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CUMENE
PROJECT REPORT
Submitted by
OF
DIPLOMA
IN
CHEMICAL ENGINEERING.
SHREE KJ POLYTECHNIC, BHARUCH
CERTIFICATE
This is to certify that SAVALIYA DIVYAM B., PATEL TIRTH., PATEL SHREYAS.,
successfully completed the Term-work in the Subject PROJECT (360501) offered during the
• 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.
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
• 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
We extend our sincere gratitude to our guide Shri K .J Panchal sir and Head
of department in Chemical Engineering Prof. Shri. sir in SHREE KJ
POLYTECHNIC, BHARUCH for sharing his knowledge and resources and also for
his availability.
We are also thankful to Shri K.J . Panchal sir our project group guider in
Chemical Engineering Department.
For extending his help in the course, we are also thanks to all the authors
and editors of various reference books, research paper that helped us through his
report.
From. To.
1 Introduction
1.1 Introduction
1.2 Structural formula
1.3 Market analysis
1.4 List manufacturers of cumene
1.5 Properties
1.6 Uses & Application
1.7 Raw materials
1.8 Catalyst used
3.1 Equipment
3.3 Instrumentation
4 Material balance
6 Plant location
7 Economic evaluation
8.1 Safety
8.2 Pollution
10 Conclusion
11 Preference
Chapter 1
INTRODUCTION
1.1 INTRODUCTION
hydrocarbon with an aliphatic substitution. It is a constituent of crude oil and refined fuels. It is a
flammable colorless liquid that has a boiling point of 152 °C. Nearly all the cumene that is
petrochemical C3 compound.
• The cumene molecular have can be visualize as straight chain propylene group have
• The cumene production capacity of the world is about 7 million Ton/day distribute over
40 plant.
Kieselguhr(skpa).
• Only few plants are based on the MONSANTO TECHNOLOGY, which uses aluminum
• Cumene producers account for approximately 20% of the global demand for benzene.
1.2 STRUCTURE
Essentially, all world cumene is consumed for the production of phenol and acetone. As
a result, demand for cumene is strongly tied to the phenol market. Trade In cumene accounts for
only 4% of world production. The largest exporter of cumene are the United States & Japan.
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.
Increased demand for bisphenol A and phenolic resin will result in strong Demand for
phenol, particularly in Asia (excluding Japan). As a result, consumption of cumene for phenol is
forecast to grow at approximately 8% per year in the region China alone is expected to add a
million metric ton of cumene capacity during stream in 2013) to supply its phenol/ acetone plants
that are slated to come on stream during that period. Overall, world wide cumene consumption
for the production of phenol/acetone is forecast to grow at an average annual rate of about 4.5%
during 2010–2015.
• Color :- colorless
• Odour. :- odourless
• Purity :- 99%
oxygen.
✓ C6H5CH(CH3)2 + O2 = C6H5(CH3)2COOH.
1. Cumene is a natural component of coal tar and crude oil, and also can be used as
3. Additional, cumene I’m minor amounts is used as a solvent during the manufacturing of
➢ 1.Benzene
➢ 2.Propane
➢ 3.Propylene.
➢ QZ-2000™
&
➢ QZ-2001™
y UOP
Chapter :- 2
manufacturing.
1. Raw material propylene and benzene are used for the production of cumene.
2. These are stored in the respective storage tanks of 500MT capacity in the storage yard
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
4. This reactant mixture passed through a fired super heater where reaction temperature
350℃ is obtained.
5. The vapor mixture is sent to the reactor tube side which is packed with the solid
phosphoric acid catalyst supported on the the exothermal heat is removed by the
pressurized water which is used for steam production and the effluent from the reactor
i.e. cumene, p-DIPB, unreacted benzene, propylene and propane with temperature
350℃ is used as the heating media in the vaporizer which used for the benzene
vaporizing and cooled to 40℃ in a water cooler, propylene and propane are separated
from the liquid mixture of cumene, p-DIPB, benzene in a separator operating slightly
above atmospheric and the pressure is controlled by the vapor control value of the
separator, the fuel gas is used as fuel for the furnace also.
6. The liquid mixture is sent to the benzene distillation column which operates at 1
atmospheric pressure, 98.1% of benzene is obtained as the distillate and used as recycle
and the bottom liquid mixture is pumped at bubble point to the cumene distillation
column where distillate 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 are
8. The typical reactor effluent yield contains 94.8 Wt. % cumene and 3.1 Wt. % of diiso
9. This high yield of cumene is achieved without of diiso propyl benzene and is unique
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
11. The overall yields of cumene for this process are typically 97-98 Wt. % with trans
The fresh benzene is routed through the upper midsection of the depropanizer
column to remove excess water and then sent to the alkylation reactor via a side draw.
