60% of OL, DS & CL, and M & R

= 60% of ((0.9797×10^8) + (0.1176×10^8) + (0.3402×10^8))

= Rs. 0.8625×10^8

Thus, Manufacture cost = Direct production cost + Fixed charges + Plant overhead costs.

Manufacture cost = (4.983×10^8) + (6.803×10^8) + (0.8625×10^8)

Manufacture cost = Rs. 12.6485×10^8

CUMENE 64
II. General Expenses = Administrative costs + distribution and selling costs + research and

development costs

A. Administrative costs:(2-6% of total product cost)

Consider the Administrative costs ,

= 5% of total product cost

= 0.05 ×8.1647×10^8

= Rs. 0.4082×10^8

B. Distribution and Selling costs: (2-20% of total product cost); includes costs for sales offices,

salesmen, shipping, and advertising.

Consider the Distribution and selling costs,

= 15% of total product cost

= 15% of 8.1647×10^8

= 0.15 ×8.1647×10^8

= Rs. 1.2247×10^8

C. Research and Development costs: (about 5% of total product cost)

Consider the Research and development costs,

= 5% of total product cost

= 5% of 8.1647×10^8

= 0.05 × 8.1647×10^8

= Rs. 0.4082×108

D. Financing (interest): (0-10% of total capital investment) Consider interest = 5% of total capital

investment

CUMENE 65
 = 5% of 7.8235×10^8

= 0.05×7.8235×10^8

= Rs. 0.3912×10^8

= Rs. 2.4323×10^8

2. Total Product cost = Manufacture cost + General Expenses

= (12.6485×10^8) + (2.4323×10^8)

= Rs. 15.0808×10^8

CUMENE 66
 Table.10 Total Production costs of Cumene plant

Sr.no Designation Factors Total ₹ in 10 Million

Manufacturing cost

A. Fixed Charges 13% of (TPC)

1. Depreciation 13%of (FCI) 0.9027

2. Local taxes 3% of (FCI) 0.2042

3. Insurance 0.7% of (FCI) 0.0476

4. Rents 10% of (FCI) 0.0703

Total Fixed cost 1.2247

B. Direct production costs 60% of (TPC)

1. Operating labour 12% of (TPC) 0.9797

2. Raw materials 25% of (TPC) 2.0412

3. Direct supervisor & Clerical Labour 12% of (OL) 0.1172

4. Utilities 12% of (TPC) 0.9797

5. Maintenance & Repairs 5% of ( TPC) 0.3402

6. Operating supply 15% of (mfg.) 0.05103

7. Labour charges 15% of( OL) 0.1469

8. Patent & royalty 4%of (TPC) 0.3266

Total Direct production costs 4.983

C. Plant Over head cost 60%of OL,DS, mfg 0.8625

Total plant Over head cost O. 862

Total Manufacturing cost 12.6485

CUMENE 67
 General Expenses

A. Administrative cost 5% of (TPC) 0.4082

B. Distribution & selling cost 15% of (TPC) 1.2247

C. Research & Development 15% of (TPC) 0.4082

D. Finance 5%of (TPC) 0.3912

Total General expenses 2.4323

Total Production costs 15.0808

CUMENE 68
 3. Gross Earnings/Income:

Wholesale Selling Price of cumene per kg = Rs.53

Total Income = Selling price × Quantity of product manufactured

= 53 x 30000000

= Rs. 15.9×10^8

Gross income = Total Income – Total capital

investment

= (15.9×108) – (8.1647×108)

= Rs. 7.7353×10^8

Let the Tax rate be 45% (common)

Net Profit = Gross income - Taxes

= Gross income× (1- Tax rate)

= 7.7353 x 10^8 (1-0.45)

= Rs. 4.2544×10^8

Net profit margin =(net profit/ annual income)*100

=(4.2544*10^8/15.9*10^8)/100

=26.756%

Pay back period = FCI/(net profit)

= 6.803*10^8/4.2544*10^8

= 1.6.

