Production of Phenol

Cebu Institute of Technology – University
College of Engineering and Architecture
Department of Chemical Engineering
In Partial Fulfillment of Requirements for the course

CHE 522
Production Phenol – Acetone through

Cumene Process
Prepared By:
Balili, Nina Therese
Daquiado, Elaine Jules

Lavides, Lunar Kaye
Oberero, Cornelio III
Pinatil, Patrice Alyx
Submitted to:
Engr. Vera Lanaria
March 2020
1
APPROVAL SHEET
This project design entitled “Production of Activated Carbon from Coconut ”,

prepared and submitted by Balili, Nina Therese, Daquiado, Elaine Jules,
Lavides, Lunar Kay,Oberero, Cornelio III E.,Pinatil, Patrice Alyx O., in partial
fulfilment of the requirements for the degree BACHELOR OF SCIENCE IN
CHEMICAL ENGINEERING is hereby recommended for approval.
Engr. Vera Marie Lanaria
Panelist
Date: ____________
This project design is approved in partial fulfilment of the requirements for the
degree of BACHELOR OF SCIENCE IN CHEMICAL ENGINEERING.
Engr.Vera Marie Lanaria Engr. Amis Pacamalan

ChE 522 Instructor Chair,Department of Chemical Engineering
Date: ____________ Date: ____________
Dr. Evangeline C. Evangelista Dean
College of Engineering and Architecture
Date: ____________
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EXECUTIVE SUMMARY
This project is design for an integrated process of the production of

phenol and acetone from cumene as a raw material using cumene peroxidation
process. Phenol is an aromatic organic compound which is also known as
carbolic acid with the molecular formula C6H5OH. As for acetone it is an organic
compound with the formula (CH3)2CO.
Both of these chemicals are used at home for electrical devices,
agricultural industries in the manufacturing of pesticides and herbicides. There
is no single company in the country that manufactures phenol and acetone
which opened our way to construct this kind of industry. Furthermore, the
demand of the application of these chemicals is exponentially rising in the
country.
This plant is designed to continuously produce 1,195.47 metric tons of
phenol and 1,148.85 metric tons of acetone annually from a raw material,
Cumene of 2,076 metrics tons annually. With net income total of
364,627,121.86, return of revenue of 46%, payback period of 5.051 years, and
a breakeven point of 201.69 tons a year.
The process to be used in the plant is the Hock Process. It is the process
where Cumene is oxidized to form Cumene Hydroperoxide, then decomposed
to form Phenol and Acetone with acidic medium, in our case diluted Sulfuric
Acid. To remove the acid from the phenol rich stream, it is passed in a settler
where the bottom products are distilled to fully separate acidified water waste
from the acetone which is then further mixed with the phenol rich stream, the
top product of the settler. Downstream process is performed through distillation
to extract 96% phenol together with its side product 96% acetone and 92%
alpha-methyl styrene.
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TABLE OF CONTENTS
COVER PAGE 1
APPROVAL SHEET 2
EXECUTIVE SUMMARY 3
CHAPTER I
INTRODUCTION
1.1. Market Study 7
CHAPTER II
PROCESS AND OPTION SELECTION
2.1. Process Selection 10

2.2. Equipment selection 11
CHAPTER III
BASIS OF THE DESIGN
3.1. Description of Design 21
3.2. Process Definition 21
3.3. Overall Input and Output Block Scheme 22
3.4. Basic Assumptions 22
3.5. Battery Limit 26
CHAPTER IV
THERMODYNAMIC PROPERTIES
4.1. Thermodynamic Properties of Chemicals 28
4.2. Thermodynamc Properties of Stainless Steel 29
CHAPTER V
PROCESS STRUCTURE AND DESCRIPTION
5.1. Oxidation 31
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5.2. Cleavage Unit 32
5.3. Separation –Settling 32
5.4. Distillation Unit 33
5.5. Mixer 33
5.6. Distillation Units 33
5.7 Hydrogenation 34
CHAPTER VI
MASS AND HEAT BALANCES
6.1. Mass Balance 36
6.2. Heat Balance 36
CHAPTER VII
EQUIPMENT DESIGN
7.1. Continuous Stirred Tank Reactor 37
7.2 Tray Distillation 42
7.3 Agitator 55
7.4. Settler 59
7.5. Plug Flow Reactor 62
CHAPTER VIII
PROCESS CONTROL
8.1 Oxidation Reactor 66
8.2. Cleavage Reactor 67
8.3. Separator 68
8.4 Mixer 69
8.5 Tray Distillation 70
8.6 Pre-purification Reactor 71

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8.7 `Process Flow Diagram 72
8.8 Piping and Instrumentation Diagram 73
CHAPTER IX
PROCESS WASTES
9.1 Wastewater Management 74
9.2 Air Pollution Management 77
CHAPTER X
PLANT SAFETY
10.1 Plant Safety –Definition 78
10.2 Hazard and Operability Study 79
10.3 Process and Safety Documentation 84
CHAPTER XI
ECONOMICS
11.1 Estimation for Economics 87
11.2 Calculation for Economics 89
CHAPTER XII
CONCLUSION AND RECCOMENDATIONS 91
APPENDICES 92
REFERENCES 115
CURRICULUM VITAE 199
\
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CHAPTER I
INTRODUCTION
One of the most important intermediates of chemical industries are

Phenol and Acetone, with its wide range of applications that provides an
excellent platform for design, the demand for phenol and acetone increases
over a period of time.
Phenol is an aromatic organic compound that consists of phenyl group

(-C6H5), bonded to a hydroxyl group (-OH). It is a white crystalline solid with the
molecular formula C6H5OH which is also known as carbolic acid. Phenol is
mostly used as a key precursor for different products such as polycarbonates
and epoxide resins when condensed with acetone. It is also a precursor to large
collection of drugs most notably aspirin. As for acetone, it is an organic
compound with the formula (CH3)2CO. It is a colorless, volatile, flammable liquid
and is known as the simplest ketone. It is used as a solvent in varnishes,
lacquers, paints, printing inks, and etc. .
Phenol and acetone belongs to the class of bulk commodities or bulk

chemicals which are manufactured on a large scale in order to satisfy the local
and global demands. The importation of phenol in the Philippines has increased
over time. In 2012, the trade value was $3,289,043.00 and in 2019, the trade
value was $9,596,418.00. That's an increase of 191.77% from 2012 to 20191.
This may suggest that the production of phenol in the Philippines is not
sufficient since the country is importing the particular product at an increased
rate. Also, it indicates that there is a high marketability for phenols right now
and for the following years to come in the country. It is the same with the
importation of Acetone in the country. In 2012, the trade value was
$3,557,146.00 and in 2019, it was $7,544,755.002. That's an increase of
112.10%.
Phenol and Acetone has a wide Variety of uses in our everyday life.
Firstly, in automotive industries, both of these chemicals are used in the
manufacturing of polycarbonate in chemical industries, both are used as dying
agents, solvents, chain terminators, and phenol is used in the aspirin
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production. Second, Phenol and Acetone is commonly used at home for
electrical devices and acetone is also used as basis for acrylic paint, lastly, both
chemicals are used agriculture industries in the manufacturing of pesticides and
herbicides.
There are several processes technology associated to Phenol

production, which are: (a) Cumene Peroxidation Process, which involves the
synthesis of Cumene with Oxygen to produce Cumene Peroxide and is then
decomposed to produce Phenol with by product Acetone. (b) Raschig Process,
where benzene is first converted into chlorobenzene, after separation from
unchanged reactants is hydrolyzed into Phenol and HCl as by product. (c)
Toluene Two-Stage Oxidation Process, Toluene in the liquid phase is oxidized
with air, distilled, and oxidized again to achieve a certain percent of phenol. (d)
Sulphonation Process, the oldest method of manufacture of phenol, made
through pyrolysis of sodium benzene sulfate. But with further research 3* it is
found out that Cumene Process is the best method in manufacturing Phenols
and Acetone with promising amount of percent recovery on both chemicals with
respect to the global and local demand.
The rising demand is due to the fact that there is not a single working
plant in the Philippines that manufactures large capacities of Phenol and
Acetone that can be considered as competitors of such companies: Shell, LG,
PTT Phenol, and many more companies located outside of the country4*. This
then paves the way for good business opportunity, meeting the ever rising
demands of the country through having a local industrial plant that provides raw
material for diverse companies in the Philippines; an opportunity to have the
chance of competing in the international trade of Phenols and Acetone.
The applicability of Phenol and Acetone is rapidly expanding, companies

that manufacture plastic, paints, resins, etc. are the potential buyers of Phenol
and Acetone that are located mostly in Manila, Batangas, Cavite, Bulacan, and
Laguna5*.
1* Appendix: Chart 1.0 PSA Statistics on the Market Demand of Phenols. 2* Appendix: Chart 1.1 PSA
Statistics on the Market Demand of Acetone. 3* Appendix: Chart 1.2 Processes to Produce Phenol and
their Yields. 4* Appendix: Chart 1.3 Competing Companies on the Phenol Manufacturing. 5* Appendix:
Chart 1.4 Target Market: Name of Possible buyers of Products in Philippines.
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CHAPTER II
PROCESS SELECTION
This chapter, offers the optimum choice for the selection of process,
equipment and other significant decisions, taken into account the layout of the
industrial plant. The pros and cons impact on the following factors are rated as
follows:
Criteria for Selection Ratings
Economics 4
Environment 3
Production 4
Maintenance 3
Availability 2
The criteria for selection would be its economics where all costs such as
fixed, production, and labor costs are taken into account. The environment
plays a vital role when it comes to handling of the waste of the production
process and other aspects such as emissions, noise and etc. Production,
operational time, and maximum output is a factor that would determine the type
of plant that would be designed as to attain the required quota. Maintenance is
essential in making sure that the plant does not meet any problems which would
result in loss of production and down time. Availability of raw materials,
equipment and lot area determines what scale the plant could be designed for
as to operate at an optimum level.
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2.1 Process Selection
The two common process below are evaluated and weighed accordingly
to the criteria and what would best fit the plant production, thus, the best
selection as decided is Continuous Process.
Process Advantages Disadvantages
Batch (+4) Lower initial setup cost (-4)Overall cost Processing is

Process high
(+2) Preferable for rare raw
materials (-4) Constant shutdown and
start-up of equipment
(+3) Maintenance can be
scheduled (-3) Cleaning between
batches
(+3) Employees
understand process well
(+4) Easier to scale up from

lab scale
TOTAL=5 POINTS
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(+3) Reduce waste
Continuous (-4) Periodical shutdown
(+4) Save money by
Process overall maintenance and
reducing inventory and
inspection
transportation costs
(+4) Increase productivity (-3) May rely on critical
by completing more units in equipment which can
less time potentially stop production
(+3) Improve quality by
making it easier to spot and (-3) Employees knowledge is
correct errors limited
(+4) Quality output kept

uniform
TOTAL= 8 POINTS
Selected : Continuous Process
The Continuous process earns 8 points while Batch process earns only 5
points. The former is more economic advantage than the latter.
2.2 Equipment Selection
Since, the process chosen is continuous, the following equipment to be

considered befitting the said process.
2.2.1 Mixer Selection for liquid-liquid and gas-liquid phase
The production of phenol required a multiple reaction that is called a

series reaction. Series reaction is reaction where the reactant forms an
intermediate product, which will react further to form another product. The first
reactor (oxidation column) consists of the reaction between Cumene and
Oxygen gas to form Cumene Hydroperoxide. In this reaction, reactor that will
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be chosen is Plug Flow Reactor (PFR) because the reaction consists of the gas
liquid phase reaction.
For the second reactor, that is the place where the main product is being
produce, which is Phenol. This process consist the reaction between Cumene
Hydroperoxide with Sulphuric acids. Sulphuric acids act as catalyst of this
reaction. Since that reaction is in the liquid phase and the catalyst involve also
at liquid phase so that the reactor that have been choose for the second process
is Continuous-Stirred Tank Reactor (CSTR). Tabulated selection are shown
below.
Mixer Selection Advantages Disadvantages
for gas-liquid
Batch Reactor (+3) Relatively basic design (-4) High labor costs per
and relative ease of batch
fabrication and modification.
(-4) Variability of
(+4) Widespread usage in products from batch to
applications ranging from batch
food and beverage, to
(-4) Difficulty of large-
pharmaceutical
scale production
manufacturing, to small-
scale research fermentation (-4) Is not suitable
processes. for continuous
processing
(+4) The ability to scale an
optimized process with
relative ease by increasing
the size and/or number of
reaction vessels.
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(+4) The lack of a need for TOTAL = 3 POINTS
extensive reaction cell
(re)design and fabrication
iterations during method
optimization.
Continuous (+4) Low operating(labor) (-4) It has the lowest

Stirred Tank cost conversion per unit
Reactor volume
(+4)Simple to construct
(-4) Has poor agitation
(+4) Good temperature
when conducting by-
control
pass and channeling
(+4) Operates continuously.