The recycle benzene to both the alkylation and trans alkylation reactors comes from
A mixture of fresh and recycle benzene is charged down flow through the alkylation
reactor. The fresh propylene feed is split between the four catalyst beds. An excess of benzene is
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 depropanizer column, which
removes any propane and water that may have entered with the propylene feed.
The bottoms from the depropanizer column are sent to the benzene column, where
excess benzene is collected overhead and recycled. Benzene column bottoms are sent to the
cumene column, where the cumene product is recovered overhead. The Cumene column bottom
which contains most d-isopropyl benzene is send to the DIPB stream leaves the column by way
of a side cut and is recycled to the Tran alkylation reactor. The DIPB column bottom consist of
heavy aromatic by-product, which are normally blended into fuel oil. Steam or hot oil provide
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
Figure 7, PFD. of Cumene manufacturing process with all instrumentation and fittings with feed
manufacturing of Cumene
.
3.1 MAJOR EQUIPMENT
1. Alkylation reactors.
3. Depropanizer column.
4. Benzene column.
5. Cumen column.
6. DIPB column.
1. Feed drum.
2. Feed pump.
3. Feed vaporizer.
4. Feed heater.
5. Effluent coolers.
6. Phase separator.
7. Condenser.
8. Reflux pump.
9. Reboiler.
The alkylation reactor is typically divided into four catalyst beds contained in a single
reactor shell. The fresh benzene is routed through the upper midsection of the depropanizer
column to remove excess water and then sent to the alkylation reactor via a side draw. The
recycle benzene to both the alkylation and trans alkylation reactors comes from the overhead of
reactor. The fresh propylene feed is split between the four catalyst beds. An excess of benzene is
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 depropanizer column, which
removes any propane and water that may have entered with the propylene feed.
In the trans alkylation reactor, DIPB and benzene are converted to additional cumene.
The effluent from the trans alkylation reactor is then sent to the benzene column. The QZ-2000
catalyst utilized in both the alkylation and trans alkylation reactors is regenerable. At the end of
each cycle, the catalyst is typically regenerated ex-situ via a simple carbon burn by a certified
regeneration contractor. However, the unit can also be designed for in-situ catalyst regeneration.
Mild operating conditions and a corrosion-free process environment permit the use of carbon-
impurities present in the propylene feed. The depropanizer has a total condenser, partial reboiler,
20 equilibrium stages , and operates at 17 bar. The feed streams, a saturated liquid at 101.6°C,
The bottoms from the depropanizer column are sent to the benzene column, where excess
benzene is collected overhead and recycled. Benzene column bottoms are sent to the cumene
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
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.
.
3.2 Instrumentation Required In Cumene Manufacturing Process.
• Vortex flowmeters.
• Coriolis flowmeter.
• Electro pyrometer.
6. Ph measuring instruments.
• Ph meter.
• Ph indicator.
Chapter :- 4
MATERIAL BALANCE
4.1 Overall Material Balance.
C3H7(diisopropylbenzene;DIPB;C6H4[CH(CH3)2])
C3H7–C6H4-C3H7+C6H6 2(C6H5-C3H7)
= 1050.50 Kgmole/hr
=1071.94 Kgmoles/hr
= 128836.32 Kg/hr
Hence 128836.32 kg of cumene is required to be produced per hr.
= 1105.09 Kgmole
= 1381.3625 Kgmole/hr
= 107746.27 Kg/hr
Propane acts as an inert in the whole process . It is used for quenching purpose in the
reactor. It does not take part in the chemical reaction . Also It is inevitably associated
Being an inert we are neglecting propane balance in the material balance to avoid
complexity.
Products:
Kg/hr
Reactor
Propylene = 1105.09-1071.94
= 33.15/2 kmoles/hr
= 16.575 kmoles/hr
= 2685.15 Kg/hr
= 292.85 kmoles/hr
= 22820.85 kg/hr
Input = output
2) Depropanasing 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.
Feed,
D = Benzene = 15969.41Kg/hr
Column
F=D+W
154160 = D +W
F XF = DXD +WX w
Taking XF = 0.9999
, XD = 0.05
= Benzene
W = 154160 – 15969.41
= 138190.5 Kg/hr
= cumene + DIPB
= 154160 kg/hr
Input = Output
Assuming all the Benzene present in benzene column is recycled to the feed . Hence
considering negligible amount of benzene to be part of residue. This will avoid the complexity of
= 170129.5 Kg/hr.
XF = 128836.3/138190.5 = 0.932
Cumene = D = 17065.2Kg/hr
Column
F = D +W
138190.6 = D +W
Taking XD = 0.995
XW = 0.01
D = 129051 kg/hr
= 138190.5 Kg/hr.