Rate of return = net profit* 100/(total capital investment)

= 4.2544*10^8*100 / 7.8235*10^8

= 54.38 %

CUMENE 69
 4. Cash Flow :

Fig. 15, Discounted cash flow of project.

CUMENE 70
 Chapter. 7

UTILITY REQUIRED IN CUMENE MANUFACTURING

CUMENE 71
 7.1 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.

(2) Steam for process heating.

(3) Cooling water.

(4) Water for general use.

(5) Demineralized water.

(6) Compressed air.

(7) Inert gas supplies.

(8) Refrigeration.

(9) Effluent disposal facilities.

Electricity:

.The power required for electrochemical processes, motor drives, lighting, and general use

maybe generated on site, but will more usually be purchased from the local supply company. The

voltage at which the supply is taken or generated will depend on the demand. For a large site the supply

will be taken at a very high voltage, typically 11,000 or 33,000 V. Transformers will be used to step

down the supply voltage to the voltages used on the site. In the United Kingdom a three phase 415V

system is used for general industrial purposes, and 240V single phase for lighting and other low power

requirements. If a number of large motors is used, a supply at an intermediate high voltage will also be

provided, typically 6000 or 11,000V.

CUMENE 72
 Steam:

The steam for heating is usually generated in water tube boilers using the most economical

fuel level available. The process temperatures required can usually be obtained with low temperature

steam typically 2.5 bar and steam distributed at a relatively low pressure, typically around 8 bar (100

psig). Higher steam pressures, or proprietary heat transfer fluids, such as dowtherm will be needed for

high process temperatures.

Combined Heat and Power (Co-generation):

The energy costs on a large site can be reduced if the electrical power required is generated on

the site and the exhaust steam from the turbines used for process heating. The overall thermal efficiency

of such systems can be in the range 70-80 %, compared with the 30-40 % obtained from a conventional

power station, where the heat in the exhaust steam is wasted in the condenser. Whether a combined heat

and power system scheme is worth considering for a particular site will depend on the size of the site,

the cost of fuel, the balance between the power and heating demands, and particularly on the

availability of and cost of, stand by supplies and the price paid for any surplus power electricity

generated.

Cooling Water:

Natural and forced draft cooling towers are generally used to provide the cooling water required

in a site; unless water can be drawn from a convenient river or lake in sufficient quantity.

Water for General Use:

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.

CUMENE 73
 Demineralized Water:

Demineralized water from which all the minerals have been removed by ion exchange, is used

where pure water is needed for process use, and as boiler feed water. Mixed and multiple bed ion

exchange units are used, one resin converting the cations to hydrogen and the other removing the acid

radicals. Water with less than one ppm of dissolved solids can be produced.

Refrigeration:

It will be needed for processes that require temperatures below those that can be economically

obtained with cooling water. For temperatures down to around 10 o C chilled water can be used. For

lower temperatures, down to -30oC, salt brines are used to distribute the “refrigeration” round the site

from a central refrigeration machine.

Compressed Air:

It will be needed for general use, and for the pneumatic controllers that are usually used for

chemical process plant control.

Inert Gases:

Where large quantities of inert gas are required for the inert blanketing of tanks and for

purging is usually supplied from a central facility. Nitrogen is normally used and is manufactured on

site in an air liquefaction plant, or purchased as liquid in tankers.

CUMENE 74
 Chapter:8

Plant locations, Plant layout & site selection.

CUMENE 75
 8.1 Plant location and site selection.

The location of the plant can have a crucial effect on the profitability of a project and the scope

for future expansion. Many factors must be considered when selecting a suitable site. The

factors to be considered are:

1. Location with respect to the marketing area

2. Raw material supply.

3. Transport facilities.

4. Availability of labour.

5. Availability of utilities: water, fuel, power.

6. Availability of suitable land.

7. Environmental impact, and effluent disposal.

8. Local community considerations.

9. Climate.

10. Political and strategic considerations.

1. Marketing Area:

For materials that are produced in bulk quantities such as cement, mineral acids and fertilizers

where the cost of the product per ton is relatively low and the cost of transport a significant

fraction of the sales price, the plant should be located close to the primary market. This

consideration will be less important for low volume production, high-priced products, such as

pharmaceuticals.

