Production of Phenol

MANUFACTURE OF PHENOL

INTRODUCTION

INTRODUCTION

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MANUFACTURE OF PHENOL Phenol is an aromatic compound with an OH group bonded to the phenyl ring with chemical formula C6H5OH. Phenol is used in the production of disinfectants, dyes, pharmaceuticals, plastics, germicides, preservatives, synthetic resins, antiseptic, detergents and drugs. Molecular structure:

Simple phenol is an antiseptic. A phenolic compound hexachlorophene is a constituent of several mouthwashes, deodorant soaps and medicinal skin cleansers. The largest single use of phenol is to make plastics, but it also is used to make caprolactam (used to make nylon 6 and other man-made fibers) and bisphenol A (used to make epoxy and other resins). It is also used as a slimicide (a chemical that kills bacteria and fungi found in watery slimes), as a disinfectant, and in medical products. It also commonly employed as an anti-pruritic and also as a preservative for injections. The history of phenol goes back 1834 when it was first isolated from coal tar and named carbolic acid. Until the advent of synthetic phenol production, just before World War I, coal tar remained the only source of phenol. The first synthetic phenol was produced by sulfonation of benzene and hydrolysis of the sulfonate.

PHYSICAL AND CHEMICAL PROPERTIES

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MANUFACTURE OF PHENOL PHYSICAL PROPERTIES: Phenol is a caustic, poisonous, white crystalline solid at room temperature. The molecular weight and density of phenol are 94.11g/mole and 1.07g/cm 3 respectively. Phenol is soluble in water is due to its ability to form hydrogen bonds with water.

PROPERTY

VALUE

Molecular formula

C6H6O

CAS number

108-95-2

Molecular weight

94.11 g/mole

Other names

Carbolic acid, Hydroxy benzene, Phenic acid, Oxybenzene, Phenyl benzene, Benzenol

Structure

Melting point

40.5 °C, 314 K

Boiling point

181.7 °C, 455 K

Density

1.07 g/cm³

Solubility in water

8.3g/100ml

Triple point(Ttp)

314.06 K

Critical temperature(Tc)

692.4 K

Flash point (closed cup)

358.15 K

PROPERTY

VALUE

Ignition temperature

988.15 K

Upper flammable limit

8.6% in air

Lower flammable limit

1.7% in air

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MANUFACTURE OF PHENOL Heat of vaporization

45.606 KJ/mol

Heat capacity

33.91 KJ/mol

Heat of formation of solid

-165.1 KJ/mol

Heat of formation of gas

-96.44 KJ/mol

Heat of combustion

-3067 KJ/mol

CHEMICAL PROPERTIES: (a) REACTION WITH FeCl3 : Phenol gives violet coloration with ferric chloride solution (neutral) due to the formation of a colored iron complex, which is a characteristic to the existence of keto-enol tautomerism in phenols (predominantly enolic form).

This is the test of phenol. (b) ETHER FORMATION: Phenol reacts with alkyl halides in alkali solution to form phenylethers (Williamson’s synthesis). The phenoxide ion is a nucleophile and will

replace

halogenation of alkyl halide. C6H5OH + NaOH

C6H5ONa + H2O

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MANUFACTURE OF PHENOL C6H5ONa + ClCH3 C6H5OK + IC2H5

C6H5OCH3 + NaOH C6H5OC2H5 + KI

(c) Ethers are also formed when vapours of phenol and an alcohol are heated over thoria (ThO2). ThO2 C6H5OH + HOCH3

C6H5 - O - CH3 Methoxy benzene

(d) REACTION WITH PCl5: Phenol reacts with PCl5 to form chlorobenzene. The yield of chlorobenzene is poor and mainly triphenyl phosphate is formed. C6H5OH + PCI5

C6H5CI + POCI3 + HCI

3C6H5OH + POCI3

(C6H5)3 PO4 +3HCl

(e)REACTION WITH ZINC DUST: When phenol is distilled with zinc dust, benzene is obtained. C6H5OH + Zn

C6H6 + ZnO

(F)REACTION WITH AMMONIA: Phenol reacts with ammonia in presence of anhydrous zinc chloride at 300°C or ( NH4 )2 SO3 / NH3 at 150°C to form aniline. This conversion of phenol into aniline is called Bucherer reaction.

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MANUFACTURE OF PHENOL Zncl2 C6H5OH + NH3

C6H5NH2 + H2O 300o C

(g) ACTION OF P2S5: By heating phenol with phosphorus penta sulphide, thiophenols are formed. 5C6H5OH + P2S5

BAPATLA ENGINEERING COLLEGE, BAPATLA

5C6H5SH + P2O5

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MANUFACTURE OF PHENOL

LITERATURE SURVEY

LITERATURE SURVEY

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MANUFACTURE OF PHENOL COMMERCIAL PROCESSES: 1. Raschig process 2. Toluene two stage oxidation process 3. Sulfonation process 4. Cumene peroxidation process RASCHIG PROCESS: This process was developed in Germany in 1940. Benzene is first converted into Chlorobenzene by passing a mixture of benzene vapour, hydrochloric acid vapour and air under normal pressure at about 23°c in presence of a copper iron catalyst, supported on alumina. The reaction is exothermic in nature and so the temperature is maintained constant by external cooling. The conversion per pass is 10%. The Chlorobenzene after separation from unchanged reactants is hydrolyzed into phenol by heating with steam at about 400-500°c in presence of silica catalyst. The conversion is again about 10% per pass in this second step. Hydrogen chloride set free in the reaction is recovered and recycled. Crude phenol (97%) obtained according to the above reaction is purified by distillation under vacuum. The yield is about 75-85% on benzene. A small amount of HCl is sufficient to convert large amounts of benzene into phenol.

TOLUENE TWO STAGE OXIDATION PROCESS: Toluene in liquid phase is oxidized with air in a reactor under 40-70 psi in presence of a soluble cobalt catalyst maintained at 150°C. Benzoic acid and water are thus formed. The reaction is exothermic and temperature is maintained by external cooling. The crude molten benzoic acid at about 150-200°C is transferred from the reactor to distillation column, where separation of benzoic acid from un reacted toluene and produced water take place . The toluene is separated and recycled to the first oxidizing reactor. The pure benzoic acid is fed to a second reactor, where it is oxidized to phenol by air and steam under 20-25 psi at 230°C in presence of cupric benzoate catalyst promoted with manganese. The reaction mass is periodically withdrawn from the second reactor into an extractor, where it is washed with water to remove unwanted tars and benzoic acid and steam are returned to second reactor. The phenol, water and unreacted benzoic acid are conducted BAPATLA ENGINEERING COLLEGE, BAPATLA

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MANUFACTURE OF PHENOL overhead to two distillation columns in series. In the first column, crude phenol is separated from overhead and unreacted benzoic acid is recycled to the second oxidizing reactor. Pure form phenol is obtained at the second distillation column as overhead product and supply's aromatics compounds and benzoic acid as a feed to crude phenol rectification column. The yield of phenol on benzoic acid is about 75- 80%.

