Final Report Mini DP Phenol PDF

PLANT DESIGN FOR PRODUCTION OF PHENOL i
FACULTY OF CHEMICAL ENGINEERING

UNIVERSITI TEKNOLOGI MARA
TITLE:
MINI DESIGN PROJECT
(PRODUCTION OF PHENOL)
PREPARED BY: EH2205I
1 MUHAMMAD NOR ASYRAFF BIN NOR RAHMAN 2017632104

2 PUTERA NAJMEEN FARITH BIN ABDUL RAZAK 2017632096
3 NURUL NAJIHA BINTI SURANI 2017632166
4 NURUL AMIRAH BINTI MUSDAFA KAMAL 2017632124
5 SITI NUR AISHAH BINTI MOHAMAD FAUDZI 2017632136
6 NURUL AIDA BINTI MOHAMMAD 2017632132
7 NURLINA SYAHIIRAH BINTI MD TAHIR 2017632214
8 QURRATUAINI BINTI MD ALI 2017632078
9 NURSYAWANI YASMIN BINTI RAMLI 2017632094
10 JULIA BINTI FADZLI 2017632064
DATE OF SUBMISSION:
14th DECEMBER 2018
NAME OF LECTURER:
EN AMMAR BIN MOHD AKHIR
PLANT DESIGN FOR PRODUCTION OF PHENOL ii
TABLE OF CONTENTS
1.0 HISTORY AND GENERAL INFORMATION ON PHENOL ............................................ 1

1.1 History.................................................................................................................................... 1
1.1.1 Phenol ............................................................................................................................. 1
1.1.2 The Production Of Phenol Synthesis ........................................................................... 2
1.2 General Description .............................................................................................................. 5
1.3 Usage ...................................................................................................................................... 8
2.0 PROCESS SELECTION ........................................................................................................ 10
2.1 Process in Producing Phenol .............................................................................................. 10
2.1.1 Process Selected and Selection Criteria .................................................................... 10
2.2 Profit Margin ....................................................................................................................... 16
2.2.1 Phenols from Toluene Benzoic Acid .......................................................................... 16
2.2.2 Phenols From Coal ...................................................................................................... 17
2.2.3 Phenol From Cumene Peroxidation .......................................................................... 18
3.0 SITE SELECTION ................................................................................................................. 20
3.1 Kerteh, Terengganu ................................................................................................................ 23
3.1.1 Market Availability ..................................................................................................... 23
3.1.2 Transportation ............................................................................................................ 23
3.1.3 Availability Of Labor.................................................................................................. 27
3.1.4 Utilities and Facilities.................................................................................................. 28
3.1.5 Land Estimation .......................................................................................................... 29
3.1.6 Climate ......................................................................................................................... 30
3.1.7 Waste Management..................................................................................................... 30
3.2 Gebeng, Pahang................................................................................................................... 32
3.2.2 Transportation ............................................................................................................ 33
3.2.5 Land Estimation .......................................................................................................... 34
3.2.6 Climate ......................................................................................................................... 36
3.3 Pasir Gudang Industrial Estate, Johor Bahru ................................................................. 37
3.3.2 Transportation ............................................................................................................ 37
PLANT DESIGN FOR PRODUCTION OF PHENOL iii

3.3.5 Land Estimation .......................................................................................................... 39
3.3.6 Climate ......................................................................................................................... 40
4.0 BLOCK FLOW DIAGRAM FOR PHENOL PLANT ........................................................ 41
5.0 PROCESS FLOW DIAGRAM FOR PHENOL PLANT .................................................... 42
6.0 MATERIALS BALANCE ...................................................................................................... 44
6.1 Reactor 1 – Oxidation Reactor .......................................................................................... 44
6.2 Reactor 2 - Cleavage Unit................................................................................................... 46
6.3 Separator 1 - Phase Separator (Gravity Settler) .............................................................. 48
6.4 Separator 2 – Scrubber....................................................................................................... 49
6.5 Distillation Unit ................................................................................................................... 50
6.5.1 Separator 3 – Distillation Unit 1 ................................................................................ 51
6.6 Reactor 3 – Pre - Purification Reactor .............................................................................. 56
7.0 ENERGY BALANCE ............................................................................................................. 57
7.1 Sample Calculation ............................................................................................................. 57
7.1.1 Pump 1 – Cumene Feed Pump ................................................................................... 58
7.1.2 Compressor 1 – Air Feed ............................................................................................ 59
7.1.3 Reactor 1 – Oxidation Reactor .................................................................................. 60
7.1.4 Reactor 2 – Cleavage Unit .......................................................................................... 62
7.1.5 Heat Exchanger 1 – Cooling ....................................................................................... 63
7.1.6 Separator 1 - Phase Separator (Gravity Settler) ...................................................... 64
7.1.7 Separator 2 – Scrubber............................................................................................... 65
8.0 SIZING OF EQUIPMENTS .................................................................................................. 74
8.1 Sizing Of The Equipments ................................................................................................. 74
PLANT DESIGN FOR PRODUCTION OF PHENOL iv
8.1.1 Reactor 1 – Oxidation Reactor CSTR ....................................................................... 75

8.1.2 Reactor 2 – Cleavage Unit CSTR .............................................................................. 76
8.1.3 Reactor 3 – Pre-Purification Reactor CSTR ............................................................ 77
8.1.4 Separator 1 - Phase Separator (Gravity Settler) ...................................................... 77
8.1.5 Separator 2 - Scrubber ............................................................................................... 80
8.1.6 Separator 3 – Distillation Column Unit 1 ................................................................. 82
9.0 COSTING OF EQUIPMENTS ............................................................................................ 104
9.1 Reactor 1 – Oxidation Reactor CSTR ............................................................................. 104
9.2 Reactor 2 – Cleavage Unit CSTR .................................................................................... 104
9.3 Reactor 3 – Pre-Purification Reactor CSTR .................................................................. 104
9.4 Separator 1 – Phase Separator (Gravity Settler) ........................................................... 105
9.5 Separator 2 – Scrubber..................................................................................................... 107
9.6 Separator 3 – Distillation Column Unit 1 ....................................................................... 109
9.10 Separator 7 – Distillation Column Unit 5 ...................................................................... 122
9.11 Total Equipment Cost....................................................................................................... 126
10.0 OPERATING LABOUR COST .......................................................................................... 127
12.0 CONCLUSION ..................................................................................................................... 129
BIBLIOGRAPHY ............................................................................................................................. 130
PLANT DESIGN FOR PRODUCTION OF PHENOL 0
1.0 HISTORY AND GENERAL INFORMATION ON PHENOL
1.1 History
1.1.1 Phenol
Phenol is a constituent of coal tar and was partly isolated from coal tar in 1834 by Runge, who
called it ‘Carbolic Acid’ or ‘coal oil acid’. Friedlieb Ferdinand Runge who is born on 8
February 1795, began his career in Breslau, Germany. Runge published several scientific and
technological papers and books (Megson.N.J.L 1958).
Pure Phenol was first prepared by Laurent in 1841. Auguste Laurent born 4 September
1808, the son of a wine merchant, was assistant to Dumas at the Ecole Centrale (1831) and to
Brongniart at the Sevres porcelain factory (1833–1835) in France. Since 1845, he worked in a
laboratory at the Ecole Normale in Paris. In his studies of the distillate from coal-tar and
chlorine, Laurent isolated Dichlorophenol, C24H8Cl4O2 and trichlorophenol (acide
chlorophénisique) C24H6Cl6O2, which both suggested the existence of phenol. He give it the
name phène. He provided the table of ‘general formulae’ of the derived radicals of phène
where phenol was indicated by the incorrect formula C24H12 + H4O2 (C6H8O, in modern
notation) (L.Ross 2003).
In 1841, Laurent isolated and crystallized phenol for the first time. He called it ‘hydrate
de phenyle’ or ‘acide phenique’. His reported the Melting point between 34 and 35˚C and
Boiling point of 187 and 188 ˚C which are rather similar with the values we known today.
Lauren also measure the elementary physical properties of the chemical.
Lauren try to apply the phenyle as a painkiller for the toothache. The effect on the pain
was rather unclear, but the substance was ‘very aggressive on the lips and the gums’. In the
analysis of his experiments, Laurent applied the substitution hypothesis that was originally
proposed by his former supervisor, Dumas. However, Laurent went further than Dumas and
assumed that the substitution reaction did not change the structural formula of the reactant and
the product, whereas Dumas limited himself to the claim that the removal of one hydrogen
atom was replaced by the addition of another group, leaving open the possibility of a complete
rearrangement of the molecule (F.L Tobiason 2012).
Yet, the substitution hypothesis (especially in the form proposed by Laurent) was
attacked rather strongly by Berzélius, who claimed that a simple replacement of the hydrogen
atom should be utterly impossible. Instead, he reinterpreted all the results of Laurent by
breaking up the reaction product into smaller molecules.
In 1843, Charles Frederic Gerhardt also prepared phenol by heating salicylic acid with
lime and gave it the name ‘phenol’ (Looney 1995). He subsequently published a paper on ‘The
Negative Nature Of The Phenyl Group’, where he noted how phenyl together with other
‘negative groups’ can make the hydrogen atoms in methylene groups more reactive. In 1867,
Heinrich von Brunck defended his Ph.D. thesis on the theme ‘About Derivatives of Phenol’,
where he particularly studied the isomers of nitrophenol.
The Raschig–Dow process of manufacturing phenol by cumene was discovered by

Wurtz and Kekule in 1867, although the earlier synthesis was recorded by Hunt in 1849.
Interestingly, Friedrich Raschig, working earlier as a chemist at BASF and known for his work
on the synthesis of phenol, later established his own company in Ludwigshafen (L.Ross 2003).
During World War I, Phenol was misuse by the Nazis in 1942 for execution by injection into
the prisoners. They justify their action as an experimental procedure towards human.
1.1.2 The Production Of Phenol Synthesis
Phenol can be produced from many sources such as cumene, toluene and benzene with different
processes. There are several processes technology associated to Phenol production, which are:-
i) 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 isopropyl
benzene is formed. The cumene thus formed is made into 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 a 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
hydroperoxide 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 decomposition, phenol
(15%), acetone (9%), cumene (73%) are formed along with some α-methylstyrene and
acetophenone. These separated by a separator. The cumene is recycled to be used again and
phenol is either extracted or recovered by distillation. The yield is about 92%. Acetone is
formed as a by-product (0.6 lb. per lb of phenol).
ii) Rasching 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 .the 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% of benzene. A small amount of HCl is
sufficient to convert large amounts of benzene into phenol.
iii) Toluene Two-Stage Oxidation Process
Toluene in the liquid phase is oxidized with air in a reactor under 40-70psi in presence of a
soluble cobalt catalyst maintained at 150°C. Benzoic acid and water are thus formed. The
reaction is exothermic and the 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 unreacted 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 20-25psi 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 the second reactor. The phenol, water
and unreacted benzoic acid are conducted 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 for
crude phenol rectification column. The yield of phenol on benzoic acid is about 75- 80%.
iv) Sulphonation 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 150-170°C.
The water formed during sulphonation process is distilled out because sulfuric acid gets diluted
and conditions accelerate backward reaction to the process. Benzene sulphonic acid should be
neutralized by reacting it with aqueous sodium sulphite to form the 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% of benzene. The lower layer contains sodium sulphite which is separated and used for the
neutralization of benzene sulphonic acid.
Table 1 Shows the Differences between Processes to Produce Phenol
No Existing Methods Raw Materials / Yield Products Comments

Catalyst
1. Cumene Cumene, Air, 92% Phenol and Produces
Peroxidation Sulfuric acid and acetone valuable co-
Emulsifying agents product acetone
2. Toluene Two- Toluene, Air, 80% Phenol and Low-cost
Stage Oxidation Cobalt napthalate, Carbon operation by
Cupric benzoate dioxide direct toluene
catalyst application
3. Rasching Phenol Benzene, Air, 75% Phenol and Feasible under
Process Hydrochloric acid Hydrochloric large units
acid as
recycling
4. Chlorobenzene Benzene, Chlorine, 95% Phenol, Economically
caustic hydrolysis Sodium hydroxide, Sodium not feasible
Hydrochloric acid chloride
5. Benzene sulfonate Benzene, Sulfuric 87% Phenol, Operates on
process acid , Sodium Sodium large batch cycle
hydroxide sulphite,
Sodium
sulphate
1.2 General Description
A phenol is an organic compound in which an -OH group is attached to a carbon atom that is
part of an aromatic carbon ring system. The name phenol is derived from a combination of the
term phenyl and alcohol.
Figure 1 Shows Structure Of Phenols
The general formula for phenols is Ar-OH, where Ar represents an aryl group. An aryl
group is an aromatic carbon ring system from which one hydrogen atom has been removed.
The reaction chemistry for phenols differs from non-aromatic alcohols to justify these
compounds separately. Phenols contain a “benzene ring” and the chemistry of benzene differs
from other unsaturated hydrocarbons. The followings are examples of compound that classified
as phenols:
Figure 2 Shows Classification Of Phenols
For the naming of phenols simply depends on the IUPAC rules where the extensions of
the rules used to name benzene derivatives with hydrocarbon or halogen substituents. The
parent name is phenol. Ring numbering always begins with the hydroxyl group and proceeds
in the direction which gives lower number next to the carbon atom bearing a substituent. The
numerical position of the hydroxyl group is not specified in the name because it is 1 by
definition (H. Stephen Stoker; 2016).
Figure 3 shows examples of names of phenols given by the IUPAC rules
Figure 4 shows methyl and hydroxy derivatives of phenols, cresol
Figure 5 shows hydroxyphenols three isomers with different names
Physical and Chemical Properties of Phenols
Phenols are generally low-melting solids or oily liquids at room temperature. Most phenols are
slightly soluble in water. Many phenols have antiseptic and disinfectant properties. The
simplest phenol, phenol itself, is a colorless solid with a medicinal odor. Its melting point is
41°C, and is more soluble in water than are most other phenols.
Basically, the chemical properties of phenols differ from those of alcohols. The
similarities and differences between these two reactions are as follows:
Table 2 Shows Similarities And Differences Between Alcohols And Phenols
Alcohols Relation Phenols

Flammable Similarities Flammable
Undergoes halogenation Undergoes halogenation
Dehydrates Differences Does not dehydrates
Undergoes oxidation Does not undergoes oxidation
Acidity of Phenols
One of the important properties of phenols is their acidity. Unlike alcohols, phenols are weak
acids in solution. As acids, phenols have Ka values of about 10-10. Such Ka values are lower
than those of most weak inorganic acids (10-5 to 10-10). The acid ionization reaction for phenol
itself is:
Figure 6 shows ionization reaction for phenol itself
Meanwhile, for negative ion produced from ionization is called phenoxide ion. When
phenol itself is reacted with sodium hydroxide (a base), salt sodium phenoxide is produced.
Figure 7 Shows Process For Phenoxide Ion

1.3 Usage
There are a few uses of phenol in terms of health, industrial and daily uses. Firstly, the uses of
Bisphenol A (BPA). Bisphenol A was created from a condensation reaction of phenol and
acetone with hydrogen chloride, an acid catalyst and a promoter such as methyl mercaptan.
Once formed by this reaction, BPA is washed with water, neutralized with calcium hydroxide
and distilled under vacuum. BPA can be purified further by distillation and extractive
crystallization. Higher purity BPA is used to make polycarbonate plastic while the lower purity
BPA is used to make epoxy resin. Many water bottles are polycarbonate plastic made of BPA
(Kennepohl, 2017). Besides that, BPA is especially used for the production of high grade
polycarbonates for compact disc, glazing and for automotive industry (Elyers, 2011).
The second largest consumption of phenol is for the production of phenolic resins with
formaldehyde. There are mainly used for underseal applications in the automotive industry
(Elyers, 2011). The phenolic resins may be considered to be the first polymeric products
produced commercially from simple compounds of low molecular weight i.e they were the first
truly synthetic resins to be exploited. Furthermore, phenolic resins continue to be used for a
wide variety of applications such as moulding powders, laminating resins, adhesives, binders,
surface coatings and impregnates. Until very recently the market has continued to grow but not
at the same rate as for plastic materials in general. For example, in 1957 production of phenolic
resins was of the same order as for PVC and polyethylene and about twice that of polystyrene.
Today it is less than a tenth that of polyethylene and about one-third that of polystyrene
(Brydson, 1999).
Phenols also are widely used as antiseptics (substances that kill microorganisms on
living tissue) and as disinfectants (substance intended to kill microorganisms on inanimate
objects such as furniture or floors). The first widely used antiseptic was phenol however phenol
is toxic to humans which can cause severe burns when applied to the skin. One of the safer
phenolic antiseptic is 4-hexylresorcinol (4-hexyl-1,3-dihydroxybenzene; resorcinol is the
common name for 1,3-dihydroxybenzene, and 4-hexylresorcinol). It is much more powerful
than phenol as a germicide and has fewer undesirable side effects. Indeed it is safe enough to
be used as the active ingredients in some mouthwashes and throat lozenges (Kennepohl, 2017).
As the automotive industry is an important consumer of phenol derivatives such as

polycarbonates and phenolic resins, the entire phenol demand still tends to be cyclical and
closely tied to the market. The dominant synthetic route is cumene oxidation, which accounts
for about 95% of the total phenol production. This process will maintain its leading position as
long as a market exists for the coproduct acetone. The classic synthetic routes such as
sulfonation or chlorination of benzene are no longer because of the formation of considerable
quantities of sodium salts as byproducts. Commercial production of phenol by direct oxidation
of benzene with byproduct nitrous oxide does not seem to be viable in the near future (Elyers,
2011).
Table 3 Worldwide production capacity and demand for phenol (in 1000 t/a).
2000 2003 2007 2010

Production capacity from
Cumene 7641 8490 9879 10079
Toluene 307 307 307 307
Coal tar 291 291 291 291
Total 8239 9088 10477 10677
Demand for
Bisphenol A 2306 2678 3446 3864
Phenolic resins 2236 2419 2564 2709
Caprolactam 739 705 724 728
Others 1335 1454 1576 1686
Total 6616 7256 8306 8987
2.0 PROCESS SELECTION
2.1 Process in Producing Phenol
2.1.1 Process Selected and Selection Criteria
This section will explain the reasons why the selected process has been chosen and the
disadvantages of the unselected processes.
In this world there are various ways of producing phenol. Obviously, all the processes have
their own advantages and disadvantages. This considerations is important to choose the most
efficient and profitable process in order to have a good and nearly perfect production of phenol.
Here are the lists of the processes in producing phenol.
a) Production of phenol from cumene

b) Benzene Sulfonation
c) Oxidation of Toluene
d) Phenol from coal
e) Toluene Benzoic Acid Process
For this mini project, we have decided to choose production of phenol from cumene.
This is the route from cumene to produce phenol.
𝐂𝟔 𝐇𝟓 𝐂𝐇(𝐂𝐇𝟑 ) + 𝐎𝟐 → 𝐂𝟔 𝐇𝟓 𝐂(𝐂𝐇𝟑 )𝟐 𝐎𝐎𝐇

Cumene + Oxygen Gas → Cumeneperoxide
𝐂𝟔 𝐇𝟓 𝐂(𝐂𝐇𝟑 )𝟐 𝐎𝐎𝐇 + 𝐇𝟐 𝐒𝐎𝟒 ↔ 𝐂𝟔 𝐇𝟓 𝐎𝐇 + 𝐂𝐇𝟑 𝐂𝐎𝐂𝐇𝟑

Cumeneperoxide + Sulfuric Acid → Phenol + Acetone
Phenol can also be produced by free radical chain reaction of cumeneperoxide. The side
product from this reaction is Acetone which also high demand in the industry. Cumeneperoxide
can be obtained from air oxidation of cumene (isopropyl benzene). Approximately over 90%
cumene produced in industry, in order to satisfies the feedstock for phenol production. An
article entitled ‘Industrial Catalytic Processes – Phenol Production’ written by Robert J.
Shcmidt explain the details of the reaction and the benefits associates with the process
(Schmidt, 2005).
The Sunoco/UOP Phenol process produces high-purity phenol and acetone by the
cumene peroxidation route, using oxygen from air. This process features low-pressure
oxidation for improved yield and safety, advanced CHP cleavage for high product selectivity,
an innovative direct product neutralization process that minimizes product waste, and an
improved, low cost product recovery scheme. The process also produces an ultra-high product
quality at relatively low capital and operating costs. The main reactions for phenol and acetone
production via cumene peroxidation are both reactions are highly exothermic.
Oxidation of cumene to cumene hydroperoxide (CHP) proceeds via a free-radical

mechanism that is essentially auto-catalyzed by CHP. The decomposition reaction is catalyzed
by strong mineral acid and is highly selective to phenol and acetone. The unstable peroxide
and many side reactions which take place simultaneously with the above reactions are
controlled and minimized by optimization of the process conditions. Dimethylphenylcarbinol
is the main oxidation by-product, and the DMPC/AMS reactions play a significant role in the
plant. The figure 8 below shows block flow diagram in using the Sunoco/UOP.
Figure 8 Sunoco/UOP Phenol process.