CUMENE 76
 2. Raw Materials:

The availability and price of suitable raw materials will often determine the plant location.

Plant producing bulk chemicals are best located close to the source of the major raw material:

where this is also close to the marketing area.

3. Transport:

The transport of materials & products to & from the plant will be an overriding consideration in

site selection. If practicable, site should be selected that is close to at least two major forms of

transport road, rail, waterway (canal or river) or a sea port. Road transport is being increasingly

efficient for the movement of personnel &essential equipment & supplies & the proximity of

the site airport should be considered.

4. Availability of 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 labour for recruitment & training.

5. Utilities(Services)

Chemical processes invariably require large quantities of water for cooling & general process

use, & the plant must be located near a source of water of suitable quantity. Process water may

be drawn from a river, from wells, or purchased from a local authority. At some sites the

CUMENE 77
 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.

6. Environment impact,& disposal:

All industrial processes produce waste products & full consideration must be given to the

difficulties & cost of their disposal. The disposal of toxic & harmful effluents will be

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.

7. Local community considerations:

The proposed plant must fit in with & be acceptable to the local community. Full consideration

must be given to the safe location of the plant so that it does not impose a significant additional

risk to the community. On a new site, the local community must be able to provide adequate

facilities for the plant personnel: school, banks, housing & recreational & cultural facilities

8. Land (site selection)

Sufficient suitable land must be available for the proposed plant & for future expansion. The

land should ideally be flat, well drained & have suitable load bearing characteristics. A full site

evaluation should be made to determine the need of piling or other special formations.

CUMENE 78
 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.

10. Political & Stratergic Considerations:

Capital grants tax concessions & other inducements are often given by the government to direct

renew investments to preferred locations, such as areas of high unemployment. The availability

of such grants can be the overriding consideration in site selection.

CUMENE 79
8.2 plant layout
The economic construction & efficient operation of a process unit will depend on how well he

plant & equipment specified on the process flow-sheet is laid out. The principal factors to be

considered are:

1. Economic consideration: construction & operating cost

2. The process requirements

3. Convenience of operation

4. Convenience of maintenance

5. Safety

6. 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 head for a thermosyphon reboiler.

5. 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

CUMENE 80
 and heights. Sufficient working space and head room must be provided to allow easy access to

equipment.

6. Maintenance:

Heat exchangers need to be cited so that the tube bundles can be easily withdrawn for cleaning

and tube replacement. Vessels that require frequent replacement of catalyst or packing should

be located on the outside of buildings. Equipment that requires dismantling for maintenance,

such as compressors and large pumps, should be placed under cover.

7. 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.

8. 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 allow for future requirements.

9. 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

modules are then transported to the plant site, by road or sea.

CUMENE 81
8.3 Plant layout.

Fig. 12, Plant layout.

CUMENE 82
 CHAPTER. 9

IMPORTANT ASPECT OF SAFETY AND POLLUTION

CUMENE 83
 9.1 MSDS of Raw materials and product.

HAZARDS IDENTIFICATION

Inhalation -

Breathing high concentrations may be harmful. Mist or vapor can irritate the throat and lungs.

Breathing this material may cause central nervous system depression with symptoms including nausea,

headache, dizziness, fatigue, drowsiness, or unconsciousness.

Eye Contact -

This material can cause eye irritation with tearing, redness, or a stinging or burning feeling.

Further, it can cause swelling of the eyes with blurred vision. Effects may become more serious with

repeated or prolonged contact.

Skin Contact

May cause mild skin irritation with redness and/or an itching or burning feeling. Effects may

become more serious with repeated or prolonged contact. It is likely that some components of this

material are able to pass into the body through the skin and may cause similar effects as from

breathing or swallowing it.