(-4) Not suitable for gas-
(+4) Reactor has large heat liquid mixing

capacity.
(-3) Requires more
(+3) Interior of reactor is maintenance

easily accessed
TOTAL =8 POINTS
Plug Flow Reactor (+4) High volumetric unit (-4) Temperatures are
conversion hard to control and can
result in undesirable
(+4) More suitable for gas-
temperature gradients
liquid mixing
(+4) No axial mixing
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(+3) Run for long periods of (-4) Its maintenance is
time without maintenance more expensive than
CSTR maintenance.
(+3) Heat transfer rate can
be optimized by using more,
thinner tubes or fewer,
TOTAL= 10 POINTS
thicker tubes in parallel
Selected: Plug Flow Reactor
It is more suitable for mixing gas-liquid phase reactions and less hassle for
maintenance.
Mixer Selection
Advantages Disadvantages
for liquid-liquid
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(+3) Relatively basic
design and relative ease
of fabrication and
modification.
(-4) High labor costs per
(+4) Widespread usage batch
in applications ranging
from food and (-4) Variability of
beverage, to products from batch to

pharmaceutical batch
manufacturing, to small-
(-4) Difficulty of large-
scale research
scale production
fermentation processes.
Batch Reactor (-4) Is not suitable
(+4) The ability to scale
for continuous
an optimized process
processing
with relative ease by
increasing the size
and/or number of
reaction vessels.
(+4) The lack of a need

for extensive reaction TOTAL = 3 POINTS
cell (re)design and
fabrication iterations
during method
optimization.
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(+4) Low
operating(labor) cost
(+3) Easy to clean

(-4) It has the lowest
(+4) Simple to conversion per unit
construction volume
(+4) Good temperature (-4) Has poor agitation

control when conducting by-
Continuous Stirred pass and channeling
Tank Reactor (+4) Operates
continuously.
(+4) Reactor has large

heat capacity.
(+4) Suitable for liquid-

TOTAL =22 POINTS
liquid complete mixing
(+3) Interior of reactor is

easily accessed
(+4) High volumetric unit (-4) Temperatures are

conversion hard to control and can
result in undesirable
(+3) Run for long
temperature gradients
periods of time without
maintenance (-4) Its maintenance is
Plug Flow Reactor
more expensive than
(+3) Heat transfer rate
CSTR maintenance.
can be optimized by
using more, thinner
tubes or fewer, thicker
tubes in parallel TOTAL= 2 POINTS
Selected: Continuous Stirred Tank Reactor

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The continuous stirred tank is chosen among the other mixers. It has the most
economic advantages than the others.
2.2.2 Phase Separator
Along the process after the oxidation, Sulfuric Acid (aqueous), is added,
although it is not directly involved in the reaction of the reactants to produce
products. However, the aqueous acid solution is required to enable the
hydrolysis of Cumene Peroxide. To extract the Phenol rich stream from the
mixture, it is separated from the aqueous stream of H2SO4.
Separator Advantages Disadvantages

Selection
Settling (+3) Simple construction (-4) Low separation

Separator yield
(+4) Low investment costs
(-4) Unsuitable for
(+3) Simple operation
separating smaller
(+3) Little maintenance particles.
(+4) Low pressure drop (-4) Longer time

needed in sepation
(+4)Can be used for applications in
extreme situations; low and high
temperatures
TOTAL = 9 POINTS
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Mixer (+4) Suitable for continuous mode (-4) Settling process
Settler operation. requires considerable
amount of time
(+4) Highly effective and efficient in
extraction and separation processes. (-4) High investment
costs
(+4) Practical for processes with
challenging characteristics such as TOTAL= 15 POINTS
difficulty dispersing, high interfacial
tension and large phase density
differential.
(+4) Operates with stage-wise

contact.
(+4) Long phase separation
(+3) Simple to construct
Selected : Mixer Settler
It is more practical to use in extracting and separation because of its

reliability, flexibility and ability to handle high volumes of product.
2.2.3 Distillation Equipment Selection
This phase is also known as the downstream process, purifying the

product in order to achieve a certain percentage. As there are 2 main kinds of
distillation. Among the two, Packed Bed Distillation is chosen fit for the plant.
Distillation Advantages Disadvantages

Selection
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Tray (+4) It’s easy to implement. (-4) It can be expensive.
Distillation
(+4) It’s highly effective and (-3) It comes with
efficient. operational hazards.
(+4) It can handle wide range (-3) It can contribute to

of gas and liquid flow rates. environmental pollution.
(+4) It helps produce much-

needed fuel.
TOTAL = 6 POINTS
Packed (+4) Most cost-efficient (-4) Packing can break

Tower distillation column when the during installation, or due
Distillation diameter of the column is less to thermal expansion.
than 0.6 m.
(-4) Not cost efficient for
(+4) Because packing can be high liquid flow rates.
made from inert materials,
(-4) Not very accurate
packed beds are able to handle
corrosive materials. (-4) Contact efficiencies
are decreased when the
(+4) Lower pressure drop than
liquid flow rate is too low.
in plate columns preventing
column flooding.
(+4) Good for thermally

sensitive liquids.
(+3) Suitable for low pressure

operations.
TOTAL = 3 POINTS
Selected: Tray Distillation
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Tray Distillation is more efficient in terms of its operation and is easier to
implement.
SUMMARY
2.1 Process Selection: CONTINUOUS PROCESS
2.2 Equipment Selection
2.2.1.1 CONTINUOUS STIRRED TANK REACTOR
2.2.1.2 PLUG FLOW REACTOR
2.2.2. MIXER SETTLER
2.2.3. TRAY DISTILLATION
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CHAPTER III
BASIS OF DESIGN
3.1 Description of Design
This plant is designed to continuously produce per day of Phenol with

7992 operating hours for 333 days. To manufacture Phenol, Cumene as the
raw material will undergo oxidation, and during the production process there
would be by-products produced such as Acetone, α-methylstyrene and
acetophenone. The byproducts would be utilized, refined to extract further the
pure Acetone, Phenol, and Cumene. Achieving 96% Phenol and 96% acetone
in the overall process with excess Cumene recycled to be reacted in the feed
stream.
3.2 Process Definition
The design that will be used will be Cumene process. Acquiring Cumene
is done by mixing Benzene and purified propylene obtained from petroleum
industry are mixed in liquid or vapor phase in the presence of phosphoric acid
on. As a result, Cumene or isopropyl benzene is formed. But since the raw
material chosen for this process is readily made Cumene, the process above
will not be performed.
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, acetone, 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.
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3.3 Overall Input and Output Block Scheme
Phenol
Cumene
3.483 tons/day
6.24 tons/day
Acetone
Oxygen Gas 3.448 tons/day
0.329 tons/day
Acidified Waste
0.281 tons/day
Hydrogen Gas
1.084 tons/day Vent Gas
3.448 tons/day
Sulfuric Acid Alpha methyl styrene

0.0026 tons/day 0.11178 tons/day
TOTAL = 7.656 TONS/DAY TOTAL = 7.656 TONS/DAY
3.4 Basic Assumptions
3.4.1 Plant Capacity
The plant manufactures Phenol as the main product with by-

product of Acetone. And utilizes Cumene as the raw material. It aims to
produce 3.59 MT/day of 96% Phenol while the by-products have a
capacity to produce 3.4 MT/day of 96% and 0.045 MT/day of 75%
acetone.
3.4.2 Plant Location
In choosing the location for our plant, several parameters are

considered such as the raw material availability, site location,
topography, climate, availability of labor, and flood risks. The chosen site
location is Hermosa Ecozone Industrial Park, Bataan, Philippines.
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Plant Location
(Source: www.googlemaps.com)
Hermosa is a first class municipality in the province of

Bataan. According to the 2015 census, it has a population of
65,862 people. It has a total land area of 15,730 hectares and it
is composed of 23 barangays [1]. It lies on the northern portion of
the province of Bataan about 100 kilometers from Manila which
can be reached within two hours by land from Manila through the
North Luzon Expressway and about 36 minutes (shortest route)
from Subic Bay Freeport in Subic Bay, Bataan, where we get our
loaded raw materials after it is shipped from China. Also, it is
significant that it near to Clark Diosdado Macapagal International
Airport which is 35 kilometers away.
23
Subic Bay Freeport Zone to Hermosa Ecozone Industrial Park
(Source: www.googlemaps.com)
3.4.3 Power and Water Supply

The main sources of electricity of this municipality are from
Manila Electric Company (MERALCO) and Peninsula Electric
Company (PENELCO). Water is supplied from its own water
system which is The Hermosa Water District. So, energy source
is convenient for our plant location.
3.4.4 Raw Material Availability

There is no raw material available which is cumene in the
Philippines. Thus, in order to acquire the raw material, we must
import it from overseas market which is China. We import our raw
material from a certain company namely, CEPSA Chemical
Shanghai Co. Ltd. It is the first chemical plant in Asia and the
world’s leading producer of cumene. The annual production
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capacity of cumene in this company is 360, 000 tons. The price
would be US$0.10/KG (509.95 Philippine pesos per kilogram)
which is already cheap compare to other producers but would not
compromise its quality [2].
3.4.5. Climate and Flood risks

The climate in Hermosa is classified as a tropical Savanna
(winter dry season), with a tropical moist forest biozone. There is
a medium-low occurrence of periods with extreme drought and
flooding risk is low. Also, it has a zero chance of having a
landslide even during rainy season. So, our location is ideal for
our plant design [1].
3.4.6 Plant Layout
Site Development Plan Layout
25
Phenol and Acetone Plant Layout
3.5 Battery Limit
Each activity involved within the processing and production of this

distinguished, whether it is not involved within or outside the plant and its
operation. The selection of which process activity is set to be within the plant
falls solely to what extent the plant designers can attain and what they cannot.
The table below presents the scope and limitations of the entire project.
Inside Battery Limit Outside Battery Limit
 Preparation of the feed

 Equipment design and
 Installation and maintenance
specifications
of equipment
 Process safety specifications
 Design of adequate
and prepare a process control
wastewater treatment
and instrumentation diagram
 Design of quality control
for the process
laboratories, process control
 Specify packaging, handling,
centers
and storage conditions of the
 Transportation of delivery
product
products
 Assume 100% conversion of
Cumene Peroxide to Phenol
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and Acetone with little to  Design of adequate air
negligible other by products. pollution control
 Assume that pre-purification  Design of adequate treatment
stage has 100 percent for sludge
conversion of AMS to  Design for the proper solid
Cumene. waste management
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CHAPTER IV
THERMODYNAMIC PROPERTIES
Thermodynamics properties are the characteristics (identifiable and

observable) of a system by which it can be specified. Without it, a plant design
cannot be performed. These properties of process materials are needed at all
stages of design. In this chapter, the estimation of the physical properties being
involved in the process is being tabulated.
4.1 Thermodynamic Properties of Chemicals
4.1.1 Thermodynamic Properties of Cumene
Properties Values
Density, kg/m3 861.8
Heat Capacity, J/(kg K) 197
Thermal Conductivity, W/(m K) 0.125
Formation Enthalpy, MJ/kmol -43.1
Entropy, kJ/kmol 277.57
Boiling Point, Celsius 152.4
4.1.2 Thermodynamic Properties of Phenol
Properties Values
Heat Capacity, J/(mol K) 127.21
Formation Enthalpy, KJ/kmol -165
Entropy, J/mol K 144.01
Boiling Point, Celsius 181.7
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4.1.3 Thermodynamic Properties of Acetone
Properties Values
Heat Capacity, kJ/(kg K) 2.14
Flashpoint, K 256
Formation Enthalpy, kJ/kg -4287
Boiling Point. Celsius 56.05
4.2 Thermodynamic Properties of Stainless Steel
4.2.1 Chemical Properties
Element Percentage Present
Carbon 0.12
Chromium 16.0-18.0
Manganese 1.00
Nickel 0.75
Phosphorus 0.040
Silicon 1.00
Sulfur 0.030
4.2.2 Mechanical Properties
Properties Value
Elongation, min(%) 22
Hardness, max (Rb) 89
Tensile Strength, min (ksi) 65
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Yield Strength, min. (ksi) 30
4.2.3 Physical Properties
Properties
Coefficient of Thermal Expansion, 68 – 212˚F, (/˚F) 5.7 x 10-6
Density, (lb/in3) 0.276
Electrical Resistivity, (µΩ-in) 23.6
Modulus of Elasticity, (psi) 29.0 x 106
Specific Heat, Btu/lb-˚F 0.11
Thermal Conductivity, Btu/ft-hr-˚F 13.8
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CHAPTER V
PROCESS STRUCTURE AND DESCRIPTION
The production of Phenol involves choosing the most efficient

process to obtain the desired percentage purity of the products. Because of
this, in Chapter 2, advantages and disadvantages are taken to account in order
to achieve standards. This chapter deals with the selection of the unit
operations, process conditions and process chemicals that were introduced in
this plant.
5.1 Oxidation
Oxidation is the process when oxygen combines with an element, changing the
appearance of the element. Cumene together with oxygen gas are pumped into
the first reactor to oxidize the Cumene with the help of 0.1 gram Cu/MgO /50
ml Cumene fed as the catalyst to form Cumene Hydroperoxide (CHP). The
flowrate of Oxygen is 160 ml/min, this is the fractional ratio needed to convert
60% of Cumene to CHP as the main product with side products, namely: α-
dimethylbenzyl alcohol (DMBA) (conversion 6% from feed), acetophenone and
methanol (2.5% conversion from feed) and unreacted Cumene. (Shuai Xu et al,
2009)
Main Reaction:
C6H5CH(CH3)2 (ℓ) + O2 (g) → C6H5COOH(CH3)2 (ℓ)
Cumene + Oxygen → Cumene Peroxide
Side Reactions:
 2C6H5CH(CH3)2 (ℓ) + O2 (g) → 2C6H5COH(CH3)2 (ℓ)
2 Cumene + Oxygen → α-dimethylbenzyl alcohol (DMBA)
 C6H5COOH(CH3)2 (ℓ) → C6H5COCH3 (ℓ) + CH3OH (ℓ)
Cumene Peroxide → Acetonephenone + Methanol
31
5.2 Cleavage Unit
Cumene Hydroperoxide (CHP) is then hydrolysed in an acidic medium (the

Hock rearrangement) to give phenol and acetone. The acidic medium used in
this process is 0.003% wt Sulfuric Acid, as it plays a big role and is required for
the Hydrolysis of CHP. The hydrolysis of CHP produces Phenol and Acetone
as the main reaction with side products: α – methylstyrene (AMS) and water.
For every 100 kmol/h of Cumene fed to reactor 1 (oxidizer), 0.7 kmol/h of
sulphuric acid is fed for reactor 2 (Cleavage Unit – Hydrolysis). (Zakoshansky
et. al, 2009)
Main Reaction:
C6H5COOH(CH3)2 (ℓ) → C6H5OH (g) + (CH3)2CO (g)
Cumene Peroxide → Phenol + Acetone
Side Reactions:
C6H5COH(CH3)2 (ℓ) → C6H5C(CH2)CH3 (g) + H2O (ℓ)
DMBA → α – methylstyrene + Water
Assumptions:
Overall conversion of DMBA and Cumene Peroxide are 100%.
 Main reaction: Selectivity of Phenol over Acetone is 65%.