The major processing steps include:

1. liquid-phase oxidation of cumene to cumene hydroperoxide (CHP)
2. concentration of CHP
3. acid-catalyzed decomposition of concentrated CHP to phenol and acetone
4. neutralization of acidic decomposition product
5. fractionation of the neutralized decomposition product for recovery of acetone,
phenol, AMS, and residue
6. recovery of phenol and the effluent wastewater via an extraction process to
prepare it for further downstream treatment required to meet effluent quality
specifications
7. Hydrogenation of AMS back to cumene for recycling to synthesis or refining of
AMS for sale as a product.
Here are the disadvantages of the other processes that have not been selected.
2.1.1.1 Benzene Sulphonation
The main disadvantage was the poor atom economy (36.7%) of the reaction (which is the
percent ratio of molecular mass of the desired product to the molecular mass of reactant). This
means that considerably less than half the mass of reactants ends up in the required product,
even if we assume 100% yield. In practice the yield is more likely to be in the region of 88%,
giving an atom economy of 32.3%, barely a third of the reactant mass. Sodium sulphite is
consumed in the wood pulp and paper industries but the large amount of waste produced was
one of the reasons why the benzene sulphonation route is no longer used (Sayyar, 2008).
Figure 9 - The mechanism of the benzene sulfonation process.

2.1.1.2 Oxidation Of Toluene
There are two types reaction in chlorination of benzene:
1. Alkaline Hydrolysis.
According to the (Ullmann, 2005) , the chlorobenzene being formed from the chlorinated of
benzene at 38°C to 608°C in the presence of ferric chloride catalyst in the process. The
chlorobenzene hydrolyzed with caustic soda (NaOH) at temperature of 4008°C and 2.56 kPa
to form sodium phenoxide and sodium cloride. The impure sodium phenoxide reacts with
hydrochloric acid to release the phenol from the sodium salt. The yield of phenol is about 82%
to that of the theoretical value based on benzene. Typically, the process combined with chloro-
alkali electrolysis to recover chlorine from the sodium chlorid (Kirk-Othmer, 2006).
Figure 10 The Alkaline Hydrolysis Of Benzene In Production Of Phenol
2. Raschig-Hooker Process.
The Raschig-Hooker Process is oxychlorination of benzene reaction which benzene is
oxychlorinated with hydrochloric acid, air, and with the presence of iron and copper chloride
catalyst to form chlorobenzene. Based on the (Kirk-Othmer, 2006) .The reaction occurs at
200–2608°C and atmospheric pressure. The chlorobenzene hydrolyzed at 4808°C in the
presence of a suitable catalyst to produce phenol and hydrochloric acid. Thus, the hydrochloric
acid is recycled and the process called as regenerative Raschig process. The yield of phenol is
90 mol% of theoretical (Ullmann, 2005)
Figure 11 The Raschig-Hooker Process In Production Of Phenol

2.1.1.3 Phenol From Coal
For this process, there are many disadvantages that lead to the inefficient production.
Obviously, this production must be heat until 900°C with exclusion of air in coke oven. This
process condition may lead to higher cost operating. The other condition that leads to higher
operating cost is this process needs at least 7 columns in the plant. This process also produced
solid residue. This problem requires a larger area for disposal purpose. Human being will be
affected by this process. Skin cancer, malignant skin tumor and scrotal cancer are the examples
of problem that human will be faced when decided to have this process without any proper
safety precaution or equipment. In conclusion, studies in experimental systems and in surrogate
tissues of humans provide strong evidence for a genotoxic/mutagenic mechanism underlying
the effects of occupational exposures during coal-tar distillation (Ullmann, 2005).
2.1.1.4 Toluene – Benzoic Acid Process
About 5% of phenol is produced using the oxidation of toluene, a process which also known
as the Dow and California Research Process. In this process, phenol is produced by undergoing
two times oxidation and one hydrolysis process. Thus, it includes three main reaction before
producing phenol as product. The first reaction is oxidation of toluene to form benzoic acid.
Toluene will react with air that being supply to the reactor with the presence of catalyst. The
catalyst used in this process is cobalt salt with concentration between 0.1% and 0.3%. The
process undergo under temperature between 121˚C and 177˚C and the reactor where the
process takes place is operated at pressure of 206 kPa. The reactor effluent will be distilled and
the purified benzoic acid is collected for further process. The overall yield of this process is
believed to be about 68 mol% of toluene (Kirk-Othmer).
The second reaction is the oxidation of benzoic acid and being hydrolyzed into phenol
that carried out in two reactors that are in series. In the first reactor, oxidation of benzoic acid
produced phenyl benzoates also with presence of catalyst. The catalyst used in this process is
mixture of copper and magnesium salts. The reactor operates at temperature of 243˚C and
pressure of 147 kPa. The phenyl benzoates will then transferred to the second reactor and
hydrolysed with steam to produced phenol and carbon dioxide as by-product. The process
occurs at 200˚C and at atmospheric pressure and the overall yield of phenol from benzoic acid
is around 88 mol% (Kirk-Othmer).
The reaction equations of this process are as follows:

O
CH3 + KMnO4 COH

‖
O O
2 COH
‖ + 1/2O2 C‖ O + H2O + CO2
O O
C‖ O + H2O OH + COH
‖
The price of raw material known as toluene is 7162.50 RMB which equals to 4,316.77
Malaysian Ringgit/1040.78 US Dollar per metric tonne. The focusing price in this process is
the price of phenol which China price list have stated on 10th October 2018 to be 11937.50
RMB that is equal to 7,194.61 Malaysian Ringgit/1734.64 US Dollar (Industrial Sector, 2018).
Thus, the economic potential of this process is said to be 2877.84 Malaysian Ringgit/693.86
US Dollar. However, this process also has its drawback especially regarding catalyst. Catalyst
recovery can be another problem for homogenous catalytic systems. Heterogeneous catalysts
for selective oxidation of toluene in liquid phase have been proposed and may be employed.
However, this form of catalysis also has disadvantages because the industrial waste
generated involves solids containing transition metals of environmental concern, such as
copper, 5 manga-nite and chromite. Recently, the use of Au–Pd alloy nanoparticles as highly
active catalysts was reported for the oxidation of the carbon-hydrogen alkyl groups in toluene
at 160˚C and under 10 bar with the main product generated being benzyl benzoate (Sarina,
Huaiyong, Zhanfeng, & Guoran, 2012). Other case, this process is high energy-consumed.
Especially in present times, it will consumed up to 3 to 4 times more energy compared to
oxidation of cumene process. Thus, it is not widely used in present industrial activities to
produce phenol.
2.2 Profit Margin
2.2.1 Phenols from Toluene Benzoic Acid

From process of Toluene-Benzoic Acid Process in producing cumene, the following prices
for raw material(s) and product(s) are found:
Toluene = 4,316.77 Malaysian Ringgit per tonne
= 1040.78 US Dollar per tonne
Phenol = 7,194.61 Malaysian Ringgit per tonne
= 1734.64 US Dollar per tonne
Molecular weight (MW) of Toluene is 92.14 kg/kmol and Phenol is 100.15 kg/kmol. By
using 100 kmol of toluene as feed basis,
Cost of Raw Material:

Cost of Raw Material = Feed Basis x MW x Cost of Material per tonne
kg RM4316.77 1 tonne
Cost of Toluene = 100 kmol(92.14 )( )( )
kmol tonne 1000 kg
𝐂𝐨𝐬𝐭 𝐨𝐟 𝐓𝐨𝐥𝐮𝐞𝐧𝐞 = 𝐑𝐌 𝟑𝟗, 𝟕𝟕𝟒. 𝟕𝟐
𝐂𝐨𝐬𝐭 𝐨𝐟 𝐓𝐨𝐥𝐮𝐞𝐧𝐞 = $ 𝟗, 𝟒𝟗𝟒. 𝟔𝟐
Cost of Product:
Cost of Product = Feed Basis x MW x Cost of Material per tonne
Cost of Phenol = 100 kmol(100.15 )( )( )
kmol tonne 1000 kg
𝐂𝐨𝐬𝐭 𝐨𝐟 𝐏𝐡𝐞𝐧𝐨𝐥 = 𝐑𝐌 𝟕𝟐, 𝟎𝟓𝟒. 𝟎𝟐
𝐂𝐨𝐬𝐭 𝐨𝐟 𝐏𝐡𝐞𝐧𝐨𝐥 = $ 𝟏𝟕, 𝟐𝟎𝟎. 𝟎𝟐
In order to find the profit margin, equation below is used:

Profit Margin = Total Cost of Product − Total Cost of Raw Material
Profit Margin = RM 72,054.02 − RM 39,774.72 = 𝐑𝐌 𝟑𝟐, 𝟐𝟕𝟗. 𝟗𝟑
Profit Margin = $ 17,200.02 − $ 9,494.62 = $ 𝟕, 𝟕𝟎𝟓. 𝟒𝟎
2.2.2 Phenols From Coal

The following prices for raw material(s) and product(s) are found Raw Material
1) Coal = RM 414.94/ton as to May 2018
(Coal, Australian thermal coal monthly price-Malaysian Ringgit per Metric Ton)
2) Cresol = USD 2593/ton = RM 10 864.67/ton
(Cresol Price-China Cresol Price Manufacturers&Suppliers|made in China)
3) Xylenols = USD 8000/ton =RM 33 520/ton
4) Phenols = RM 7 194.61/ton
(Sunsirs Commodity Data Group, 2018)
Molecular weight (MW) of Coal, Cresol, Xylenols, and Phenols are 92.14 kg/kmol and Phenol
are 207.252 kg/kmol, 108.14 kg/kmol, 122.167 kg/kmol and 100.15 kg/kmol, respectively. By
using 100 kmol of coal as feed basis,

kg RM414.94 1 tonne
Cost of Coal = 100 kmol(207.252 )( )( )
kmol tonne 1000 kg
𝐂𝐨𝐬𝐭 𝐨𝐟 𝐂𝐨𝐚𝐥 = $ 𝟐 𝟎𝟓𝟏. 𝟒𝟔 = 𝐂𝐨𝐬𝐭 𝐨𝐟 𝐂𝐨𝐚𝐥 = 𝐑𝐌 8 599.71
Cost of Product:

kmol tonne 1000 kg
𝐂𝐨𝐬𝐭 𝐨𝐟 𝐏𝐡𝐞𝐧𝐨𝐥 = $ 𝟏𝟕 𝟐𝟎𝟎. 𝟎𝟐

kg RM10 864.67 1 tonne
Cost of Cresols = 100 kmol(108.14 )( )( )
kmol tonne 1000 kg
𝐂𝐨𝐬𝐭 𝐨𝐟 𝐂𝐫𝐞𝐬𝐨𝐥𝐬 = 𝐑𝐌 𝟏𝟏𝟕 𝟒𝟗𝟎. 𝟓𝟒
𝐂𝐨𝐬𝐭 𝐨𝐟 𝐂𝐫𝐞𝐬𝐨𝐥𝐬 = $ 𝟐𝟖 𝟎𝟐𝟕. 𝟑𝟕
Cost of Xylenols = Feed Basis x MW x Cost of Material per tonne
kg RM 33 520 1 tonne
Cost of Xylenols = 100 kmol(122.167 )( )( )
kmol tonne 1000 kg
𝐂𝐨𝐬𝐭 𝐨𝐟 𝐗𝐲𝐥𝐞𝐧𝐨𝐥𝐬 = 𝐑𝐌 𝟒𝟎𝟗 𝟓𝟎𝟑. 𝟕𝟑
𝐂𝐨𝐬𝐭 𝐨𝐟 𝐗𝐲𝐥𝐞𝐧𝐨𝐥𝐬 = $ 𝟗𝟕 𝟔𝟖𝟕. 𝟏𝟏
Profit Margin = RM 599 048.29 − RM 8 599.71 = 𝐑𝐌 𝟓𝟗𝟎 𝟒𝟒𝟖. 𝟓𝟖
Profit Margin = $ 17,200.02 − $ 9,494.62 = $ 𝟏𝟒𝟎 𝟖𝟓𝟏. 𝟓𝟏
2.2.3 Phenol From Cumene Peroxidation
From process of production of phenol from cumene the following are the prices for raw
material(s) and product(s):
Cumene = 6,093.39 Malaysian Ringgit per tonne
= 1,455 US Dollar per tonne
Phenol = 7,194.61 Malaysian Ringgit per tonne
= 1,734.64 US Dollar per tonne
Acetone = 14,238.86 Malaysian Ringgit per tonne
Crude Alpha Methyl Styrene = 6,072.45 Malaysian Ringgit per tonne
Tar = 1,612.34 Malaysian Ringgit per tonne
= 385 US Dollar per tonne
Molecular weight (MW) of Cumene is 120.19 kg/kmol, Phenol is 100.15 kg/kmol, Acetone is
58.08kg/kmol, Crude Alpha Methyl Styrene is 118.18kg/kmol and Tar is 15,000kg/kmol. By
using 100 kmol of cumene as feed basis,

Cost of Cumene = 100 kmol(120.19 )( )( )
kmol tonne 1000 kg
𝐂𝐨𝐬𝐭 𝐨𝐟 𝐂𝐮𝐦𝐞𝐧𝐞 = 𝐑𝐌 𝟕𝟑, 𝟐𝟑𝟔. 𝟒𝟓
𝐂𝐨𝐬𝐭 𝐨𝐟 𝐂𝐮𝐦𝐞𝐧𝐞 = $ 𝟏𝟕, 𝟒𝟖𝟕. 𝟔𝟑
Cost of Product:
kmol tonne 1000 kg
𝐂𝐨𝐬𝐭 𝐨𝐟 𝐏𝐡𝐞𝐧𝐨𝐥 = $ 𝟏𝟕, 𝟐𝟎𝟎. 𝟎𝟐
Cost of Acetone = 100 kmol(58.08 )( )( )
kmol tonne 1000 kg
𝐂𝐨𝐬𝐭 𝐨𝐟 𝐀𝐜𝐞𝐭𝐨𝐧𝐞 = 𝐑𝐌 𝟖𝟐, 𝟔𝟗𝟗. 𝟑𝟎
𝐂𝐨𝐬𝐭 𝐨𝐟 𝐀𝐜𝐞𝐭𝐨𝐧𝐞 = $ 𝟏𝟗, 𝟕𝟒𝟕. 𝟐𝟎
kg RM6,072.45 1 tonne
Cost of Crude Alpha Methyl Styrene = 100 kmol(118.18 )( )( )
kmol tonne 1000 kg
𝐂𝐨𝐬𝐭 𝐨𝐟 𝐂𝐫𝐮𝐝𝐞 𝐀𝐥𝐩𝐡𝐚 𝐌𝐞𝐭𝐡𝐲𝐥 𝐒𝐭𝐲𝐫𝐞𝐧𝐞 = 𝐑𝐌 𝟕𝟏, 𝟕𝟔𝟒. 𝟐𝟏
𝐂𝐨𝐬𝐭 𝐨𝐟 𝐂𝐫𝐮𝐝𝐞 𝐀𝐥𝐩𝐡𝐚 𝐌𝐞𝐭𝐡𝐲𝐥 𝐒𝐭𝐲𝐫𝐞𝐧𝐞 = $ 𝟏𝟕, 𝟏𝟑𝟔. 𝟎𝟖
kg RM1,612.34 1 tonne
Cost of Tar = 100 kmol(15,000 )( )( )
kmol tonne 1000 kg
𝐂𝐨𝐬𝐭 𝐨𝐟 𝐓𝐚𝐫 = 𝐑𝐌 𝟐, 𝟒𝟏𝟖, 𝟓𝟏𝟎
𝐂𝐨𝐬𝐭 𝐨𝐟 𝐓𝐚𝐫 = $ 𝟓𝟕𝟕, 𝟒𝟗𝟗. 𝟒𝟔

Profit Margin = (RM 72,054.02 + RM 82,699.30 + RM 71,764.21 + RM 2,418,510) −
RM 73,236.45
Profit Margin = 𝐑𝐌 𝟐, 𝟓𝟕𝟏, 𝟕𝟗𝟏. 𝟎𝟖
Profit Margin = $ 631,588.03 − $ 1,455 = $ 𝟔𝟑𝟎, 𝟏𝟑𝟑. 𝟎𝟑
3.0 SITE SELECTION
There are 3 places that have been decided which are Pasir Gudang, Kerteh and Gebeng. The
place chosen based on several general descriptions. The general description of places is as
follow:-
1. Market Availability
The market must be available to ensure the product can be sold to generate profit. The
proximity to the major markets is vital for the site selection. It give an advantages to the
customer to purchase from nearby sources, thus the location needs to be near the market
demand as to reduce the product cost distribution and time required for shipping. The side
– product which is acetone also need to be considered for the market since this chemical
also plays an important part in the chemical industries.
2. Transportation
Water, railroads and highways are the common means of transportation used by major
industrial concerns. The local freight rates and existing railroad lines should be considered.
The proximity to railroad centers and the possibility of ocean transport must be considered.
The kind and amount of products and raw materials determine the most suitable type of
transportation facilities.
3. Availability of labor
Labour supply is needed for construction of the plant and its operation. There should be
an adequate pool of skilled and unskilled labour locally and the labour is suitable to be
trained for enhancement of their skill. The prevailing pay scales, restrictions on number of
hours worked per week should also be considered.
4. Utilities and Facilities

Utilities Supply is another crucial requirement in selecting the site for plant. Utilities
supplies includes power supply and water supply. Power supply will be received from the
nearest Tenaga Nasional Berhad (TNB) as TNB is the main electricity power generator
and supplier in Peninsular Malaysia.
5. Land Estimation
Land and soil structure should be examined carefully before selecting the site. The
difference in soil structure should be study earlier because it can be divided into three types
of soil which are loam-type, laterite-type and sandy-type. Topography of land must also
be considered as it will affect the construction cost. This is because if a plant is built on a
hilly area, there will be an extra cost to levelling the hills. Thus, a study on the topography
of the site must be inspected as well and a satisfying area which is a flat area, should be
first to be chose as the site of the plant. Additional space is required for a preparation in
future changes. This is due to the company’s target which is after 10 years of production,
scaling up will be performed to increase the methanol production in order to meet the
customer needs. The cost of the plant is also important as well as local building costs and
living condition.
6. Climate
Climate is also one of the important selectivity to be brought into account. The extreme
condition of a place is required for consideration since excessive humidity or extremes of
hot or cold weather will induce a need for the plant to have a special consideration on the
plant equipment.
7. Waste Management
Methods of disposing waste materials from the process industries must obliges the legal
restrictions. The selected site should have adequate capacity and facilities for correct waste
disposal. The area should has minimal restrictions on pollution. The permissible tolerance
levels for various methods of waste disposal and potential requirements for additional
waste treatment facilities should be considered.
8. Raw Material Availability

The raw materials availability is an important aspect in the site selection consideration.
Without raw material, there will be no product. Thus, the associates’ factor of the raw
material resources should be determined at the considered location. The location must be
closed with the raw materials source in order to reduce the transportation and storage
charges. The price of the raw materials must be low and the raw material must be pure.
The storage requirements should also be considered for this part.
Table 4 Shows The Criteria Of The Site Selection
Site Suggestion
No Selection Criteria Kerteh, Pasir Gebeng,
Terengganu Gudang, Pahang
Johor
1 Raw Material Availability 3 3 3
2 Market Availability 5 5 4
3 Energy Availability and 4 3 4
Water Supply
4 Climate Conditions 3 4 3
5 Transportation facilities 5 5 5
6 Land Estimation 4 4 3
7 Waste Management 3 5 4
8 Labour Supply 4 4 3
Total 31 33 29
1 = Very Bad , 2 = Bad , 3 = Moderate , 4 = Good , 5 = Very Good
Based on the market survey and preliminary feasibility study, there are few places have been
considered for the site selection. Three sites within Peninsular Malaysia were selected for
further consideration which are Kerteh, Pasir Gudang and Gebeng. The location chosen is Pasir
Gudang, Johor.
Raw Material Availability