Ingestion –

Swallowing this material may be harmful. Swallowing this material may cause stomach or

intestinal upset with pain, nausea, and/or diarrhea. This material can get into the lungs during

swallowing or vomiting. Small amounts in the lungs can cause lung damage, possibly leading to

chronic lung dysfunction or death. Swallowing this material may cause effects.

Chronic Health Effects Summary -

Secondary effects of ingestion and subsequent aspiration into the lungs may cause pneumatically

(Lung cavity) formation and chronic lung dysfunction.

CUMENE 84
 Conditions Aggravated by Exposure -

Disorders of the following organs or organ systems that may be aggravated by significant

exposure to this material or its components include: Skin, Respiratory System, Central Nervous

System (CNS).

Target Organs –

May cause damage to the following organs: kidneys, liver, mucous membranes, spleen, upper

respiratory tract, skin, adrenal, central nervous system (CNS), eye, lens or cornea.

Carcinogenic Potential –

This product is not known to contain any components at concentrations above 0.1% which are

considered carcinogenic by OSHA, IARC or NTP.

CUMENE 85
 1. FIRST AID MEASURES

Take proper precautions to ensure your own health and safety before attempting rescue or

providing first aid.

Inhalation –

Move victim to fresh air. If victim is not breathing, immediately begin rescue breathing. If

breathing is difficult, 100 percent humidified oxygen should be administered by a qualified individual.

Seek medical attention immediately. Keep the affected individual warm and at rest.

Eye Contact –

Check for and remove contact lenses. Flush eyes with cool, clean, low-pressure water for at least

15 minutes while occasionally lifting and lowering eyelids. Do not use eye ointment unless directed to

by a physician. Seek medical attention if excessive tearing, irritation, or pain persists.

Skin Contact –

Remove contaminated shoes and clothing. Flush affected area with large amounts of water. If

skin surface is damaged, apply a clean dressing and seek medical attention. Do not use ointments. If

skin surface is not damaged, clean affected area thoroughly with mild soap and water. Seek medical

attention if tissue appears damaged or if pain or irritation persists.

Ingestion –

Do not induce vomiting. If spontaneous vomiting is about to occur, place victim’s head below

knees. If victim is drowsy or unconscious, place on the left side with head down. Never give anything

by mouth to a person who is not fully conscious. Do not leave victim unattended. Seek medical

attention immediately.

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 2. FIRE FIGHTING MEASURES

NFPA Flammability Classification - NFPA Class-IC flammable liquid.

Flash Point - Closed cup: 36°C (96°F). (Pesky-Martens.)

Lower Flammable Limit - AP 0.9 %

Upper Flammable Limit - AP 6.5 %

Auto ignition Temperature - 424°C (795°F)

Hazardous Combustion Products - Carbon dioxide, carbon monoxide, smoke, fumes,

and/or unburned h0.ydrocarbons. Special Properties –

This material releases vapors at or below ambient temperatures. When mixed with air in certain

proportions and exposed to an ignition source, its vapor can cause a flash fire. Use only with adequate

ventilation. Vapors are heavier than air and may travel long distances along the ground to an ignition

source and flash back. A vapor and air mixture can create an explosion hazard in confined spaces such

as sewers. If container is not properly cooled, it can rupture in the heat of a fire.

Extinguishing Media –

SMALL FIRE: Use dry chemicals, carbon dioxide, foam, water fog, or inert gas
(nitrogen).

LARGE FIRE: Use foam, water fog, or water spray. Water fog and spray are effective in

cooling containers and adjacent structures. However, water can cause frothing and/or may not

extinguish the fire. Water can be used to cool the external walls of vessels to prevent excessive

pressure, auto ignition or explosion. Do not use a solid stream of water directly on the fire as the water

may spread the fire to a larger area.