SULFONATION PROCESS: It is one of the oldest methods of manufacture of phenol. Benzene sulphonic acid is first prepared by passing vapour of benzene into concentrated sulphuric acid is about 150170°C.The water formed during sulphonation process is distilled out because sulfuric acid gets diluted and conditions accelerates backward reaction of the process. Benzene sulphonic acid should be neutralized by reacting it with aqueous sodium sulphite to form salt of benzene sulphonic acid. The sodium salt is filtered off and then fused with caustic in a cast iron vessel at about 340-380°C in the ratio (1:3) for about 5-6 hours. As a result, sodium phenate is formed. The melt is cooled, extracted with water and then acidified with sulphur dioxide. The latter is obtained as a result of neutralization of benzene sulphonic acid with sodium sulphite. The upper oily layer of crude phenol is distilled under vacuum to get pure phenol. The yield is about 80-90% on benzene. The lower layer contains sodium sulphite which is separated and used for the neutralization of benzene sulphonic acid.

CUMENE PEROXIDATION PROCESS: Benzene and purified propylene obtained from petroleum industry are mixed in liquid or vapour phase in presence of phosphoric acid on kieselguhr. As a result, Cumene or iso propyl benzene is formed. The Cumene thus formed is made in to the form of an emulsion with dilute aqueous sodium carbonate solution, using sodium stearate as an emulsifier. The emulsion is then oxidized in an oxidizer with air under atmospheric pressure for 3 – 4 hours in presence of catalyst, such as copper, cobalt or manganese salt. The temperature and Ph of the reaction are maintained between 160-260°C and 8.5-10.5 respectively. As a result of oxidation, Cumene hydro peroxide is formed. The peroxide thus formed is then decomposed by 5-50%sulphuric acid in an acidifier at 45-65°C under pressure. As a result of

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MANUFACTURE OF PHENOL decomposition, phenol (15%), acetone (9%), Cumene (73%) are formed along with some αmethylstyrene and acetophenone. These separated in a separator. The Cumene is recycled to be used again and phenol is either extracted or recovered by distillation. The yield is about 92%.

SUPPLY AND DEMAND OF PHENOL DEMAND OF PHENOL: BAPATLA ENGINEERING COLLEGE, BAPATLA

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MANUFACTURE OF PHENOL The phenol/acetone capacity expansion in the world has been brisk in recent years due to the strong demand for its derivatives such as Bisphenol A and phenolic resins. The largest single market for phenol is in the production of Bisphenol A (BPA), which is manufactured from phenol and acetone. About 40% of BPA is made up from phenol. World consumption of phenol for BPA is estimated to grow at a good average annual rate during 2009–2014. Increased demand and capacity for BPA will result in strong demand for phenol in these regions. Bisphenol A of Asian demand is expected to increase by 13% this year. The secondlargest derivative market for phenol is phenol resins which are used in the moulding of heatresistant components for household appliances, counter-top and flooring laminates, and foundry castings. From ICIS news, the global phenol market has been growing at an average of 5% per year and total demand will recover from 7.9M tonnes in 2009 to reach 10.6M tonnes by 2015. The phenol markets look especially promising in China since 2000.

SUPPLY OF PHENOL: Shell, Sunoco, Georgia Gulf, Dow, JLM and INEOS are the major producer in United State. Shell Chemical LP have a facility that is fully integrated from raw materials to end products gives Shell Chemical LP a significant advantage in operating as a low cost producer of phenol. However, INEOS Chemical is the world largest phenol producer. INEOS Chemical produce 540 kilo tonne per year to USA and 1330 kilo tonne per year to Europe while Sunoco produces over 590,000 TPA of phenol in its facility in Philadelphia, Penn, USA. Sunoco/UOP phenol technology is currently used in 11 plants worldwide having a total phenol capacity of more than 1,500,000 TPA. The capacity of phenol in China still cannot meet the demand thus many enterprises are plan to expand or construct the new units.

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MANUFACTURE OF PHENOL

PROCESS DESCRIPTION

PROCESS DESCRIPTION In this production process, purified Cumene is used as raw material input and is mixed with recycle Cumene in the main feed stream. It is feed to the oxidation vessel which

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MANUFACTURE OF PHENOL the condition is maintained at 110-115 ˚C and pH range of 6.0 to 8.0. In the vessel, the mixture from the feed is exposed to compressed air until Cumene has converted into Cumene Hydroperoxide. This is the stoichiometry equation of the reaction.

C6H5CH (CH3)2 + O2

C6H5C (CH3)2OOH

Here in this reactor a side reaction also takes place. Cumene reacts with oxygen to produce acetophenone and methylstyrene along with methane gas. The reaction involved is

2C6H5CH (CH3)2 + 1/2O2

C6H5CC2H5 + C6H5COCH3+ CH4

The crude mixture from the oxidizer is concentrated before entering the reactor where the Cumene Hydroperoxide is cleavage to phenol and acetone. The reaction is carried out in mild temperature and pressure around 70 ˚C and atmospheric pressure. Small amount of sulphuric acid is added to the reactor as the reaction takes place. Here sulphuric acid acts as catalyst. The reaction that takes place in this reactor is

C6H5C (CH3)2OOH

C6H5OH + CH3COCH3

Then the produced products are sent to the separator. In the separator all the gases are allowed to outlet.

Now the entire crude is sent through a series of distillation columns. In the first distillation column acetone is removed as the top. For this the distillation column is maintained at the temperature of 100 ˚C and normal atmospheric pressure. Then acetone is obtained as a by-product from the top. Then the bottom product is sent to next distillation column. BAPATLA ENGINEERING COLLEGE, BAPATLA

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MANUFACTURE OF PHENOL The second distillation column is maintained at the temperature of 160 ˚C and a normal atmospheric pressure. Here 95% of Cumene is separated as top product. Here separated Cumene may be used as recycle. Then the remaining crude is sent to next distillation column. Third distillation column is used to separate methylstyrene. Here the temperature is maintained at 175˚C and normal atmospheric pressure is maintained. Here 95% of methyl styrene is removed as top along with traces of left out Cumene. Then the remaining crude is sent to next distillation column. In the fourth distillation column phenol and acetophenone are separated. Here, in this distillation column the temperature is maintained at 190˚C and a pressure of normal atmospheric pressure is maintained. Here all the phenol is separated as top and acetophenone is removed from the bottom. Then the removed phenol is sent to crystallizer to form crystal form of phenol which is 99% pure is obtained.

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MANUFACTURE OF PHENOL

PROCESS FLOW DIAGRAM

FLOW DIAGRAM

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MANUFACTURE OF PHENOL

B1=OXIDISER, B2= CLEAVAGE TANK, B3= SEPERATOR, B4= DISTILLATION H2SO4 B4

GASES CUMENE

B1

B8

ACETONE

B3 11

AIR 8 5 METSTY

CUMENE1 14

17 B10

B5

B9

B11

PHENOL

16 15 ACETOPHE

COLUMN I, B5= DISTILLATION COLUMN II, B9= DISTILLATION COLUMN III, B10= DISTILLATION COLUMN IV, B11= CRYSTALLIZER.