 Side reaction: Selectivity of α – methylstyrene over water is 87%.
5.3 Separation
After CHP and DMBA is fully converted to Phenol, Acetone, AMS and water in
an acidic medium, the solution is then passed to a mixer settler that separates
the solution with respect to their miscibility. The top product: Phenol, AMS,
Cumene,and Acetophenone. The bottom product: Phenol (solubility=0.6 grams
phenol/ 100 grams water), Acetophenone (Solubility= 0.08 grams
Acetophenone/100 grams water), acetone and water.
32
5.4 Distillation
The bottom stream of the mixer setter proceeds to the next unit process. To
fully recover acetone in the bottom product a distillation unit is placed. At 80C
acetone is recovered at 80% with 20% water as distillate. The bottom product,
acidified water, phenol and acetophenone are then discarded as waste.
5.5 Mixer
The top stream from the Mixer Settler and the Distillate form the first distillation
s thoroughly mixed to achieve homogenous solution before it is fed to the
purifying process.
5.5 Purification - Distillation Units
This process is the Downstream Processing, it refers to the recovery and the
purification of a product, in this case Phenol and Acetone. The crude phenol
(organic rich stream) 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.
5.5.1 Distillation 1
The first distillation unit is mainly for separation of acetone

from the crude phenol stream. At 373 kelvin and atmospheric pressure
the Distillate will consist of acetone (boils at 56°C), water (100°C) and
0.4% cumene (152.4°C) from the crude phenol stream. Bottoms will
consist of the following products with their respective boiling points:
Phenol (181.7 °C), 99.6% cumene (152.4°C) from the stream, 2%
acetone (56°C), Acetophenone (202 °C), and α – methylstyrene (AMS
,166 °C).
33
5.5.2 Distillation Unit 2
Functioning at a temperature of 175 °C at atmospheric

pressure. The second distillation unit separates mainly cumene and α –
methylstyrene from the other components. Distillate is expected to have
99% of cumene from inlet stream, 70% of α – methylstyrene from inlet
stream and the rest is found in the bottoms.
Just like the Distillation Unit 2, this unit also aims to extract
cumene from the rest of its components. Acquiring 99% of cumene from
the other components operating at a temperature of 152 °C at
atmospheric pressure, recovering 20% of AMS with it. The bottom
stream is sent to the pre – purification reactor.
The fourth distillation unit then again is ffocused on the

separation of 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,
recovering 75% in compostion of Acetone, 5% in composition AMS and
20% cumene from the feed stream.
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, the top product
is then treated as wastewater for waste.
5.6 Pre-Purification Reactor - Hydrogenation
The alpha methyl styrene AMS 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
34
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.
35
CHAPTER VI
MASS AND HEAT BALANCES
6.1 Material Balances

In order to identify the parameters and properties involved in this whole
plant, a mass balance is required. The table below is a representation of the
inlet stream and the outlet stream of mass in tons per day.
MASS IN MASS OUT

C = 6.235 VG = 0.327
O = 0.329 OP = 8.463
Catalyst = 0.007 CP = 8.466
R = 2.226 MT = 8.105
OP = 8.463 MB = 0.360
SA = 0.003 MP = 8.195
CP = 8.470 B0 = 0.281
MT = 8.105 B1 = 4.784
MP = 8.185 T1 = 3.400
TO = 0.070 T2 = 1.190
B1 = 4.784 B2 = 3.590
MB = 0.360 T3 = 1.178
T2 = 1.190 B3 = 0.012
B2 = 3.590 T4 = 0.047
T3 = 1.178 B4 = 1.130
B3 = 0.012 R = 2.226
B4 = 1.130 T5 = 0.112
AG = 1.084 B5 = 3.483
TOTAL = 55.414 TOTAL = 55.349
6.2 Heat Balance

Heat Out, KJ/kmol Heat In , KJ/kmol
OO= 49088.117 OI=49088.117
H2=8900.01 H20=8900.01
DOT=11386.02 H1=8901.01
DBO=18713.15 DI=2179.17
DIT=1005.19 D1=17089.11
DIB=8114.65 DIB=8114.65
DBI=4169.74 D2B=1278.801
BT=1896.32 D1B=4169.74
DI0=4731.27 D4O=4311.27
D4B=2110.93 Gases=3600.145
D5T=5617
TOTAL = 108737.097 TOTAL= 108737.098
36
CHAPTER VII
EQUIPMENT DESIGN
7.1 Continuous Stirred Tank Reactor
7.1.1 Equipment Description
Also known as the Vat or Backmix reactor, is a common model for

chemical reactor in chemical engineering. A CSTR often refers to a model that
is used to estimate the key unit operation variables when using a continuous
agitated tank reactor to reach a specified input. It is an open system that
operates in a steady state with continuous flow where the material is open to
enter or exit from the system where the reactor conditions do not change at any
time. Reactants into the reactor are continually inserted and goods are
continually removed. This reactor is very well blended, with standardized
features like temperature, density, etc. Conditions in the exit flow of the reactor
are also identical to those in the reservoir. The following is a CSTR with a
bending scheme still to be installed. Systems that connect several CSTRs are
used when the response is too slow. When two immiscible fluids are available
and need a high level of agitation, a multiple CSTR can be used.
7.1.2 Main Body Design
1. Agitator motor – An electric motor which powers the agitator; which is a

device or mechanism that put something into motion.
2. Reducer – It is a structure that holds or supports the agitator motor. Reducer

can reduce vibration caused by the rotation in the shaft of electric motor.
3. Motor and Reducer Rigid – A support structure that holds the motor and
reducer together
4. Vessel – A container that is a closed cylindrical structure that is designed for

gases and liquids in which the mixing process occurs
5. Stainless Tube Structural Base – It serves as a leg or support of the vessel
6. Outlet pipe – It is the pipe where the product goes out
37
7. Inlet pipe – It is the pipe where the feed enters
8. Sight Glass – It is a transparent tube or window through which the level of

liquid in a reservoir or supply line can be checked visually
Table 7.1.1 Continuous Stirred Tank Reactor Specification Sheet
Identification Item: Continuous Stirred Tank

Reactor
Mode/Item Number: GSH-2000L
Number Required: 1
Net weight: 2010 kg
Function The Continuous Stirred Tank

Reactors (CSTRs) are open systems
that operate in a steady state and
where the material is open to enter or
exit from the system where the
reactor conditions do not change at
any time.
Operation Batch/Semi-batch
Type Mixer
Design Materials of Construction: Stainless

Steel SS304, TA2
Norminal Capacity:2000L
Volume in Jacketed space: 850 L
Inner Diamater: 1400mm
Outer Diamater: 1600mm
Supporting screw diameter: 1840mm
Expander Capacity: 40
38
Heating Power: 36 KW
Stirring Rate 80r/min
Temperature Range(oC): -196 – 350
Working Pressure (MPa): -0.1-9.8
Maintenance Easy to operate and corrosive

resistant so it is cost effective.
Provides reactor routine maintenance
and training service in
troubleshooting of common faults,
provides remote or on-site reactor
review and operation and installation
technical guidance. The product is
ISO 9001 approved.
Power Consumption 5.5KW
Electricity 380V
Cost Php1,013,412.00
39
Electrical Panel
Agitator Motor
Inlet Pipe
1.4 meters
Vessel
Sight Glass
Stainless Tube Man Way Cover
Vessel Vent
Figure 7.1 Top View of CSTR Mixer

5.5meters
1. Agitator Motor
2. Reducer
3. Vessel
4. Stainless Tube Base
5. Outlet Pipe
6. Inlet Pipe
7. Man Way Cover
8. Sight Glass
1.5 meters
9. Vessel Vent
10. Homogenizer
Figure 7.2 Front Elevation of CSTR
40
1. Agitator Motor
2. Reducer
3. Motor and Reducer Rigid
4. Vessel
5. Stainless Tube Base
6. Outlet Pipe
7. Inlet Pipe
8. Man Way Cover
9. Sight Glass
10. Vessel Vent
11. Ladder
12. Homogenizer
Figure 7.3 Overall Isometric View of CSTR
41
7.2 Tray Distillation
Distillation is a separation processes involving both heat and mass

transfer. While there are many methods for separating chemical compounds,
distillation has been proven to be most reliable and economical design for many
applications. At its most basic definition, distillation is the separation of
components in a solution based on their relative volatility. To accomplish the
process, the liquid and vapor interact in a counterflow arrangement within a
vertical column. There are two main column options for a distillation system:
trayed columns and packed columns, which differ in shape, reliability and ability
to withstand pressure. Tray distillation columns are primarily used in services
that process a liquid feed with solids present or in a service that has the
propensity to foam while processing. Regardless of the tray design being used,
each stage of a trayed column operates in a similar fashion and each tray is
designed to approach the concept of a true equilibrium stage. All mass transfer
takes place within the frothy mixture maintained on the tray. Care is taken to
separate the flow path of the liquids and vapor between adjacent trays so
recycling or bypassing is eliminated. A tray essentially acts as a mini-column,
each accomplishing a fraction of the separation task. From this, the more trays
there are, the better the degree of separation and that overall separation
efficiency will depend significantly on the design of the tray. Trays are designed
to maximize vapor-liquid contact by considering the liquid and vapor distribution
on the tray. This is because better vapor-liquid contact means better separation
at each tray, translating to better column performance. A weir in the tray
ensures that there is always some liquid hold up on the tray.
1. Vertical Shell – it is where the separation of liquid components are carried

out
2. Column Internals (Sieve Trays) – are simply metal plates with holes in them.
3. Reboiler – it provides the necessary vaporization for the distillation process.
42
4. Condenser – It is to cool and condensate the vapor leaving the top of the
column.
5. Reflux Drum – to hold the condensed vapor from the top of the column so
that the reflux can be recycled back to the column.
Table 7.2.1 Tray Distillation Column Unit 0 Specification Sheet
Identification Item: Tray Distillation Column
Mode/Item Number: JH-800
Number Required: 1
Net weight: 3000 kg
Function Column is a kind of chemical

equipment used to make a close
contact between gas and liquid, gas
and solid, liquid and liquid, and to
complete the process of heat
transferring by catalyzing their
interaction. Tray Distillation is used
commonly as separator.
Operation Batch/Continuous
Tray Type Sieve

Steel SS304, TA2
Tray Numbers: 3
Diameter: 1.35m
Length: 4.65m
Recycling Concentration(%): 93-99
Reflux: 0.99065
43
Temperature: 350oC

Product is tested in an advanced
machining equipment and product
testing equipment before shipping.
Can provide a sophisticated product
after-sale service and can ensure the
implementation, maintenance and
commission projects. The product is
ISO CE and ASME approved.
Power Consumption 15 KW
Electricity 220V
Cost Php608,047.20
Number Required: 1
Net weight: 3550 kg

44
Type Sieve

Steel SS304, TA2
Tray Numbers: 6
Diameter: 1.35m
Length: 6.3m
Reflux: 0.1684278
Temperature: 350oC

Electricity 220V
Cost Php708,000.00
45
Number Required: 1
Net weight: 4500 kg

Tray Type Sieve

Steel SS304, TA2
Tray Numbers: 17
Diameter: 1.35m
Length: 12.3m
Reflux: 8.3440
Temperature: 350oC

46
Electricity 220V
Cost Php956,078.00
Table 7.2.4. Tray Distillation Column Unit 3 Specification Sheet
Number Required: 1
Net weight: 5300 kg

Tray Type Sieve

Steel SS304, TA2
Tray Numbers: 22
Diameter: 1.35m
47
Length: 15.1m
Reflux: 2.2948
Temperature: 350oC

Electricity 220V
Cost Php1,358,000.20
Number Required: 1
Net weight: 2300 kg

48
Tray Type Sieve

Steel SS304, TA2
Tray Numbers: 4
Diameter: 1.35m
Length: 5.2m
Reflux: 57.28995
Temperature: 350oC

Electricity 220V
Cost Php665,590.00
49
Number Required: 1
Net weight: 2000 kg

Tray Type Sieve

Steel SS304, TA2
Tray Numbers: 80
Diameter: 2m
Length: 47m
Reflux: 79.44956
Temperature: 350oC

resistant so it is cost effective. Product
is tested in an advanced machining
50
equipment and product testing
equipment before shipping. Can
provide a sophisticated product after-
sale service and can ensure the
Electricity 220V
Cost Php15,134,070.00
51
Figure 7.1 Cross Section View of Tray Distillation Colum
52
Figure 7.2 Top View of Base Ring Figure 7.3 Details of Base
Ring
Figure 7.4 Odd Sieve Plate Layout Figure 7.5 Top View of Odd
Sieve Plate
53
Figure 7.6 Even Sieve Plate Layout Figure 7.7 Top View of Even
Sieve Plate
Figure 7.8 Side

View of Sieve Plates with Liquid Flow Demonstration
54
7.3 Agitator
Mixing is a simple operation carried out to homogenize the the

components from both streams before it is fed to a reactor or another unit
operation. At most mixing is defined as the stirring or agitating if a liquid until it
achieves even distribution of its components. The impeller is design to
demonstrate axial direction of mixing to meet homogeneity in a certain amount
of time set.
1. Vertical Shell – it is where the agitation of liquid components are carried out
2. Impeller –rotating apparatus that agitates the mixture to an axial direction

and helps achieve homogenous mixture.


reducer together


55
Table 7.3.1. Agitator Specification Sheet
Identification Item: Agitator Tank
Mode/Item Number:XB-3500
Number Required: 1
Net weight: 7280 kg
Function Agitates inlet fluid to evenly distribute

and mix components before it is fed to
another unit operation. Additional
capabilities: milling.