For all three chosen site there is no raw material availability which is cumene. Thus, the
required raw material is to be imported from overseas market which is India, and Japan.
3.1 Kerteh, Terengganu
3.1.1 Market Availability
Figure 12 Based on “Statistical Review of World Energy 2008”
Based on the figure above, at Kerteh there is no production of phenol. Kerteh is one of chemical
industries known as ethylene based production. The advantages of our company to open at
Kerteh are high due to no competition from the other company at Kerteh. The demands for
phenol exactly high from years to years due to highly produce phenol based product.
3.1.2 Transportation
3.1.2.1 Air
It is convenient not only for business and leisure travelers but also for transporting cargos.
Terengganu’s main air hub, Sultan Mahmud Airport in Kuala Terengganu has new terminal
building and runway that is constructed to cater passengers and cargo traffic. Thus, if we want
to purchase equipment or machinery, we can use the air service as the airport flies about half a
dozen flights per day.
It is easy for people working in our industry to travel in and out of Kerteh either for
business or personal purpose. For instance, when there is an urgency for meeting somewhere
out of Kerteh, it is easy for us to travel.
Figure 13 Sultan Mahmud Airport in Kuala Terengganu
3.1.2.2 Roads and Highways

Terengganu has invested billions in a well-connected network of roads and highways which
links major towns, seaports, airports and industrial centers in east, west, south and north
Peninsular Malaysia. Currently, Terengganu has about 1,071 km federal roads and about 1,660
km state roads. It is targeted to complete the phase 2 of East Coast Highway which links Kuala
Lumpur and Kuala Terengganu.
Interstate travel and commerce has also risen with the opening of the Simpang Pulai-
Lojing, Kuala Berang road that links Hulu Terengganu district to Grik in Perak, West Malaysia
which slashes travel time from East Coast to West Cost of Peninsula down to 4 hours instead
of 10 hours.
Roads and highways in Terengganu make it easy for transportation of materials,

equipment and machinery from Kuala Lumpur for instance. Transportation such as cars, lorries,
tankers can be used to transport our raw materials and products to West Coast of Peninsular
Malaysia which are more cheaper compared to air transportation.
Figure 14 shows East Coast Expressway (Phase 2)

Table 5 Shows The Container Haulage Rates (The Hauliers)
State
Kerteh, Terengganu
Haulage Rates 20’ & 40’ RM2,782.00
Road Tolls RM197.80
FAF (16% Period from 1st June 2011) RM450.41
Total RM3430.21/ US$803.33
3.1.2.3 Railway
A 77 km dedicated industrial railroad from Kerteh to Kuantan serves companies in
petrochemical corridor. Built and operate by Petronas, this railroad helps in transporting cargo
back and forth between key seaports in Kuantan and Kerteh. Extensions are planned for Paka
and Kemaman.
The existence of railway also makes it easy for us to either import or export raw
materials or products for our industry whereby such option, gives us the opportunity to choose
which transportation is better and easier. It is also can be used by people working in our industry
to travel back and forth.
Figure 15 shows East Coast Rail Line (ECRL)

3.1.3 Availability Of Labor

There are few programs that has been introduced by the Malaysian government. One of the
programs include a training centre which is Institut Teknologi Petroleum Petronas (INSTEP).
There are three main areas involved at INSTEP which are:
1) Bridging Programmes – A program that has been developed to produce job-ready
technicians and operators, as well as advanced programmes for engineers.
2) Professional Development Programmes- Developed to upskill working technicians and
operators, as well as engineers.
3) Competency Based Assessment and Certification- Developed for industry workforce in
meeting statutory requirements.
This INSTEP program helps Malaysian industries to have continuous workforce and to
have employees whom are ready for challenges in industries. It also makes it easy for our
neither industry to look for new employees whether engineers nor technicians. With this
training centre, it makes it easy for us to direct employees and time saving for us where it
reduces our workload of training untrained employees.
Figure 16 shows statistics for employment in Malaysia from 2007 to 2017

(Source: Statista)
Referred to the figure, it shows that there is always and employment for industries.
However, the employment availability surely depends on states and our country’s economics
besides demands of our products. In every 5 years, the economic cycle will keep repeating but
we can never know what challenges await upon us.
3.1.4 Utilities and Facilities

Infrastructural facilities such as road accesses, electricity supply from the TNB, water supply,
gas supply and telecommunications are readily available at Kerteh, Terengganu. There also
have facilities such as banking, hospital and fresh water supply. The water supply falls under
the jurisdiction of the state, and is treated and distributed by the Terengganu Water Company
(SATU). Industrial sectors are charge RM1.15 per m3 with a rm50.00 minimum charge.
Figure 17 Shows The Tariff Of Water For Terengganu.

3.1.5 Land Estimation

The land price is around RM0.18 – RM5.60 which is the cheapest compared to other states in
Malaysia. Where land sells from as low as RM2.00 – RM4.50 per square feet to highs of
RM18.00 – RM22.00 per square feet.
Figure 18 shows the Terengganu industrial area.

3.1.6 Climate
Figure 19 Shows Average Temperature And Precipitation (Source: Meteoblue)
Referred to the figure, the mean daily maximum (solid red line) shows maximum temperature
of an average day for every month in Kerteh. For mean daily minimum (solid blue line) shows
average minimum temperature. Hot and cold nights (dashed red and blue lines) shows average
hottest and coldest day and night for each moth of the last 30 years. Precipitation chart is used
in identifying seasonal effects such as monsoon climate or wet season. Monthly precipitations
above 150 mm are considered wet while below 30 mm are considered dry.
3.1.7 Waste Management

Kerteh employs an integrated environmentally friendly waste-management from the industrial
waste. There are two types of waste management (Packaged waste or Bulk Waste). Scheduled
waste management is provided by Aldwech-Enviro Management At Teluk Kalong Industrial
Estate.
Table 6 Shows The Packaged Waste Price
Packaged Waste
1. Pumpable Liquid per tonne From 810.00 – RM3,150.00

Depending from the type of the waste.
2. Solid Waste per tonne From 2,790.00 – RM 3,600.00

Table 7 Shows The Bulk Waste Price
Bulk Waste
1. Pumpable Liquid per tonne RM630.00 – RM1,800.00
2. Solid Waste per tonne RM2,700.00
Sewage services are carried by Indah Water Consortium. Charges are based on number of
employee.
Table 8 Shows The Category Of Price Rate
Category Rate based on number of employees
Premises receiving Individual Sepic Tanks RM2.00 per head per month
services
Premises with Connected Sewerage Services RM2.50 per head per month
Table 9 Shows Transportation Rates For Waste (KualitiAlam, n.d.)
State Per pallet (min 18 pallet)
Kerteh, Terengganu
1st tier RM180.17/US$42.19
2nd tier RM90.09/US$21.10
Per metric tonne RM225.22/ US$52.74
3.2 Gebeng, Pahang
Table 10 List of Products Manufactured in Gebeng.
Petrochemicals
Facilities & Infrastructure Products
Zone
• Acrylic Acid and Esters

• Syngas
• Butyl Acrylate
• Oxo-alcohols
• Phthalic Anhydride and
Plasticizers
• Butanediol
• Peninsular Gas Utilisation (PGU) • Tetrahydrofurane
project
• Gamma-butyrolastone
• Centralized utility facilities
Gebeng, • Polyester Copolymers
Pahang • Kuantan Port
• Purified Terephthalic Acid
• Environment Technology Park
• Dispersion Polyvinyl Chloride
• East Coast Highway
• Methyl Methacrylates
Copolymers
• MTBE
• Propylene
• Polyacetals
• Polypropylene
• Polybutylene Terephthalate
(PBT)
Based on Table 10, it shows “Statistical Review of World Energy 2008” for Gebeng Industrial
Estate. The area indicates that there is no production of phenol at the zone area, which it gives
some advantages to manufactures due to less competition. However, it finds disadvantageous
to purchase the raw material from nearby sources. These will affect the high of production or
distribution cost, and also the time required for shipping.
The location of the plant is at Gebeng. Pahang is the convenient and efficient because easy
access due to its closeness to the international port which is Kuantan port. Our product can be
exported easily to the international market because the facility at Kuantan port is very good.
Besides that, our product can be selling in local market easily because there are highways which
connect the east peninsula Malaysia to west peninsula Malaysia. For example Jalan Pintasan
Kuantan highway and PLUS highway are the examples for road transportation.
State
Kuantan, Pahang
Road Tolls RM197.80
Total RM2902.70/ US$679.79
*FAF = Fuel Adjustment Factor

Plant location must require skilled labors. The labors and skilled workers are easily found in
Gebeng Industrial Estate. It is because the location is near to the community and many factories
around there so one of the place to find job. In Gebeng, there are also can provide intern and
workers from local university or international university such as UiTM Jengka students,
University Malaysia Pahang students and other.

The Gebeng Industrial Estate (GIE) obtains its power supply from the Tanjung Gelang
substation which generates power at a capacity of 2x15 MVA. Power supply is available via
the exiting TNB substation (intake station) located within the GIE less than 3 km south to the
south of the project site. The main electricity supplier is Tenaga Nasional Berhad (TNB). The
electricity supply provided by TNB for Phase I and II is supported by its 132/11kV main intake
and for Phase III, two sources of electricity supply are available which are Centralised Utility
Facilities (CUF) and 12/275 kV main intake.
The water supply is supplied from the Semambu Water Treatment Plant. The current
capacity of water supply is 2MG/D. The Government of Pahang is committed in ensuring an
efficient water supply in Gebeng. The steps that have been taken are increase of water supply
to 64 MG/D, building of a new 200 acre dam in Sungai Lembing, Kuantan and building of new
pipes and water tanks in Gebeng Industrial Estate. Malaysia has one of the largest natural gas
reserves in the Asia Pacific region; an estimated 85 trillion cubic feet. Currently, the natural
gas suppliers for Gebeng Industrial Estate are Gas Malaysia and Petronas Gas Berhad. They
supply industrial gases within the estate to cater for the overwhelming demand from existing
and future petrochemical projects in the area.
The main telecommunication supplier is Telekom Malaysia. They provide state-of-the-

art facilities and services such as Integrated Systems Digital Network (ISDN), digital line,
MAYPAC, Internet and video conferencing. Accessibility to Gebeng Industrial Estate is
excellent. The East Coast Highway which links Kuantan and Kuala Lumpur has an estimated
travel time of just 2 hours. In addition, a railway link connects the integrated petrochemical
complex in Kerteh (Terengganu) to Gebeng and Kuantan Port. This railway link further
strengthen the chemical and petrochemical linkage between Gebeng and other industrial
centres thus ensures safe transport as compared to transportation of dangerous goods by road.
The Pahang Fire and Rescue Department is located near Gebeng in order to handle any
emergencies. In addition, located within the vicinity of Gebeng is Petronas Centralised
Emergency Facilities. Both stations are equipped with HAZMAT (hazardous material)
facilities. Another services provided is the Gebeng Emergency Mutual Aid (GEMA), a
voluntary crisis management organisation, set up from an alliance between Government
agencies and private manufacturers in Gebeng. The main objective of GEMA is to execute
proactive action and they also offer expert services to counter emergencies.

The land price at Gebeng range is between RM 14.00 - RM 23.00 per square feet. The
possibility to occur flooding disaster is low because Gebeng is a hilly location. Besides that,
sufficient and suitable land must be available for the proposed plant and for future expansion.
Safety precaution must be taken when building plants near the ocean to make sure whether it
has the possibility to cause the tsunami disaster. Based on Figure 21, Gebeng have many
petrochemical industry and moreover, the propose plant far from the community. It can affect
the community because some of the industry will produce hazardous substance to surroundings.
Figure 20 Gebeng Industrial Estate Map
Figure 21 The Location Of Propose Plant From Port Kuantan

3.2.6 Climate
Climate and environment affect the operational efficiency of workers which excess cold may
cause tiredness, fatigue or disease among workers. Decreased humidity and climate
temperature high can cause dehydration to the employees while working. Therefore, the
climate in Gebeng Industrial Estate are hot and wet all year which the temperature range is
30°C to 32°C and have the northeast monsoon that supplied humidity in that area.

The primary source of sewage and waste are sanitary waste, process drains and surface
drainage. The sewage system designed separately to conduct these to disposal without logged
with solid or filled with dangerous concentration of explosive.
Table 12 Shows The Transportation Rates For Waste (KualitiAlam, n.d.)
Gebeng, Pahang
1st tier RM84.21/US$19.72
3.3 Pasir Gudang Industrial Estate, Johor Bahru
The product of the plant is phenol and acetone. However the company is aiming for phenol as
the main product. Phenol is widely used in industry and the precursor to many materials and
useful compounds. The global phenol market predicts to witness a robust CAGR of 6.8% from
2017 to 2022. The cumene process segment should be worth almost US$12.3 billion in 2017.
Table 13 Shows A Few Prospect Market Available In Pasir Gudang
Product Produced From Phenol Company

Paint Nippon Paint (M) Sdn Bhd
23, Jalan Bacang 36, Taman Kota
Masai, 81700 Pasir Gudang.
Further Processed Food PK Agro Industrial Products Sdn
Bhd
100, Jalan Nibong 3, Kawasan
Perindustrian Tanjung Langsat, Pasir
Gudang.
Protective Coating TK Blasting & Coating Sdn Bhd
PTD 662, Jalan Platinum Utama, 81700
Pasir Gudang, Johor.
Epoxy coating EEW Malaysia Sdn Bhd
PLO 109, Jalan Tengar, Tanjung
Langsat Industrial Complex, 81700
Pasir Gudang.
Pasir Gudang Industrial Estate is strategic as it is connected to Johor Bahru through a four-lane
Lebuhraya Pasir Gudang, JB Eastcoast Highway and a trunk road. There are also several main
roads connected from this area to Pasir Gudang city centre which ease the transportation
network.
State
Pasir Gudang Industrial Estate, Johor Bahru

Road Tolls RM211.00
Total RM3485.23/ US$816.21
*FAF = Fuel Adjustment Factor

Pasir Gudang is currently rising in terms of the industrial industry. So, people migrates to the
city for the job opportunities. Johor Skills Hub is one of the platform to develop suitably skilled
workforce for Johor in particular. According to (Payscale, 2018), the average salary is RM46
378. Mechanical engineer, Account Executive and Project Engineer range of salary between
RM 39 076 and RM 50 330 per year. A single operator is believed to work for 5 days per week
with each day of 8 hour shifts a week. An analysis from MIDA, unskilled employee range
salary from RM1,253/month until RM3,683/month for non – executive position. In addition,
the average monthly salary for executives, senior manager and top executives are RM3,779,
RM15,614 and RM32,043, respectively. (MIDA, 2017)

The power is supply through 500kVcable running at 275kV which is connected to the grid.
While water supply will be received from Syarikat Air Johor Sdn.Bhd (SAJ Holdings) as it is
the department that have been obligated to serve water supply to the communities and
industries within Pasir Gudang area.
Table 15 Shows The Water Supply Prices In Johor
State Per m3

0 – 35 m3 RM2.80
More than 35 m3 RM3.30
Minimum charge RM30.00

The most suitable soil for site of the new chemical plant is a loam-type soil with a big ratio of
hard rock in the layers of the ground. Natural soils in the site area include acidic soils of Kranji
series which consist of saline gley soil and acid sulphate soils. This site also satisfies the
consideration for a flat area instead of hilly area. For heavy industries the cost for land is RM
2400/hectar with annual assessment rate of 0.33% up to 1% of property value (MIDA States).
Figure 22 shows the Pasir Gudang Industrial Estate Map

3.3.6 Climate
The climatic information of Pasir Gudang area is based from data obtained from
Meteorological Station, Senai. From the data, this area is likely to be influenced by two
different monsoonal seasons which are Northeast Monsoon and Southwest Monsoon which are
likely occurred from March to April and September to October respectively. It is expected that
high rainfall with high relative humidity will hit this area with average annual rainfall of 2498.9
mm and 24 hours mean relative humidity from 83.2% to 87.8%. The mean annual temperature
would likely to be 26.1˚C.

Acid waste without chromate is at RM1440 per 800 litre pallet tank per tonned or US$337 per
800 litre pallet tank per pallet. For 200 L drum per tonne is at RM1620 and per pallet is at
US$379. Table 2 shows the transportation rates for waste for the respective state
Table 16 Transportation Rates for Waste (Source: (KualitiAlam, n.d.))

1st tier RM82.25/US$19.26
4.0 BLOCK FLOW DIAGRAM FOR PHENOL PLANT

Vent Gases H2 O
NaOH Aqueous Stream Organic Stream
H2 SO4
Cumene
Oxidation Phase Crude Phenol
Air Cleavage Unit Scrubber
Reactor Separator
(R2) (S2)
(R1) (S1)
Distillation Unit 4
Acidified Wash Water
Distillation Unit 3
H2
Distillation Unit 2
Distillation Unit 1
Pre –
Purification
Reactor
(R3)
Distillation Unit 5
𝐏𝐡𝐞𝐧𝐨𝐥 𝟗𝟔% 𝐏𝐮𝐫𝐢𝐭𝐲
5.0 PROCESS FLOW DIAGRAM FOR PHENOL PLANT

Table 17 Shows The No Of Stream, Temperature, Pressure, Molar Flow Rate and Heat Flow For Phenol Production Plant
Stream 1 2 3 4 5 6 7 8
Temperature (°C) 25 25 - 100 100 - 110 25
Pressure (atm) 6 6 - 6 6 - 6 6
Molar Flow rate (Kmol/h) 100 1904.76 - 100 719 - 100 100
Heat flow (kJ/h) 0 0 - 358888951.1 3610304.4 - 151857055.6 0
Stream 9 10 11 12 13 14 15 16
Temperature (°C) 25 - 100 - 100 100 175 152
Pressure (atm) 6 - 1 - 1 1 1 1
Molar Flow rate (Kmol/h) 0 - 100 - 72.41 28.14 18 17.87
Heat flow (kJ/h) 0 - 136337110 - 1359110318.3 415108.87 99225378 83369109.6
Stream 17 18 19 20 21 22 23
Temperature (°C) 152 100 25 25 175 180 180
Pressure (atm) 1 1 1 1 1 1 1
Molar Flow rate (Kmol/h) 3.06 5.36 26.16 100 53.84 0.51 5.36
Heat flow (kJ/h) 13245557.8 508273.85 0 0 172595120.2 169324023.7 9024639.35
6.0 MATERIALS BALANCE
6.1 Reactor 1 – Oxidation Reactor
Vent Gases
NaOH n4 O2
n5 N2
n6 CH3 OH
n1 C6 H5 CH(CH3 )2 n7 C6 H5 CH(CH3 )2
Oxidation Reactor
(R1) n8 C6 H5 COOH(CH3 )2
kmol
n2 x1 = 0.21 O n9 C6 H5 COH(CH3 )2
kmol 2
kmol n10 C6 H5 COCH3
n3 x2 = 0.79 N
kmol 2
Chemical Reaction Involved In The Oxidation Reactor

Sodium hydroxide, NaOH acts as the emulsification agent for the emulsification of cumene in
the reactor and not directly involve in the reaction of the reactants to produce the products.
Thus, is not considered for the material balance. Emulsification increase the interfacial area to
enhance the rate of reaction. After reaction, the vent gases is recycled back and the product is
sent to the second reactor which is the cleavage unit.
Main Reaction
1) C6 H5 CH(CH3 )2 (ℓ) + O2 (g) → C6 H5 COOH(CH3 )2 (ℓ)____________________ξ1
Cumene + Oxygen → Cumene Peroxide
Side Reactions
1) 2C6 H5 CH(CH3 )2 (ℓ) + O2 (g) → 2C6 H5 COH(CH3 )2 (ℓ)____________________ξ2
2 Cumene + Oxygen → a,a – dimethylbenzyl alcohol (DMBA)
2) C6 H5 COOH(CH3 )2 (ℓ) → C6 H5 COCH3 (ℓ) + CH3 OH (ℓ) __________________ξ3
Cumene Peroxide → Acetonephenone + Methanol
Assumptions
1) Ratio of feed; Cumene : Oxygen Gas = 1 : 4.
2) Fractional conversion of Cumene to Cumene Peroxide is 80%.
3) Fractional conversion of Cumene to DMBA is 6%.
4) Fractional conversion of Cumene Peroxide to Acetonephenonee and Methanol is 2.5%.
Material Balance
Basis of Calculation = 100 kmol/h Cumene fresh feed
Type of reaction = Reactive reaction
Method = Extend of Reaction, ξ
Input Output
Component Molar Composition Component Molar Composition
Flow Flow Rate
Rate (kmol/hr)
(kmol/hr)
Gas Phase Gas Phase
Oxygen 400 0.2100 Methanol 2 0.0011
(O2) (CH3OH)
Nitrogen 1504.7619 0.7900 Oxygen 317 0.1738
(N2) (O2)
Nitrogen 1504.7619 0.8251
(N2)
Total 1904.7619 1.0000 Total 1823.7619 1.000
Liquid Phase Liquid Phase
Cumene 100 1.0000 Cumene 14 0.1400
(C9H12) (C9H12)
Cumene 78 0.7800
Peroxide
(C9H12O2)
DMBA 6 0.0600
(C9H12O)
Acetonephenone 2 0.0200
(C8H8O)
Total 100 1.0000 Total 100 1.0000
6.2 Reactor 2 - Cleavage Unit