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MANUFACTURE OF PHENOL

MATERIAL BALANCES

MATERIAL BALANCE

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MANUFACTURE OF PHENOL BASIS: 100 TPD OF PHENOL Here we have a yield of 90% and conversion is 60%. From the reactions all the stoichiometric coefficients are same. So in order to produce one mole of phenol one mole of cumene and one mole of air are required if the conversion is 100%. But here conversion is only 60%. So in order to produce 100 tons i.e. 1063 kmol of phenol we need 1968.52 kmol of cumene. Out of which 90% converted to phenol and remaining will be converted as by-products methylstyrene and acetophenone. Here we are taking 50% excess air for better reactivity. We are also considering air contains only oxygen and nitrogen in the ratio 21:79 respectively. So the feed for the process is 1968.52 kmol of cumene, 2952.78 kmol of oxygen and 11108.07714 kmol of nitrogen.

OXIDISER: INPUT COMPONENT CUMENE BAPATLA ENGINEERINGOXYGEN COLLEGE, BAPATLA NITROGEN TOTAL

WEIGHT(kgs) 236222.44 94488.96 311026.1599 641737.5599

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MANUFACTURE OF PHENOL

OUTPUT

CLEAVAGE INPUT

COMPONENT

WEIGHT(kgs)

NITROGEN

311026.1599

CUMENE HYDROPEROXIDE

161576

CUMENE

94488.96

OXYGEN

59528.0704

METHYLSTYRENE

6968.5608

ACETOPHENONE

7086.672

METHANE

944.8896

HYDROGEN

118.1112

TOTAL

641737.424

COMPONENT

WEIGHT(kgs)

NITROGEN

311026.1599

CUMENE HYDROPEROXIDE

161576

CUMENE

94488.96

OXYGEN

59528.0704

METHYLSTYRENE

6968.5608

ACETOPHENONE

7086.672

METHANE

944.8896

BAPATLA ENGINEERING COLLEGE, BAPATLA HYDROGEN

TOTAL

118.1112 641737.424

TANK:

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MANUFACTURE OF PHENOL

OUTPUT COMPONENT

WEIGHT(kgs)

NITROGEN

311026.1599

CUMENE

94488.96

OXYGEN

59528.0704

METHYLSTYRENE

6968.5608

ACETOPHENONE

7086.672

METHANE

944.8896

HYDROGEN

118.1112

PHENOL

99922

ACETONE

61654

TOTAL

641737.424

SEPERATOR: INPUT

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MANUFACTURE OF PHENOL COMPONENT

WEIGHT(kgs)

NITROGEN

311026.1599

CUMENE

94488.96

OXYGEN

59528.0704

METHYLSTYRENE

6968.5608

ACETOPHENONE

7086.672

METHANE

944.8896

HYDROGEN

118.1112

PHENOL

99922

ACETONE

61654

TOTAL

641737.424

OUTPUT COMPONENT

TOP(kgs)

BOTTOM (kgs)

NITROGEN

311026.1599

---

CUMENE

---

94488.96

OXYGEN

59528.0704

---

METHYLSTYRENE

---

6968.5608

ACETOPHENONE

---

7086.672

METHANE

944.8896

---

HYDROGEN

118.1112

---

PHENOL

---

99922

ACETONE

---

61654

TOTAL

371671.2311

641737.424

DISTILLATION COLUMN I

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MANUFACTURE OF PHENOL INPUT COMPONENT

WEIGHT(kgs)

CUMENE

94488.96

METHYLSTYRENE

6968.5608

ACETOPHENONE

7086.672

PHENOL

99922

ACETONE

61654

TOTAL

270120.1928

OUTPUT COMPONENT

TOP(kgs)

BOTTOM (kgs)

ACETONE

61654

---

CUMENE

---

94488.96

METHYLSTYRENE

---

6968.5608

ACETOPHENONE

---

7086.672

PHENOL

---

99922

TOTAL

61654

208466.2

DISTILLATION COLUMN II

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MANUFACTURE OF PHENOL INPUT COMPONENT

WEIGHT(kgs)

CUMENE

94488.96

METHYLSTYRENE

6968.5608

ACETOPHENONE

7086.672

PHENOL

99922

TOTAL

208466.2

OUTPUT COMPONENT

TOP(kgs)

BOTTOM (kgs)

CUMENE

89764.512

4724.448

METHYLSTYRENE

---

6968.5608

ACETOPHENONE

---

7086.672

PHENOL

---

99922

TOTAL

89764.512

118701.688

DISTILLATION COLUMN III

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MANUFACTURE OF PHENOL INPUT COMPONENT

WEIGHT(kgs)

CUMENE

4724.448

METHYLSTYRENE

6968.5608

ACETOPHENONE

7086.672

PHENOL

99922

TOTAL

118701.688

OUTPUT COMPONENT

TOP(kgs)

BOTTOM (kgs)

CUMENE

4724.448

---

METHYLSTYRENE

6620.13276

348.4

ACETOPHENONE

---

7086.672

PHENOL

---

99922

TOTAL

11344.58

107357.072

DISTILLATION COLIMN 1V

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MANUFACTURE OF PHENOL INPUT COMPONENT

WEIGHT(kgs)

METHYLSTYRENE

348.4

ACETOPHENONE

7086.672

PHENOL

99922

TOTAL

107357.072

OUTPUT COMPONENT

TOP(kgs)

BOTTOM (kgs)

METHYLSTYRENE

348.4

---

ACETOPHENONE

---

7086.672

PHENOL

99922

---

TOTAL

100270.4

7086.672

CRYSTALLIZER OUTPUT(kgs) TOP BOTTOM

COMPONENT

INPUT (kgs)

METHYLSTYRENE

348.4

348.4

---

PHENOL

99922

---

99922

TOTAL

100270.4

348.4

99922

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MANUFACTURE OF PHENOL

ENERGY BALANCE

ENERGY BALANCE

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MANUFACTURE OF PHENOL

Heat capacities of the compound are calculated by GROUP CONTRIBUTION METHOD. By Group Contribution Method Cp values of the compound are calculated by following procedure: Cp = R (A+B*T/100+D*(T/100)²) Where R is the gas constant and T is temperature in K. Parameters A, B, and D are obtained from A = ∑niai, B = ∑nibi, D = ∑nidi Where ni is the number of groups of type i, k is the total number of different kinds Of groups, and the parameters ai, bi, ci are listed.