Protection of Fire fighters –

Firefighters must use full bunker gear including NIOSH-approved positive pressure self-

contained breathing apparatus to protect against potential hazardous combustion or decomposition

CUMENE 87
products and oxygen deficiencies. Evacuate area and fight the fire from a maximum distance or use

unmanned hose holders or monitor nozzles. Cover pooling liquid with foam. Containers can build

pressure if exposed to radiant heat; cool adjacent containers with flooding quantities of water until

well after the fire is out. Withdraw immediately from the area if there is a rising sound from a venting

safety device or discoloration of vessels, tanks, or pipelines. Be aware that burning liquid will float

on water. Notify appropriate authorities of potential fire and explosion hazard if liquid enter sewers

or waterways.

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 3. ACCIDENTAL RELEASE MEASURES

Flammable Liquid! Release causes an immediate fire or explosion hazard. Evacuate all

nonessential personnel from immediate area and establish a "regulated zone" with site control and

security. A vapor-suppressing foam may be used to reduce vapors. Eliminate all ignition sources. All

equipment used when handling this material must be grounded. Stop the leak if it can done without risk.

Do not touch or walk through spilled material. Remove spillage immediately from hard, smooth

walking areas. Prevent spilled material from entering waterways, sewers, basements, or confined areas.

Absorb or cover with dry earth, sand, or other non-combustible material and transfer to appropriate

waste containers. Use clean, non-sparking tools to collect Absorbed material. For large spills, secure

the area and control access. Prevent spilled material from entering sewers, storm drains, other drainage

systems, and natural waterways. Dike far ahead of a liquid spill to ensure complete collection. Water

mist or spray may be used to reduce or disperse vapors; but, it may not prevent ignition in closed

spaces. This material will float on water and its run-off may create an explosion or fire hazard. Verify

that responders are properly

HAZWOPER-trained and wearing appropriate respiratory equipment and fire-resistant

protective clothing during cleanup operations. In an urban area, cleanup spill as soon as possible; in

natural environments, cleanup on advice from specialists. Pick up freeliquid for recycle and/or disposal

if it can be accomplished safely with explosion-proof equipment. Collect any excess material with

absorbent pads, sand, or other inert non-combustible absorbent materials. Place into appropriate waste

containers for later disposal. Comply with all applicable local, state and federal laws and regulations.

CUMENE 89
 4. HANDLING AND STORAGE

Handling

A spill or leak can cause an immediate fire or explosion hazard. Keep containers closed and do

not handle or store near heat, sparks, or any other potential ignition sources. Avoid contact with

oxidizing agents. Do not breathe vapor. Use only with adequate ventilation and personal protection.

Never siphon by mouth. Avoid contact with eyes, skin, and clothing. Prevent contact with food and

tobacco products. Do not take internally. When performing repairs and maintenance on contaminated

equipment, keep unnecessary persons away from the area. Eliminate all potential ignition sources.

Drain and purge equipment, as necessary, to remove material residues. Follow proper entry procedures,

including compliance with 29 CFR 1910.146 prior to entering confined spaces such as tanks or pits.

Use gloves constructed of impervious materials and protective clothing if direct contact is anticipated.

Use appropriate respiratory protection when concentrations exceed any established occupational

exposure level Promptly remove contaminated clothing. Wash exposed skin thoroughly with soap and

water after handling. Non-equilibrium conditions may increase the fire hazard associated with this

product. A static electrical charge can accumulate when this material is flowing through pipes, nozzles

or filters and when it is agitated. A static spark discharge can ignite accumulated vapors particularly

during dry weather conditions. Always bond receiving containers to the fill pipe before and during

loading. Always confirm that receiving container is properly grounded.

Bonding and grounding alone may be inadequate to eliminate fire and explosion hazards associated

with electrostatic charges. Carefully review operations that may increase the risks associated with

static electricity such as tank and container filling, tank cleaning, sampling, gauging, loading, filtering,

mixing, agitation, etc. In addition to bonding and grounding, efforts to mitigate the hazards of an

electrostatic discharge may include, but are not limited to, ventilation, inerting and/or reduction of

transfer velocities. Dissipation of electrostatic charges

CUMENE 90
may be improved with the use of conductivity additives when used with other mitigation efforts,

including bonding and grounding. Always keep nozzle in contact with the container throughout the

loading process. Do not fill any portable container in or on a vehicle. Do not use compressed air for

filling, discharging or other handling operations. Product container is not designed for elevated

pressure. Do not pressurize, cut, weld, braze solder, drill, or grind oncontainers. Do not expose product

containers to flames, sparks, heat or other potential ignition sources. Empty containers may contain

material residues which can ignite with explosive force. Observe label precautions.