H2 SO4
n7 C6 H5 CH(CH3 )2 n11 C6 H5 CH(CH3 )2

Cleavage Unit
n8 C6 H5 COOH(CH3 )2 (R2) n12 C6 H5 COCH3
n9 C6 H5 COH(CH3 )2 n13 C6 H5 OH
n10 C6 H5 COCH3 n14 (CH3 )2 CO

n15 C6 H5 C(CH2 )CH3
n16 H2 O
H2 SO4
Chemical Reaction Involved In The Cleavage Unit

Sulfuric Acid, H2SO4 (aq) is not directly involve in the reaction of the reactants to produce
products. Thus, is not considered for the material balance. However, the aqueous acid solution
is required to enable the hydrolysis of cumene peroxide.
Main Reaction
1) C6 H5 COOH(CH3 )2 (ℓ) → C6 H5 OH (g) + (CH3 )2 CO (g)
Cumene Peroxide → Phenol + Acetone
Side Reactions
2) C6 H5 COH(CH3 )2 (ℓ) → C6 H5 C(CH2 )CH3 (g) + H2 O (ℓ)
DMBA → α – methylstyrene + Water
Assumptions
1) Overall conversion of DMBA and Cumene Peroxide are 100%.
2) Main reaction: Selectivity of Phenol over Acetone is 65%.
3) Side reaction: Selectivity of α – methylstyrene over water is 87%.
4) Ratio of Sulfuric Acid. Cumenefeed at R1 : Sulphuric Acid = 100 : 0.7. Thus, molar flowrate
of sulphuric acid, H2SO4 = 0.7 kmol/h.
Material Balance
Type of reaction = Non – reactive reaction
Input Output
Flow Flow
Rate Rate
(kmol/hr) (kmol/hr)
Cumene 14.0000 0.1400 Cumene 14.0000 0.1400
(C9H12) (C9H12)
Cumene 78.0000 0.7800 Acetonephenone 2.0000 0.0200
Peroxide (C8H8O)
(C9H12O2)
DMBA 6.0000 0.0600 Phenol 50.7000 0.5070
(C9H12O) (C6H5OH)
Acetonephenone 2.0000 0.0200 Acetone 27.3000 0.2730
(C8H8O) (C3H6O)
α– 5.2200 0.0522
methylstyrene
(C9H10)
Water 0.7800 0.0078
(H2O)
Total 100.0000 1.0000 Total 100.0000 1.0000
Molar flowrate of sulphuric acid,

For every 100 kmol/h of cumene fed to reactor 1, 0.7 kmol/h of sulphuric acid is fed for reactor
2.
6.3 Separator 1 - Phase Separator (Gravity Settler)

The gravity settling yields to two streams which are phenol rich organic stream and acid rich
aqueous stream. The aqueous stream is recycling back to the second reactor unit.
Organic Stream
n11 C6 H5 CH(CH3 )2
n12 C6 H5 COCH3
n13 C6 H5 OH
n11 C6 H5 CH(CH3 )2 Phase Separator
(S1) n14 (CH3 )2 CO
n12 C6 H5 COCH3
n13 C6 H5 OH
n16 H2 O
n14 (CH3 )2 CO
Aqueous Stream
H2 SO4
n16 H2 O
Traces of H2 O from n16
H2 SO4
Material Balance
Input Output
Flow Flow
Rate Rate
(kmol/hr) (kmol/hr)
Cumene 14.0000 0.1400 Cumene 14.0000 0.1400
(C9H12) (C9H12)
Acetonephenone 2.0000 0.0200 Acetonephenone 2.0000 0.0200
(C8H8O) (C8H8O)
Phenol 50.7000 0.5070 Phenol 50.7000 0.5070
(C6H5OH) (C6H5OH)
Acetone 27.3000 0.2730 Acetone 27.3000 0.2730
(C3H6O) (C3H6O)
α– methylstyrene 5.2200 0.0522 α – methylstyrene 5.2200 0.0522
(C9H10) (C9H10)
Water 0.7800 0.0078 Water 0.7800 0.0078
(H2O) (H2O)
Total 100.0000 1.0000 Total 100.0000 1.0000
6.4 Separator 2 – Scrubber

Absorption technique is used with water as the solvent. The water extracts the remaining acids
in the organic stream from phase separator and leaves as acidified wash water. The presence
of the sulphuric acid even after going to gravity settler is due to the equilibrium separation
factors for the sulphuric acid since although the acid has propensity to remain maximum in the
aqueous phase, it also do have a little extent towards the organic phase.
H2 O
Crude Phenol
n11 C6 H5 CH(CH3 )2 n11 C6 H5 CH(CH3 )2
Scrubber
n12 C6 H5 COCH3 (S2) n12 C6 H5 COCH3
n13 C6 H5 OH n13 C6 H5 OH
n14 (CH3 )2 CO n14 (CH3 )2 CO
n15 C6 H5 C(CH2 )CH3 n15 C6 H5 C(CH2 )CH3

n16 H2 O n16 H2 O
H2 SO4 traces
Material Balance
Input Output
Flow Flow
Rate Rate
(kmol/hr) (kmol/hr)
Cumene 14.0000 0.1400 Cumene 14.0000 0.1400
(C9H12) (C9H12)
Acetonephenone 2.0000 0.0200 Acetonephenone 2.0000 0.0200
(C8H8O) (C8H8O)
Phenol 50.7000 0.5070 Phenol 50.7000 0.5070
(C6H5OH) (C6H5OH)
Acetone 27.3000 0.2730 Acetone 27.3000 0.2730
(C3H6O) (C3H6O)
α– methylstyrene 5.2200 0.0522 α– methylstyrene 5.2200 0.0522
(C9H10) (C9H10)
Water 0.7800 0.0078 Water 0.7800 0.0078
(H2O) (H2O)
Total 100.0000 1.0000 Total 100.0000 1.0000
6.5 Distillation Unit

The crude phenol enters a series of distillation column to separate the products from the
reaction. Since few component form azeotropes at atmospheric pressure when fractionated,
vacuum condition is applied to the distillation units to bypass the formation of azeotropes. The
pressure reduction enhances the relative volatility making it farther from unity and eliminates
the formation of azeotrope. Thus, allowing purer products to be obtained.
n17 C6 H5 CH(CH3 )2
n21 C6 H5 CH(CH3 )2
n18 (CH3 )2 CO
n20 (CH3 )2 CO
n16 H2 O
Distillation Unit 1
Distillation Unit 2
Distillation Unit 3
From Scrubber
n11 C6 H5 CH(CH3 )2
n19 C6 H5 CH(CH3 )2
n12 C6 H5 COCH3
n20 (CH3 )2 CO
n13 C6 H5 OH
n12 C6 H5 COCH3
n14 (CH3 )2 CO
n13 C6 H5 OH
n27 C6 H5 CH(CH3 )2
n16 H2 O
n23 C6 H5 CH(CH3 )2
n29 C6 H5 CH(CH3 )2
n33 C6 H5 OH
n20 (CH3 )2 CO
Distillation Unit 4
Distillation Unit 5
n23 C6 H5 CH(CH3 )2 n25 C6 H5 CH(CH3 )2

n12 C6 H5 COCH3 n20 (CH3 )2 CO
n13 C6 H5 OH n26 C6 H5 C(CH2 )CH3

n31 C6 H5 CH(CH3 )2
n12 C6 H5 COCH3
n36 C6 H5 OH
Figure 23 Shows The Distillation Units For The Phenol Plant

6.5.1 Separator 3 – Distillation Unit 1

The first distillation unit separates mainly acetone from the other components. Inlet stream
from scrubber which is the crude phenol.
Assumptions
1) Distillate composition: 98% of acetone from crude phenol, 100% of water from crude
phenol, and 0.4% Cumene separated from the crude phenol.
2) Bottom composition: Remaining.
Material Balance
Input Output
Flow Flow
Rate Rate
(kmol/hr) (kmol/hr)
Cumene 14.0000 0.1400 Distillate
(C9H12)
(C8H8O) (C3H6O)
Phenol 50.7000 0.5070 Water 0.7800 0.0283
(C6H5OH) (H2O)
Acetone 27.3000 0.2730 Cumene 0.0560 0.0020
(C3H6O) (C9H12)
α– methylstyrene 5.2200 0.0522 Total 28.1360 1.0000
(C9H10)
Water 0.7800 0.0078 Bottom
(H2O)
Cumene 13.9440 0.1926
(C9H12)
Acetone 0.5460 0.0075
(C3H6O)
Acetonephenone 2.0000 0.0276
(C8H8O)
Phenol 50.7000 0.7002
(C6H5OH)
α– methylstyrene 5.2200 0.0721
(C9H10)
Total 100.0000 1.0000 Total 72.4100 1.0000

The second distillation unit separates mainly cumene and α – methylstyrene from the other
components. Inlet stream from the bottom product of Distillation Unit 1.
Assumptions
1) Distillate composition: 99% of cumene from inlet stream, 70% of α – methylstyrene from
inlet stream.
Material Balance
Input Output
Flow Flow
Rate Rate
(kmol/hr) (kmol/hr)
(C9H12)
Acetone 0.5460 0.0075 Cumene 13.8046 0.7667
(C3H6O) (C9H12)
(C8H8O) (C3H6O)
Phenol 50.7000 0.7002 α– methylstyrene 3.6540 0.2029
(C6H5OH) (C9H10)
α– methylstyrene 5.2200 0.0721 Total 18.0046 1.0000
(C9H10)
Bottom

(C8H8O)
Cumene 0.1394 0.0026
(C9H12)
(C9H10)
Phenol 50.7000 0.9319
(C6H5OH)
Total 72.4100 1.0000 Total 54.4054 1.0000

The third distillation unit separates mainly cumene from the other components. Inlet stream
from the top product of Distillation Unit 2. The bottom stream is sent to the pre – purification
reactor.
Assumptions
1) Distillate composition: 99% of cumene from inlet stream, 20% of α– methylstyrene from
inlet stream.
Material Balance
Input Output
Flow Flow
Rate Rate
(kmol/hr) (kmol/hr)
(C9H12)
Acetone 0.5460 0.0303 Cumene 13.6666 0.7649
(C3H6O) (C9H12)
α– methylstyrene 3.6540 0.2029 Acetone 0.5460 0.0306
(C9H10) (C3H6O)
(C9H10)
Total 17.8666 1.0000
Bottom
Cumene 0.1380 0.0451

(C9H12)
(C9H10)
Total 18.0046 1.0000 Total 3.0612 1.0000

The fourth distillation unit separates mainly cumene from the other components. Inlet stream
from the top product of Distillation Unit 3. The bottom stream is sent to the pre – purification
reactor. The top product is sent to acetone product vessel.
Assumptions
1) Distillate composition: 100% of Acetone, 1% of α – methylstyrene and 1% of cumene
from inlet stream.
Material Balance
Input Output
Flow Flow
Rate Rate
(kmol/hr) (kmol/hr)
(C9H12)
Acetone 0.5460 0.0306 α– methylstyrene 0.0365 0.0508
(C3H6O) (C9H10)
α– methylstyrene 3.6540 0.2045 Acetone 0.5460 0.7592
(C9H10) (C3H6O)
Cumene 0.1367 0.1901
(C9H12)
Total 5.3580 1.0000
Bottom
Cumene 13.5299 0.7890

(C9H12)
(C9H10)
Total 17.8666 1.0000 Total 0.5070 1.0000

The fifth distillation unit separates mainly phenol from the other components. Inlet stream from
the bottom product of Distillation Unit 2. The bottom stream is sent to the product vessel.
Assumptions
1) Distillate composition: 100% of cumene from inlet stream, 0.01% of phenol from inlet
stream, 99% of α– methylstyrene from inlet stream.
Material Balance
Input Output
Flow Flow
Rate Rate
(kmol/hr) (kmol/hr)
Acetonephenone 2.0000 0.0368 Distillate
(C8H8O)
Cumene 0.1394 0.0026 Cumene 0.1394 0.0823
(C9H12) (C9H12)
α– methylstyrene 1.5660 0.0288 α– methylstyrene 1.5503 0.9147
(C9H10) (C9H10)
Phenol 50.7000 0.9319 Phenol 0.0051 0.0030
(C6H5OH) (C6H5OH)
Total 1.6948 1.0000
Bottom

(C8H8O)
(C9H10)
Phenol 50.6949 0.9618
(C6H5OH)
Total 54.4054 1.0000 Total 52.7106 1.0000
6.6 Reactor 3 – Pre - Purification Reactor

The alpha methyl styrene is converted to cumene by feeding the reactor with hydrogen gas and
the aid of Nickel catalyst. This step converts the unsaturated hydrocarbon to saturated
hydrocarbon. The unsaturated compound might yield to other than cumene peroxide, this is the
reason for this pre – purification method as to eliminate the availability of the unsaturated in
the feed stock. The product from this reactor is mix to the fresh cumene feed by a recycle
stream. Hydrogen gas is fed with 4:1 ratio with α – methylstyrene fed to the reactor.
Bottom From DU3

H2
Bottom From DU4
n31 + n27 C6 H5 CH(CH3 )2 Pre – Purification n37 C6 H5 CH(CH3 )2

Reactor
n32 + n28 C6 H5 C(CH2 )CH3 (R3)
Chemical Reaction Involved In Pre – Purification Reactor

1) C6 H5 C(CH2 )CH3 (ℓ) + H2 (g) → C6 H5 CH(CH2 )CH3 (ℓ)__________________ξ4
α – methylstyrene + Hydrogen gas → Cumene
Material Balance
Type of reaction = Reactive reaction
Input Output
Flow Flow
Rate Rate
(kmol/hr) (kmol/hr)
Cumene 13.6679 0.2947 Cumene 20.2086 1.0000
(C9H12) (C9H12)
α – methylstyrene 6.5407 0.1411
(C9H10)
Hydrogen 26.1628 0.5642
(H2)
Total 46.3714 1.0000 Total 20.2086 1.0000
7.0 ENERGY BALANCE
7.1 Sample Calculation
Assumption in calculation
1) The open system at steady state
2) No moving parts in the system
3) The linear velocities of all streams at single height.
4) The effects of pressure will be neglect if the pressure of the system under 30 atm.
5) The heat of formation for certain substances will be neglected since the limitation of
physical properties data.
6) All the physical and chemical properties of substances was refer from Perry’s Chemical
Engineer’s Handbook, Perry, R.H. and Elementary Chemical Process.
General Energy Balance Equation

Q − Wt = ∆H + ∆Ek + ∆Ep
Based on the assumptions stated above,

Wt = 0, ∆Ek = 0, ∆Ep = 0
Hence, the equation can be reduced to

Q = ∆H
Equation for reactive system:

̌ 𝐭 + ∆𝐇
∆𝐇 = ∑ 𝐧𝐢 (∆𝐇 ̌ 𝐟 ) − ∑ 𝐧𝐢 (∆𝐇
̌ 𝐭 + ∆𝐇
̌ 𝐟)
𝐨𝐮𝐭𝐥𝐞𝐭 𝐢𝐧𝐥𝐞𝐭
Equation for non-reactive system:

̌ 𝐭 ) − ∑ 𝐧𝐢 (∆𝐇
∆𝐇 = ∑ 𝐧𝐢 (∆𝐇 ̌ 𝐭)
𝐨𝐮𝐭𝐥𝐞𝐭 𝐢𝐧𝐥𝐞𝐭
T
̌t = ∫
Which, ∆H Cp dT
T ref
T T
∫T Cp dT = ∫T (a + bT + cT 2 + dT 3 + eT 4 )dT
ref ref
Where,
a, b, c, d, e = the heat capacities from Perry’s handbooks
The reference conditions for the system:
i. Tref = 25°C
ii. Pref = 1 atm
7.1.1 Pump 1 – Cumene Feed Pump

∆𝐻2
T = 25°C
∆𝐻1 P = 6 atm
T = 25°C
P = 1 atm
Energy balance for Pump 1:

̌ t ) − ∑ ni (∆H
∆H = ∑ ni (∆H ̌ t)
outlet inlet
Reference state: C9H12 (l, 25°C, 1 atm)

Substances Inlet Outlet
nin (kmol/h) ̌ in (kJ/h)
H nout (kmol/h) ̌ out (kJ/h)
H
Cumene(C6 H5 CH(CH3 )2 ) 100 H1 100 H2
Inlet:
̌ t ) = 𝟎 𝐤𝐉 (Since the stream in references condition)
∆H1 = ∑inlet ni (∆H 𝐡
Outlet:
̌ t ) = 𝟎 𝐤𝐉 (Heat changes from pressure differences was neglected)
∆H2 = ∑outlet ni (∆H 𝐡
̌ t ) − ∑inlet ni (∆H
∆H = ∑outlet ni (∆H ̌ t ) = 0 kW (Power for Pump 1)
7.1.2 Compressor 1 – Air Feed
Energy balance for Compressor 1:
̌𝑡 ) − ∑ 𝑛𝑖 (∆𝐻
∆H = ∑ 𝑛𝑖 (∆𝐻 ̌𝑡 )
𝑜𝑢𝑡𝑙𝑒𝑡 𝑖𝑛𝑙𝑒𝑡
Reference state: O2, N2 (g, 25°C, 1 atm)

nin (kmol/h) ̌ in (kJ/h)
H nout (kmol/h) ̌ out (kJ/h)
H
Oxygen (O2) 400 H3a 400 H4a
Nitrogen (N2) 1504.76 H3b 1504.76 H4b
Inlet:
̌ t ) = 𝟎 𝒌𝑱 (Since the stream in references condition)
∆H3 = ∑inlet ni (∆H 𝒉
Outlet:
̌ t ) = 𝟎 𝐤𝐉 (Heat changes from pressure differences was neglected)
∆H4 = ∑outlet ni (∆H 𝐡
̌ t ) − ∑inlet ni (∆H
∆H = ∑outlet ni (∆H ̌ t ) = 0 kW (Power for Compressor 1)
7.1.3 Reactor 1 – Oxidation Reactor

∆𝐻5
NaOH T = 100°C, P = 6 atm
∆𝐻6
∆𝐻2
T = 100°C, P = 6 atm
∆𝐻4 Oxidation Reactor
(R1)
Energy balance for Reactor 1:

̌𝑡 + ∆𝐻
∆H = ∑ 𝑛𝑖 (∆𝐻 ̌𝑓 ) − ∑ 𝑛𝑖 (∆𝐻
̌𝑡 + ∆𝐻
̌𝑓 )
Reference state: O2, N2, H2 (g, 25°C, 1 atm) and C(s, 25°C, 1 atm)
nin (kmol/h) ̌ in
H nout (kmol/h) ̌ out
H
(kJ/h) (kJ/h)
Cumene(C6 H5 CH(CH3 )2 ) 100 H2 14 H6a
Oxygen (O2 ) 400 H4a 317 H5a
Nitrogen (N2 ) 1504.76 H4b 1504.76 H5b
Methanol (CH3 OH) - - 2 H5c
Cumene Peroxide( C6 H5 COOH(CH3 )2) - - 78 H6b
DMBA(C6 H5 COH(CH3 )2 ) - - 6 H6c
Acetonephenone (C6 H5 COCH3 ) - - 2 H6d
Inlet:
𝐤𝐉⁄
∆H2 = 𝟎 𝐡
𝐤𝐉
∆H4 = 𝟎 ⁄𝐡
Outlet:
∆H5 = nH5a + nH5b + nH5c
100
𝑘𝑚𝑜𝑙 kJ 𝑚𝑜𝑙 𝑘𝑗
nH5a = 𝑛𝑖 (∫ ̌𝑓 ) = 317
Cp dT + ∆𝐻 2.24 + 0 (1000 ) = 710080
25 ℎ mol 𝑘𝑚𝑜𝑙 ℎ
100
𝑘𝑚𝑜𝑙 kJ 𝑚𝑜𝑙
nH5b = 𝑛𝑖 (∫ ̌𝑓 ) = 1504.76
Cp dT + ∆𝐻 2.19 + 0 (1000 )
25 ℎ mol 𝑘𝑚𝑜𝑙
𝑘𝑗
= 3295424.4
ℎ
100
𝑘𝑚𝑜𝑙 𝑘𝑗 𝑘𝐽 𝑚𝑜𝑙
nH5c = 𝑛𝑖 (∫ ̌𝑓 ) = 2
Cp dT + ∆𝐻 (3.6025 − 201.2 ) 1000
25 ℎ 𝑚𝑜𝑙 𝑚𝑜𝑙 𝑘𝑚𝑜𝑙
𝑘𝑗
= −395200
ℎ
𝒌𝒋
∆H5 = nH5a + nH5b + nH5c = 710080 + 3295424.4 − 395200 = 𝟑𝟔𝟏𝟎𝟑𝟎𝟒. 𝟒
𝒉
∆H6 = nH6a + nH6b + nH6c + nH6d