Hydrocarbon Groups =C—(H,C) =C—(2C) =C—(2H) C—(3H,C) CO—(2C)

ai 4.0749 1.9570 4.1763 3.8452 5.43750

bi -1.0735 -0.31938 -0.47392 -0.33997 0.72091

di 0.21413 0.11911 0.099928 0.19489 -0.18312

Cp values of compounds are Cumene

= (139.2

×

10-3) + (53.76 × 10-5) T + (-39.79 × 10-8) T2 + (120.5

× 10-12) T3 Oxygen

= (29.1 ×

10-3) + (1.158 × 10-5) T + (-0.6076 × 10-8) T2 + (1.311

× 10-12) T3 Cumene peroxide = (1.345 × 105) + (3.806 × 102) T

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MANUFACTURE OF PHENOL Methyl styrene = 268.625 -0.567T + (1.33 × 10-3) T2 Acetophenone = 262.84 -0.44113T + (9.989 × 10-4) T2 Phenol = (187.858) - (0.565) T + (1.468 × 10-3) T2 Acetone = (187.858) - (0.565) T + (1.468 × 10-3) T2

Heats of formation of compounds are Methane = -74.856 KJ/mol Cumene peroxide = -149.6 KJ/mol Cumene = -41.1 KJ/mol Acetone = -249.4 KJ/mol Phenol = 158.16 KJ/mol Methylstyrene = 80 KJ/mol Acetophenone = -142.5 KJ/mol

Latent heats of vaporization of compounds are 2 Phenol = 3.0 ×10 KJ/Kg

2

Acetone = 5.11 ×10

KJ/Kg 2

Acetophenone = 3.5 ×10 Cumene = 3.12× 10

2

KJ/Kg

KJ/Kg

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MANUFACTURE OF PHENOL 2 Methylstyrene = 3.26 ×10 KJ/Kg

OXIDISER: Reference temperature: 25˚C Reactor temperature:

110˚C

Enthalpy of inlet + Heat of reaction = enthalpy of outlet + heat added (or) evolved Enthalpy associated with inlet =

∫m

CpT

=55105.85 KJ/day Enthalpy associated with outlet =

∫m

CpT

= 24886763 KJ/day Heat of reaction = heat of formation of products – heat of formation of reactants Heat of reaction = -114172.078 KJ/mol So, heat evolved from the reactor = 2547742 KJ/day

CLEAVAGE: Reference temperature: 25˚C Reactor temperature:

70˚C

Enthalpy of inlet + Heat of reaction = enthalpy of outlet + heat added (or) evolved Enthalpy associated with inlet =

∫m

CpT

=22288834 KJ/day

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MANUFACTURE OF PHENOL Enthalpy associated with outlet =

∫m

CpT

= 24396697.87 KJ/day Heat of reaction = heat of formation of products – heat of formation of reactants Heat of reaction = 62036.78 KJ/mol So, heat evolved from the reactor = 2045826.31 KJ/day

DISTILLATION COLUMN I Reference temperature = 25˚C Entering stream temperature =700C

Leaving stream top product temperature =550C Bottom product temperature =1100C

Energy Balance Equation: Enthalpy of feed + reboiler feed = enthalpy of bottom + enthalpy of top + condenser load

Condenser is used to cool vapours coming out of distillation column. Condenser load = m λ Here λ , is latent heat of vaporization Balance heat = 31788.7 KJ/day Therefore reboiler load = 23.7*10^5KJ/day

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MANUFACTURE OF PHENOL DISTILLATION COLUMN II Reference temperature = 25˚C Entering stream temperature =1100C

Leaving stream top product temperature =1200C Bottom product temperature =600C Energy Balance Equation: Enthalpy of feed + reboiler feed = enthalpy of bottom + enthalpy of top + condenser load

Condenser is used to cool vapours coming out of distillation column. Condenser load = m λ Here λ , is latent heat of vaporization Balance heat = 24876.7 KJ/day Therefore reboiler load = 19.8545*10^5KJ/day

DISTILLATION COLUMN III Reference temperature = 25˚C Entering stream temperature =600C

Leaving stream top product temperature =1200C Bottom product temperature =1400C Energy Balance Equation:

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MANUFACTURE OF PHENOL Enthalpy of feed + reboiler feed = enthalpy of bottom + enthalpy of top + condenser load

Condenser is used to cool vapours coming out of distillation column. Condenser load = m λ Here λ , is latent heat of vaporization Balance heat = 25432.7 KJ/day Therefore reboiler load = 28.7*10^5/day

DISTILLATION COLUMN IV Reference temperature = 25˚C Entering stream temperature =600C

Leaving stream top product temperature =1200C Bottom product temperature =1400C Energy Balance Equation: Enthalpy of feed + reboiler feed = enthalpy of bottom + enthalpy of top + condenser load Condenser is used to cool vapours coming out of distillation column. Condenser load = m λ Here λ , is latent heat of vaporization Balance heat = 21654.987KJ/day Therefore reboiler load = 24.7*10^5/day

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MANUFACTURE OF PHENOL

CRYSTALLIZER: Phenol crystallizes at 40.5˚C. Phenol comes out from the distillation column at 120˚C. Feed rate of phenol = 99922 Kg/day Enthalpy to be removed =

∫m

CpT = 24.9 × 103 KJ/day

DESIGN OF DISTILLATION COLUMN BAPATLA ENGINEERING COLLEGE, BAPATLA

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MANUFACTURE OF PHENOL

DESIGN OF DISTILLATION COLUMN Total number of stages = 14 Assume the tray spacing (Lt) = 0.5m The top section allowance in distillation column = 0.5m The top section allowance in distillation column = 0.5m The total height of column = 0.5 + 0.5 + 0.5 × 12 =7m Distillate rate D = 99922 Kg/day Bottom rate B = 7086.672 Kg/day R=

L D

=2

L = 2 × D = 2 × 99922 = 199844 Kg/day V =L + D = 199844 + 99922 = 299766 Kg/day Vapour flow rate is constant throughout the column BASED ON TOP CONDITIONS: Column diameter (De) =

√

4Vw π ρv U v

Maximum vapour velocity, (Uv) = (-0.171 × Lt2 + 0.27 × Lt – 0.047)

√

ρl −ρv ρv

Here, ρl = 1070 Kg/m3 ρv = 3.892 Kg/m3

BAPATLA ENGINEERING COLLEGE, BAPATLA

Page 34

MANUFACTURE OF PHENOL Then, Uv = (-0.171 × 0.52 + 0.27 × 0.5 – 0.047)

√

1070−3.892 ρv 3.892

= 0.7849 m/s (De) =

√

4 × 299766 π ×3.892× 0.7849 ×24 × 3600

= 1.2025m

Consider safety factor = 1.3 So Dc = 1.3 × 1.2025 = 1.56325 m

PLATE DESIGN:

π × Cross sectional area of column, (Ac) = 4 Dc2

=

π × 1.563252 4

= 1.9193 m2 Down comer area Ad = 12 % of Ac = 0.12 × 1.9193 = 0.2303 m2 Net area An = Ac - Ad = 1.9193 – 0.2303 = 1.698 m2 Hole area Ah = 10% of net area = 0.1 × An = 0.1689 m2

WEIR LENGTH (Wl):