Storage

Keep container tightly closed. Store in a cool, dry, well-ventilated area. Store only in approved

containers. Do not store with oxidizing agents. Do not store at elevated temperatures or in direct

sunlight. Protect containers against physical damage. Head spaces in tanks and other containers may

contain a mixture of air and vapor in the flammable range. Vapor may be ignited by static discharge.

Storage area must meet OSHA requirements and applicable fire codes. Additional information

regarding the design and control of hazards associated with the handling and storage of flammable and

combustible liquids may be found in professional and industrial documents including, but not limited

to, the National Fire Protection Association (NFPA) publications NFPA 30 ("Flammable and

Combustible Liquid Code"), NFPA 77 ("Recommended Practice on Static Electricity") and the

American Petroleum

Institute (API) Recommended Practice 2003, (“Protection Against Ignitions Arising Out of Static,

Lightning, and Stray Currents"). Consult appropriate federal, state and local authorities before reusing,

reconditioning, reclaiming, recycling or disposing of empty containers or waste residues of this

product.

CUMENE 91
 5. EXPOSURE CONTROLS AND PERSONAL PROTECTION

Engineering Controls

Provide ventilation or other engineering controls to keep the airborne concentrations of vapor

or mists below the applicable workplace exposure limits indicated below. All electrical equipment

should comply with the National Electrical Code. An emergency eye wash station and safety shower

should be located near the work-station.

Personal Protective Equipment

Personal protective equipment should be selected based upon the conditions under which this

material is used. A hazard assessment of the work area for PPE requirements should be conducted by a

qualified professional pursuant to OSHA regulations. The following pictograms represent the minimum

requirements for personal protective equipment. For certain operations, additional PPE may be

required.

Eye Protection

Safety glasses equipped with side shields are recommended as minimum protection in industrial

settings. Chemical goggles should be worn during transfer operations or when there is a likelihood of

misting, splashing, or spraying of this material. A suitable emergency eye wash water and safety

shower should be located near the work station.

Hand Protection

Avoid skin contact. Use heavy duty gloves constructed of chemical resistant materials such as

Viton® or heavy nitrile rubber. Wash hands with plenty of mild soap and water before eating, drinking,

smoking, use of toilet facilities or leaving work. Do not use gasoline, kerosene, solvents or harsh

abrasives as skin cleaners.

CUMENE 92
 11111Body Protection

Avoid skin contact. Wear long-sleeved fire-retardant garments (e.g., Nomex®) while working

with flammable and combustible liquids. Additional chemical-resistant protective gear may be required

if splashing or spraying conditions exist. This may include an apron, boots and additional facial

protection. If product comes in contact with clothing, immediately remove soaked clothing and shower.

Promptly remove and discard contaminated leather goods.

Respiratory Protection

For known vapor concentrations above the occupational exposure guidelines (see below), use a

NIOSH-approved organic vapor respirator if adequate protection is provided. Protection factors vary

depending upon the type of respirator used. Respirators should be used in accordance with OSHA

requirements (29 CFR 1910.134).General Comments

Use of this material in spaces without adequate ventilation may result in generation of hazardous levels

of combustion products and/or inadequate oxygen levels forbreathing. Odor is an inadequate warning

for hazardous conditions

CUMENE 93
 6. STABILITY AND REACTIVITY

Chemical Stability - Normally stable but may form peroxides when stored for prolonged time

periods in contact with air.

Conditions to Avoid - Keep away from heat, sparks and flame. Forms peroxides with

prolonged storage.

Materials Incompatibility -Strong acids, alkalis, and oxidizers..