100
𝑘𝑚𝑜𝑙 𝑘𝐽 𝑘𝐽 𝑚𝑜𝑙
nH6a = 𝑛𝑖 (∫ ̌𝑓 ) = 14
Cp dT + ∆𝐻 2920.62 − 38.40 1000
25 ℎ 𝑚𝑜𝑙 𝑚𝑜𝑙 𝑘𝑚𝑜𝑙
𝑘𝑗
= 40351.08
ℎ
100
nH6b = 𝑛𝑖 (∫ ̌𝑓 ) = 78
Cp dT + ∆𝐻 4263.6 −0 1000
𝑘𝑗
= 332560800
ℎ
100
nH6c = 𝑛𝑖 (∫ ̌𝑓 ) = 6
Cp dT + ∆𝐻 3559.8 −0 1000
𝑘𝑗
= 21358800
ℎ
100
𝑘𝑚𝑜𝑙 kJ 𝑚𝑜𝑙 𝑘𝑗
nH6d = 𝑛𝑖 (∫ ̌𝑓 ) = 2
Cp dT + ∆𝐻 2464.5 −0 1000 = 4929000
25 ℎ mol 𝑘𝑚𝑜𝑙 ℎ
∆H6 = nH6a + nH6b + nH6c + nH6d

𝒌𝑱
= 40351.08 + 332560800 + 21358800 + 4929000 = 𝟑𝟓𝟖𝟖𝟖𝟖𝟗𝟓𝟏. 𝟏
𝒉
∆H = (∆H5 + ∆H6 ) − (∆H2 + ∆H4 )

𝑘𝐽 ℎ
= 358888951.1
ℎ 3600𝑠
= 99691.37 𝑘𝑊 (𝑝𝑜𝑤𝑒𝑟 𝑜𝑓 𝑟𝑒𝑎𝑐𝑡𝑜𝑟 1)
7.1.4 Reactor 2 – Cleavage Unit

H2 SO4
∆𝐻6 ∆𝐻7
T = 110°C, P = 6 atm
Cleavage Unit
(R2)
Energy balance for Reactor 2:

̌𝑡 + ∆𝐻
∆H = ∑ 𝑛𝑖 (∆𝐻 ̌𝑓 ) − ∑ 𝑛𝑖 (∆𝐻
̌𝑡 + ∆𝐻
̌𝑓 )
Reference state: O2, N2, H2 (g, 25°C, 1 atm) and C(s, 25°C, 1 atm)
nin ̌ in
H
(kmol/h) (kJ/h) (kJ/h)
Cumene(C6 H5 CH(CH3 )2 ) 14 H6a 14 H7a
Cumene Peroxide( C6 H5 COOH(CH3 )2) 78 H6b - -
DMBA(C6 H5 COH(CH3 )2 ) 6 H6c - -
Acetonephenone (C6 H5 COCH3 ) 2 H6d 2 H7b

Phenol (C6 H5 OH) - - 50.7 H7c
Acetone ((CH3 )2 CO) - - 27.3 H7d
α − methylstyrene(C6 H5 C(CH2 )CH3 ) - - 5.22 H7e
Water (H2 O) - - 0.78 H7f
Inlet:
kJ
∆H6 = 358888951.1 h
Outlet:
kJ
∆H7 = 151857055.6
h
𝑘𝐽 ℎ
∆H = ∆H7 − ∆H6 = −207031895.5
ℎ 3600𝑠
= −57508.86 𝑘𝑊 ( 𝑃𝑜𝑤𝑒𝑟 𝑜𝑓 𝑅𝑒𝑎𝑐𝑡𝑜𝑟 2)
7.1.5 Heat Exchanger 1 – Cooling
∆𝐻7 ∆𝐻8
T = 25°C, P = 6 atm
Heat exchanger 1
Energy balance for Heat exchanger 1:

̌𝑡 ) − ∑ 𝑛𝑖 (∆𝐻
∆H = ∑ 𝑛𝑖 (∆𝐻 ̌𝑡 )
Reference state: liquid substances at 25°C, 1 atm

nin (kmol/h) ̌ in
H
(kJ/h) (kJ/h)
Acetonephenone (C6 H5 COCH3 ) 2 H7b 2 H8b
Phenol (C6 H5 OH) 50.7 H7c 50.7 H8c
Acetone ((CH3 )2 CO) 27.3 H7d 27.3 H8d
α − methylstyrene(C6 H5 C(CH2 )CH3 ) 5.22 H7e 5.22 H8e
Water (H2 O) 0.78 H7f 0.78 H8f
Inlet:
kJ
∆H7 = 151857055.6
h
Outlet:
kJ
∆H8 = 0
h
kJ ℎ
∆H = ∆H8 − ∆H7 = 151857055.6
h 3600𝑠
= 42182.52 𝑘𝑊 ( 𝑃𝑜𝑤𝑒𝑟 𝑜𝑓 𝐻𝑒𝑎𝑡 𝐸𝑥𝑐ℎ𝑎𝑛𝑔𝑒𝑟 1)
7.1.6 Separator 1 - Phase Separator (Gravity Settler)

∆𝐻9
T = 25°C, P = 6 atm
∆𝐻8
Phase Separator
(S1)
H2 SO4
Energy balance for Phase Separator (S1):
̌𝑡 ) − ∑ 𝑛𝑖 (∆𝐻
∆H = ∑ 𝑛𝑖 (∆𝐻 ̌𝑡 )

nin ̌ in
H nout ̌ out
H
(kmol/h) (kJ/h) (kmol/h) (kJ/h)
Phenol (C6 H5 OH) 50.7 H8c 50.7 H9c
Water (H2 O) 0.78 H8f 0.78 H9f
Inlet:
kJ
∆H8 = 0
h
Outlet:
kJ
∆H9 = 0
h
∆H = ∆H9 − ∆H8 = 0 𝑘𝑊 ( 𝑃𝑜𝑤𝑒𝑟 𝑜𝑓 𝑃ℎ𝑎𝑠𝑒 𝑆𝑒𝑝𝑎𝑟𝑎𝑡𝑜𝑟)
7.1.7 Separator 2 – Scrubber

H2 O
∆𝐻10
∆𝐻9
Scrubber T = 100°C, P = 1 atm

(S2)

Energy balance for Scrubber (S2):
̌𝑡 ) − ∑ 𝑛𝑖 (∆𝐻
∆H = ∑ 𝑛𝑖 (∆𝐻 ̌𝑡 )

nin ̌ in
H
Phenol (C6 H5 OH) 50.7 H9c 50.7 H10c
Water (H2 O) 0.78 H9f 0.78 H10f
Inlet:
kJ
∆H9 = 0
h
Outlet:
kJ
∆H10 = 136337110
h
kJ ℎ
∆H = ∆H10 − ∆H9 = 136337110 = 37871.42 𝑘𝑊 ( 𝑃𝑜𝑤𝑒𝑟 𝑜𝑓 𝑆𝑐𝑟𝑢𝑏𝑏𝑒𝑟)
h 3600𝑠

∆𝐻10 ∆𝐻11
T = 80°C, P = 1 atm
Heat exchanger 2
Energy balance for Heat exchanger 2:

̌𝑡 ) − ∑ 𝑛𝑖 (∆𝐻
∆H = ∑ 𝑛𝑖 (∆𝐻 ̌𝑡 )

nin ̌ in
H
Phenol (C6 H5 OH) 50.7 H10c 50.7 H11c
Water (H2 O) 0.78 H10f 0.78 H11f
Inlet:
kJ
∆H10 = 136337110
h
Outlet:
kJ
∆H11 = 99980603.9
h
𝑘𝐽 ℎ
∆H = ∆H11 − ∆H10 = −36356506.1
ℎ 3600𝑠
= −10099.03 𝑘𝑊 ( 𝑃𝑜𝑤𝑒𝑟 𝑜𝑓 𝐻𝑒𝑎𝑡 𝐸𝑥𝑐ℎ𝑎𝑛𝑔𝑒𝑟 2)

∆𝐻12
T = 100°C, P = 1 atm
Distillation Unit 1
∆𝐻11
∆𝐻13
T = 100°C, P = 1 atm
Energy balance for distillation unit 1:
̌𝑡 ) − ∑ 𝑛𝑖 (∆𝐻
∆H = ∑ 𝑛𝑖 (∆𝐻 ̌𝑡 )

nin ̌ in
H
Cumene(C6 H5 CH(CH3 )2 ) 14 H11a 0.056 H12a
Cumene(C6 H5 CH(CH3 )2 ) 13.94 H13a
Phenol (C6 H5 OH) 50.7 H11c 50.7 H13c
Acetone ((CH3 )2 CO) 27.3 H11d 26.75 H12b
Acetone ((CH3 )2 CO) 0.55 H13d
Water (H2 O) 0.78 H11f 0.78 H12c
Inlet:
kJ
∆H11 = 99980603.9
h
Outlet:
kJ
∆H12 = 415108.87
h
kJ
∆H13 = 135910318.3
h
𝑘𝐽 ℎ
∆H = (∆H12 + ∆H13 ) − ∆H11 = 36344823.22
ℎ 3600𝑠
= 10095.78 𝑘𝑊 ( 𝑃𝑜𝑤𝑒𝑟 𝑜𝑓 𝐷𝑖𝑠𝑡𝑖𝑙𝑙𝑎𝑡𝑖𝑜𝑛 𝑈𝑛𝑖𝑡 1)

∆𝐻14
T = 175°C, P = 1 atm
Distillation Unit 2
∆𝐻13
∆𝐻15
T = 175°C, P = 1 atm

̌𝑡 ) − ∑ 𝑛𝑖 (∆𝐻
∆H = ∑ 𝑛𝑖 (∆𝐻 ̌𝑡 )

nin ̌ in
H
Cumene(C6 H5 CH(CH3 )2 ) 13.94 H13a 13.8 H14a
Cumene(C6 H5 CH(CH3 )2 ) 0.14 H15a
Phenol (C6 H5 OH) 50.7 H13c 50.7 H15c
Acetone ((CH3 )2 CO) 0.55 H13d 0.55 H14b
α − methylstyrene(C6 H5 C(CH2 )CH3 ) 5.22 H13e 3.65 H14c
α − methylstyrene(C6 H5 C(CH2 )CH3 ) 1.57 H15d
Inlet:
kJ
∆H13 = 135910318.3
h
Outlet:
kJ
∆H14 = 99225378
h
kJ
∆H15 = 172595120.2
h
kJ h
∆H = (∆H14 + ∆H15 ) − ∆H13 = 135910179.9
h 3600s
= 37752.83 kW ( Power of Distillation Unit 2)
∆𝐻14 ∆𝐻16
T = 150°C, P = 1 atm
Heat exchanger 3
Energy balance for heat exchanger 3:
̌𝑡 ) − ∑ 𝑛𝑖 (∆𝐻
∆H = ∑ 𝑛𝑖 (∆𝐻 ̌𝑡 )

nin ̌ in
H
Acetone ((CH3 )2 CO) 0.55 H14b 0.55 H16b
α − methylstyrene(C6 H5 C(CH2 )CH3 ) 3.65 H14c 3.65 H16c
Inlet:
kJ
∆H14 = 99225378
h
Outlet:
kJ
∆H16 = 82689030
h
kJ h
∆H = ∆H16 − ∆H14 = −16536348
h 3600s
= −4593.43 kW ( Power of Heat Exchanger 3)

∆𝐻17
T = 152°C, P = 1 atm
Distillation Unit 3
∆𝐻16
∆𝐻18
T = 152°C, P = 1 atm
̌𝑡 ) − ∑ 𝑛𝑖 (∆𝐻
∆H = ∑ 𝑛𝑖 (∆𝐻 ̌𝑡 )

nin ̌ in
H
𝐶𝑢𝑚𝑒𝑛𝑒(C6 H5 CH(CH3 )2 ) 13.80 H16a 13.67 H17a
𝐶𝑢𝑚𝑒𝑛𝑒(C6 H5 CH(CH3 )2 ) 0.13 H18a
𝐴𝑐𝑒𝑡𝑜𝑛𝑒 ((CH3 )2 CO) 0.55 H16b 0.55 H17b
𝛼 − 𝑚𝑒𝑡ℎ𝑦𝑙𝑠𝑡𝑦𝑟𝑒𝑛𝑒(C6 H5 C(CH2 )CH3 ) 3.65 H16c 3.65 H17c
𝛼 − 𝑚𝑒𝑡ℎ𝑦𝑙𝑠𝑡𝑦𝑟𝑒𝑛𝑒(C6 H5 C(CH2 )CH3 ) 2.92 H18b
Inlet:
kJ
∆H16 = 82689030
h
Outlet:
kJ
∆H17 = 83369109.6
h
kJ
∆H18 = 13245557.8
h
kJ h
∆H = (∆H17 + ∆H18 ) − ∆H16 = 13925637.4
h 3600s

∆𝐻19
T = 100°C, P = 1 atm
Distillation Unit 4
∆𝐻17
∆𝐻20
T = 100°C, P = 1 atm
̌𝑡 ) − ∑ 𝑛𝑖 (∆𝐻
∆H = ∑ 𝑛𝑖 (∆𝐻 ̌𝑡 )

nin ̌ in
H nout (kmo ̌ out
H
(kmol/h) (kJ/h) l/h) (kJ/h)
𝐶𝑢𝑚𝑒𝑛𝑒(C6 H5 CH(CH3 )2 ) 13.67 H16a 0.14 H18a
𝐶𝑢𝑚𝑒𝑛𝑒(C6 H5 CH(CH3 )2 ) 13.53 H19a
𝐴𝑐𝑒𝑡𝑜𝑛𝑒 ((CH3 )2 CO) 0.55 H16b 0.55 H18b
𝛼 − 𝑚𝑒𝑡ℎ𝑦𝑙𝑠𝑡𝑦𝑟𝑒𝑛𝑒(C6 H5 C(CH2 )CH3 ) 3.65 H16c 0.037 H18c
𝛼 − 𝑚𝑒𝑡ℎ𝑦𝑙𝑠𝑡𝑦𝑟𝑒𝑛𝑒(C6 H5 C(CH2 )CH3 ) 3.62 H19b
Inlet:
kJ
∆H17 = 83369109.6
h
Outlet:
kJ
∆H19 = 508273.85
h
kJ
∆H20 = 48742644.6
h
𝑘𝐽 ℎ
∆H = (∆H19 + ∆H20 ) − ∆H17 = −34118191.15
ℎ 3600𝑠
= −9477.28 𝑘𝑊 ( 𝑃𝑜𝑤𝑒𝑟 𝑜𝑓 𝐷𝑖𝑠𝑡𝑖𝑙𝑙𝑎𝑡𝑖𝑜𝑛 𝑈𝑛𝑖𝑡 4)

∆𝐻21
T = 180°C, P = 1 atm
Distillation Unit 5
∆𝐻15
∆𝐻22
T = 180°C, P = 1 atm

̌𝑡 ) − ∑ 𝑛𝑖 (∆𝐻
∆H = ∑ 𝑛𝑖 (∆𝐻 ̌𝑡 )

nin ̌ in
H
Acetonephenone (C6 H5 COCH3 ) 2 H15b 2 H22a
Phenol (C6 H5 OH) 50.7 H15c 0.005 H21b
Phenol (C6 H5 OH) 50.695 H22b
α − methylstyrene(C6 H5 C(CH2 )CH3 ) 1.57 H15d 1.55 H21c
α − methylstyrene(C6 H5 C(CH2 )CH3 ) 0.02 H22c
Inlet:
kJ
∆H15 = 172595120.2
h
Outlet:
kJ
∆H21 = 9024639.35
h
kJ
∆H22 = 169324023.7
h
kJ h
∆H = (∆H21 + ∆H22 ) − ∆H15 = 5753542.8
h 3600s
8.0 SIZING OF EQUIPMENTS
8.1 Sizing Of The Equipments

The flow sheet of cumene oxidation is shown in process flow diagram. The oxidation of
cumene as the first reaction usually carried out in a bubble column reactor with temperature
inlet is 25°C and pressure 6 atm meanwhile, the product will be yielded at temperature 100°C
and pressure remain the same. Fresh cumene are fed to the first reactor (R-101). Oxygen is
used in each reactor as oxidant. For first reactor, the bubble column reactor is chosen as the
relevant equipment. This is because we have oxidation process occur at first reactor. Based on
(Mengmeng & Ekaterina, 2017) they stated in their article, bubble column reactor is used in
chemical process which involved oxidation, chlorination, polymerization and hydrogenation.
This bubble column reactor also was chosen because of their technical structure. Founded by
(Kantarci, Borak, & Ulgen, 2005) in (Mengmeng & Ekaterina, 2017) article, bubble column
reactor has high heat and mass transfer coefficient, need little maintenance and have low
operating cost due to lack of moving parts and compactness compared to batch reactor. Before
choosing the bubble column reactor, the three main phenomena which are 1) heat and mass
transfer characteristics 2) mixing characteristic and 3) system have been taking in considered
before establishing the decision to use this type of reactor.
For reactor R-102 and R-103, the reactor use is Continous Stirred Tank Reactor
(CSTR). Beside, can produce the large amount of our product which is Phenol, according to
(Chaplin, 2014), CSTR is an easily constructed, versatile and cheap reactor. It allows simple
catalyst (Nickel, Ni in R-103) charging and replacement. It is well-mixed nature permits
straightforward control over the temperature and pH of the reaction and able to supply or
remove unwanted gasses easily. He continued that, CSTR tend to be as large as need to be
efficiently mixed to yield product. CSTR has the advantage that there is very little resistance
to the flow of the reactant stream which might contain colloidal or insoluble reactants.
Furthermore, the mechanical of its structure which is stirring limits which will support the
immobilized enzymes to easily disintegrate to give ‘fines’ shape to enter the product stream.
In addition, CSTR has complete back-mixing which will results in minimization of the reactant
concentration but at the same time, maximize the product concentration, relative to final
conversion, at every point within the effectiveness factor being uniform throughout. Thus,
CSTR are the preferred reactors, everything being equal in the reactor for process involving
reactant inhibition or product activation (Chaplin, 2014).
8.1.1 Reactor 1 – Oxidation Reactor CSTR

kg
Mass Flowrate ( )
Volumetric Flowrate, vo = h
kg
Density ( )
m3
V = space time, τ × vo
kmol kg kg
1. vo cumene = 14 × 120.19 kmol ÷ 862 m3
hr
m3
= 1.952
hr
kmol kg kg
2. vo cumene peroxide = 78 × 150 ÷ 1.02
hr kmol m3
m3
= 11470.59 hr
kmol kg kg
3. vo DMBA = 6 ÷ 1013 m3 × 256.35
hr kmol
m3
= 1.518
hr
kmol kg kg
4. vo Acetonephenone = 2 ÷ 1.03 × 120.15
hr m3 kmol
m3
= 233.01
hr
𝐦𝟑
5. Total volumetric, 𝐯𝐨 = 11704.51 𝐡𝐫
From Rule 5 Heuristics for Reactor, table 11.17;
Ideal CSTR behavior is approached when the mean of residence time is 5 to 10 times the
length needed to achieve homogeneity, which is accomplished with 500-2000 revolutions
of a properly designed stirrer.
We assumed that,𝛕 = 𝟎. 𝟎𝟏𝟓 𝐦𝐢𝐧, 𝐥 = 𝟎. 𝟏𝟓 𝐦;