BAPATLA ENGINEERING COLLEGE, BAPATLA

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MANUFACTURE OF PHENOL Fig 11.31, Coulson & Richardson, (6th vol) Ad From graph ( A c ¿

Lw ¿ × 100 vs ( Dc 0.2303 ¿ = ( 1.9193

Corresponding, (

× 100 = 12

Lw ¿ = 0.74 Dc

So, Lw = 0.74 × 1.56325 = 1.1568m

Assume parameters Weir height (hw) = 50mm Hole diameter (dh) = 5mm Plate thickness (pt) = 5mm

CHORD LENGTH (Lh): Lh Lw ¿ From plot ( D c vs ( D c ¿ Lw We have ( D c ¿

Fig 11.31, Coulson & Richardson, (6th vol)

= 0.74

Lh Corresponding ( D c ¿ = 0.18 Therefore Lh = 0.18 × 1.56325 = 0.281m BAPATLA ENGINEERING COLLEGE, BAPATLA

Page 36

MANUFACTURE OF PHENOL HOLE PITCH: Hole pitch (distance between the hole centres) ‘L p’ should not be less than 2.0 hole diameter, and the normal range will be 2.5 to 4.0 diameter. Consider, Hole pitch (Lp) = 3 × hole diameter =3 × 5 =15 mm Consider the holes are in equilateral triangle pattern. Then,

Ah Ap

2

[ ]

dh 0.9 = Lp

Ap = perforated area =

[ ]

5 = 0.9 15

Ah 0.1

=

2

= 0.1

0.1689 0.1

1.689 m2

FLOODING VELOCITY:

Ut = K1

√

ρ v −ρv ρv

Here, K1 is constant from K1 vs FLV

BAPATLA ENGINEERING COLLEGE, BAPATLA

Page 37

MANUFACTURE OF PHENOL Here, FLV is liquid vapour flow rate =

=

√

Lw ρv V w ρl

√

1.1658 3.892 299760 1070

=0.0707 From graph, K1 = 0.15 Then, Uf = 2.104 m/s Height of the bottom edge of apron above the plate,

hap=hw

– (5 to 10 mm)

The height is normally set at 5 to 10 mm below the outlet of the weir height, take it as 7mm. Then,

hap=hw

– (8 mm)

= 42 mm

PRESSURE DROP CALCULATIONS: Bottom densities ρl = 1030 Kg/m3 , ρv = 4.1 Kg/m3

Residual drop = hr =

12.5 ×10 3 ρl

Liquid weir height, how = 750

Lw =¿

= 12.1359mm

[ ] Lw lw . ρ L

Liquid feed rate below feed plate

= L+F=72719.6694 Kg/hr = 20.1999 Kg/sec

BAPATLA ENGINEERING COLLEGE, BAPATLA

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MANUFACTURE OF PHENOL l w =¿

Weir length =2.1773m,

ρL

=710.94 Kg/m3

how =33.675mm hd

Dry plate pressure drop,

2

[ ]

Uh = 51 C o

ρL ρV K 2−0.9 ( 25.4−d h )

Where Uh = The minimum design vapour velocity =

[ ρV ]

1/ 2

;(

dh

in mm) Here

, K2

is a constant, dependent on the depth of clear liquid on plate

hw +h ow

=50+33.675 = 83.675 mm

Corresponding

K2

=30.6

Then Uh =6.5655 m/sec

Here,

Ah Ap

×100=10

Corresponding Then,

hd

Co

=0.842

=15.1593 mm

Total plate drop

ht

=

hd

+(

hw +h ow

)+

hr

=15.1593 + (50+33.675) + 17.5824 =116.4167 mm Total pressure drop, (

∆ Pt

−3 ) = 9.81 × ρ L ×h t ×10 =811.9273 Pa

BAPATLA ENGINEERING COLLEGE, BAPATLA

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MANUFACTURE OF PHENOL

CLEARANCE AREA: A ap∨ A m=h ap . l w = 0.1253 m2

HEADLOSS IN DOWNCOMER:

[

Lwd hdc =166 ρL . Am

Where,

Lwd

]

2

= liquid flow rate in down comer in Kg/sec = 12934.57/3600 =

3.59244Kg/s ρl=710.94 Kg /m

3

A m =0.1253 m2

Then,

hdc =8.5357 mm

RESULTS: Total no of stages

= 14

Tray spacing (lt)

= 0.5 m

Column height

=7m

Column diameter (De)

= 1.2025 m

Superficial velocity (uv)

= 0.7849 m/s

Area of column (Ac)

= 1.9193 m2

Down corner area (Ad)

= 0.2303 m2

BAPATLA ENGINEERING COLLEGE, BAPATLA

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MANUFACTURE OF PHENOL Net area (An)

= 1.689 m2

Hole area

= 0.1689 m2

Weir length (lw)

= 1.1568 m

Weir height (hw)

= 50 mm

Hole diameter (dh)

= 5 mm

Plate thickness (pt)

= 5mm

Chord length (lh)

= 0.281 m

Hole pitch (lp)

= 15mm

Perforated Area (Ap)

= 1.689 m2

Residual Drop (hr)

= 12.1359 mm

Liquid Weir Crust (how)

= 33.6750 mm

Dry Plate Pressure Drop (hd)

= 15.1593 mm

Vapour Velocity through holes (Uh)

= 6.5655 m/s

Plate Total Pressure Drop (ht)

= 116.4167mm

Total Pressure Drop ( ∆ Pt)

= 811.9273Pa

Flooding Velocity (Uf)

= 2.1401 m/s

Liquid vapour flow factor (Flv)

= 0.0707

Height of bottom edge of apron

= 4.2mm

Clearance area (Aap)

= 0.1253m

Head loss in down corner (hdc)

= 208.6274 mm

Residence time in down corner (tr)

= 11.2402 sec

BAPATLA ENGINEERING COLLEGE, BAPATLA

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MANUFACTURE OF PHENOL

COST ESTIMATION

BAPATLA ENGINEERING COLLEGE, BAPATLA

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MANUFACTURE OF PHENOL

COST ESTIMATION

An acceptable plant must design a process that is capable of operating under conditions, which yield a profit. Capital must be allocated for direct labour and equipment. Besides many plant expenses many other indirect plant expenses are included and these must be included in the total cost analysis of plant.

A capital investment is required for any other industrial process. The capital investment plus working capital must be available to pay salaries, keep raw materials and product on hand and handle other special items required a direct cash outlay thus in an analysis of costs, manufacturing costs and general expenses including income tax must be taken into consideration.

Capital investment is defined as the total amount of money needed to supply the necessary plant and manufacturing facilities plus the amount of money required as working capital for operating of the facilities. Total capital cost = Fixed capital investment + Working capital requirement Fixed capital investment = Direct cost + Indirect cost

Fixed capital investment represents the capital necessary for the installed process equipment with all auxiliaries that are needed for complete process operation. Expenses for piping, instruments, insulation, foundations and site preparation are typical examples of costs included in the manufacturing fixed capital investment.