7. TOXICOLOGICAL INFORMATION

Toxicity Data –

Effects from Acute Exposure:

Overexposure to cumene may cause upper respiratory tract irritation and severe CNS
depression.

Effects from Prolonged or Repeated Exposure:

High-level exposure to cumene vapors significantly increases renal tubule adenoma in male rats.

Furthermore this exposure is associated with increased alveolar/broncheolar adenoma and carcinoma in

mice and with increased hepatocellular carcinoma in female mice. At this time the relevance of these

finds to human health are not clear.

CUMENE 94
 8. ECOLOGICAL INFORMATION

Eco toxicity - LC50 (fish): 1- 10 mg/l. This product is potentially toxic to freshwater and

saltwater ecosystems.

Environmental Fate - This product will normally float on water. Components will evaporate

rapidly. Aquatic toxicity values are expected to be in the range of 1 - 10 mg/l based upon data from

components and similar products. This material may be harmful to aquatic organisms and may cause

long term adverse effects in the aquatic environment. The log Kow value for this product is 3.66.

9. DISPOSAL CONSIDERATIONS

Hazard characteristic and regulatory waste stream classification can change with product use.

Accordingly, it is the responsibility of the user to determine the proper storage, transportation,

treatment and/or disposal methodologies for spent materials and residues at the time of disposition. If

discarded, Cumene is regulated by US EPA as a listed hazardous waste (U055). Transportation,

Treatment storage and disposal of waste materials must be conducted in accordance with RCRA

regulations (see 40 CFR 260 through 40 CFR 271). State and/or local regulations may be more

restrictive. Contact the RCRA/Superfund Hotline at your regional US EPA office for guidance

concerning case specific disposal issue.

CUMENE 95
 9.2 Gaseous/Liquid/Solid Waste Treatment.

Gaseous, liquid and solid waste is treated in Effluent treatment plant..

EFFLUENT TREATMENT PROCESS.

Fig.15, Cumene Effluent treatment process.

CUMENE 96
1. Screen chamber:

Remove relatively large solids to avoid abrasion of mechanical equipments and

clogging of hydraulic system.

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

• Stainless steel net with varying pore size can be utilized.

• Screens are cleaned regularly to avoid clogging.

2. Collection tank:

The collection tank collects the effluent water from the screening chamber,

stores and then pumps it to the equalization tank.

3. Equalization tank:

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

• time to timetan Effluents are stored from 8 to 12 hours in the equalization tank resulting in a

homogenous mixing of effluents and helping in neutralization.

• It eliminates shock loading on the subsequent treatment system.

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

• Reduces SS, TSS.

• Equalization makes the waste water homogenous.

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

4. Flash mixer:

CUMENE 97
Coagulants were added to the effluents:

1. Lime: (800-1000 ppm) To correct the pH up to 8-9

2. Alum: (200-300 ppm) To remove color

3. Poly electrolyte: (0.2 ppm) To settle the suspended matters & reduce SS, TSS. The addition of the

above chemicals by efficient rapid mixing facilitates homogeneous combination of flocculates to

produce microflocs.

5. Clarriflocculator:

In the clarriflocculator the water is circulated continuously by the stirrer.

• Overflowed water is taken out to the aeration tank.

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

• Flocculation provides slow mixing that leads to the formation of macro flocs, which then settles

out in the clarifier zone.

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

6. Aeration tank:

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

• Dosing of Urea and DAP is done.

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

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

• .Function of aeration is oxidation by blowing air.

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

7. Clarifier:

• The clarifier collects the biological sludge.

CUMENE 98
 • The overflowed water is called as treated effluent and disposed out.

• The outlet water quality is checked to be within the accepted limit as delineated in the norms of

the Bureau of Indian standards.

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

etc.

8. Sludge thickener:

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

• The effluent is passed through the centrifuge.

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

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

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

• Here sludge is dried and discharged.

• Partial amount of sludge is returned back to the aeration tank from thickening unit through

recycle tank called return sludge tank and disperse tank.

9. Drying beds:

Primary and secondary sludge is dried on the drying beds.