Input = output
Chapter: 5
Capacity,(kmol/h),110
Catalyst, Zeolite -Y
Catalystregenerationfrequency,years2
Catalystlife,years6
Pressure,bar14
Conversion,%: Propylene%100
Benzene%55
Catalyst Zeolite-Y
Catalystlife,years6
Temperature,°C140-150
ConversionofDIPB,%50
Separations Units:
• Benzene column:
Operational pressure:0.3bar
• Cumene column:
Utilities:
The word utilities is not generally used for the ancillary services needed in the operation
of any production process. These services will normally be supplied from a central site facility,
(1) Electricity.
(8) Refrigeration.
Electricity:
.The power required for electrochemical processes, motor drives, lighting, and general
use maybe generated on site, but will more usually be purchased from the local supply company.
The voltage at which the supply is taken or generated will depend on the demand. For a large site
the supply will be taken at a very high voltage, typically 11,000 or 33,000 V. Transformers will
be used to step down the supply voltage to the voltages used on the site. In the United Kingdom a
three phase 415V system is used for general industrial purposes, and 240V single phase for
lighting and other low power requirements. If a number of large motors is used, a supply at an
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,
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
Cooling Water:
Natural and forced draft cooling towers are generally used to provide the cooling water
required in a site; unless water can be drawn from a convenient river or lake in sufficient
quantity.
The water required for general purposes on a site will usually be taken from the local
mains supply, unless a cheaper source of suitable quantity water is available from a river, lake or
well.
Demineralized Water:
Demineralized water from which all the minerals have been removed by ion exchange, is
used where pure water is needed for process use, and as boiler feed water. Mixed and multiple
bed ion exchange units are used, one resin converting the cations to hydrogen and the other
removing the acid radicals. Water with less than one ppm of dissolved solids can be produced.
Refrigeration:
It will be needed for processes that require temperatures below those that can be
economically obtained with cooling water. For temperatures down to around 10 o C chilled water
can be used. For lower temperatures, down to -30oC, salt brines are used to distribute the
Compressed Air:
It will be needed for general use, and for the pneumatic controllers that are usually used
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
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
3. Transport facilities.
4. Availability of labour.
9. Climate.
1. Marketing Area:
For materials that are produced in bulk quantities such as cement, mineral acids and
fertilizers where the cost of the product per ton is relatively low and the cost of transport
a significant fraction of the sales price, the plant should be located close to the primary
market. This consideration will be less important for low volume production, high-priced
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
3. Transport:
The transport of materials & products to & from the plant will be an overriding
least two major forms of transport road, rail, waterway (canal or river) or a sea port. Road
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 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,
priced fuel must be available on site for steam & power generation.
All industrial processes produce waste products & full consideration must be given to the
difficulties & cost of their disposal. The disposal of toxic & harmful effluents will be
coverd by local regulations & the appropriate authorities must be consulted during the
initial site survey to determine the standards that must be met. An environmental impact
assessment should be made for each new project or major modification or addition to an
existing process.
The proposed plant must fit in with & be acceptable to the local community. Full
consideration must be given to the safe location of the plant so that it does not impose a
significant additional risk to the community. On a new site, the local community must be
able to provide adequate facilities for the plant personnel: school, banks, housing &
The land should ideally be flat, well drained & have suitable load bearing characteristics.
A full site evaluation should be made to determine the need of piling or other special
formations.
9. Climate:
Adverse climate conditions at a site will increase cost. Abnormally low temperatures will
require the provisition of additional insulation & special heating for equipment & pipe
runs. Stronger structures will be needed at locations subject to high winds (cyclone
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
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
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
2. Process Requirements:
Equipment that needs to have frequent operator attention should be located convenient to
the control room. Valves, sample points, and instruments should be located at convenient
positions and heights. Sufficient working space and head room must be provided to allow
3. Maintenance:
Heat exchangers need to be cited so that the tube bundles can be easily withdrawn for
cleaning and tube replacement. Vessels that require frequent replacement of catalyst or
dismantling for maintenance, such as compressors and large pumps, should be placed
under cover.
4. Safety:
Blast walls maybe needed to isolate potentially hazardous equipment, and confine the
effects of an explosion. At least two escape routes for operators must be provided from
5. Plant Expansion:
Equipments should be located so that it can be conveniently tied in with any future
expansion of the process. Space should be left on pipe alleys for future needs, and
6. Modular Constructions:
In resent years there has been a move to assemble sections of plant at the plant
manufacturers site. These modules will include the equipment, structural steel, piping and
instrumentation. The modules are then transported to the plant site, by road or sea.
6.3 Plant layout.
Chapter:7
The most important aspect of plant process design is the economics behind the plant’s
construction and the future value. The initial year for the plant is 2013, and all prices and
discounts will reference to 2013 dollars. All equations used in economic analysis are included in
appendix C. The economics will be displayed in four categories: fixed capital investment,
working capital investment, capital costs, depreciation, and discounted cash flow.