BAPATLA ENGINEERING COLLEGE, BAPATLA

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MANUFACTURE OF PHENOL

DIRECT COST: 1. PURCHASED EQUIPMENT COST:

EQUIPMENT

COST/UNIT

NUMBER OF

TOTAL COST

IN $

UNITS

IN $

REACTOR

600 ×10

3

2

1200 ×10

3

DISTILLATION

3 100 ×10

4

3 400 ×10

SEPERATOR

3 200 ×10

1

3 200 ×10

CRYSTALLIZER

60 ×10

1

200 ×10

8

9.3 Cr

COLUMN

3

TOTAL

3

2. INSULATION COST: Insulation cost is 10 – 15 % of PEC Assuming 15% Therefore Insulation cost (IC) = 1.395 Cr 3. PIPING & INSTALLATION COST: It is 18 – 25% of PEC Assuming 22% Therefore Piping and installation cost (PIC) = 1.86Cr

BAPATLA ENGINEERING COLLEGE, BAPATLA

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MANUFACTURE OF PHENOL

4. INSTRUMENT AND CONTROL INSTALLED: It is 50 – 70 % of PEC Assuming 60% Therefore instrument & control installed (ICI) = 5.58 Cr 5. INSTALLATION COST: It is 10 – 40 % of PEC Assuming 30% Therefore installation cost (EIC) = 2.79 Cr 6. BUILDING PROCESS AUXILIARY: It is 10 – 70 % of PEC Assuming 50% Therefore building process auxiliary (BPA) = 4.65Cr 7. SERVICE FACILITIES: It is 30 – 80 % of PEC Assuming 40% Therefore service facilities = 3.72Cr 8. YARD IMPROVEMENT: It id 10 – 20 % PEC Assuming 15% Therefore yard improvement (YI) = 1.395 Cr

BAPATLA ENGINEERING COLLEGE, BAPATLA

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MANUFACTURE OF PHENOL

9. LAND COST: It is 20% of PEC Therefore land cost (LC) = 1.86 Cr 10. TECHNOLOGY & ENGG FIELD: It is 20% of PEC Therefore technology & engg field(TEF ) = 1.86 Cr TOTAL DIRECT COST = Rs. 34.41 Cr

INDIRECT COST: 1. ENGG & SUPERVISION COST: It is 15 – 30 % of PEC Assuming 25% Therefore Engg & supervision cost (ESC) = 2.325 Cr 2. CONSTRUCTION EXPENSES & CONTRACTORS FEE: It is 34% of PEC Therefore Construction Expanses & Contractors Fee (ESC) = 3.162 Cr 3. CONTINGENCY: It is 8 – 20% 0f PEC Assuming 15% Therefore contingency = 1.395 Cr TOTAL INDIRECT COST = Rs. 6.882 Cr

BAPATLA ENGINEERING COLLEGE, BAPATLA

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MANUFACTURE OF PHENOL

Therefore, FIXED CAPITAL INVESTMENT (FCI) = DIRECT COST + INDIRECT COST = 34.14 + 6.882 = Rs.41.292 Cr

WORKING CAPITAL INVESTMENT: It is 10 – 20 % of FCL Assuming 15% Therefore Working Capital Investment (WCI) = Rs. 6.1938 Cr TOTAL CAPITAL INCVESTMENT (TCI) = FIXED CAPITAL INVESTMENT + WORKING CAPITAL INVESTMENT = 41.292 + 6.1938 = Rs. 47.4858 Cr

ESTIMATION OF TOTAL PRODUCT COST: TOTAL PRODUCT COST = MANUFACTURING COST + GENERAL EXPENSES MANUFACTURING COST = FIXED COST + DIRECT PRODUCTION COST + PLANT OVERHEAD COST

1. FIXED COST: a. DEPRECIATION: It is 10% of FCI

BAPATLA ENGINEERING COLLEGE, BAPATLA

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MANUFACTURE OF PHENOL Therefore depreciation = 4.1292 Cr

b. LOCAL TAXES: It is 3 – 4% of FCI Assuming 4% Therefore local taxes = 1.65168 Cr c. INSURANCE: It is 0.4 – 1% Assuming 1% Therefore insurance = 0.41292 Cr TOTAL FIXED CHARGES = Rs. 6.1938 Cr BUT FIXED CHARGES = 15% OF TOTAL PRODUCTION COST (TPC) THEREFORE TPC = 6.1938 ×(100/15) = 41.292 Cr

2. DIRECT PRODUCTION COST: a. RAW MATERIALS: It is 10 – 15% of TPC Assuming 15 % Therefore Raw Material Cost (RMC) = 5.36796 Cr b. OPERATING LABOUR: It is 10 – 20% of PEC

BAPATLA ENGINEERING COLLEGE, BAPATLA

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MANUFACTURE OF PHENOL Assuming 15 % Therefore Operating labour cost (OLC) = 6.1938 Cr c. DIRECT SUPERVISORY & ELECTRICAL LABOUR It is 20 % of Operating Labour Therefore Direct Supervisory & electrical labour (DSEL) = 1. 23876 Cr d. UTILITIES: It is 10 – 20% of TPC Assuming 13% Therefore cost of utilities = 6 1938 Cr e. MAINTENANCE: It is 2 – 10% of FCI Assuming 5% Therefore maintenance cost (MC) = 2.0646 Cr f. OPERATING SUPPLIES: It is 10 – 20% of maintenance cost Assuming 15% Therefore operating supplies cost (OSC) = 0.30969 Cr g. LABORATORY CHARGES: It is 10 – 20 % of Operating Labour cost Assuming 15 % Therefore labour charges = 0.92907 Cr h. PATENT AND ROYALITIES: It is 2 – 6% of TPC BAPATLA ENGINEERING COLLEGE, BAPATLA

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MANUFACTURE OF PHENOL Assuming 3% Therefore Patent & Royalties (PAR) = 1.23876 Cr

Therefore, TOTAL DIRECT PRODUCTION COST = Rs. 23.53644 Cr

3. PLANT OVERHEAD COST: It is 50 – 70% of Operating Labour, Supervisory and Maintenance. Assuming 60% Therefore Plant overhead cost (POC) = 5.6983 Cr

TOTAL MANUFACTURING COST = 6.1938 + 23.53644 + 5.6983 = RS. 35.42854 Cr

GENERAL EXPENSES: a. ADMINISTRATION COST: It is 20 – 30% of Operating Cost Assuming 25% Therefore Administration Cost (AC) = 1.58485 Cr

b. DISTRIBUTION AND MARKENTING COST: It is 2 – 20 % of total direct production cost Assuming 15% BAPATLA ENGINEERING COLLEGE, BAPATLA

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MANUFACTURE OF PHENOL Therefore distribution & Marketing cost (DMC) = 3.530466 Cr

c. RESEARCH AND DEVELOPMENT COST: It is 3% of total direct production cost Therefore Research & Development Cost (RDC) = 0.7060932 Cr TOTAL GENERAL EXPENSES =5.8214 Cr Therefore, TOTAL PRODUCT COST = 35.42854 + 5.8214 = Rs. 41.24994 Cr