𝐕 = 𝟐. 𝟗𝟑 𝐦𝟑
V = πr 2 l
2.93 = π r 2 (0.15)
𝐫 = 𝟐. 𝟒𝟗 𝐦
8.1.2 Reactor 2 – Cleavage Unit CSTR
kmol kg kg
1. vo cumene = 14 × 120.19 kmol ÷ 862 m3
hr
m3
= 1.952
hr
kmol kg kg
2. vo Acetonephenone = 2 ÷ 1.03 × 120.15
hr m3 kmol
m3
= 233.01
hr
kmol kg kg
3. vo phenol = 50.7 ÷ 1.07 m3 × 100.15 kmol
hr
3
m
= 4745.43
hr
kmol kg kg
4. vo acetone = 27.3 ÷ 784 × 58.08
hr m3 kmol
m3
= 2.022
hr
kmol kg kg
5. vo α − methylstyrene = 5.22 ÷ 910 × 118.18
hr m3 kmol
3
m
= 0.678
hr
kmol kg kg
6. vo water = 0.78 hr ÷ 997 m3 × 18.02 kmol
m3
= 0.0141
hr
𝐦𝟑
7. Total volumetric, 𝐯𝐨 = 4983.11 𝐡𝐫
From Rule 5 Heuristics for Reactor, table 11.17;
Ideal CSTR behavior is approached when the mean of residence time is 5 to 10 times
the length needed to achieve homogeneity, which is accomplished with 500-2000
revolutions of a properly designed stirrer.
We assumed that,𝛕 = 𝟎. 𝟑𝟓 𝐦𝐢𝐧, 𝐥 = 𝟑. 𝟓 𝐦;
𝐕 = 𝟐𝟗. 𝟎𝟔𝟖 𝐦𝟑
V = πr 2 l
29.068 = π r 2 (3.5)
𝐫 = 𝟏. 𝟔𝟑 𝐦
8.1.3 Reactor 3 – Pre-Purification Reactor CSTR
kmol kg kg
1. vo cumene = 14 × 120.19 kmol ÷ 862 m3
hr
𝟑
𝐦
= 𝟐. 𝟔𝟕
𝐡𝐫
Ideal CSTR behavior is approached when the mean of residence time is 5 to 10 times the
length needed to achieve homogeneity, which is accomplished with 500-2000
revolutions of a properly designed stirrer.
We assumed that,𝛕 = 𝟐. 𝟐𝟓 𝐦𝐢𝐧, 𝐥 = 𝟓 𝐦;
𝐕 = 𝟎. 𝟏 𝐦𝟑
V = πr 2 l
0.1 = π r 2 (5)
𝐫 = 𝟎. 𝟎𝟖 𝐦
8.1.4 Separator 1 - Phase Separator (Gravity Settler)
Substances Molecular weight (MW), Density (ρ), kg/m3

kg/kmol
Cumene (C9H12) 120.19 862.00
Acetophenone (C8H8O) 120.15 1.03
Phenol (C6H5OH) 100.15 1.07
Acetone (C3H6O) 58.08 784.00
α– methylstyrene (C9H10) 118.18 910.00
Water (H2O) 18.02 997.00
Sulphuric Acid (H2SO4) 98.08 1.84
Temperature inlet 25.0 °C Pressure inlet 6.0 atm
Temperature outlet 25.0 °C Pressure outlet 6.0 atm

From Table 11.6, the following heuristics are used:
Rule 3 – Vertical vessel.
Rule 4 – L/D between 2.5 and 5 with optimum at 3.0.
Rule 5 – Liquid holdup time is 5 min based on ½ volume of vessel.
Rule 9 – Gas velocity, u is given by
ρv
u = k√ − 1 m/s
ρl
Where k = 0.0305(0.1) for vessels without mesh entrainer.
Rule 12 – Good performance obtained at 30% - 100% of u from Rule 9; typical value is 75%.
From Table 1.5,
Vapour flow = 9,217.11 kg/h, P = 6.01325 bar, T = 25°C
Liquid flow = 98.08 kg/h, P = 6.01325 bar, T = 25°C
kg kg
ρv = 335.28 , ρl = 1.84
m3 m3
From Rule 9,
335.28 m
u = 0.00305√ − 1 m/s = 0.0411
1.84 s
Use uact = (0.75)(0.0411 m/s) = 0.0308 m/s
Thus,
uρv πD2
= mass flowrate of vapour
4
m kg
(0.0308 s ) 335.28 3 πD2 kg 1h
m
= 9217.11
4 h 3600 s
kg
103.27 πD2 kg
m2 s
= 2.56
4 s
kg
2.56 s (4)
D=√ = √0.3157 m2 = 0.56 m
kg
103.27 2 π
m s
From Rule 5,
0.5 LπD2 0.5 Lπ(0.56)2

Volume of liquid = = = 0.1232L m2
4 4
From Rule 4, L/D should be in the range 2.5 to 5. For this case, L/D = 2.29 m3
60 s kg 1h
(5 min) (
1 min) 9217.11 h (3600 s)
5 min of vapour flow = = 2.29 m3
kg
335.28 3
m
Equation the two results above,
0.1232L m2 = 2.29 m3
2.29 m3
L= = 18.59 m
0.1232 m2
From Rule 4, L/D should be in the range 2.5 to 5. For this case, L/D = 18.59/0.56 = 33. Because
this is out of range, change to L = 2.5D = 2.5(0.56 m) = 1.4 m. Heuristics from Table 11.6
suggest that Phase Separator should be a vertical vessel with D = 0.56 m and L = 1.4 m. Thus,
the L/D is to be in the minimum range which is 2.5. It can be concluded that the design of Phase
Separator is consistent with the heuristics given in Table 11.6. The small differences in L and
D are to be expected in a comparison such as this calculation.
8.1.5 Separator 2 - Scrubber

Scrubber is used to wash the acid with water. The water extracts the remaining acids in the
organic stream and leaves as acidified wash water.
Substances Molecular weight (MW), Density (ρ), kg/m3

kg/kmol
Cumene (C9H12) 120.19 862.00
Acetophenone (C8H8O) 120.15 1.03
Phenol (C6H5OH) 100.15 1.07
Acetone (C3H6O) 58.08 784.00
α– methylstyrene (C9H10) 118.18 910.00
Water (H2O) 18.02 997.00
Temperature inlet 25.0 °C Pressure inlet 6.0 atm
Temperature outlet 100.0 °C Pressure outlet 1.0 atm
From Table 11.6, the following heuristics are used:
Rule 3 – Vertical vessel.
Rule 4 – L/D between 2.5 and 5 with optimum at 3.0.
Rule 5 – Liquid holdup time is 5 min based on ½ volume of vessel.
Rule 9 – Gas velocity, u is given by
ρl
u = k√ − 1 m/s
ρv
Where k = 0.0305(0.1) for vessels without mesh entrainer.
Rule 12 – Good performance obtained at 30% - 100% of u from Rule 9; typical value is 75%.
From Table 1.5,
Vapour flow = 9,217.11 kg/h, P = 6.01325 bar, T = 25°C
Liquid flow = 98.08 kg/h, P = 6.01325 bar, T = 25°C
kg kg
ρv = 335.28 , ρl = 1.84
m3 m3
From Rule 9,
335.28 m
u = 0.00305√ − 1 m/s = 0.0411
1.84 s
Use uact = (0.75)(0.0411 m/s) = 0.0308 m/s
Thus,
uρv πD2
= mass flowrate of vapour
4
m kg
(0.0308 s ) 335.28 3 πD2 kg 1h
m
= 9217.11
4 h 3600 s
kg
103.27 πD2 kg
m2 s
= 2.56
4 s
kg
2.56 s (4)
D=√ = √0.3157 m2 = 0.56 m
kg
103.27 2 π
m s
From Rule 5,
0.5 LπD2 0.5 Lπ(0.56)2

Volume of liquid = = = 0.1232L m2
4 4
From Rule 4, L/D should be in the range 2.5 to 5. For this case, L/D = 2.29 m3
60 s kg 1h
(5 min) ( ) 9217.11 ( )
1 min h 3600 s
5 min of vapour flow = = 2.29 m3
kg
335.28 3
m
Equation the two results above,
0.1232L m2 = 2.29 m3
2.29 m3
L= = 18.59 m
0.1232 m2
From Rule 4, L/D should be in the range 2.5 to 5. For this case, L/D = 18.59/0.56 = 33. Because
this is out of range, change to L = 2.5D = 2.5(0.56 m) = 1.4 m. Heuristics from Table 11.6
suggest that scrubber should be a vertical vessel with D = 0.56 m and L = 1.4 m. Thus, the
L/D is to be in the minimum range which is 2.5. It can be concluded that the design of scrubber
is consistent with the heuristics given in Table 11.6. The small differences in L and D, are to
be expected in a comparison such as this calculation.
8.1.6 Separator 3 – Distillation Column Unit 1

Distillation column 1 is used for separating acetone. Thus, it is also known as Acetone column.
Rule 2 (Table 11.13) : Relative volatility
P1sat
αavg =
P2sat
For multi-component system, the relative volatility is as follows:
αavg = 3√αFij αBij αDij
In order to find the vapor pressure of each component, Antoine equation is used as below:
B
log10 P (mmHg) = A −
T(˚C) + C
For Feed:
Vapor pressure of Acetone at 80˚C, P1sat :
1277.03
log10 P1sat = 7.2316 −
80 + 237.23
P1sat = 1607.0706 mmHg
P1sat = 2.1146 atm
Vapor pressure of Cumene at 80˚C, P2sat :
1460.793
log10 P2sat = 6.93666 −
80 + 207.777
P2sat = 72.5323 mmHg
P2sat = 0.0954 atm
Relative volatility for feed:
P1sat 2.1146 atm

αFij = =
P2sat 0.0954 atm
𝛂𝐅𝐢𝐣 = 𝟐𝟐. 𝟏𝟔𝟓𝟔
For Distillate:
Vapor pressure of Acetone at 100˚C, P1sat :
1277.03
log10 P1sat = 7.2316 −
100 + 237.23
P1sat = 2784.6970 mmHg
P1sat = 3.6641 atm
1460.793
log10 P2sat = 6.93666 −
100 + 207.777
P2sat = 155.0205mmHg
P2sat = 0.2040 atm

P1sat 3.6641 atm

αDij = sat =
P2 0.2040 atm
𝛂𝐃𝐢𝐣 = 𝟏𝟕. 𝟗𝟔𝟏𝟑
For Bottom:
The relative volatility of the bottom part of the column is same as the distillate because its
temperature condition is same which is 100˚C. Thus,
𝛂𝐁𝐢𝐣 = 𝛂𝐃𝐢𝐣 = 𝟏𝟕. 𝟗𝟔𝟏𝟑
The average volatility is:
3
αavg = √22.1656(17.9613)(17.9613)
𝛂𝐚𝐯𝐠 = 𝟏𝟗. 𝟐𝟔𝟓𝟕
Rule 7 (Table 11.13) : The minimum number of trays with Fenske-Underwood equation.
For multi-component system using Fenske equation:
(xDi /xBi )
ln [ ]
(xDj /xBj
Nmin = −1
ln α
(0.9697/0.0075)
ln [ ]
(0.0020/0.1926
Nmin = −1
ln 19.2657
𝐍𝐦𝐢𝐧 = 𝟐. 𝟏𝟖𝟕𝟓
Rule 6 (Table 11.13) : The optimum number of theoretical trays is near 2Nmin
Nopt = 2Nmin = 4.375
Rule 9 (Table 11.13) : A safety factor of 10% on number of trays
2Nmin (1 + 0.1)
Nactual =
ε
4.375(1 + 0.1)
Nactual =
0.85
𝐍𝐚𝐜𝐭𝐮𝐚𝐥 = 𝟓. 𝟔𝟔
Rule 4 (Table 11.14) : Tray efficiencies for distillation of light hydrocarbons and aq. Solution
ε = 60 → 90%
It is assumed that the tray efficiencies is 𝛆 = 𝟖𝟓%
Rule 8 (Table 11.13) : Minimum reflux at bubble point
kmol kmol
(F/D) (100 /27.59 )
R min = = hr hr
(α − 1) (19.2657 − 1)
𝐑 𝐦𝐢𝐧 = 𝟎. 𝟏𝟗𝟖𝟒
Rule 5 (Table 11.13) : The optimum reflux in the range of 1.2-1.5R min
R = (1.2 → 1.5)R min
The optimum reflux is assumed to be 1.35𝐑 𝐦𝐢𝐧
R = (1.35)R min = 1.35(0.1984)
𝐑 = 𝟎. 𝟐𝟔𝟕𝟖
m
Rule 2 (Table 11.14) : Peak efficiency of vapor factor in range 1.2-1.5 [kg/m3 ]0.5
s
Fs = uρ0.5
v
𝐦
The efficiency of vapor factor is assumed to be 1.35 [𝐤𝐠/𝐦𝟑 ]𝟎.𝟓
𝐬
In order to find the density of the vapor in the distillate, equation below is used:
ρn = ∑(xi ρi )n
For substance at distillate:
Substances Molar Molecular Mass Mass Density, xρ

flowrate weight flowrate fraction, ρ (kg/m3)
(kmol/hr) (kg/kmol) (kg/hr) x
Cumene 0.0560 120.19 6.7306 0.0043 862.00 3.7066
Acetone 26.7540 58.08 1553.8723 0.9868 784.00 773.6512
Water 0.7800 18.02 14.0556 0.0089 997.00 8.8733
Total 1574.6585 1.0000 786.2311
ρv = 786.2311 kg/m3
Fs 1.35
u= =
ρ0.5
v 786.23110.5
𝐮 = 𝟎. 𝟎𝟒𝟖𝟏 𝐦/𝐬
The diameter, D of the tower is assumed to be 1.35m.
Rule 13 (Table 11.13) : Add spacing for top and bottom vapor and liquid return
The tray spacing is assumed to be 0.55m.
H = (tray spacing x Nactual ) + 3m
H = (0.55m x 5.66) + 3m
𝐇 = 𝟔. 𝟏𝟏𝟑𝐦
Rule 14 (Table 11.13) : Limit tower height to 53 m or L/D<30
𝐋 𝟔. 𝟏𝟏𝟑𝐦
= = 𝟒. 𝟓𝟐𝟖𝟏 < 𝟑𝟎
𝐃 𝟏. 𝟑𝟓𝐦

Distillation column 2 is used for separating cumene. Thus, it is also known as Cumene column.
P1sat
αavg =
P2sat
B
T(˚C) + C
For Feed:
1460.793
log10 P1sat = 6.93666 −
100 + 207.777
P1sat = 155.0205 mmHg
P1sat = 0.20397 atm
Vapor pressure of α– methylstyrene at 100˚C, P2sat :
1582.7
log10 P2sat = 7.0924 −
100 + 206.01
P2sat = 0.10953 atm
P1sat 0.20397 atm

αFij = =
P2sat 0.10953 atm
𝛂𝐅𝐢𝐣 = 𝟏. 𝟖𝟔𝟐𝟐
For Distillate:
1460.793
log10 P1sat = 6.93666 −
165 + 207.777
P1sat = 1042.2744 mmHg
P1sat = 1.37141 atm
1582.7
log10 P2sat = 7.0924 −
165 + 206.01
P2sat = 670.6212mmHg
P2sat = 0.88240 atm

P1sat 1.37141 atm

αDij = sat =
P2 0.88240 atm
𝛂𝐃𝐢𝐣 = 𝟏. 𝟓𝟓𝟒𝟐
For Bottom:
𝛂𝐁𝐢𝐣 = 𝛂𝐃𝐢𝐣 = 𝟏. 𝟓𝟓𝟒𝟐
3
αavg = √1.8622(1.5542)(1.5542)
𝛂𝐚𝐯𝐠 = 𝟏. 𝟔𝟓𝟎𝟕
(xDi /xBi )
ln [ ]
(xDj /xBj
Nmin = −1
ln α
(0.7667/0.0026)
ln [ ]
(0.2029/0.0288)
Nmin = −1
ln 1.6507
𝐍𝐦𝐢𝐧 = 𝟔. 𝟒𝟓𝟎𝟔
Nopt = 2Nmin = 12.9012
2Nmin (1 + 0.1)
Nactual =
ε
12.9012(1 + 0.1)
Nactual =
0.85
𝐍𝐚𝐜𝐭𝐮𝐚𝐥 = 𝟏𝟔. 𝟔𝟗𝟓𝟕

ε = 60 → 90%
kmol kmol
(F/D) (72.4100 /18.0046 )
R min = = hr hr
(α − 1) (1.6507 − 1)
𝐑 𝐦𝐢𝐧 = 𝟔. 𝟏𝟖𝟎𝟕
R = (1.2 → 1.5)R min
R = (1.35)R min = 1.35(6.1807)
𝐑 = 𝟖. 𝟑𝟒𝟒𝟎
m
s
Fs = uρ0.5
v
𝐦
𝐬
ρn = ∑(xi ρi )n

(kmol/hr (kg/kmol) (kg/hr) x
)
Cumene 13.8046 120.19 1659.1749 0.7816 862.00 673.7392
Acetone 0.5460 58.08 31.7117 0.0149 784.00 11.6816
α– 3.6540 118.18 431.8297 0.2034 910.00 185.094
methylstyrene
Total 2122.7163 1.0000 870.5148
ρv = 870.5148 kg/m3
Fs 1.35
u= 0.5
=
ρv 870.51480.5
𝐮 = 𝟎. 𝟎𝟒𝟓𝟖 𝐦/𝐬
H = (0.55m x 16.6957) + 3m
𝐇 = 𝟏𝟐. 𝟏𝟖𝟐𝟔𝐦
𝐋 𝟏𝟐. 𝟏𝟖𝟐𝟔𝐦
= = 𝟗. 𝟎𝟐𝟒𝟏 < 𝟑𝟎
𝐃 𝟏. 𝟑𝟓𝐦

P1sat
αavg =
P2sat
B
T(˚C) + C
For Feed:
Vapor pressure of cumene at 150˚C, P1sat :

1460.793
log10 P1sat = 6.93666 −
150 + 207.777
P1sat = 717.6386 mmHg
P1sat = 0.94426 atm
1582.7
log10 P2sat = 7.0924 −
150 + 206.01
P2sat = 443.3415 mmHg
P2sat = 0.58334 atm
P1sat 0.94426 atm

αFij = =
P2sat 0.58334 atm
𝛂𝐅𝐢𝐣 = 𝟏. 𝟔𝟏𝟖𝟕 𝐚𝐭𝐦

For Distillate:

1460.793
log10 P1sat = 6.93666 −
152 + 207.777
P1sat = 752.2922 mmHg
P1sat = 0.98986 atm
1582.7
log10 P2sat = 7.0924 −
152 + 206.01
P2sat = 469.4332 mmHg
P2sat = 0.61768 atm
Relative volatility for distillate:
P1sat 0.98986 atm

αDij = =
P2sat 0.61768 atm
𝛂𝐃𝐢𝐣 = 𝟏. 𝟔𝟎𝟐𝟓 𝐚𝐭𝐦
For Bottom:
𝛂𝐁𝐢𝐣 = 𝛂𝐃𝐢𝐣 = 𝟏. 𝟔𝟎𝟐𝟓
3
αavg = √1.6187(1.6025)(1.6025)
𝛂𝐚𝐯𝐠 = 𝟏. 𝟔𝟎𝟕𝟗
(xDi /xBi )
ln [ ]
(xDj /xBj
Nmin = −1
ln α
(0.7649/0.0451)
ln [ ]
(0.2045/0.9549
Nmin = −1
ln 1.6079
𝐍𝐦𝐢𝐧 = 𝟖. 𝟐𝟎𝟓𝟒 𝐭𝐫𝐚𝐲
Nopt = 2Nmin = 16.4108 tray
2Nmin (1 + 0.1)
Nactual =
ε
16.4108(1 + 0.1)
Nactual =
0.85
𝐍𝐚𝐜𝐭𝐮𝐚𝐥 = 𝟐𝟏. 𝟐𝟑𝟕𝟔 𝐭𝐫𝐚𝐲
ε = 60 → 90%
kmol kmol
(F/D) (18.0046 /17.8666 )
R min = = hr hr
(α − 1) (1.6079 − 1)
𝐑 𝐦𝐢𝐧 = 𝟏. 𝟔𝟓𝟕𝟕
R = (1.2 → 1.5)R min
R = (1.35)R min = 1.35(1.6577)
𝐑 = 𝟐. 𝟐𝟑𝟕𝟗
m
s
Fs = uρ0.5
v
𝐦
𝐬
ρn = ∑(xi ρi )n

Cumene 13.6666 120.1900 1642.5887 0.7799 862.0000 672.2738
α– methylstyrene 3.6540 118.1800 431.8297 0.2050 910.0000 186.5500
Acetone 0.5460 58.08 31.7112 0.0151 784.0000 11.8384

Total 5.3580 2106.1296 1.0000 870.6622
ρv = 818.7084kg/m3
Fs 1.35
u= 0.5
=
ρv 870.66220.5
𝐮 = 𝟎. 𝟎𝟒𝟓𝟕𝟓 𝐦/𝐬
H = (0.55m x 21.2376) + 3m
𝐇 = 𝟏𝟒. 𝟔𝟖𝟎𝟕 𝐦
𝐋 𝟏𝟒. 𝟔𝟖𝟎𝟕 𝐦
= = 𝟏𝟎. 𝟖𝟕𝟒𝟔 < 𝟑𝟎
𝐃 𝟏. 𝟑𝟓𝐦