Steel SS304, TA2
Capacity Volume: 2.5 m3
Diameter: 1.3 m
Length: 1.5
Diameter of Impeller: 0.386 m
Height from the base of the the tank

to the impeller: 0.386 m
Rotational speed of impeller: 120 rpm
Velocity of the Tip of Impeller :
2.423 m/s

56
Electricity 220V
Cost Php199,950.00
57
Front View of the Mixer
Top View of the Mixer
Isometric View of the Mixer Bottom View of the Mixer
58
7.4 Settler
Mixing is a simple operation carried out to homogenize the components

from both streams before it is fed to a reactor or another unit operation. At most
mixing is defined as the stirring or agitating if a liquid until it achieves even
distribution of its components. The impeller is design to demonstrate axial
direction of mixing to meet homogeneity in a certain amount of time set.
1. Vertical Shell – it is where the agitation of liquid components are carried out
2. Impeller –rotating apparatus that agitates the mixture to an axial direction

and helps achieve homogenous mixture.


reducer together


9. Holding Tank- It is where the liquid is left to separate with respect to

miscibility of the both solution and retention time.
59
Table 7.4.1 Mixer settler Specification Sheet
Identification Item: Mixer Settler
Mode/Item Number: LST-I & LST-II
Number Required: 1
Net weight: 1500 kg
Function Mixer settler is a liquid extraction

mechanism that mixes and at the
same time separates two immiscible
liquids.
Tray Type Sieve
Design Materials of Construction: Carbon

Steel SU8S304
Capacity : 200 m3/h

Electricity 220V-380V
Cost Php 595,000.00
60
61
7.5 Plug Flow Reactor
Plug flow, or tubular, reactors consist of a hollow pipe or tube through

which reactants flow. In a plug flow reactor, nutrients are introduced to the
reactor continuously and move through the reactor as a “plug”. The PFR model
can be used to model multiple reactions as well as reactions involving changing
temperatures, pressures and densities of the flow.
1. Horizontal Shell – it is where the fluid flows
2. Vessel - A container that is a closed cylindrical structure that is designed for

gases and liquids
3. Inlet Pipe – It is the pipe where the feed enters
4. Outlet Pipe – It is the pipe where the product goes out

Table 7.5.1. Plug Flow Reactor 1 Specification Sheet
Identification Item: Plug Flow Reactor
Mode/Item Number:39090
Number Required: 1
Net weight: 105 kg
Function Mixing of liquid and gaseous

components in any given tube cross
section
62
Design Materials of Construction: 316
Stainless Steel Hastelloy C276 alloy
Capacity : 200 L
Maintenance Easily maintained since there are no

moving parts and is mechanically
simple. Unvarying product quality and
tubes are easy to clean.
Electricity 220V
Cost Php 101,020.00
Table 7.5.2. Plug Flow Reactor 2 Specification Sheet
Identification Item: Plug Flow Reactor
Mode/Item Number:39090
Number Required: 1
Net weight: 5775 kg
Function Mixing of liquid and gaseous

components in any given tube cross
section
Design Materials of Construction: 316

Stainless Steel Hastelloy C276 alloy
Capacity : 11000 L
Maintenance Easily maintained since there are no

moving parts and is mechanically
63
simple. Unvarying product quality and
tubes are easy to clean.
Electricity 220V
Cost Php 252,550.00
Plug Flow Reactor 1
Plug Flow Reactor 2
64
CHAPTER VIII
PROCESS CONTROL
Process control is an engineering discipline that deals with mechanisms

and algorithms for maintaining the output of a specific process within a desired
range. It is important because process control technology allows manufacturers
to keep operations running within the specified limits and to set precise limits to
certain parameters to maximize profitability, ensure quality and prioritize safety.
Process control is basically the study and application of automatic

control in the field of chemical engineering. Its primary objective is to maintain
a process at a desired operating conditions, safely and efficiently, while
satisfying environmental aspects including the quality requirements.
In this chapter, details of process instrumentation and control equipment

are presented.
The objectives of the process control specifications are:
1. Keep key process-operating parameters within narrow bounds of the

reference value or set point
2. Enhance process safety
3. Satisfy environmental constraints
4. Meet product quality specifications
5. Use more efficiently of raw materials and energy
6. Increase profitability
Hence, with proper and improved process instrumentation and control,

all benefits will be attained, such as achieving production level of consistency,
efficiency, economy and safety which could not be achieved purely by human
manual control.
65
8.1 Oxidation Reactor
8.1.1 P&ID of Oxidation Reactor
8.1.2 Description of Oxidation Reactor
Oxidation reaction is basically the reaction in which oxygen

combines with other elements. In this process, cumene is oxidized with
air to produce cumene peroxide. The cumene is fed by a feed pump and
the air is forced by a feed compressor into the oxidation reactor. While
the 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. Emulsification
increases the interfacial area to enhance the rate of reaction. After the
reaction, the vent gases are recycled back and the product is sent to the
second reactor which is the cleavage reactor.
66
8.2 Cleavage Reactor
8.2.1 P&ID of Cleavage Reactor
8.2.2 Description of Cleavage Reactor
The cleavage stage is an essential part of the phenol process.

Cleavage reaction is the splitting of chemical bonds. It is referred to as
dissociation when a molecule is cleaved into two or more fragments. A
part of the cleavage is a circulation loop with one heat exchanger to
remove the heat since the process undergoes exothermic reaction in
homogeneous liquid phase. The cleavage unit consists of a stirrer and
is fed with fresh sulfuric acid, H2SO4 (aq), which acts as the catalyst so,
it is not directly involve in the reaction of the reactants to produce
products. However, the aqueous acid solution is required to enable the
hydrolysis of cumene peroxide.
67
8.3 Separator 1 - Phase Separator (Mixer Settler)
8.3.1 P&ID of Phase Separator (Mixer Settler)
8.3.2 Description of Phase Separator (Mixer Settler)
Settling is the process by which the particulates settle to the

bottom of a liquid and form a sediment. For gravity settling, this means
that the particles will tend to fall to the bottom forming a slurry at the
vessel base. 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 which is the cleavage reactor.
The aqueous stream consists of the sulfuric acid and sent back as a
recycle stream, while the organic stream consists of cumene
(unreacted), phenol (product), and acetone (side product).
68
8.4 Mixer
8.4.1 P&ID of a Mixer
8.4.2 Description of a Mixer
Mixing is a simple operation carried out to homogenize the the

components from both streams before it is fed to a reactor or another unit
operation. At most mixing is defined as the stirring or agitating if a liquid until it
achieves even distribution of its components. The impeller is design to
demonstrate axial direction of mixing to meet homogeneity in a certain amount
of time set.
69
8.5 Tray Distillation Column
8.5.1 P&ID of Tray Distillation Column
8.5.2 Description of Tray Distillation Column
Distillation is a process of refining a liquid through separating the

components from a mixture by using selective boiling and condensation.
It is basically a method of separating mixtures based on the differences
in volatility. The crude phenol from the wet scrubber is the inlet stream
that enters a series of distillation column to separate the products from
the reaction. The first distillation unit separates mainly acetone from the
other components. The second distillation unit separates mainly cumene
and α – methylstyrene from the other components. The third distillation
unit separates mainly cumene from the other components. The bottom
stream is sent to the pre – purification reactor. The fourth distillation unit
separates mainly cumene from the other components. The bottom
stream is sent to the pre – purification reactor. The top product is sent to
acetone product vessel. The fifth distillation unit separates mainly phenol
70
from the other components. The bottom stream is sent to the product
vessel.
8.6 Pre-Purification Reactor
8.6.1 P&ID of Pre-Purification Reactor
8.6.2 Description of Pre-Purification Reactor
The alpha methyl styrene is converted to cumene by feeding the

reactor with hydrogen gas by a compressor 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.
71
8.7 Process Flow Diagram
72
8.8 Piping and Instrumentation Diagram
73
CHAPTER IX
PROCESS WASTES
9.1 Wastewater Management
In designing a plant, several factors must be considered to make the plant

environmentally friendly. Proper waste management and treatment of the
generated wastes should be taken seriously to avoid environmental problems. The
chemical process for the production of phenol impacts the environment due to the
different kinds of waste that is being generated throughout the whole process.
Wastes generated comes from the different stages of the production which also
has its environmental impacts. These wastes are Acetophenone and Acidified
water. In this process, Phenol is the major product while Acetophenone is the by-
product.
Acetophenone is the major by-product for the production of Phenol.

Acidified water comes from the processes that take place in the separation
chamber. When the pH water is decreased, the acidified water waste is generated
and is accumulated through means of precipitation. When not disposed properly,
it could cause harmful effects which disrupts the significant nutrient flow and could
possibly lead to the death of freshwater fish and plants which depends on the pH
conditions of the marine ecosystem [1]. The tables shown below are the physical
and chemical properties of Acetophenone and Acidified water.
74
The physical and chemical properties for Acetophenone [2]:
Physical Properties Data
Synonyms Methyl phenyl ketone Acetylbenzene
Chemical Formula 𝐶6 𝐻5 𝐶𝑂𝐶𝐻
Physical State at room temperature Liquid
Odor -
Appearance Colorless Liquid
Boiling Point 201.7 °C
Melting Point 19.7 °C
Relative Density 𝑔
4.1
𝑐𝑚3
𝑔
120.16
Molar Mass 𝑚𝑜𝑙
Soluble in water, methanol, diethyl

ether
Solubility
8.90 × 10−4 𝑃𝑎 ⋅ 𝑠
Viscosity
3.0
Ph
The physical and chemical properties of Acidified Wash Water [3]:
Physical Properties Data
Synonyms Water
Chemical Formula 𝐻2 𝑂
75
Physical State at room temperature Liquid
Odor Sweet, punget
Appearance Colorless Liquid
Boiling Point 100 °C
Melting Point 0 °C
Relative Density 𝑔
1
𝑐𝑚3
𝑔
18.00
Molar Mass 𝑚𝑜𝑙
Infinity
Solubility
8.90 × 10−4 𝑃𝑎 ⋅ 𝑠
Viscosity
3.0
pH
When humans are exposed to acetophenone, it has been observed to

cause hypnotic or sedative effects, hematological effects, and could cause a
weakened pulse in humans. It has been detected in drinking waters, surface
waters, groundwaters and waste effluent waters. The presence of acetophenone
in environmental waters is most likely the result of discharges from industrial
sources. Metabolism and toxicity data indicate that acetophenone is absorbed by
both gastrointestinal and respiratory tracts.
Potential health effects can be through inhalation that may cause irritation
to the respiratory tract with symptoms of sore throat, coughing, headache, and
dizziness. Higher concentrations may cause narcosis. Through Ingestion may
cause sore throat abdominal pain, nausea, coughing, headache, dizziness,
anesthetic effects, and central nervous system effects. Skin contact which may
cause irritation with redness and pain. Eye contact which may cause severe
irritation, redness, pain, and transient corneal injury. When prolonged or repeated
76
skin exposure causes dermatitis, this is called chronic exposure and the
aggravation of pre-existing conditions.
Another wastewater is acidified wash water. For the production of Phenol,

0.03% by weight of Acidified wash water exits as wastewater effluent. This could
be harmful to the environment if we release it in the exceeded limit.
In order to contain these wastes, it should be kept in a tightly closed

container and stored in a cool, dry, well-ventilated area away from incompatible
substances and to protect it against any physical damage. The container should
be secluded from any source of heat or ignition and from oxidizing materials.
Always observe all precautionary measures and warnings listed for the product
especially when handling empty containers since they retain product residues
which could be hazardous.
The wastes are then carried and transported by ADL

ENVIRONTECHNOLOGY INC. This facility operates as a Treatment, Storage and
Disposal (TSD) facility of hazardous wastes. It provides classification, segregation
and applicable treatment methods for liquid and solid wastes which includes
wastewater treatment and acid/alkali treatment. It is located in Hermosa, Bataan
which is very convenient for our plant as it is also located in Hermosa, Bataan [5]
9.3 Air Pollution Management
Gas emissions from industrial plants are hazardous to the surrounding

communities. In order to ensure clean and breathable air, precautionary measures
of gas emissions are being made. In the process, Methanol is the gas that is being
emitted that needs to be treated to avoid polluting the air.
The methane gas is sent into a wet scrubber where in the dirty gas stream
is introduced with a scrubbing liquid, typically water. The gas is collected in the
scrubbing liquid forming methanol liquid which can be easily stored in a storage
tank.
This waste is also carried and transported by the same third party treater,
ADL ENVIRONTECHNOLOGY INC.
77
CHAPTER X
PLANT SAFETY
10.1 Plant safety
Safety and health awareness have a long history, tragedies are along with
it and thus making the safety movement even more developed. Safety plays a
major role in manufacturing plants because of all the people working in one area
and also with all the machinery that everyone is working around with. Safety is
primarily a management activity in which it is concerned with reducing, controlling
and eliminating hazards from different industries.
According to Kharbanda and Stallworthy (1988) safety is a concept covering

hazard identification, risk assessment and accident prevention. Safety should
always come first and remain so despite of costs. Good design and forethought
can often bring increased safety at less cost. One known measure for safety is risk
that is defined as the possibility of loss (Taylor, 1994). According to the Chartered
Insurance Institute (1974), risk is the mathematical probability of a specified
undesired event occurring, in specified circumtances or within a specified period.
In a process plant the losses may be such as a damage to equipment, a loss of
production or an environmental damage as well as an injury or a death. Risk
involves two measurable parameters (Taylor, 1994): consequence and probability.
A hazard is a condition with the potential of causing an injury or a damage