CUMENE 99
 Chapter: 10

REFERENCE & CONCLUSION

CUMENE 100
10.1. Conclusion.

As the first step preliminary analysis was carried out on the basis of the properties and application of
cumene and various processes used in its manufacture.

Cumene is used as a feed for the production of phenol its co-product acetone.

Cumene oxidation process for phenol synthesis has been growing in popularity since the 1960 and
prominent today.

The first steeps of this process are the formation of cumene Hydroperoxide .The hydroperoxideis then
selectively cleaved to Phenol and acetone

We have focused on alkylation of benzene to produce cumene Process in this project and carried out
literature survey.

The process has many advantage over its alternative processes With benchmark in parameters of
economic consideration i.e.Profitable and economically.

Viable batthesame time environment aspect and impact of pollution.

Machine requirement and raw material are easily available along with skill and unskilled labours are
available.

Cumene is nonhazardous material and safety parameters areEasily complied with.

The effluent treatment can be carried out within pollution control board norms .Hence it is as a feand
ecofriendly process.

CUMENE 101
10.2. REFERENCE.

 K. Weissermel, H.-J. Arpe Industrial Organic Chemistry fourth, Completely, Revised Edition
 http//www.cdtech.com/indexset.html.
 http://www.businesswire.com/news/home/20110921005269/en/Badger-Licensing-Provide-
CumeneBPA-Licenses-LG
 http://www.sbioinformatics.com/design_thesis/Cumene/Cumene_Properties
 http://www.dequi.eel.usp.br/~barcza/Fenol%20UOP.pdf
 http://www.primaryinfo.com/projects/cumene.html
 http://www.icis.com/v2/companies/9146114/polimeri-europa.html)
 Alkylation faromatics with ethylene and propylene :recent developments in commercial
processes Thomas F.Degnan Jr.∗, C. orriss mithh, Chaya R. Venkat)
 IntroductiontoZeoliteScienceandPractice,page853
 http://ip.com/IPCOM/000217241
 http://www.icis.com/Articles/1994/04/04/35102/kelloggdow-detail-new-route-to-cumene.html
 ChemicalprocesstechnologyJacobA.MoulijnMichielMakeeeAnneliesVanDiepenpage/279-281
 http://www.icis.com/Articles/1997/12/08/51748/mobilbadger-make-the-most-of-catayst-
use.html
 http://www.icis.com/v2/companies/9146114/polimeri-europa.html
 www.Lummus.CBI.com
 Petrochemical Production Processes Nauid Naderpour page/77-78
 Chemical process technology Jacob A. Moulijn Michiel Makeee AnneliesVan Diepen
 http://www.surechem.org/index.php?Action=document&docId=267794&db=EPA
 &tab=desc&lang=&db_query=0%3A%3A0%3A%3A0%3A&markupType=all
 “Energy Efficient Catalytic Reaction and Production of Cumene”, Russell L. Jarek, Steven M.
hornbergg, Stacia Barrow,Daniel E. Trudell, and Tina M. Neroff.
 (Ullmans Encyclopedia of Chemical Technology, Wiley-VCH, Weinheim, Germany,2003)
 http://www.cbi.com/images/uploads/tech_sheets/MTBE_Sheet_R-3.pdf
 www.encyclopedia.co.in.
 www.wekipedia.org
 www.technicaltopic.com
 www.ask.com
 www.siteselectioncriteria.com
 6-Peters,M.S.andK.D.Timmerhaus,"PlantDesignand
 EconomicsforChemicalEngineers",4thEditionMcGrawHill,
 NewYork,1991..
 Agency for toxic substances and disease from petrochemicals.
 4770BufordhighwayNe
 Atlanta,GA30341
 888232-6348
 Indian Oil Corporation Ltd. Upendramishra
 989699503

CUMENE 102
  Outline of chemical technology, Dryden’s ,gopal rao.
 Pollution control effluent treatments. s.rao.
 Unit operation of chemical engineering Mc Cabeand smith
 Instrumentation,KirkandRimboi

CUMENE 103