P1sat
αavg =
P2sat
B
T(˚C) + C
For Feed:

1460.793
log10 P1sat = 6.93666 −
152 + 207.777
P1sat = 752.2922 mmHg
P1sat = 0.98995 atm
1582.7
log10 P2sat = 7.0924 −
152 + 206.01
P2sat = 0.61768 atm

P1sat 0.98995 atm

αFij = sat =
P2 0.61768 atm
𝛂𝐅𝐢𝐣 = 𝟏. 𝟔𝟎𝟐𝟕
For Distillate:

1460.793
log10 P1sat = 6.93666 −
165 + 207.777
P1sat = 1042.2744 mmHg
P1sat = 1.37141 atm
1582.7
log10 P2sat = 7.0924 −
165 + 206.01
P2sat = 670.06212 mmHg
P2sat = 0.88166 atm
Relative volatility for distillate:
P1sat 1.37141 atm

αDij = sat =
P2 0.88166 atm
𝛂𝐃𝐢𝐣 = 𝟏. 𝟓𝟓𝟓𝟔
For Bottom:
𝛂𝐁𝐢𝐣 = 𝛂𝐃𝐢𝐣 = 𝟏. 𝟓𝟓𝟓𝟔
3
αavg = √1.6027(1.5556)(1.5556)
𝛂𝐚𝐯𝐠 = 𝟏. 𝟓𝟕𝟏𝟏
(xDi /xBi )
ln [ ]
(xDj /xBj
Nmin = −1
ln α
(0.1901/0.7890)
ln [ ]
(0.0508/0.2110
Nmin = −1
ln 1.3677
𝐍𝐦𝐢𝐧 = 𝟏. 𝟐𝟏𝟓𝟏 𝐭𝐫𝐚𝐲
2Nmin (1 + 0.1)
Nactual =
ε
2.4302(1 + 0.1)
Nactual =
0.85
𝐍𝐚𝐜𝐭𝐮𝐚𝐥 = 𝟑. 𝟏𝟒𝟓𝟎 𝐭𝐫𝐚𝐲
ε = 60 → 90%
kmol kmol
(F/D) (17.8666 /5.3580 )
R min = = hr hr
(α − 1) (1.5711 − 1)
𝐑 𝐦𝐢𝐧 = 𝟓. 𝟖𝟑𝟖𝟖
R = (1.2 → 1.5)R min
R = (1.35)R min = 1.35(5.8388)
𝐑 = 𝟕. 𝟖𝟖𝟐𝟒
m
s
Fs = uρ0.5
v
𝐦
𝐬
ρn = ∑(xi ρi )n

Cumene 0.1367 120.1900 16.4300 0.3132 862.0000 269.9784
α– methylstyrene 0.0365 118.1800 4.3136 0.0822 910.0000 74.8020
Acetone 0.5460 58.08 31.7112 0.6045 784.0000 473.9280

Total 5.3580 52.4548 1.0000 818.7084
ρv = 818.7084kg/m3
Fs 1.35
u= =
ρ0.5
v 818.70840.5
𝐮 = 𝟎. 𝟎𝟒𝟕𝟏𝟖 𝐦/𝐬

H = (0.55m x 3.1450) + 3m
𝐇 = 𝟒. 𝟕𝟑𝟎𝟎 𝐦
𝐋 𝟒. 𝟕𝟑𝟎𝟎 𝐦
= = 𝟑. 𝟓𝟎𝟑𝟕 < 𝟑𝟎
𝐃 𝟏. 𝟑𝟓𝐦

Distillation column 5 is used for separating phenol. Thus, it is also known as Phenol column.
P1sat
αavg =
P2sat
B
T(˚C) + C
For Feed:

1582.7
log10 P1sat = 7.0924 −
175 + 206.01
P1sat = 867.8422 mmHg
P1sat = 1.1419 atm

Vapor pressure of Phenol at 175˚C, P2sat :
1516.07
log10 P2sat = 7.1345 −
175 + 174.57
P2sat = 627.3981 mmHg
P2sat = 0.8255 atm
P1sat 1.1419 atm

αFij = =
P2sat 0.8255 atm
𝛂𝐅𝐢𝐣 = 𝟏. 𝟑𝟖𝟑𝟑
For Distillate:

1582.7
log10 P1sat = 7.0924 −
180 + 206.01
P1sat = 982.3068 mmHg
P1sat = 1.2925 atm
Vapor pressure of Phenol at 180˚C, P2sat :
1516.07
log10 P2sat = 7.1345 −
180 + 174.57
P2sat = 722.2726 mmHg
P2sat = 0.9504 atm
P1sat 1.2925 atm

αDij = sat =
P2 0.9504 atm
𝛂𝐃𝐢𝐣 = 𝟏. 𝟑𝟔𝟎𝟎
For Bottom:
𝛂𝐁𝐢𝐣 = 𝛂𝐃𝐢𝐣 = 𝟏. 𝟑𝟔𝟎𝟎
3
αavg = √1.3833(1.3600)(1.3600)
𝛂𝐚𝐯𝐠 = 𝟏. 𝟑𝟔𝟕𝟕
(xDi /xBi )
ln [ ]
(xDj /xBj
Nmin = −1
ln α
(0.9147/0.0003)
ln [ ]
(0.0030/0.9618
Nmin = −1
ln 1.3677
𝐍𝐦𝐢𝐧 = 𝟒𝟑. 𝟎𝟒𝟖𝟎 𝐭𝐫𝐚𝐲
2Nmin (1 + 0.1)
Nactual =
ε
86.0959(1 + 0.1)
Nactual =
0.85
𝐍𝐚𝐜𝐭𝐮𝐚𝐥 = 𝟏𝟏𝟏. 𝟒𝟏𝟖𝟐 𝐭𝐫𝐚𝐲
ε = 60 → 90%

kmol kmol
(F/D) (54.4054 /1.6948 )
R min = = hr hr
(α − 1) (1.3677 − 1)
𝐑 𝐦𝐢𝐧 = 𝟖𝟕. 𝟑𝟎𝟑𝟐
R = (1.2 → 1.5)R min
R = (1.35)R min = 1.35(87.3032)
𝐑 = 𝟏𝟏𝟕. 𝟖𝟓𝟗𝟑
m
s
Fs = uρ0.5
v
𝐦
𝐬
ρn = ∑(xi ρi )n

Cumene 0.1394 120.1900 16.7545 0.0836 862.0000 72.0390
α– methylstyrene 1.5503 118.1800 183.2145 0.9139 910.0000 831.6311
Phenol 0.0051 100.1500 0.5108 0.0025 1.070000 0.0027

Total 1.6948 200.4797 1.0000 903.6729
ρv = 903.6729 kg/m3
Fs 1.35
u= =
ρ0.5
v 903.67290.5
𝐮 = 𝟎. 𝟎𝟒𝟒𝟗 𝐦/𝐬
H = (0.45m x 111.4182) + 3m
𝐇 = 𝟓𝟑. 𝟏𝟑𝟖𝟐 𝐦
𝐋 𝟓𝟑. 𝟏𝟑𝟖𝟐 𝐦
= = 𝟐𝟗. 𝟓𝟐𝟏𝟐 < 𝟑𝟎
𝐃 𝟏. 𝟖𝐦
9.0 COSTING OF EQUIPMENTS
9.1 Reactor 1 – Oxidation Reactor CSTR

From figure A.16, for V = 2.93 m3
Cpo = 7663
For FBM from table A.17, Reactor jacketed and agitated, FBM = 4
CBM = 7663 × 4 = 30 652
567.5
CBM,2017 = 30 652 ×
394
CBM = 𝟒𝟒 𝟏𝟒𝟗. 𝟕𝟕
9.2 Reactor 2 – Cleavage Unit CSTR

Cpo = 2714.86
CBM = 2714.86 × 4 = 10 859.43
567.5
CBM,2017 = 10 859.43 ×
394
CBM = 𝟏𝟓 𝟔𝟒𝟏. 𝟒𝟒
9.3 Reactor 3 – Pre-Purification Reactor CSTR

Cpo = 37 000
CBM = 37 000 × 4 = 148 000
567.5
CBM,2017 = 148 000 ×
394
CBM = 𝟐𝟏𝟑 𝟏𝟕𝟐. 𝟓𝟗
9.4 Separator 1 – Phase Separator (Gravity Settler)

Based on Table 7.4, given CEPCI for year 2001 is 394 and CEPCI found for year 2017 is
567.5.
πD2 L π(0.56 m)2 (1.4 m)

𝐕𝐨𝐥𝐮𝐦𝐞 = = = 𝟎. 𝟑𝟒 𝐦𝟑
4 4
From Table A.1, Equipment data cost data for vertical process vessels is;
K1 3.4974
K2 0.4485
K3 0.1074
From Equation A.1,
𝐥𝐨𝐠 𝟏𝟎 𝐂°𝐩 (𝟐𝟎𝟎𝟏) = 𝐊 𝟏 + 𝐊 𝟐 𝐥𝐨𝐠 𝟏𝟎 (𝐀) + 𝐊 𝟑 [𝐥𝐨𝐠 𝟏𝟎 (𝐀)]𝟐
log10 C°p (2001) = 3.4974 + 0.4485 log10 (0.34) + 0.1074 [log10 (0.34)]2
log10 C°p (2001) = 3.4974 − 0.2101 + 0.0236
C°p (2001) = 103.3109 = $ 2,045.97
The CEPCI for year 2017 is to be found as 567.5, so below is the calculation for 𝐂°𝐩 (2017):
567.5
𝐂°𝐩 (𝟐𝟎𝟏𝟏) = $ 2,045.97 = $ 𝟐, 𝟗𝟒𝟔. 𝟗𝟐
394
Table A.3 and Table A.4 shows,
B1 2.25
B2 1.82
FM 1.00
From Equation A.3,
𝐅𝐁𝐌 = 𝐁𝟏 + 𝐁𝟐 𝐅𝐩 𝐅𝐌
From Equation A.2,
(𝐏 + 𝟏)𝐃
+ 𝟎. 𝟎𝟎𝟑𝟏𝟓
𝟐[𝟖𝟓𝟎 − 𝟎. 𝟔(𝐏 + 𝟏)]
𝐅𝐩,𝐯𝐞𝐬𝐬𝐞𝐥 =
𝟎. 𝟎𝟎𝟔𝟑
(6.01325 + 1)(0.56)
+ 0.00315
2[850 − 0.6(6.01325 + 1)]
Fp,vessel =
0.0063
0.00232
𝐅𝐩,𝐯𝐞𝐬𝐬𝐞𝐥 = = 0.3685
0.0063
Thus,
𝐅𝐁𝐌 = 2.25 + 1.82(0.3685)(1) = 2.9207
To obtain the Bare Module Cost for this phase separator, Equation 7.6 is used as following;
𝐂𝐁𝐌 = 𝐂°𝐩 𝐅𝐁𝐌
𝐂𝐁𝐌 = ($ 2,946.92)(2.9207) = $ 𝟖, 𝟔𝟎𝟕. 𝟎𝟕

9.5 Separator 2 – Scrubber

567.5.
πD2 L π(0.56 m)2 (1.4 m)

𝐕𝐨𝐥𝐮𝐦𝐞 = = = 𝟎. 𝟑𝟒 𝐦𝟑
4 4
From Table A.1, Equipment data cost data for vertical process vessels is;
K1 3.4974
K2 0.4485
K3 0.1074
From Equation A.1,
log10Cop 2001  K1  K 2log10 A   K 3 log10 A 

2
log10C0p 2001  3.4974  0.4485log 10 0.34   0.1074log10 0.34 

2
Cop (2001)  10 3.3109

Cop (2001)  $2,045.97
 567.5 
Cop (2017)  $2,045.97    $2946.92
 394 
B1 2.25
B2 1.82
FM 1.00
From Equation A.3,
FBM  B1  B2 Fp FM
From Equation A.2,
(P  1)D
 0.00315
2[850  0.6(P  1)]
Fp,vessel 
0.0063
(6.01325  1)(0.56)
 0.00315
2[850  0.6(6.0135  1)]
Fp,vessel 
0.0063
0.00232
Fp,vessel   0.3685
0.0063
Thus,
FBM  2.25  1.82(0.368 5)(1)  2.9207
C BM  C op FBM
C BM  ($2946.92) (2.9207)
C BM  $8607.07
9.6 Separator 3 – Distillation Column Unit 1

For Tower:
567.5.
πD2 L π(1.35 m)2 (6.113 m)
𝐕𝐨𝐥𝐮𝐦𝐞 = = = 𝟖. 𝟕𝟓𝟎𝟏 𝐦𝟑
4 4
From Table A.1, Equipment data cost data for towers tray and packed is;
K1 3.4974
K2 0.4485
K3 0.1074
From Equation A.1,
log10 C°p (2001) = 3.4974 + 0.4485 log10 (8.7501) + 0.1074 [log10 (8.7501)]2
log10 C°p (2001) = 3.4974 + 0.4225 + 0.0953
C°p (2001) = 104.0152 = $ 10,356.19
567.5
𝐂°𝐩 (𝟐𝟎𝟏𝟏) = $ 10,356.19 = $ 𝟏𝟒, 𝟗𝟏𝟔. 𝟓𝟗
394

For vertical carbon steel (CS) process vessels, the identification number is 18.
B1 2.25
B2 1.82
FM 1.00
From Equation A.3,
From Equation A.2,
(𝐏 + 𝟏)𝐃
+ 𝟎. 𝟎𝟎𝟑𝟏𝟓
𝟐[𝟖𝟓𝟎 − 𝟎. 𝟔(𝐏 + 𝟏)]
𝟎. 𝟎𝟎𝟔𝟑
(1.01325 + 1)(1.35)
+ 0.00315
2[850 − 0.6(1.01325 + 1)]
Fp,vessel =
0.0063
0.00475
0.0063
Thus,
𝐅𝐁𝐌 = 2.25 + 1.82(0.7541)(1) = 3.6225
𝐂𝐁𝐌,𝐭𝐨𝐰𝐞𝐫 = ($ 14, 916.59)(3.6225) = $ 𝟓𝟒, 𝟎𝟑𝟓. 𝟑𝟓
For Tray:
567.5.
.
πD2 π(1.35 m)2

𝐕𝐨𝐥𝐮𝐦𝐞 = = = 𝟏. 𝟒𝟑𝟏𝟒 𝐦𝟐
4 4
From Table A.1, Equipment data cost data for sieve trays is;
K1 2.9949
K2 0.4465
K3 0.3961
From Equation A.1,
log10 C°p (2001) = 2.9949 + 0.4465 log10 (1.4314) + 0.3961 [log10 (1.4314)]2
log10 C°p (2001) = 2.9949 + 0.0695 + 0.0096
C°p (2001) = 103.074 = $ 1,185.77
567.5
𝐂°𝐩 (𝟐𝟎𝟏𝟏) = $ 1,185.77 = $ 𝟏, 𝟕𝟎𝟕. 𝟗𝟑
394
From Table A.5 shows,
For sieve trays with N<20 due to N=5.66:
𝐥𝐨𝐠 𝟏𝟎 𝐅𝐪 = 𝟎. 𝟒𝟕𝟕𝟏 + 𝟎. 𝟎𝟖𝟓𝟏𝟔𝐥𝐨𝐠 𝟏𝟎 (𝐍) + 𝟎. 𝟑𝟒𝟕𝟑[𝐥𝐨𝐠 𝟏𝟎 (𝐍)]𝟐
log10 Fq = 0.4771 + 0.08516log10 (5.66) + 0.3473[log10 (5.66)]2
log10 Fq = 0.4771 + 0.0641 + 0.1968
𝐅𝐪 = 100.738 = 𝟓. 𝟒𝟕𝟎𝟐
From Table A.6,

For stainless steel (SS) trays, the identification number is 61.
𝐅𝐁𝐌 = 𝟏. 𝟖
To obtain the Bare Module Cost for trays, Equation from Table A.5 is used for sieve trays
as following;
𝐂𝐁𝐌 = 𝐂°𝐩 𝑵𝐅𝐁𝐌 𝑭𝒒
𝐂𝐁𝐌,𝐭𝐫𝐚𝐲 = ($ 1,707.93)(5.66)(1.8)(5.4702) = $ 𝟗𝟓, 𝟏𝟖𝟑. 𝟔𝟐

To obtain the Bare Module Cost for this distillation column,
CBM = CBM,tower + CBM,tray
CBM = $ 54,035.35 + $ 95,183.62
𝐂𝐁𝐌 = $ 𝟏𝟒𝟗, 𝟐𝟏𝟖. 𝟗𝟕

For Tower:
567.5.
πD2 L π(1.35 m)2 (12.1826 m)

𝐕𝐨𝐥𝐮𝐦𝐞 = = = 𝟏𝟕. 𝟒𝟑𝟖𝟎 𝐦𝟑
4 4
K1 3.4974
K2 0.4485
K3 0.1074
From Equation A.1,
log10 C°p (2001) = 3.4974 + 0.4485 log10 (17.4380) + 0.1074 [log10 (17.4380)]2
log10 C°p (2001) = 3.4974 + 0.5568 + 0.1655
C°p (2001) = 104.2197 = $ 16,584.41

567.5
𝐂°𝐩 (𝟐𝟎𝟏𝟏) = $ 16,584.41 = $ 𝟐𝟑, 𝟖𝟖𝟕. 𝟒𝟒
394

B1 2.25
B2 1.82
FM 1.00
From Equation A.3,
From Equation A.2,
(𝐏 + 𝟏)𝐃
+ 𝟎. 𝟎𝟎𝟑𝟏𝟓
𝟐[𝟖𝟓𝟎 − 𝟎. 𝟔(𝐏 + 𝟏)]
𝟎. 𝟎𝟎𝟔𝟑
(1.01325 + 1)(1.35)
+ 0.00315
2[850 − 0.6(1.01325 + 1)]
Fp,vessel =
0.0063
0.00475
0.0063
Thus,
𝐅𝐁𝐌 = 2.25 + 1.82(0.7541)(1) = 3.6225
𝐂𝐁𝐌,𝐭𝐨𝐰𝐞𝐫 = ($ 23,887.44)(3.6225) = $ 𝟖𝟔, 𝟓𝟑𝟐. 𝟐𝟓

For Tray:
567.5.
πD2 π(1.35 m)2

𝐕𝐨𝐥𝐮𝐦𝐞 = = = 𝟏. 𝟒𝟑𝟏𝟒 𝐦𝟐
4 4
K1 2.9949
K2 0.4465
K3 0.3961
From Equation A.1,
log10 C°p (2001) = 2.9949 + 0.4465 log10 (1.4314) + 0.3961 [log10 (1.4314)]2
log10 C°p (2001) = 2.9949 + 0.0695 + 0.0096
C°p (2001) = 103.074 = $ 1,185.77
567.5
𝐂°𝐩 (𝟐𝟎𝟏𝟏) = $ 1,185.77 = $ 𝟏, 𝟕𝟎𝟕. 𝟗𝟑
394
For sieve trays with N<20 due to N= 𝟏𝟔. 𝟔𝟗𝟓𝟕:
𝐥𝐨𝐠 𝟏𝟎 𝐅𝐪 = 𝟎. 𝟒𝟕𝟕𝟏 + 𝟎. 𝟎𝟖𝟓𝟏𝟔𝐥𝐨𝐠 𝟏𝟎 (𝐍) + 𝟎. 𝟑𝟒𝟕𝟑[𝐥𝐨𝐠 𝟏𝟎 (𝐍)]𝟐
log10 Fq = 0.4771 + 0.08516log10 (16.6957 ) + 0.3473[log10 (16.6957)]2
log10 Fq = 0.4771 + 0.1041 + 0.5191
𝐅𝐪 = 101.1003 = 𝟏𝟐. 𝟓𝟗𝟖𝟎

From Table A.6,

𝐅𝐁𝐌 = 𝟏. 𝟖
as following;
𝐂𝐁𝐌,𝐭𝐫𝐚𝐲 = ($ 1,185.77)(16.6957 )(1.8)(12.5980) = $ 𝟒𝟒𝟖, 𝟗𝟑𝟎. 𝟓𝟗
CBM = $ 86,532.25 + $ 448,930.59
𝐂𝐁𝐌 = $ 𝟓𝟑𝟓, 𝟒𝟔𝟐. 𝟖𝟒

For Tower:
Based on Table 7.4, given CEPCI for year 2001 is 394 and 2017 is 567.5.
πD2 L π(1.35 m)2 (14.6807 m)