(Heinrich, 1968). A chemical process normally has a number of potential hazards,
for example raw material and intermediate toxicity and reactivity, energy release
from chemical reactions, high temperatures, high pressures, quantity of material
used etc. Each of these hazards impacts the overall process risk (Hendershot,
1995). A pursuit of safety is largely a matter of identifying hazards, eliminating them
where possible or otherwise protecting against their consequences.
In practice the main purpose of the process plant design is to minimize the
total process risk for the limitation of effects. Here risk is the product of the
probability of an incident to happen and the possible consequences of that
78
incident. In this thesis the limitation of effects by the means of inherent safety
principles is evaluated.
10.2 Hazard and Operability Studies (HAZOP) On Selected Major Equipment
HAZOP is a technique of hazard identification (and evaluation) that has

been developed in the chemical and process industries. The technique essentially
involves a multidisciplinary team of chemists engineer, safety advisors, production
management, designers etc, critically examine each aspect of a process at the
design stage, in order to eliminate hazards from the process at that early stage,
rather than to find them later and have to modify the plant to eliminate them. The
selected major equipments in these Hazard and Operability Studies are the
following; Continuous Stirred Tank Reactor, Distillation, Plug Flow Reactor and the
Mixer Settler. In identifying the deviations and the parameters of the selected
equipments, hazards can be eliminated and injuries can be avoided.
79
Item Deviation Cause Consequence Action
- Hot Weather/High Ambient -Potential overheating
Temperature -Potential decrease in
Higher -High water Supply digester efficiency
-Install Temperature indicator
Temperature Temperature -Potential personnel
-Injection of Cooling water
-Hot water temperature exposure to hot fluids
transmitter fails LOW (>140F)
-Cold Weather/ Low
Ambient Temperature -Reactor Cools
-Install Temperature Indicator
CONTINUOUS Lower -Low water Supply Reactants
-Local temperature and
STIRED TANK Temperature Temperature -Concentration Builds up
pressure indicators
REACTOR -Partial Plugged Cooling -Possible runaway on heating
-pump failure alarm in the DC
Line
-Yeast Growth -Install pH meter
Low pH level -Low H2SO4
-Low Alcohol Yield -Sterilization of Reactor Tank
-Consider verifying ladder and
-Accessing -Potential guardrails are included in the tank
Tank
instruments on top of the personnel fall specification
Maintenance
tank hazard -Practice Standard Operating
Procedure
MIXER SETTLER Above the -Defective inlet or -The separator cannot handle -Observe routinely maintenance of
fluid limit outlet valve the amount of fluid inside the valves
80
Pressure
inside is -Fluctuations of pressure
-The separator cannot handle -Install Pressure Indicators
Above or within the process of the
the pressure inside -Proper Maintenance of the valve
below the separator
set point
Outlet Stream
Temperature
-Temperature of the hot fluid -Operability of the setller will
is Above or -Proper Maintenance of the valve
entering the separator be affected
below the
set point
- More steam flow at inlet
- Higher steam pressure
inside - Install high pressure alarm
- Changes in product quality
- Fouled or failed exchanger - Particular attention to heat input
- Caused column flooding
Higher tube and output control
- Film boiling in column and
Column - Cooling water in condenser - Instruct operators on procedure
reboiler (equipment failure)
Temperature failure - Install additional high
- Phase effect
- Reboiler control failure. temperature alarm linked to
- Pressure changes
- Heating medium leak into furnace gas inlet shut off
process
- Loss of Feed
Lower - Less steam flow - Changes in product quality - Particular attention to heat -
DISTILLATION
Column - Low steam pressure and - Phase effect Instruct operators on procedure
Temperature temperature - Pressure changes - Upgrade isolation
81
- Loss of heating (steam - Ineffective separation
leakage) process
- Fouled or failed exchanger
tube
- Cooling water leak into
pressure
-condenser breakdown
- Ineffective isolation
- Outlet isolated or blocked
- Flooding in column - Quality
- Inflow greater than outflow
More Bottom change product - Install level controller and level
control failure (mechanical
Column Level - Uncompleted separation alarm
breakdown)
- Higher impurities
- Faulty level measurement
- Inlets flow stop or blockage
- Leak
Less Bottom - Install level controller
- Outflow greater than inflow - Pump failure
Column Level - Install level alarm
- Control faulty level
measurement
-Overflow
More Reflux - Same as bottom column - Install level controller and level
- Packed pressure
Drum Flow level alarm.
82
- Dry reflux drum
Less Reflux - Same as bottom column - Install level controller and level
- Pump failure(locking)
Drum Flow level alarm.
- Reduce reflux ratio
--Vapor pressure high - Low efficiency of separation

-Pressure indicator -Rupture of column or other -Install high pressure alarm
High Pressure
controller fail related equipment -Install pressure relief valve
-Water Failure -Product loss
-Low efficiency of separation

Low Pressure -Vapour line leakage -Install pressure indicator
-Loss of products
Process
-Leakage of tube -Contamination of Process -Proper maintenance
Contaminatio
-Cooling water goes in Fluid -Operator alert
n
-Use dedicated catalyst charge

tank sized to hold only the amount
PLUG FLOW -Overcharge of catalyst of catalyst needed
High Pressure -Runaway Reaction
REACTOR -Loss of cooling -Emergency relief device
-Install pressure and temperature
sensors
83
10.3 Process Safety Documentation
The need for safety management is rendered necessary by the presence

of flammable and toxic materials. The process should consider control of
process quality and deviations within the processes. In the manufacturing
industry of Phenol and Acetone, acquiring knowledge of the chemicals being
used and produced is necessary. So below are some chemicals that is widely
used and their description and potential hazards and their safety handling
precautions. The Safety Data Sheet (SDS) of the chemicals such as Cumene,
Sodium Hydroxide, Sulfuric Acid, etc are summarized in the Appendix section.
10.3.1Cumene
This chemical appears as a clear colorless liquid with an aromatic

odor and has a flash point of 115oF. It is an irritant to both skin and eyes.
When inhaled or ingested, ensuring that adequate decontamination
must be carried out by rinsing. This chemical should be handled with
care and put in a storage where precaution mounds should be around
the storage tanks, sills at doorways and especially designed floor is
needed to limit escaping of liquid. An outside or detached storage is
preferred, an open flame and other sources of ignition should be
excluded in the area. The substance is possibly carcinogenic to humans.
An appropriate clothing to prevent repeated or prolonged skin contact is
a must.
10.3.2. Sulfuric Acid
It is a highly corrosive chemical that is clear, colourless, oily liquid

and has a pungent odour. Exposure of concentrated sulphuric acid in air,
it can cause nose irritation and if mixed with water, the solution gets very
hot. This chemical can catch fire or explode when in contact with
chemicals including acetone, alcohols and some finely divided metals.
When heated, it emits highly toxic fumes. Direct exposure to this
chemical can cause local effects on skin, eyes and respiratory
gastrointestinal tracts. When spilled, dilute with large amount of water
and mop up then stop the leakage without risk and absorb with dry earth,
84
sand and other non combustible material. Prevent the entry of chemical
into the sewers, basements or confined areas. To avoid safety hazard
given by this chemical, a personal protection must be used such as a full
suit, vapour respirator, gloves, boots and face shields.
10.3.3.Phenol
The chemical is a colourless or pink crystalline solid or viscous

liquid with a characteristic sweet, medicinal odour. It is corrosive and
considered moderately toxic. It can affect the body if it is inhaled,
ingested, or contacts eyes or skin. Exposure to vapors may cause eye,
nose and throat irritation. It is hazardous in case of contact or inhalation.
Phenol should be used with adequate ventilation to minimize inhalation.
When heating phenol, use a water bath inside a chemical fume
hood. Never heat or melt phenol in an incubator, microwave, drying
oven, or similar appliance. Prevent contact with skin by wearing
neoprene gloves, lab coat, and chemical resistant apron. Small liquid
spills of 50 ml or less may be absorbed using paper towels, or
commercially available absorbent and placed in a sealed container or
double plastic bags. If the spill is larger than 50 ml, remove ignition
sources, provide adequate ventilation, evacuate the laboratory, close the
doors, and call the fire department.
10.3.4. Acetone
It is also known as propanone, is a clear, colourless, volatile liquid

that is highly flammable in liquid and vapour. It is widely used product
but is considered a hazardous waste material that needs to be handled
and disposed properly. Long term exposure to this chemical can result
in dry, cracked skin and possible damage to nervous system. When
inhaled, it can irritate the nose and throat and can cause nausea,
dizziness, drowsiness and confusion. First eliminating heat and ignition
sources and posting of “No Smoking” signs in handling. A tight fitting lid
or tank in a space where there is no presence of electrical outlets, stoves
or heat-producing sources or a fireproof container is a great storage for
acetone. Usage of non-sparkling ventilation systems, approved
85
explosion-proof equipments and safe electrical systems in areas where
the products is stored and used is necessary. Wearing of proper
protective equipments such as gloves, face masks, goggles, and
laboratory gowns or suits are advisable when handling this chemical. In
the working environment, it must be well ventilated and consulting local
fire departments first to ascertain some hazards regarding the
manufacturing of acetone.
86
CHAPTER XI
Economics
One of the many reasons this industrial plant is designed is for it to gain
profit from the manufacturing of Phenol. A profitability analysis using different
equations and correlations to aid in the feasibility economic study of the plant.
11.1 Estimation for Economics

Table 45: Estimation for Fixed and Total Capital Investment
Direct Cost
A. Equipment + Installation + Instrumentation + Piping + Electrical +
Insulation + Painting
1. Purchased Equipment 174,666,309.00
2. Installation, Including Insulation and 69,866,523.60
Painting (40% of Purchased Equipment)
3. Instrumentation and Controls 17,466,630.90
(10% of Purchased Equipment)
4. Piping 17,466,630.90
5. Electrical Installation 17,466,630.90
B. Buildings, Process, and Auxiliary 69,866,523.60
C. Service Facilities and Yard Improvements 69,866,523.60
D. Land 17,466,630.90
Total Direct Cost 454,132,403.40
Indirect Cost
A. Engineering and Supervision 68,119,860.51
(15% Total Direct Cost)
B. Construction Expense and Contractor’s 45,413,240.34
Cost (10%
Total Direct Cost)
C. Contingency 63,073,944.92
(10% of Fixed Capital Investment)
Total Indirect Cost 176,607,045.77
Fixed Capital Investment 630,739,449.17

(Direct + Indirect Cost)
Working Capital 111,306,961.62
(15% Total Capital Investment)
Total Capital Investment 742,046,410.78
87
Table 46: Estimation of Total Product Cost
Manufacturing Cost
Direct Production Cost
A. Raw Materials 1,616,359,401.18
B. Operating Labor 52,272,000.00
C. Utility
(10% Total Product Cost) 287,570,914.51
D. Maintenance and Repairs
(30% Fixed Capital Cost) 189,221,834.75
E. Operating Supplies (0.5%
Fixed Capital Cost) 3,153,697.25
F. Laboratory Charges (10%
Operating Labor) 5,227,200.00
G. Patents and Royalties (1%
Total Product Cost) 28,757,091.45
Total Direct Production Cost 2,182,562,139.14
2. Fixed Charges
A. Depreciation (10% Fixed Capital Cost) 63,073,944.92
B. Local Taxes (1% Fixed Capital Cost) 6,307,394.49

C. Insurance (10% Fixed Capital Cost) 6,307,394.49
D. Plant Overhead Cost (50% Operating
Labor) 26,136,000.00
Fixed Charges 101,824,733.90
Total Manufacturing Cost 2,284,386,873.04
General Expenses
A. Administrative Cost
(15% Operating Labor) 7,840,800.00
B. Distribution and Selling Cost
C. Research and Development Cost
D. Financing
Research and Development Cost
Financing
Total General Expenses 591,322,272.04
Total Product Cost 2,875,709,145.08
88
11.2 Calculations for Economics
a) Net Income
𝑁𝑒𝑡 𝐼𝑛𝑐𝑜𝑚𝑒 = 𝑇𝑜𝑡𝑎𝑙 𝐴𝑛𝑛𝑢𝑎𝑙 𝑆𝑎𝑙𝑒𝑠 − 𝑇𝑜𝑡𝑎𝑙 𝑃𝑟𝑜𝑑𝑢𝑐𝑡 𝐶𝑜𝑠𝑡

= 3,240,336,266.93 − 2,875,709,145.08
= 364,627,121.86
b) Return Of Investment
𝑁𝑒𝑡 𝐼𝑛𝑐𝑜𝑚𝑒
𝑅𝑒𝑡𝑢𝑟𝑛 𝑜𝑓 𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡𝑠 = 𝑥 100
𝑇𝑜𝑡𝑎𝑙 𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡
364,627,121.86
= 𝑥100
742,046,410.78
= 𝟒𝟔%
c) Economic Margin
Purchase
Materials PriceS (Php) MT/ Day Annual Cost
Cumene 599,950.00 6.23 1,245,549,295.58
Oxygen Gas 1,012,120.00 0.33 110,966,258.73
1% wt Cu/MgO 707,140.00 0.01 1,648,343.34
0.03 % wt Sulfuric acid 12,122.40 0.00 10,395.58
Hydrogen Gas 699,500.00 1.11 258,185,107.96
TOTAL: 3,030,832.40 7.68 1,616,359,401.18
Sales
Materials Prices (Php) MT/Day Annual Cost
Phenol 1,010,200.00 3.59 1,209,257,099.47
Acetone 1,767,850.00 3.45 2,030,994,472.50
alpha- methylstyrene 757,650.00 0.11 84,694.96
-
TOTAL: 3,535,700.00 7.16 3,240,336,266.93
89
d) Breakeven Analysis
𝑇𝑜𝑡𝑎𝑙 𝐹𝑖𝑥𝑒𝑑 𝐶ℎ𝑎𝑟𝑔𝑒𝑠

𝐵𝑟𝑒𝑎𝑘𝑒𝑣𝑒𝑛 𝐴𝑛𝑎𝑙𝑦𝑠𝑖𝑠 =
𝑆𝑒𝑙𝑙𝑖𝑛𝑔 𝑃𝑟𝑖𝑐𝑒 − 𝑉𝑎𝑟𝑖𝑎𝑏𝑙𝑒 𝐶𝑜𝑠𝑡
101,824,733.90
=
3,535,700 − 3,030,832.40
= 𝟐𝟎𝟏. 𝟔𝟗
e) Payback Period
1
𝑃𝑎𝑦𝑏𝑎𝑐𝑘 𝑃𝑒𝑟𝑖𝑜𝑑 = + 𝑆𝑡𝑎𝑟𝑡 𝑈𝑝 𝑌𝑒𝑎𝑟
%𝑅𝑂𝑅
1
= +3
0.49
= 𝟓. 𝟎𝟑𝟓𝟏 𝒚𝒆𝒂𝒓𝒔
90
CHAPTER XII
CONCLUSION
A plant producing Phenol with side products AMS and Acetone with the
use of Hock Process is successfully designed. The unit operations involved and
the adopted process required for oxidation, separation, scrubbing,
hydrogenation, and distillation processes are prudently selected to ensure the
most efficient and desired products with high output, cost, and energy
efficiency. In addition, the plant design economic study shows that it is viable
and has a large annual cash flow, a return rate of 46% and a decent payback
period of 5 years inclusive of its 3 years of construction, demonstrate that the
design is cost-efficient.
The design is inclusive of process safety with health measures to ensure

safe operations, safety to the workers and to minimize the possibility of
accidents. In the environmental aspects minimum waste is generated that are
handled with proper industrial waste management ensuring an environmentally
friendly operation.
Nevertheless, to enhance productivity and financial sustainability, the

design process can still be improved. One way is to diversify the current
process or create an innovative technique to minimize utility costs. Likewise, to
meet the competition, improving the recovery rates of the mills is important and
this will require sufficient quantity and good-quality sugarcane to process.
Maintaining the product yield and quality would also mean higher profitability.
91
Appendices
i. Charts and Tables