GROSS EARNING AND RATE OF RETURN: Number of operating days in an year = 330 days Cost of phenol = 117 Rs / Kg 3 Product annual sales = 100 ×10 ×330 ×117

= 386.1 Cr Gross profit = Total income – Total production cost = 386.1 – 41.24994 = 344.85 Cr Assuming tax to be 35% Net profit = Gross profit × ( 1−tax ) = 344.85× ( 1−0.35 )

BAPATLA ENGINEERING COLLEGE, BAPATLA

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MANUFACTURE OF PHENOL = 244.1525 Cr

Rate of return = (Net profit / Total sales) × 100 = (244.1525/386.1) ×

100

= 63.23% Payout period = TCI / (Net profit + Depreciation) = 47.4858 / (244.1525 + 4.1292) = 0.1912 years

BAPATLA ENGINEERING COLLEGE, BAPATLA

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MANUFACTURE OF PHENOL

PLANT LAYOUT

BAPATLA ENGINEERING COLLEGE, BAPATLA

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MANUFACTURE OF PHENOL

PLANT LAYOUT

The success of an industrial venture greatly depends on geographical location of the plant. Enough care must be exercised in selecting the plant site and different factors must be considered before finalising the plant location. The plant should be located where the minimum cost of production and distribution can be obtained, also keeping in view other factors, such as room for expansion, safe living conditions for plant operating people and the surrounding community, which is also important. Consciences regarding plant location should be obtained before a design project reaches detailed estimate stage and firm location should be established upon completion of detailed design.

The choice of final site should be based on complete survey advantages and disadvantages of various geographical areas and, ultimately, on the advantages and disadvantages of available real estate.

The source of raw material is one of the most important factors influencing the location of the plant site because location near the raw materials source permits considerable reduction in transportation and storage charges. Proximity to major markets is one important consideration in selection of plant site. It should be noted that markets are needed for byproducts as well as for major final products. Power and fuel can be combined as another major factor in the choice of a plant site as their requirements are high in most of the industrial plants. A location near a source of fuel supply or large hydro electric installations may be essential for economic operations.

BAPATLA ENGINEERING COLLEGE, BAPATLA

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MANUFACTURE OF PHENOL The plant site should have access to all types of transportation; certainly two types should be available. The proximity to rail road centers and possibility of canal, river, lake or oceans transport must be considered. The kind and amount of products and raw materials determine the most suitable type of transportation facilities. Attention should be paid to local freight rates and existing road lines.

Climate is a factor that should be examined when selecting a plant site. Improper selection can have serious effect on the economic operation of a plant. The process industries use large quantities of water for cooling, washing, steam generation and as a raw material. The plant therefore must be located where a dependable supply of water is available. The temperature, mineral content silt or sand content, bacteriological content and cost for supply and purification treatment must also be considered while choosing the water supply. The site selected for a plant should have adequate capacity and facilities for waste water disposal.

The permissible tolerance levels for various methods of waste disposal should be consider carefully and potential requirements for additional waste treatment facilities should be consider, even though a given area has minimal restrictions on pollution.

Type and supply of skilled and unskilled work force available in the vicinity of proposed plant should be examined. Similarity state and local tax rates on property income, unemployed insurance, local regulations on zoning, building codes, nuisance aspects and transportation facilities have a major influence on the final choice of plant site.

Considering all the above factors and keeping in view the latest development trends, storage facilities for raw materials and intermediate and finished products may be located, in isolated areas or in adjoining areas. The plant can be located near any refinery such as MRPL, IOCL, OR IPCL. As water needed in large quantity, the site near river will be quite feasible as water can be obtained from it.

BAPATLA ENGINEERING COLLEGE, BAPATLA

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MANUFACTURE OF PHENOL Plant layout involves the layout of process units in a plant and the equipment within these process units. The layout can play an important parting determining construction and manufacturing costs and thus be planned carefully with the attention being gives to future problems that may arise. Plant layout means the disposition of the various equipment’s, material and man power etc., and services of the plant within the area of the site selected previously. The plant layout begins with the design of the factory building and goes up to the location and movement of the work table. All the facilities like equipment’s, raw materials, machinery, tools, fixtures workers etc., are given a proper place. Rational design must include arrangement of processing areas, storage areas and handling areas in efficient co-ordination and with regards to such factors as 1. New site development or addition to a previously developed site. 2. Future expansion. 3. Economic distribution of services- water, process steams, power and gas. 4. Weather condition. 5. Safety consideration- possible hazards of fire, explosion and fumes. 6. Building code requirements. 7. Waste disposal problems. 8. Sensible use of floor and elevation space.

PRINCIPLES OF PLANT LAYOUT: A few sound principals of plant layout have been brief as under, they are the principles of a. INTEGRATION: It means the integration of production centre facilities like workers, machinery, raw materials etc., in a logical and balanced manner. b. MINIMUM MOVEMENTS AND MATERIAL HANDLING:

BAPATLA ENGINEERING COLLEGE, BAPATLA

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MANUFACTURE OF PHENOL The number of movements of workers and materials should be minimized. It is better to transport materials in optimum bulk rather than in small amounts.

c. SMOOTH AND CONTINUOUS FLOW: Bottle necks, congestion points and back tracking should be removed by proper line balancing techniques. d. CUBIC SPACE UTILIZATION: Besides using the floor space of the room, the ceiling height is also to be utilized, so that more materials can be accommodated in the same room. Overhead material handling equipments save a lot of valuable floor space. e. SAFE AND IMPROVED ENVIRONMENT: Working places-safe, well ventilated and free from dust, noise, fumes, odours and other hazardous conditions decidedly increases the operating efficiency of the workers and improve their moral. All this leads to satisfaction amongst the workers and thus better employer employee relations. f. FLEXIBILITY: In automotive and other industries where models of products change after some time, it is better to permit all possible flexibility in the layout. The machinery is arranged in such a way that charges of the production process can be achieved at the least cost of disturbance. g. STORAGE FACILITIES AND RAW MATERIALS: Intermediates and finished products may be located in isolated areas or in adjoining areas. Hazardous materials stored in the large quantities should be isolated. Arranging storage of materials so as to facilitate or simplify handling is also a point to be considered in design.

BAPATLA ENGINEERING COLLEGE, BAPATLA

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MANUFACTURE OF PHENOL

h. ECONOMY OF FLOOR SPACE: Consistent with good housekeeping in the plant with proper considerations given to line of flow of materials, access to materials, space to permit working on parts of equipment that needed frequent servicing and safety and comfort of the operations. It is fundamental in chemical engineering industries that the buildings should be around the process instead of process being made to fit in buildings of conventional design of a new building to meet the requirements of the process is more scientific. i. LABOUR SUPPLY: Skilled and unskilled labour is obtained in Indian states. The villagers near the sites can accommodate

for enough of unskilled labour and all the engineering

graduates of colleges can form the skilled labour. j. MARKET: This is one of the major declining factors of plant location and in this respect the plant should be near a big city, which should be a major trade centre so that a lot of money can be saved on transportation charges and final product will have a heavy demand.