𝐕𝐨𝐥𝐮𝐦𝐞 = = = 𝟐𝟏. 𝟎𝟏𝟑𝟖 𝐦𝟑
4 4
K1 3.4974
K2 0.4485
K3 0.1074
From Equation A.1,
log10 C°p (2001) = 3.4974 + 0.4485 log10 (21.0138 ) + 0.1074 [log10 (21.0138 )]2
log10 C°p (2001) = 3.4974 + 0.5931 + 0.1878
C°p (2001) = 104.2783 = $ 18,980.17
567.5
𝐂°𝐩 (𝟐𝟎𝟏𝟏) = $ 18,980.17 = $ 𝟐𝟕, 𝟑𝟑𝟖. 𝟏𝟖
394

B1 2.25
B2 1.82
FM 1.00
From Equation A.3,
From Equation A.2,
(𝐏 + 𝟏)𝐃
+ 𝟎. 𝟎𝟎𝟑𝟏𝟓
𝟐[𝟖𝟓𝟎 − 𝟎. 𝟔(𝐏 + 𝟏)]
𝟎. 𝟎𝟎𝟔𝟑
(1.01325 + 1)(1.35)
+ 0.00315
2[850 − 0.6(1.01325 + 1)]
Fp,vessel =
0.0063
0.00475
0.0063
Thus,
𝐅𝐁𝐌 = 2.25 + 1.82(0.7541)(1) = 3.6225
𝐂𝐁𝐌,𝐭𝐨𝐰𝐞𝐫 = ($ 27,338.18)(3.6225) = $ 𝟗𝟗, 𝟎𝟑𝟐𝟓. 𝟓𝟔
For Tray:
πD2 π(1.35 m)2

𝐕𝐨𝐥𝐮𝐦𝐞 = = = 𝟏. 𝟒𝟑𝟏𝟒 𝐦𝟐
4 4
K1 2.9949
K2 0.4465
K3 0.3961
From Equation A.1,
log10 C°p (2001) = 2.9949 + 0.4465 log10 (1.4314) + 0.3961 [log10 (1.4314)]2
log10 C°p (2001) = 2.9949 + 0.0695 + 0.0096
C°p (2001) = 103.074 = $ 1,185.77
567.5
𝐂°𝐩 (𝟐𝟎𝟏𝟏) = $ 1,185.77 = $ 𝟏, 𝟕𝟎𝟕. 𝟗𝟑
394
For sieve trays with N>20 due to N= 𝟐𝟏. 𝟐𝟑𝟕𝟔
𝐅𝐪 = 𝟏
From Table A.6,

𝐅𝐁𝐌 = 𝟏. 𝟖
as following;
𝐂𝐁𝐌,𝐭𝐫𝐚𝐲 = ($ 1,707.93)(21.2376 )(1.8)(1) = $ 𝟔𝟓, 𝟐𝟗𝟎. 𝟐𝟎
CBM = $ 99,0325.56 + $ 65,290.20
𝐂𝐁𝐌 = $ 𝟏, 𝟎𝟓𝟓, 𝟔𝟏𝟓. 𝟕𝟔


For Tower:
567.5.
πD2 L π(1.35 m)2 (4.7300 m)

𝐕𝐨𝐥𝐮𝐦𝐞 = = = 𝟔. 𝟕𝟕𝟎𝟓 𝐦𝟑
4 4
K1 3.4974
K2 0.4485
K3 0.1074
From Equation A.1,
log10 C°p (2001) = 3.4974 + 0.4485 log10 (6.7705) + 0.1074 [log10 (6.7705)]2
log10 C°p (2001) = 3.4974 + 0.3725 + 0.0741
C°p (2001) = 103.9440 = $ 8,790.23
567.5
𝐂°𝐩 (𝟐𝟎𝟏𝟏) = $ 8,790.23 = $ 𝟏𝟐, 𝟔𝟔𝟏. 𝟎𝟓
394

B1 2.25
B2 1.82
FM 1.00
From Equation A.3,
From Equation A.2,
(𝐏 + 𝟏)𝐃
+ 𝟎. 𝟎𝟎𝟑𝟏𝟓
𝟐[𝟖𝟓𝟎 − 𝟎. 𝟔(𝐏 + 𝟏)]
𝟎. 𝟎𝟎𝟔𝟑
(1.01325 + 1)(1.35)
+ 0.00315
2[850 − 0.6(1.01325 + 1)]
Fp,vessel =
0.0063
0.00475
0.0063
Thus,
𝐅𝐁𝐌 = 2.25 + 1.82(0.7541)(1) = 3.6225
𝐂𝐁𝐌,𝐭𝐨𝐰𝐞𝐫 = ($ 12,661.05)(3.6225) = $ 𝟒𝟓, 𝟖𝟔𝟑. 𝟔𝟓
For Tray:
567.5.
πD2 π(1.35 m)2

𝐕𝐨𝐥𝐮𝐦𝐞 = = = 𝟏. 𝟒𝟑𝟏𝟒 𝐦𝟐
4 4
K1 2.9949
K2 0.4465
K3 0.3961
From Equation A.1,
log10 C°p (2001) = 2.9949 + 0.4465 log10 (1.4314) + 0.3961 [log10 (1.4314)]2
log10 C°p (2001) = 2.9949 + 0.0695 + 0.0096
C°p (2001) = 103.074 = $ 1,185.77
567.5
𝐂°𝐩 (𝟐𝟎𝟏𝟏) = $ 1,185.77 = $ 𝟏, 𝟕𝟎𝟕. 𝟗𝟑
394
For sieve trays with N<20 due to N=5.66:
𝐥𝐨𝐠 𝟏𝟎 𝐅𝐪 = 𝟎. 𝟒𝟕𝟕𝟏 + 𝟎. 𝟎𝟖𝟓𝟏𝟔𝐥𝐨𝐠 𝟏𝟎 (𝐍) + 𝟎. 𝟑𝟒𝟕𝟑[𝐥𝐨𝐠 𝟏𝟎 (𝐍)]𝟐
log10 Fq = 0.4771 + 0.08516log10 (3.1450 ) + 0.3473[log10 (3.1450)]2
log10 Fq = 0.4771 + 0.0424 + 0.0860
𝐅𝐪 = 100.6055 = 𝟒. 𝟎𝟑𝟏𝟖
From Table A.6,

𝐅𝐁𝐌 = 𝟏. 𝟖
as following;
𝐂𝐁𝐌,𝐭𝐫𝐚𝐲 = ($ 1,707.93)(3.1450 )(1.8)(4.0318) = $ 𝟑𝟖, 𝟗𝟖𝟏. 𝟖𝟑
CBM = $ 45,863.65 + $ 38,981.83
𝐂𝐁𝐌 = $ 𝟖𝟒, 𝟖𝟒𝟓. 𝟒𝟖

For Tower:
πD2 L π(1.8 m)2 (53.1382 m)

𝐕𝐨𝐥𝐮𝐦𝐞 = = = 𝟏𝟑𝟓. 𝟐𝟐𝟎𝟐 𝐦𝟑
4 4
K1 3.4974
K2 0.4485
K3 0.1074
From Equation A.1,
log10 C°p (2001) = 3.4974 + 0.4485 log10 (135.2202) + 0.1074 [log10 (135.2202)]2
log10 C°p (2001) = 3.4974 + 0.9558 + 0.4877
C°p (2001) = 104.9409 = $ 87 277.04
From Table 7.4, the latest year for Equipment Cost Index is year 2017. Hence, the purchased
cost of vertical process vessels for year 2017 is shown below;
567.5
𝐂°𝐩 (𝟐𝟎𝟏𝟏) = $ 87 277.04 = $ 𝟏𝟐𝟓 𝟕𝟎𝟗. 𝟗𝟓
394

B1 2.25
B2 1.82
FM 1.00
From Equation A.3,
From Equation A.2,
(𝐏 + 𝟏)𝐃
+ 𝟎. 𝟎𝟎𝟑𝟏𝟓
𝟐[𝟖𝟓𝟎 − 𝟎. 𝟔(𝐏 + 𝟏)]
𝟎. 𝟎𝟎𝟔𝟑
(1.01325 + 1)(1.8)
+ 0.00315
2[850 − 0.6(1.01325 + 1)]
Fp,vessel =
0.0063
0.00528
0.0063
Thus,
𝐅𝐁𝐌 = 2.25 + 1.82(0.8381)(1) = 3.7753
𝐂𝐁𝐌,𝐭𝐨𝐰𝐞𝐫 = ($ 125 709.95)(3.7753) = $ 𝟒𝟕𝟒 𝟓𝟗𝟐. 𝟕𝟕
For Tray:
πD2 π(1.8 m)2

𝐕𝐨𝐥𝐮𝐦𝐞 = = = 𝟐. 𝟓𝟒𝟒𝟕 𝐦𝟐
4 4
K1 2.9949
K2 0.4465
K3 0.3961
From Equation A.1,
log10 C°p (2001) = 2.9949 + 0.4465 log10 (2.5447) + 0.3961 [log10 (2.5447)]2
log10 C°p (2001) = 2.9949 + 0.1811 + 0.0652
C°p (2001) = 103.2412 = $ 1742.61
From Table 7.4, the latest year for Equipment Cost Index is year 2017. Hence, the purchased
cost of vertical process vessels for year 2017 is shown below;
567.5
𝐂°𝐩 (𝟐𝟎𝟏𝟏) = $ 1,742.61 = $ 𝟐 𝟓𝟎𝟗. 𝟗𝟖
394

For sieve trays with N>20 due to N=111.4182 trays:
𝐅𝐪 = 𝟏. 𝟎
From Table A.6,

𝐅𝐁𝐌 = 𝟏. 𝟖
as following;
𝐂𝐁𝐌 = 𝐂°𝐩 𝐍𝐅𝐁𝐌 𝐅𝐪
𝐂𝐁𝐌,𝐭𝐫𝐚𝐲 = ($ 2509.98)(111.4182)(1.8)(1.0) = $ 𝟓𝟎𝟑 𝟑𝟖𝟑. 𝟒𝟐
CBM = $ 474 592.77 + $ 503 383.42
𝐂𝐁𝐌 = $ 𝟗𝟕𝟕 𝟗𝟕𝟔. 𝟏𝟗

9.11 Total Equipment Cost

No Equipments Price ($)
1 Oxidation Reactor 44,149.77
2 Cleavage Unit Reactor 15,641.44
3 Pre-Purification Reactor 213,172.59
4 Phase Separator 8,607.07
5 Scrubber 8,607.07
6 Distillation Column 1 149,218.97
8 Distillation Column 3 1,055,615.76
TOTAL 3,093,297.18
10.0 OPERATING LABOUR COST
A year consists of 52 weeks. A single operator will work on average of 49 weeks per year with
3 weeks off on 8 hours per shift and 5 shift per week.
Usually a chemical plant operates for 24 hours so it requires 3 shift per day for 365 days. Thus,
(49 weeks/year) x (5 shifts/week) = 245 shifts/year

(365 days/year) x (3 shifts/day) = 1095 shifts/year
(1095 shifts/year) x (Operator.year/245 shifts) = 4.5 operators
Four and one-half operators are hired for each operator needed in the plant at any time.
In order to find the value of number of operating labor required to run the process unit per shift,
equation as stated below is used:
𝐍𝐎𝐋 = (𝟔. 𝟐𝟗 + 𝟑𝟏. 𝟕𝐏 𝟐 + 𝟎. 𝟐𝟑𝐍𝐧𝐩 )𝟎.𝟓

NOL = Number of operating labor operating per shift
P2 = Particulate processing steps
Nnp = Non-particulate processing steps
Table 20 Shows The Result For The Estimation Of Operating Labor Requirements For
The Process Using The Equipment Module Approach
Equipment Type Number of Equipment Nnp

Compressors 2 2
Heat Exchangers 12 12
Heaters/Furnaces 0 0
Pumps* 9 -
Reactors 3 3
Towers 6 6
Vessels* 5 -
Total 23
*Pumps and vessels are not counted in evaluating Nnp.
P2 = 0 because there is no particulate processing steps in this process.
NOL = (6.29 + 31.7(0)2 + 0.23Nnp )0.5
NOL = (6.29 + 31.7(0)2 + 0.23(23))0.5
𝐍𝐎𝐋 = 𝟑. 𝟒𝟎
Number of operators required per shift is 3.40.
Number of operator needed as operating labor:
3.40 x 4.5 operators = 15.3 (rounding up yields 16 operators)
For all equipment, cost of operating labor per year:
(RM 6.25/hour.operator) x (8 hours/day) x (365 days/year) x (16 Operator) = RM 292,000/year

12.0 CONCLUSION
Phenol is the precursor to many materials and a very useful compounds. The global phenol
market predicts to witness a robust CAGR of 6.8% from 2017 to 2022. The cumene process
segment should be worth almost US$12.3 billion in 2017. The plant is to be built in Malaysia
and three chosen state which is Kerteh (Terengganu), Gebeng (Pahang) and Pasir Gudang
(Johor) is scored using Scoring Method to choose for the plant site. Pasir Gudang Industrial
Estate, Johor is chosen for the plant site. The Block Flow Diagram (BFD) and Process Flow
Diagram (PFD) is made based on the selected process of production. The process chosen for
the plant operation is production of phenol from cumene peroxide using cumene as the main
raw material. The equipment cost is predicted from the sizing which revealed the bare module
cost of the equipment yielding to approximately $3,093,297.18. The operating labour cost
approximately RM 292,000/year is estimated using the Equipment Module Approach. The
plant is estimated to produced 51 kmol/h of phenol for every 100 knol/h of cumene over the
plant start-up.
BIBLIOGRAPHY
Brydson, J. (1999). Phenolic Resins. Polymer Matrtix Composites and Technology, 1.
Chaplin, M. (6 August, 2014). Enzyme Technology. Retrieved from

http://www1.lsbu.ac.uk/water/enztech/cstr.html
Commodity, S. (10 October, 2018). Industrial Sector. Retrieved from Sunsirs Commodity
Data Group: http://www.sunsirs.com/uk/sectors-14.html
Elvers, B. (2011). Ullmann’s Encyclopedia of Industrial Chemistry. Wiley- VCH Verlag

GmbH & Co.
Elyers, B. (2011). Ullmann's Encyclopedia of Industrial Chemistry . Wiley-VCH Verlag

GmbH & Co.
Estate, G. I. (n.d.). Facilities and Infrastructure. Retrieved from Invest In Pahang:

http://www.investinpahang.gov.my/index.php?rp=gebeng_facilities_infra.pdf
Guide, E. (2007). Types of Phenol Manufacturing Process. Retrieved from Engineers Guide:
http://enggyd.blogspot.com/2010/07/phenol-manufacturing-process.html
Industrial Sector. (10 October, 2018). Retrieved from Sunsirs Commodity Data Group:
http://www.sunsirs.com/uk/sectors-14.html
Kantarci, N., Borak, F., & Ulgen, K. (2005). Review: bubble column reactors. Process
Biochemistry , 2263-2283.
Kennepohl, D. (2017). Phenol And Their Uses. Chemistry and Libretexts.
Kirk-Othmer. (n.d.). Encyclopedia of Chemical Technology Fifth Edition.
KualitiAlam. (n.d.). Retrieved from Kualiti Alam: www.kualitialam.com
L. Ross C. Barclay, M. B. (2003). Chemistry of Phenol. England: John Wiley & Sons Ltd.
Megson, N. J. (1958). Phenolic Resin Chemistry . London: Butterworths Scientific

Publications.
Mengmeng, S., & Ekaterina, S. (2017). Design of Bubble Column Reactor.

MIDA. (2017). Malaysia Costs Of Doing Business. Malaysia: The Malaysian Investment
Development Authority (MIDA).
Payscale. (Dec, 2018). Average Salary in Johor Bahru, Malaysia. Retrieved from Payscale:
https://www.payscale.com/research/MY/Location+Johor-
Bahru/Hourly_Rate#by_Skill
Sarina, S., Huaiyong, Z., Zhanfeng, Z., & Guoran, L. (2012). Driving selective aerobic
oxidation of alkyl aromatics by sunlight on alcohol grafted metal hydroxides.
Chemical Science, 2138-2146.
Sayyar, M. H. (2008). Direct Oxidation of Benzene to Phenol .
Schmidt, R. (2005). Industrial catalytic processes-phenol production.
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http://www.sciencelab.com/msdsList.php
Solomon, M. G. (1995). Aust. J. Chem, 323.
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Science Symposium, 2, 201–212.
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Weber, Phenol. Germany: Wiley Publisher.

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PLANT DESIGN FOR PRODUCTION OF PHENOL i

FACULTY OF CHEMICAL ENGINEERING

PREPARED BY: EH2205I

1 MUHAMMAD NOR ASYRAFF BIN NOR RAHMAN 2017632104

1.0 HISTORY AND GENERAL INFORMATION ON PHENOL ............................................ 1

3.3.4 Utilities and Facilities.................................................................................................. 38

8.1.1 Reactor 1 – Oxidation Reactor CSTR ....................................................................... 75

1.0 HISTORY AND GENERAL INFORMATION ON PHENOL

The Raschig–Dow process of manufacturing phenol by cumene was discovered by

1.1.2 The Production Of Phenol Synthesis

i) Cumene Peroxidation Process

ii) Rasching Process

This process was developed in Germany in 1940. Benzene is

iii) Toluene Two-Stage Oxidation Process

iv) Sulphonation Process

Table 1 Shows the Differences between Processes to Produce Phenol

No Existing Methods Raw Materials / Yield Products Comments

1.2 General Description

Figure 1 Shows Structure Of Phenols

Figure 2 Shows Classification Of Phenols

Figure 3 shows examples of names of phenols given by the IUPAC rules

Figure 4 shows methyl and hydroxy derivatives of phenols, cresol

Figure 5 shows hydroxyphenols three isomers with different names

Physical and Chemical Properties of Phenols

Table 2 Shows Similarities And Differences Between Alcohols And Phenols

Alcohols Relation Phenols

Figure 6 shows ionization reaction for phenol itself

Figure 7 Shows Process For Phenoxide Ion

As the automotive industry is an important consumer of phenol derivatives such as

2000 2003 2007 2010

2.0 PROCESS SELECTION

2.1 Process in Producing Phenol

2.1.1 Process Selected and Selection Criteria

a) Production of phenol from cumene

𝐂𝟔 𝐇𝟓 𝐂𝐇(𝐂𝐇𝟑 ) + 𝐎𝟐 → 𝐂𝟔 𝐇𝟓 𝐂(𝐂𝐇𝟑 )𝟐 𝐎𝐎𝐇

𝐂𝟔 𝐇𝟓 𝐂(𝐂𝐇𝟑 )𝟐 𝐎𝐎𝐇 + 𝐇𝟐 𝐒𝐎𝟒 ↔ 𝐂𝟔 𝐇𝟓 𝐎𝐇 + 𝐂𝐇𝟑 𝐂𝐎𝐂𝐇𝟑

Oxidation of cumene to cumene hydroperoxide (CHP) proceeds via a free-radical

Figure 8 Sunoco/UOP Phenol process.

The major processing steps include:

Figure 9 - The mechanism of the benzene sulfonation process.

2.1.1.2 Oxidation Of Toluene

There are two types reaction in chlorination of benzene:

Figure 10 The Alkaline Hydrolysis Of Benzene In Production Of Phenol

Figure 11 The Raschig-Hooker Process In Production Of Phenol

2.1.1.3 Phenol From Coal

2.1.1.4 Toluene – Benzoic Acid Process

The reaction equations of this process are as follows:

CH3 + KMnO4 COH

2.2 Profit Margin

2.2.1 Phenols from Toluene Benzoic Acid

Cost of Raw Material:

In order to find the profit margin, equation below is used:

2.2.2 Phenols From Coal

Cost of Raw Material:

Cost of Raw Material = Feed Basis x MW x Cost of Material per tonne

Cost of Product = Feed Basis x MW x Cost of Material per tonne

Cost of Product = Feed Basis x MW x Cost of Material per tonne

Cost of Xylenols = Feed Basis x MW x Cost of Material per tonne

𝐂𝐨𝐬𝐭 𝐨𝐟 𝐗𝐲𝐥𝐞𝐧𝐨𝐥𝐬 = 𝐑𝐌 𝟒𝟎𝟗 𝟓𝟎𝟑. 𝟕𝟑

𝐂𝐨𝐬𝐭 𝐨𝐟 𝐗𝐲𝐥𝐞𝐧𝐨𝐥𝐬 = $ 𝟗𝟕 𝟔𝟖𝟕. 𝟏𝟏

In order to find the profit margin, equation below is used:

Profit Margin = Total Cost of Product − Total Cost of Raw Material

Profit Margin = RM 599 048.29 − RM 8 599.71 = 𝐑𝐌 𝟓𝟗𝟎 𝟒𝟒𝟖. 𝟓𝟖