Chart 1.0: Statistics on the Market Demand of Phenols in the Philippines
Year Trade Value ($) Weight (kg)

2012 3,289,043.00 4,210,294
2013 3,925,254.00 4,729,661
2014 8,759,526.00 8,119,113
2015 5,116,802.00 3,178,904
2016 4,866,149.00 2,750,262
2017 6,562,576.00 5,976,583
2018 7,989,744.00 6,526,523
2019 9,596,418.00 8,860,717
Source: UN Comtrade: International trade statistics
Chart 1.1: Statistics on the Market Demand of Acetone in the Philippines
Year Trade Value ($) Weight (kg)

2012 3,557,146.00 4,833,998
2013 4,282.399.00 4,990,219
2014 6,425,215.00 7,001,214
2015 4,642,314.00 5,211,154
2016 5,394,532.00 6,424,550
2017 6,622,314.00 7,080,224
2018 6,700,254.00 7,294,320
2019 7,544,755.00 7,802,801
Source: UN Comtrade: International trade statistics
Chart 1.2: Processes to Produce Phenol and their Yields.
Processes Brief Description Percentage Yield
a. Cumene Involves the liquid phase Phenol and Acetone:

Peroxidation oxidation to cumene to 90-95%
Process cumene peroxide, which in
92
turn is decomposed to phenol
and acetone by the action of
acid.
b. Raschig Oxychlorination of benzene Phenol: 90%

Process reaction which benzene is
Acetone: 0%
oxychlorinated with
hydrochloric acid, air and
with the presence of iron and
copper chloride catalyst to
form cholorobenzene. With
the presence of catalyst, the
cholorobenze hydrolyzed at
4808 degree Celsius to
produce phenol and
hydrochloric acid.
c. Toluene Two- Phenol is produced by Phenol: 88%

Stage undergoing two times
Acetone: 0%
Oxidation oxidation and one hydrolysis
Process processes.
d. Sulphonation Benzene sulphonic acid is Phenol: 33%

process reacted with NaOH to form
Acetone: 0%
sodium benzene sulphonate,
which is fused with excess
NaOH to give sodium
phenoxide. Sodium
phenoxide so obtained is
acidified to get phenol.
Chart 1.3: Competing Companies on the Phenol Manufacturing:

Recent Phenol capacities/expansions and active phenol projects
Company Name Location Product
INEOS Phenol Antwerp, Belgium Phenol and Acetone
The Dow Chemical U.S.A Phenol and Acetone

Company
Formosa Chemical and Taiwan Phenol and Acetone

Fibre Corporation
93
LG Expansion Korea Phenol and Acetone
Kumho Expansion Korea Phenol and Acetone
PTT Phenol Thailand Phenol and Acetone
FCFC Mailiao, Taiwan Phenol and Acetone
Esfahan Iran Phenol and Acetone
Pars Phenol Iran Phenol and Acetone
Saudi Kayan Saudi Arabia Phenol and Acetone
Sinopec Tianjin China Phenol and Acetone
Ertisa China Phenol and Acetone
Shell Singapore Phenol and Acetone
FCFC Ningbo, China Phenol and Acetone
Chart 1.4: Target Market: Name of Possible buyers of Products in Philippines.
Most of these companies are located in Manila, Batangas, Cavite, Bulacan,

Laguna, which are all near to the plant site.
Table 1: Paint Manufacturers in the Philippines
Company Name Address Tel no
NIPPON PAINT #4 HOLOGRAM ST. (049)543-0763 / 845-

PHILIPPINES INC. LISP BRGY. DIEZMO 1176
Cabuyao , Laguna
GOLDEN SUN PAINT 195 MOLINO HEIGHTS (02)3616930 8815819

MANUFACTURING MOLINO III Bacoor,
Cavite
198 Manila East Road 652-0565

Binangonan , Rizal
Mega Paint & Coating
Corp
Triple E Paint Trade JP Laurel Lipa City , (043) 312-5214

Batangas
94
Mega Paint & Coatings Traders Arcade (032) 3441195
Corp Mandaue City , Cebu
Tanville Paint 8001 Singer Compound

Manufacturing Inc Sitio Simona San Isidro
Taytay Rizal
ULTRACOTE PAINT & E. RODRIGUEZ AVE., 6713410

COATINGS PASIG , METRO
CORPORATION MANILA
Paint Plas Corporation San Antonio 722 (049)868-6416

Magsaysay Road ,
Laguna
PACIFIC PAINT 292 D. Tuazon St. 364-3505; 365-0561 to

(BOYSEN) Quezon City, NCR - 64
PHILIPPINES, INC. Second District 1115
SUPER GLOBE, INC. C. RAYMUNDO AVE., 6439840

PASIG , METRO
MANILA
Pacific Paint & Oil D. Tuazon Quezon City, 02 364 3505

Manufacturing, Inc. Metro Manila
MAGNAFLO, INC. ( 97 1707 E ANTEL

03203 ) GLOBAL CORPORATE
CENTER JULIA
VARGAS AVE.
ORTIGAS PASIG ,
METRO MANILA
FH Colors & Coating 34 S Reyes SPL, (049) 869-7562

Corp Laguna
Techno Development & AC Cortes Ave (032) 3440268

Chemicals Corp Mandaue City , Cebu
MARDUKE 5 Mindanao St. Filipinas 02 941 9549

INDUSTRIAL SALES Village Malanday CITY
OF MARIKINA, NCR
95
SSCP Mla. Inc. Lot 1 Blk 9 Phase 1 046 437-1053 / 0558 /
PEZA, Rosario, Cavite 0358
Crystal Resins 141 Cabrera Road, Sitio 22863011

Incorporated Burol San Juan
TAYTAY, RIZAL
UNI-JJET INDUSTRIAL The Rose 02 2127419

Condominium,Meralco
Ave., San Antonio CITY
OF PASIG, NCR
Table 2: Plastic Product Manufacturers in the Philippines
NICO PLASTIC 2 Sta Sabina, Villa (632) 9394931

PRODUCTS Sabina Subd. Talipapa
Novaliches Quezon
City, Metro Manila
JR Plastic Cadena De Amor San (049) 868-8235

Manufacturing Pedro Laguna ,
Corporation Laguna
J MCBEN PLASTIC Hon. Circle St., Sterling (044) 299-61-91/407-

MANUFACTURING Industrial Park, 1568
Meycuayan , Bulacan
No. 24 Madison St. 631-8331 to 34; 632-

Mandaluyong City, 0895
PLASTIC CONTAINER NCR - Second District
PACKAGING
CORPORATION
Altair Plastic 15 A. Marcelo St. 292-4240

Manufacturing, Valenzuela, Metro
Corporation Manila
96
NEW IDEAL PLASTIC C.M. RECTO STREET 948-5298
CORPORATION MARIKINA, METRO
MANILA
MANLY PLASTIC INC. ENERGY ST. LISP I (049)531-6158

DIEZMO Cabuyao ,
Laguna
Pan-Asia Plastic Mould 13 Humilidad St., (63) 02 514 8759

Marulas CITY OF
VALENZUELA, Metro
Manila
ERTESS PLASTIC #297 Provincial Rd., (044) 668-9503

INDUSTRIES INC. Meycuayan , Bulacan
PROLINE PLASTIC Lot1 Blk3 FVI 044-432-0766

CO. Compound,
Meycuayan , Bulacan
GIPICOM PLASTIC 80044-Florida St., MIS

INDUSTRIES II, Meycuayan ,
Bulacan
INTERWORLD ILAYA ST. NIOG III (046) 870-0456

PLASTIC Bacoor, Cavite 09178322688
MANUFACTURING
CORP.
168 Plastic Corporation Nueva National

Highway , Laguna
FILIPINAS PLASTIC 15 LIWAYWAY ST., 288-41-30

CORPORATION ACACIA MALABON,
METRO MANILA
GREIF PHILS., INC. Brgy. Malaya, Pililla, 674-

Rizal Rizal Region 4 1375/1424/1439/1444
Table 3: Resins Manufacturers in the Philippines

97
141 Cabrera Road, Sitio 22863011

Burol San Juan
Crystal Resins TAYTAY, RIZAL
Incorporated
7/F Padilla Bldg., (632) 638-5601 to 03

Emerald Ave. Ortigas
PACIFIC RESINS, INC. Center, Pasig City
Pasig, Metro Manila
GREAT EASTERN PUROK MALIGAYA,

RESINS (PHILS) INDL MAMBUGAN,
CO INC ANTIPOLO CITY , Rizal
POLYMER 11 Joe Borris St., Bo. 671-9837 to 39

PRODUCTS (PHILS.), Bagong Ilog Pasig City,
INC. NCR - Second District
1600
ALCOS GLOBAL No. 12 Calle Obrero 635-0631

CORPORATION Bagumbayan Libis
Quezon City, NCR -
Second District 1110
RI Chemical Coporation E. Rodriguez, Jr. Ave., 671-9842 to 53

Brgy. Bagong Ilog Pasig
City, 1600
CHEMREZ 65 Industria St., 635-0680

TECHNOLOGIES, INC. BagumbayanQuezon
City 1110
MARULAS 141 McArthur Highway, (02) 291-8105 - 07

INDUSTRIAL CORP. Marulas, Valenzuela
City Valenzuela Metro
Manila
LG 05 Royal Mansion, 831-0870

Wackwack Rd.,
AKZO NOBEL / Mandaluyong City, M.M.
CASCO ADHESIVES Mandaluyong Metro
Manila
98
Solutions
a. Mass Balance
Around Distillation 0
To 80% Acetone
20% H2O
MB
0.05 Acetophenone
0.16 Sulfuric Acid Bo Phenol
4.4 Water Acetophenone
95.38 Acetone Acidified
0.01 Phenol
OMB:
MB = TO + BO
0.3602412651 = TO + BO
Water Balance
(0.044)(0.3602412651) = (0.20) (TO)
TO = 0.07925307832 tons/day
BO = MB – TO
BO = 0.2809881868 tons/day
T1
MD
B1
OMB:
MD = T1 + B1
8.184681543 = T1 + 4784254278
99
T1= 3.400427265 tons/day
T2 76.67% Cumene
3.03% Acetone
20.29% AMS
B1
19.26% Cumene
0.75% Acetone
2.76% Acetophenone
70.02% Phenol
7.21% AMS B2 3.594736394 tons/day
2.76% Acetophenone
0.26% Cumene
7.21% AMS
93.19% Phenol
OMB:
B1 = T 2 + B 2
B1 = T2 + 3.594736394
Phenol Balance:
0.7002B1 = (0.9319)(3.594736394)
B1= 4.784254278 tons/day
From OMB:
B1= T2 + B2
4.784254 = T2 + 3. 594736394
T2= 1.189517884 tons/day
T3
76.49% Cumene
3.06% Acetone
T2 20.45% AMS
76.67% Cumene
3.03% Acetone
20.29% AMS
B3
95.49% AMS
4.51% Cumene
OMB:
T 2 = T 3 + B3
1.189517884 = T3 + B3
Acetone Balance
(0.0303)(1.189517884) = (0.0306)(T3)
100
T3= 1.177855944 tons/day
From OMB:
T 2 = T 3 + B3
1.189517884 = 1.177855944 + B3
B3 = 0.01166193988 tons/day
T4
19.01% Cumene
75.92% Acetone
T3 5.07 % AMS
76.49% Cumene
3.06% Acetone
20.45% AMS
B4
4.510% Cumene
95.49% AMS
OMB:
T 3 = T 4 + B4
1.177855944 = T4 + B4
Acetone Balance:
(0.0306)(1.177856) = 0.7592T4
T4 = 0.04747417492
From OMB:
T 3 = T 4 + B4
B4 = 1.1303811769
Product: 3.48295 tons/day T5
8.230% Cumene
91.47% AMS
0.3% Phenol
B2
3.68% Acetophenone
0.26% Cumene B5
2.88% AMS 3.79% Acetophenone
93.19% Phenol 0.030% AMS
96.18% Phenol
OMB:
B2 = T 5 + B 5
B2 = T5 + 3.48295
101
Phenol Balance:
0.9319B2 = 0.0030T5 + (0.9618)(3.48295)
B2 = 3.5947363944
T5 = 0.1117863944
Around Mixer
MT MP
TO
OMB:
8.105428465 + TO = MD
MD = 8.105428465 + 0.079253
MD = 8.184681543 tons/day
Around Hydrogenation
Hydrogen Gas
B4 + B 3
Recycle
OMB:
HG + B4 + B3 = R
HG + 1.130381769 + 0.01166193988 = R
R= 1.0840694 + 1.0840694 + 1.1303818 + 0.01166194
R= 2.226113109 tons/day
Around Oxidizer
Cu/MgO Vent gas
Cumene
44.37% Cumene
Oxygen 47.0% CHP
2.73% Acetophenone
102
5.9% DMBA
R
OMB:
C + O + R = VG + Op
O= (160 ml/mol)(1L/1000ml) (60 min/ hr)(24hr/day)
O= (2.30.4 L/day)(1429 kg/L)(1ton/1000kg)
O= 0.3292416 tons/day
Cumene Balance:
C+R= (0.47)(0.66)(C) + 0.4437C + (0.60)(0.60)(0.47)(2.2261)(C)
C= 6.234501685 tons/day
From OMB:
C+O+R = VG+Op
6.235 + 0.3292416 + 2.22611 = VG + Op
6.2345 + 2.22611 = (0.45) (Op) + (0.47Op) + (2.22611)(0.60)(0.47) +
0.0065691
Op= 8.463094543
6.2345 + 0.3292416 + 2.22611 = VG + Op
VG= 0.326759 tons/day
Around Cleavage Unit

