Cumene Production Slide Show (group 7)

1. DESIGN OF A PLANT TO PRODUCE 10,000 TONS PER DAY OF CUMENE FROM THE REACTION OF PROPYLENE AND BENZENE IN THE PRESENCE OF AN ACID CATALYST An Undergraduate Design Report Presented By GROUP SEVEN TO THE DEPARTMENT OF CHEMICAL ENGINEERING, FEDERAL UNIVERSITY OF TECHNOLOGY, MINNA March, 2014.

2. PRESENTATION OUTLINE INTRODUCTION PROCESS ROUTE JUSTIFICATION FOR PROCESS ROUTE ALTERNATIVE PROCESS ROUTE PROCESS DESCRIPTION FLOW DIAGRAM BLOCK DIAGRAM RESULTS AND DISCUSSION CONCLUSION RECOMMENDATIONS REFERENCES .

3. INTRODUCTION Overview of Cumene Importance of Cumene - utilizing about 7% – 8% of worldwide propylene consumption Uses of Cumene - Phenol, Acetone, Acetophenone , Methyl styrene, D iisopropyl benzene and D icumyl peroxide.

4. PROCESS ROUTE The chosen process route is THE REACTIVE DISTILLATION PROCESS.

5. JUSTIFICATION FOR PROCESS ROUTE Lower Investment Higher Ultimate Capacity Safety and Environmental Acceptability.

6. ALTERNATIVE PROCESS ROUTE The conventional process - Furnace - Cooled P lug F low R eactor (PFR) - Distillation Columns.

7. REACTION EQUATIONS Alkylation Reaction Transalkylation Reaction

8. PROCESS DESCRIPTION Reactive Distillation Column Trans-Alkylation Reactor Benzene Distillation Column Cumene Distillation Column.

9. FLOW DIAGRAM

10. RESULTS AND DISCUSSION EQUIPMENT COMPONENT INPUT Mass Flow Rate (kg/ hr ) INPUT Molar Flow Rate ( kmol / hr ) OUTPUT Mass Flow Rate (kg/ hr ) OUTPUT Molar Flow Rate ( kmol / hr ) RD Column Benzene 577,991.732 7399.336 288,995.866 3,699.668 Propylene 155,685.729 3,699.668     Propane 8,193.986   185.817 8,193.986 185.817   Cumene 444,681.595 3,699.668 DIPB 19,366.070 119.344 Total 741,871.447 11,284.821 761237.517 7704.497 Benzene Distillation Column Benzene   438,154.862 5,609.172 438,154.862 5,609.172 Cumene 447,550.409 3,723.536 447,550.409 3,723.536 DIPB 21,302.677 131.278 21,302.677 131.278 Total 907,007.948 9463.986 907,007.948 9463.986 Cumene Cooler Cumene 447,550.409 3,723.536 447,550.409 3,723.536 Benzene 4,381.549 56.092 4,381.549 56.092 Total 451,931.958 3779.628 451,931.958 3779.628 Table 1.1 Summary of Material Balance

11. RESULTS AND DISCUSSION CONT. Equipment Component Heat in (kg/ hr ) Heat out (kg/ hr ) Reactive Distillation Column Benzene 734599729.898 396768427.86916 Propylene 92851255.41   Propane -18299107.398 -17826472.36581 Cumene   177412381.36128 DIPB   29109210.7267 Benzene Distillation Column Benzene 41348550.43741 10131551.63 Cumene 50035170.65031 65302478.4472 DIPB 2105752.53778 2874955.46452 Cumene Distillation Column Benzene 547555.0067 483094.02289 Cumene 66048237.8686 55403072.13824 DIPB 2913081.90242 5012677.9247 Cumene Distillation Column Pump Benzene 541301.2108 54755.0062 Cumene 653072478.44712 66048237.86865 DIPB 2874955.46452 2913881.90242 Table 1.2 Summary of Energy Balance