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MANUFACTURE OF PHENOL

BAPATLA ENGINEERING COLLEGE, BAPATLA

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MANUFACTURE OF PHENOL

ENGINEERING PROBLEMS AND SAFETY

BAPATLA ENGINEERING COLLEGE, BAPATLA

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MANUFACTURE OF PHENOL

ENGINEERING PROBLEMS AND SAFETY CONSIDERATIONS ENGINEERING PROBLEMS: Engineering problems in oxidation of aromatics with oxygen or air is that aromatics, being stable compounds, require relatively high reaction temperatures. However, once reaction has started, the intermediate products are much less stable and the reaction tends to drive temperatures out of control. Direct oxidation of aromatics is carried out commercially by vapour phase and liquid phase processes, the liquid phase processes are practiced at somewhat lower temperatures and therefore sophisticated systems.

SAFETY CONSIDERATIONS: There is every incentive and a real necessity foe including a survey of safety and fire hazards in a study of chemical engineering processes. Some of the important safety considerations in the chemical industries where toxic substances are manufactured, handled or used are summarized here. Suitable services should be installed where ever possible to give warning in case of liberation quantities of these substances. Every operation or process involving use of irritating and the packing of the product should be effected by mechanical means is apparatus provided with adequate enclosures and dust collecting systems in order to curtail atmospheric contamination. Any spillage of irritating or toxic dry compounds should be removed as quickly as possible, preferably by vacuum apparatus. All personnel exposed to toxic substances should be provided overalls or working clothing and also a time allowance of not less than 10 minutes at the expense of the employer for the use of baths at the end of days’ work. One or more aid tips or cabinets, containing sufficient and suitable first aid dressing and other equipment should be provided and maintained in easily available locations for immediate temporary treatment in case of accident or sudden illness. BAPATLA ENGINEERING COLLEGE, BAPATLA

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MANUFACTURE OF PHENOL

In addition to chemical hazards, mechanical hazards, electrical hazards are also to be dealt with by recognizing and incorporating with minimum safe practices prescribed by nationally recognised protection associations, engineering authorities and government bodies. Fire prevention and control, good ventilation systems are also indubitably important aspects to be considered for the safe and successful operation of chemical process industries. Measures to prevent and control circumstances which produce fatigue, such as excessive noise, inadequate ventilation, poor lighting, excessive heat and humidity, to the workers are to be taken. Sanitation in the plant should also be taken into consideration. Safety must be considered when dealing with disposal of wastes as effecting persons outside the jurisdiction of the plants. All the personnel should be thoroughly informed of the hazards connected with their duties and the measures to be taken to protect themselves there from. The management should take special responsibility of those who have placed their health, welfare and livelihood in their hands, to invite a sense of security, as safety hazards and potential deterrents to attainment of optimum technical efficiencies and product quality. No matter highly satisfactory a plant design may be from the technical and economic view point, disregard of safety, air pollutions and disposal problems will nullify an otherwise sound engineering plant design.

POLLUTION CONTROL AND SAFETY The effluent from phenol plant consists of mainly blow downs of condensers, cooler and condensates from distillation column. These may contain negligible amount of phenol. STORAGE & HANDLING Keep in a tightly closed container. Store it in a cool, dry and ventilated area from sources of ignition. Protect against physical damage. Store it separately from source of heat or ignition. Protect against physical damage. Store separately from reactive or combustible materials and out of direct sun light. Avoid dust formation and control ignition sources. Employ grounding venting and explosion relief provision in accord with accepted engineering practices in any process capable of generating dust and or static electricity. Empty only in to inert or non-flammable atmosphere. Emptying contents into a non inert atmosphere where flammable vapours may be present could cause flash fire or explosion due BAPATLA ENGINEERING COLLEGE, BAPATLA

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MANUFACTURE OF PHENOL to electrostatic discharge. All phenol workers should be properly trained on its hazards and the proper protective measure required. This training should also include emergency actions. All phenol operations should be enclosure to eliminate any potential exposure routes. Containers of this material may be hazardous when empty since they retrain product residue observe all warnings and precaution listed for the product. EXPOSURE CONTROL/PERSONAL PRODUCTION Airborne exposure limits OSHA Permissible Exposure limit (PEL) ACGIH Threshold limit value (TLV)

5ppm (TWA) (skin) 5ppm (TWA) (skin)

VENTILATION SYSTEM: A system of local is generally preferred because it can control the emission of the contaminant at its source, preventing dispersion of it into the general work area. Please refer to the ACGIH document, Industrial ventilation manual of recommended practices most recent edition for details. PERSONAL RESPIRATORS (NIOSH APPROVED): If the exposure limit is exceeded a full face piece respirator with organic vapour cartridge and dust/mist filter may be worn up to 50 times the exposure limit or the maximum use concentration specified by the appropriate regulatory agency or respirator supplier whichever is lowest. For emergencies or instance where the exposure levels are not known use a full face piece positive pressure air supplied respirator. SKIN PROTECTION: Wear impervious protective clothing including boots, gloves, lab coat, apron or coveralls to prevent skin contact. Butyl rubber and neoprene are suitable materials for personal protective equipment. EYE PROTECTION: Use chemical safety goggles and or full face shield where dusting or splashing of solution is possible. Maintain eye wash fountain and quick-drench facilities in work area.

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MANUFACTURE OF PHENOL

CONCLUSION 1. In this pre- preliminary feasibly report a design of a plant to produce 100 TPD of phenol is proposed and its feasibility was studied. 2. Demand of phenol is increasing year by year 2009 – 2015. From last year data estimation had been made until year 2015 which shown an increase quantity from 7.9 m tons in 2009 to reach 10.6 m tons by 2015. 3. After analysing properties of phenol, we found that there are many side effects if we expose to phenol such as irritation, corneal damage or blindness in humans.

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MANUFACTURE OF PHENOL

BIBLIOGRAPHY

TEXT BOOKS: 1. Analysis synthesis and design of chemical processes by Richard Turton, Richard C. Bailie, Wallanc B. Whiting, Joseph a. Shaeiwitz. 2. Plant design and economics for chemical engineers, 4th edition, by Max S. Peters, Klaus D.Timmerhaus. 3. Coulson & Richardson's Chemical Engineering by R.K. Sinnott- Volume VI, chemical Engineering design. 4. Perry's Chemical Engineers' Handbook, 8th Edition, Robert H. Perry, Don W. Green 5. Properties of Gases and Liquids, fifth edition, Bruce E.Poling, John M. Prausnitz, John P.O’Connel.

6. Optimization of Chemical Processes - Edgar, Himmelblau and Lasdon, 2nd Ed

WEB REFERENCES: 1. http://www.sciencedirect.com 2. http://webbook.nist.gov/chemistry/name-ser.html 3. http://www.wikipedia.com 4. http://www.tradeindia.com

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