0.02575% SA
Op Cp
45% Cumene 45% Cumene
47% CHP 47% Phenol
21% Acetophenone 5.13% AMS
59% DMBA 0.767% Water
2.1% Acetophenone
OMB: 0.03% Sulfuric Acid
Op + SA = Cp
8.4630945 + 0.00257523 = Cp
Cp= 8.46566973 tons/day
Around Mixer Settler
Cp MT
46% Phenol
6% AMS
47% Cumene
1% Acetophenone
MB
0.05% Acetophenone
103
0.16% Sulfuric Acid
4.4% Water
95.38% Acetone
0.01% Phenol
OMB:
Cp = MT + MB
Cumene Balance
(0.45)(8.46566973) = 0.47MT
MT = 8.105428465 tons/day
MB = Cp - MT
MB = 0.3602412657 tons/day
104
105
ii. Equipment Sizing Minimum Reflux
𝐹
𝑅𝑚𝑖𝑛 = 𝐷
Distillation Column Unit 0 𝛼−1
Acetone Column 0.36024 𝑡𝑜𝑛𝑠/𝑑𝑎𝑦
0.079253078 𝑡𝑜𝑛𝑠/𝑑𝑎𝑦
Distillate: 𝑅𝑚𝑖𝑛 =
7.11942 − 1
𝑃1 𝑅𝑚𝑖𝑛 = 0.7338217366
𝛼𝐷𝑖𝑗 =
𝑃2
𝑅𝑜𝑝𝑡 = 1.35𝑅𝑚𝑖𝑛
At 80oC
R= 0.99065
Vapor Pressure of Acetone
Minimum Number of Trays:
1277.03
𝑙𝑜𝑔10 𝑃1 = 7.2316 − Fenske- Underwood Equation:
80 + 237.33
𝑃1 = 2.12075 𝑎𝑡𝑚 𝑋𝐷1
𝑋
ln[ 𝑋𝐵1 ]
Vapor Pressure of Water 𝐷𝑗
𝑋𝐵𝑗
𝑃2 = 0.04814202 𝑀𝑃𝑎 = 𝑁𝑚𝑖𝑛 = − 1
ln 𝛼
0.4751247964 atm
0.9538
𝑃1 2.12075 𝑎𝑡𝑚 0.8 ]
𝛼𝐷𝑖𝑗 = = ln[ 0.0044
𝑃2 0.4751247964 𝑎𝑡𝑚
𝑁𝑚𝑖𝑛 = 0.2 − 1
𝛼𝐷𝑖𝑗 = 4.4635668844 𝑙𝑛7.11942
For Bottom: 𝑁𝑚𝑖𝑛 = 1.023313937
𝛼𝐷𝑖𝑗 = 𝛼𝐵𝑖𝑗 = 4.463568844 𝑁𝑜𝑝𝑡 = 2𝑁𝑚𝑖𝑛 = 2.0467
𝑁𝑜𝑝𝑡 (1 + 0.1)
For Feed: 𝑁𝑎𝑐𝑡𝑢𝑎𝑙 =
𝜀
At 25oC
2.0467(1 + 0.1)
𝑁𝑎𝑐𝑡𝑢𝑎𝑙 =
Vapor Pressure of Acetone 0.85
1277.03 𝑁𝑎𝑐𝑡𝑢𝑎𝑙 = 2.6486 = 3 𝑡𝑟𝑎𝑦𝑠
𝑙𝑜𝑔10 𝑃1 = 7.2316 −
25 + 237.33
𝑃1 = 0.303919 𝑎𝑡𝑚
Vapor Pressure of Water
Peak efficiency of vapor factor:
𝑃2 = 1.7𝑥10−3 𝑀𝑃𝑎 = 0.01678 𝑎𝑡𝑚
𝐹𝑠 = 𝑈𝜌𝑣 0.5
𝑃1 0.303919 𝑎𝑡𝑚
𝛼𝐹𝑖𝑗 = = = 18.1119 Assume: 1.35
𝑚 𝑘𝑔 0.5
[ ]
𝑃2 0.01678 𝑎𝑡𝑚 𝑠 𝑚3
3 Density of vapor in distillate:

𝛼𝑎𝑣𝑔 = √(𝛼𝐹𝑖𝑗 )(𝛼𝐷𝑖𝑗 )(𝛼𝐵𝑖𝑗 )
𝜌𝑛 = ∑(𝑋𝑖 𝜌)𝑛
3
𝛼𝑎𝑣𝑔 = √(4.636)(4.636)(18.1119)
𝛼𝑎𝑣𝑔 = 7.11942
106
Substances Xm 𝜌 X𝜌 𝑃1 𝑠𝑎𝑡
𝛼𝑎𝑣𝑔 =
𝑃2 𝑠𝑎𝑡
Acetone 0.80 784.0 627.2
For multicomponent system:
Water 0.20 997.0 199.4
3
𝛼𝑎𝑣𝑔 = √(𝛼𝐹𝑖𝑗 )(𝛼𝐷𝑖𝑗 )(𝛼𝐵𝑖𝑗 )
𝑘𝑔 Antoine Equation
𝜌𝑣 = 826.6
𝑚3
𝐵
𝐹𝑠 𝑙𝑜𝑔10 𝑃(𝑚𝑚𝐻𝑔) = 𝐴 −
𝑈= 𝑇𝑜𝐶 + 𝐶
𝜌𝑣 0.5
FEED:
1.35 𝑚
𝑈= 0.5
= 0.0469554 At 80oC;
826.6 𝑠
Assume: Acetone
D= 1.35m 1277.03
𝑙𝑜𝑔10 𝑃1 𝑠𝑎𝑡 = 7.2316 −
80 + 273.23
Spacing between trays: 0.55m
𝑃1𝑠𝑎𝑡 = 1607.0706 𝑚𝑚𝐻𝑔
L= length
𝑃1𝑠𝑎𝑡 = 2.1146 𝑎𝑡𝑚
L= (tray space x 𝑁𝑎𝑐𝑡𝑢𝑎𝑙 ) + 3m
Cumene
L= (0.55 x 3) + 3m
1460.793
L= 4.65m 𝑙𝑜𝑔10 𝑃2 𝑠𝑎𝑡 = 6.9366 −
80 + 207.777
Limited Tower Height: 𝑃2𝑠𝑎𝑡 = 72.5323 𝑚𝑚𝐻𝑔
𝐿 4.65 𝑃2𝑠𝑎𝑡 = 0.0945 𝑎𝑡𝑚
= = 3.44 < 30 − 𝐶𝑜𝑟𝑟𝑒𝑐𝑡
𝐷 1.35
Relative Volatility of Feed
𝑃1 𝑠𝑎𝑡 2.1146 𝑎𝑡𝑚
Summary: 𝛼𝐹𝑖𝑗 = =
𝑃2 𝑠𝑎𝑡 0.0945 𝑎𝑡𝑚
𝑵𝒂𝒄𝒕𝒖𝒂𝒍 𝒕𝒓𝒂𝒚𝒔 = 𝟑𝒕𝒓𝒂𝒚𝒔 𝛼𝐹𝑖𝑗 = 22.1656
Reflux = 0.99065 For Distillate:
𝒎
Flooding Velocity = 0.0469554 At 100oC
𝒔
Diameter = 1.35m Acetone
Length = 4.65m 𝑃1𝑠𝑎𝑡 = 3.6641 𝑎𝑡𝑚
Spaces between Trays = 0.55m 𝑃𝑠𝑎𝑡 = 2784.6970 𝑚𝑚𝐻𝑔

Cumene
Distillation Column Unit 1 𝑃𝑠𝑎𝑡 = 155.0205 𝑚𝑚𝐻𝑔
Acetone Column 𝑃𝑠𝑎𝑡 = 0.2040 𝑎𝑡𝑚

Relative Volatility Relative Volatility for Feed:
107
𝑃1 3.6641 𝑎𝑡𝑚 Minimum Reflux: At bubbly point:
𝛼𝐷𝑖𝑗 = =
𝑃2 0.2040 𝑎𝑡𝑚
𝐹
𝛼𝐷𝑖𝑗 = 17.9613 𝑅𝑚𝑖𝑛 = 𝐷
𝛼−1
For Bottom: Where:
O
Since Temperature of Bottom is 100 C F= Mass flowrate of feed
thus,
D= Mass flowrate of distillate
𝛼𝐷𝑖𝑗 = 𝛼𝐵𝑖𝑗 = 17.9613
8522.6313
Average Volatility is: 𝑅𝑚𝑖𝑛 = 3739.8796
19.2657 − 1
3
𝛼𝑎𝑣𝑔 = √22.1656 (17.9613)(17.9613)
𝑅𝑚𝑖𝑛 = 0.1247613
𝛼𝑎𝑣𝑔 = 19.2657
Rop + Range
Minimum Number of Trays: 1.2 1.5 𝑅𝑚𝑖𝑛
Fenske- Underwood Equation: Assume:
𝑋𝐷1
𝑋 1.35 𝑅𝑚𝑖𝑛
ln[ 𝑋𝐵1 ]
𝐷𝑗 R= 1.35𝑅𝑚𝑖𝑛
𝑋𝐵𝑗
𝑁𝑚𝑖𝑛 = − 1 R= 1.35(0.1247631)
ln 𝛼
0.9697 R= 0.1684278
ln[ 0.0075
0.0020 ] Peak efficiency of vapor factor:
𝑁𝑚𝑖𝑛 = 0.1926 − 1
𝑚 𝑘𝑔 0.5
ln 19.2657 Range: 1.2 1.5 [ ]
𝑠 𝑚3
𝑁𝑚𝑖𝑛 = 2.1875
𝑚 𝑘𝑔 0.5
Assume: 1.35 [ ]
𝑠 𝑚3
Optimum Number of Theoretical
Trays: Density of vapor in distillate:
𝑁𝑜𝑝𝑡 = 2𝑁𝑚𝑖𝑛 = 4.375 𝜌𝑛 = ∑(𝑋𝑖 𝜌)𝑛

Safety Factor 10% on number of trays
Substanc Xm 𝜌 X𝜌
2𝑁𝑚𝑖𝑛 (1 + 0.1) es
𝜀
Cumene 0.002 862. 1.724
Tray efficiency for distillation of light 0
hydrocarbons:
Acetone 0.969 784. 760.244
𝜀 = 60% − 90%
7 0 8
Assumption: 𝜀 = 85%
Water 0.283 997. 282.151
4.375(1 + 0.1) 0
0.85
𝑁𝑎𝑐𝑡𝑢𝑎𝑙 = 5.66 = 6 𝑡𝑟𝑎𝑦𝑠
108
𝑘𝑔 𝑃1 𝑠𝑎𝑡 = 155.0205 𝑚𝑚𝐻𝑔
𝜌𝑣 = 1044.1198
𝑚3
𝑃1 = 0.20397 𝑎𝑡𝑚
𝐹𝑠
𝑈= AMS at 100oC
𝜌𝑣 0.5
1.35 𝑚 1582.7
𝑈= = 0.04178 𝑙𝑜𝑔10 𝑃2 = 7.0942 −
1044.1198 0.5 𝑠 100 + 206.01
Assume: 𝑃2 = 83.2428 𝑚𝑚𝐻𝑔
D= 1.35m 𝑃2 = 0.10953 𝑎𝑡𝑚
Spacing between trays: 0.55m 0.20397

𝛼𝐹𝑖𝑗 =
0.10953
L= length
𝛼𝐹𝑖𝑗 = 1.8622
Distillate:
L= (0.55 x 6) + 3m
At 165oC
L= 6.3m
Cumene
Limited Tower Height:
1460.793
𝐿 6.3 𝑙𝑜𝑔10 𝑃1 𝑠𝑎𝑡 = 6.9366 −
= = 4.67 < 30 − 𝐶𝑜𝑟𝑟𝑒𝑐𝑡 165 + 207.777
𝐷 1.35
𝑃1 = 1.37141 𝑎𝑡𝑚
AMS at 165oC
𝑃2 = 0.88240 𝑎𝑡𝑚
Summary:
1.37141
𝑵𝒂𝒄𝒕𝒖𝒂𝒍 𝒕𝒓𝒂𝒚𝒔 = 𝟔𝒕𝒓𝒂𝒚𝒔 𝛼𝐷𝑖𝑗 = = 1.5542
0.88240
Reflux = 0.1684278 Since 𝑇𝐷 = 𝑇𝐵 = 160𝑜 𝐶
𝒎
Flooding Velocity = 𝟎. 𝟎𝟒𝟏𝟕𝟖 𝛼𝐵𝑖𝑗 = 𝛼𝐷𝑖𝑗 = 1.5542
𝒔
3
Diameter = 1.35m 𝛼𝑎𝑣𝑔 = √(1.8622)(1.5542)(1.5542)
Length = 6.3m 𝛼𝑎𝑣𝑔 = 1.6507
Spaces between Trays = 0.55m 𝑋𝐷1
𝑋
ln[ 𝑋𝐵1 ]
𝐷𝑗
Distillation Column Unit 2 𝑋𝐵𝑗
𝑁𝑚𝑖𝑛 = − 1
ln 𝛼
Cumene Column
0.77
Feed: 0.0026
ln[ 0.2 ]
At 100 oC 𝑁𝑚𝑖𝑛 = 0.0287 − 1
ln 1.6507
Cumene
𝑁𝑚𝑖𝑛 = 6.48097
1460.793
𝑙𝑜𝑔10 𝑃1 𝑠𝑎𝑡 = 6.9366 − 𝑁𝑜𝑝𝑡 = 2𝑁𝑚𝑖𝑛 = 12.96
100 + 207.777
109
Safety Factor 10% Summary:
12.96 (1 + 0.1) 𝑵𝒂𝒄𝒕𝒖𝒂𝒍 𝒕𝒓𝒂𝒚𝒔 = 𝟏𝟕𝒕𝒓𝒂𝒚𝒔
0.85
Reflux = 8.3440
𝑁𝑎𝑐𝑡𝑢𝑎𝑙 = 16.6957 = 17 𝑡𝑟𝑎𝑦𝑠 𝒎
Flooding Velocity = 0.0458 𝒔
Minimum Reflux at bubble point
Diameter = 1.35m
4782.752
𝑅𝑚𝑖𝑛 = 1195.688 Length = 12.35m
1.6507 − 1
Spaces between Trays = 0.55m
𝑅𝑚𝑖𝑛 = 6.1807
Distillation Column Unit 3
R= 1.35(6.1807) = 8.3440
Cumene Column
Peak efficiency
Feed:
𝑚 𝑘𝑔 0.5
At 150oC
Assume: 1.35 [ ]
𝑠 𝑚3
Vapor Pressure of Cumene:
Density of the vapor in distillate:
𝑝1 = 0.94426 𝑎𝑡𝑚
𝜌𝑛 = ∑(𝑋𝑖 𝜌)𝑛 Vapor Pressure of AMS:
Substances X 𝜌 X𝜌 𝑝2 = 0.58334 𝑎𝑡𝑚