12. RESULTS AND DISCUSSION CONT. Equipment Parameters Results Propane Storage Tank Storage Time Number of tanks 24 Hours 17 Volumetric flow rate m 3 /hr Volume of Tank 518.575m 3 Diameter of Tank 8.706m Height of Tank 26.118m Storage Time Number of tanks 24 Hours 17 Reactive Distillation Column Pump Diameter of pipe Relative roughness 0.322m 1.5 x 10 -4 Pipe lenght Pressure drop 31.961 KN/M 2 Pump shaft power 16.98kw Equipment Parameters Results Propane Storage Tank Storage Time Number of tanks 24 Hours 17 Volumetric flow rate Volume of Tank 518.575m 3 Diameter of Tank 8.706m Height of Tank 26.118m Storage Time Number of tanks 24 Hours 17 Reactive Distillation Column Pump Diameter of pipe Relative roughness 0.322m 1.5 x 10 -4 Pipe lenght Pressure drop 31.961 KN/M 2 Pump shaft power 16.98kw Table 1.2 Summary of Result for Equipment Design

13. RESULT AND DISCUSSION CONT. QUANTITY PRICE Total production cost (TPC) 3.416 x 10 10 NGN Total direct cost (TDC) 4.449 x 10 9 NGN Total indirect cost 1.535 x 10 9 NGN Working capital (WC) 1.178 x 10 9 NGN Fixed capital investment (FCI) 5.984 x 10 9 NGN Total capital investment (TCI) 7.162 x 10 9 NGN Total direct production cost 1.82146 x 10 10 NGN Plant overhead cost (POHC) 2.986 x 10 9 NGN Manufacturing cost 2.567 x 10 10 NGN Total general expenses 8.490 x 10 9 NGN Tax Payable 3.538 x 10 9 NGN Rate of Return 60.36% Pay Back Period 2yrs Total fixed charges 4.498x 10 9 NGN Total depreciation 7.913 x 10 8 NGN Table 1.3 Summary of Cost and Economic Analysis

14. CONCLUSION The process route chosen being Reactive Distillation Process was found to be economically viable and environmentally friendly compared to other conventional route of cumene production. The proposed capacity of 10,000 tons of cumene per day with a purity of 95 % and 99.9 % yield was achieved using the stated route. At a selling price of N13,132 per ton, net profit of N 4.323 x 10 9 was realized with a perback period of two (2) years and a Return of Investment (ROI) of 98.11 %.

15. RECOMMENDATIONS In line with the capacity required in this design which is based on daily production of cumene high enough making the design cumbersome, we wish to recommend that subsequent design should be carried out on yearly basis for ease of design operation. Due to data limitation in estimating the plant cost, it is hereby recommended that more realistic data (updated data) should be used rather than rough estimate or assumed cost data. Although RD is found viable in this work it is further recommend that future work involving use of RD should intensify effort on the safety assurance of the RD column.

16. REFERENCES Sinnot,R.K . (1996). “Richardson and Coulson Chemical Engineering”, Vol.6, 3rd edition, Butterworth, Heinemann, Oxford- U.K. Odigure J.O. (1998). “Safety, Loss and Pollution Prevention in Chemical Process Industries”, Jodigs and Associates, Nigaria . Sinnot , R. K. (2005). Coulson and Richardson’s Chemical Engineering, 5th Edition, Butterworth, Heinemann, Vol. 6, Oxford, UK. Smith J. M. and Van Ness H. C (2003). Introduction to Chemical Engineering Thermodynamics, 5th edition, McGraw-Hill Book Company. Stephanopoulos G. (2005); Chemical Process Control: An introduction to theory and practice, Prentice-Hall of India, New Delhi. Walas S.M. (1990). Chemical Process Equipment Selection and Design, 4th edition, Butterworth-Heinemann, London . Kolesnikov I.M. (2004). Kinetics of alkylation of benzene with propylene in the presence of dimethyldichlorosilane , Chemistry and Technology of Fuels and Oils 11-2004, volume 40, Issue 6, pp403-411

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