0.94426
Cumene 0.77 862.0 663.74 𝛼𝐹𝑖𝑗 = = 1.6187 𝑎𝑡𝑚
0.58334
AMS 0.2 910.0 182
For Distillate:
Acetone 0.03 784.0 23.52 At 152oC
Vapor Pressure of Cumene
𝑘𝑔 𝑝1 = 0.98986 𝑎𝑡𝑚
𝜌𝑣 = 869.26
𝑚3
Vapor Pressure of AMS:
𝐹𝑠
𝑈=
𝜌𝑣 0.5 𝑝2 = 0.61768 𝑎𝑡𝑚
1.35 𝑚 0.98986
𝑈= = 0.0458 𝛼𝐷𝑖𝑗 = = 1.6025
869.26 0.5 𝑠 0.61786
Diameter = 1.35m For Bottom:
L= (tray space x 𝑁𝑎𝑐𝑡𝑢𝑎𝑙 ) + 3m Since same temperature,
L= (0.55 x 17) + 3m 𝛼𝐵𝑖𝑗 = 𝛼𝐷𝑖𝑗 = 1.6025

3
L= 12.35m 𝛼𝑎𝑣𝑒 = √(1.6025)2 (1.6187)
Limited Tower Height: 𝛼𝑎𝑣𝑒 = 1.6079
𝐿 12.35
= = 9.1481 < 30 − 𝐶𝑜𝑟𝑟𝑒𝑐𝑡
𝐷 1.35
110
𝑋𝐷1 𝑘𝑔
𝑋 𝜌𝑣 = 847.5292
ln[ 𝑋𝐵1 ] 𝑚3
𝐷𝑗
𝑋𝐵𝑗 𝐹𝑠
𝑁𝑚𝑖𝑛 = − 1 𝑈=
ln 𝛼 𝜌𝑣 0.5
0.7644 1.35 𝑚
0.045 ] 𝑈= 0.5
= 0.0464
ln[ 0.2046 847.5292 𝑠
𝑁𝑚𝑖𝑛 = 0.955 − 1 Diameter = 1.35m

ln 1.6079
𝑁𝑚𝑖𝑛 = 8.2054
L= (0.55 x 22) + 3m
𝑁𝑜𝑝𝑡 = 2𝑁𝑚𝑖𝑛 = 16.4108 𝑡𝑟𝑎𝑦𝑠
L= 15.1m
Safety Factor 10%
Limited Tower Height:
16.4108 (1 + 0.1)
𝑁𝑎𝑐𝑡𝑢𝑎𝑙 = 𝐿 15.1
0.85 = = 11.1852𝑚 < 30 − 𝐶𝑜𝑟𝑟𝑒𝑐𝑡
𝐷 1.35
𝑁𝑎𝑐𝑡𝑢𝑎𝑙 = 21.2376 = 22 𝑡𝑟𝑎𝑦𝑠
Summary:
𝑵𝒂𝒄𝒕𝒖𝒂𝒍 𝒕𝒓𝒂𝒚𝒔 = 𝟐𝟐𝒕𝒓𝒂𝒚𝒔
1195.687928
Reflux = 2.2948
𝑅𝑚𝑖𝑛 = 1157.1173
1.6079 − 1 𝒎
Flooding Velocity = 0.0464 𝒔
𝑅𝑚𝑖𝑛 = 1.699841
Diameter = 1.35m
R= 1.35(1.699841) = 2.2948
Length = 15.1m
Peak efficiency
Spaces between Trays = 0.55m
𝑚 𝑘𝑔 0.5
Assume: 1.35 [ ]
𝑠 𝑚3
Distillation Column Unit 4
Cumene Column
𝜌𝑛 = ∑(𝑋𝑖 𝜌)𝑛 Feed:
Substanc X 𝜌 X𝜌 At 152oC
es Vapor Pressure of Cumene
Cumene 0.764 862. 658.912 1460.793
4 0 8 𝑃1 𝑠𝑎𝑡 = 6.9366 −
152 + 207.777
AMS 0.031 910. 28.21 𝑃1𝑠𝑎𝑡 = 0.98995 𝑎𝑡𝑚
0
Vapor Pressure of AMS
Acetone 0.204 784. 160.406
𝑃2𝑠𝑎𝑡 = 0.61768 𝑎𝑡𝑚
6 0 4
0.98995
𝛼𝐹𝑖𝑗 = = 1.6027 𝑎𝑡𝑚
0.61768
For Distillate:
111
At 165oC Peak efficiency
Vapor Pressure of Cumene 𝐹𝑠 = 𝑈𝜌𝑣 0.5
𝑝1𝑠𝑎𝑡 = 1.37141 𝑎𝑡𝑚 𝑚 𝑘𝑔 0.5
Assume: 1.35 [ ]
𝑠 𝑚3
1582.7
𝑃2 𝑠𝑎𝑡 = 7.0924 − 𝜌𝑛 = ∑(𝑋𝑖 𝜌)𝑛
165 + 206.01
𝑝2𝑠𝑎𝑡 = 0.88166 𝑎𝑡𝑚 Substanc X 𝜌 X𝜌
1.37141 es
𝛼𝐷𝑖𝑗 = = 1.555
0.88166
Cumene 0.19 862. 163.78
For Bottom: 0
TD= TB= 𝛼𝐵𝑖𝑗 = 1.555 AMS 0.050 910. 46.228
3 8 0
𝛼𝑎𝑣𝑒 = √(1.555)2 (1.6027)
Acetone 0.759 784. 595.212
𝛼𝑎𝑣𝑒 = 1.5711
2 0 8
𝑋𝐷1
𝑋
ln[ 𝑋𝐵1 ]
𝐷𝑗 𝑘𝑔
𝑋𝐵𝑗 𝜌𝑣 = 805.2208
𝑁𝑚𝑖𝑛 = − 1 𝑚3
ln 𝛼
𝐹𝑠
0.1901 𝑈=
𝜌𝑣 0.5
ln[ 0.7890 ]
0.0508
1.35 𝑚
𝑁𝑚𝑖𝑛 = 0.2110 − 1 𝑈= = 0.047574
805.22080.5 𝑠
ln 1.5711
𝑁𝑚𝑖𝑛 = 1.2154 tray Diameter = 1.35m
2𝑁𝑚𝑖𝑛 = 𝑁𝑜𝑝𝑡 = 2.4302 L= (tray space x 𝑁𝑎𝑐𝑡𝑢𝑎𝑙 ) + 3m
𝑁𝑜𝑝𝑡 (0.1 + 1) L= (0.55 x 4) + 3m

𝜀 L= 5.2m
𝜀 = 0.85 Limited Tower Height:
Safety Factor = 10% 𝐿 5.2
= = 3.852 < 30 − 𝐶𝑜𝑟𝑟𝑒𝑐𝑡
2.4302 (1 + 0.1) 𝐷 1.35
0.85 Summary:
𝑁𝑎𝑐𝑡𝑢𝑎𝑙 = 3.1450 = 4 𝑡𝑟𝑎𝑦𝑠 𝑵𝒂𝒄𝒕𝒖𝒂𝒍 𝒕𝒓𝒂𝒚𝒔 = 𝟒𝒕𝒓𝒂𝒚𝒔
Minimum Reflux at bubble point Reflux = 57.28995
1157.1173 𝒎
Flooding Velocity = 0.0476
𝑅𝑚𝑖𝑛 = 47.24794 𝒔
1.5771 − 1
Diameter = 1.35m
𝑅𝑚𝑖𝑛 = 42. 43688063
Length = 5.2m
R= 1.35(42.43688063) = 57.28995
112
Spaces between Trays = 0.55m 2𝑁𝑚𝑖𝑛 = 𝑁𝑜𝑝𝑡 = 61.26
𝑁𝑜𝑝𝑡 (0.1 + 1)
Distillation Column Unit 5 𝜀
𝜀 = 0.85
For Feed:
Safety Factor = 10%
At 150oC
61.26 (1 + 0.1)
Vapor Pressure of Cumene 𝑁𝑎𝑐𝑡𝑢𝑎𝑙 =
0.85
1460.793
𝑃1 𝑠𝑎𝑡 = 6.9366 − 𝑁𝑎𝑐𝑡𝑢𝑎𝑙 = 79.2959 = 80 𝑡𝑟𝑎𝑦𝑠
150 + 207.777
𝑃1𝑠𝑎𝑡 = 0.9391519 𝑎𝑡𝑚
3.594736394
Vapor Pressure of AMS
𝑅𝑚𝑖𝑛 = 0.111786
𝑃2𝑠𝑎𝑡 = 0.583344 𝑎𝑡𝑚 1.546414 − 1
𝑅𝑚𝑖𝑛 = 58.85
0.9391519
𝛼𝐹𝑖𝑗 = = 1.599659 𝑎𝑡𝑚
0.583344 R= 1.35(58.85) = 79.44956
For Distillate: Peak efficiency
o
At 152 C 𝐹𝑠 = 𝑈𝜌𝑣 0.5
Vapor Pressure of Cumene 𝑚 𝑘𝑔 0.5
Assume: 1.35 [ ]
𝑠 𝑚3
𝑝1 = 0.939151 𝑎𝑡𝑚
𝜌𝑛 = ∑(𝑋𝑖 𝜌)𝑛
𝑝2 = 0.617675 𝑎𝑡𝑚
0.939151 Substanc X 𝜌 X𝜌
𝛼𝐷𝑖𝑗 = = 1.5204608833 es
0.617675
For Bottom: AMS 0.914 862. 788.471
7 0 4
𝛼𝐷𝑖𝑗 = 𝛼𝐵𝑖𝑗 = 1.52046
3 Phenol 0.003 1.07 3.21x10
𝛼𝑎𝑣𝑒 = √(1.52046)2 (1.599659) -3
𝛼𝑎𝑣𝑒 = 1.546414
Cumene 0.082 910 74.893
𝑋𝐷1 3
𝑋
ln[ 𝑋𝐵1 ]
𝐷𝑗
𝑋𝐵𝑗
𝑁𝑚𝑖𝑛 = − 1 𝑘𝑔
ln 𝛼 𝜌𝑣 = 863.3965
𝑚3
0.026
0.9147 𝐹𝑠
ln[ 0.0626 ] 𝑈=
𝜌𝑣 0.5
𝑁𝑚𝑖𝑛 = 0.08230 − 1
𝑙𝑛1.54646 1.35 𝑚
𝑈= 0.5
= 0.045943
863.3965 𝑠
𝑁𝑚𝑖𝑛 = 30.637067 tray
Diameter = 2m
113
1000𝑘𝑔
L= (tray space x 𝑁𝑎𝑐𝑡𝑢𝑎𝑙 ) + 3m 0.065 𝑥
24ℎ
Vo Water = 𝑘𝑔 =
997 3
L= (0.55 x 80) + 3m 𝑚
𝑚3
2.716482782 𝑥 10−3 ℎ
L= 47m
Limited Tower Height: Total volumetric:
𝑚3
𝐿 47 Vo = 111.8231567
= = 23.5 < 30 − 𝐶𝑜𝑟𝑟𝑒𝑐𝑡 ℎ
𝐷 2
Assume:
Summary:
Residence Time
𝑵𝒂𝒄𝒕𝒖𝒂𝒍 𝒕𝒓𝒂𝒚𝒔 = 𝟖𝟎𝒕𝒓𝒂𝒚𝒔
𝜏 = 0.35 𝑚𝑖𝑛
Reflux = 79.44956
𝒎 ℓ = 0.5𝑚
Flooding Velocity = 0.045943 𝒔 ℎ𝑟
V = Vo 𝑥 60𝑚𝑖𝑛
Diameter = 2m
𝑘𝑔 0.35 𝑚𝑖𝑛
Length = 47m V = 111.8231567 ℎ
𝑥 60𝑚𝑖𝑛
Spaces between Trays = 0.55m V = 0.652017 𝑚3
V = 𝜋𝑟 2 ℓ
0.6523017 𝑚3 = 𝜋𝑟 2 (0.5𝑚)
CSTR Sizing Radius= 0.6443 m
𝑀𝑎𝑠𝑠 𝐹𝑙𝑜𝑤𝑟𝑎𝑡𝑒
Volumetric Flowrate, 𝑉𝑜 = 𝑘𝑔
Diameter = 1.3 m
𝜌( )
𝑚3
; Cp= 8.46566773 tons/day
𝑡𝑜𝑛 1𝑑𝑎𝑦 1000𝑘𝑔
3.809547 𝑥 𝑥
𝑑𝑎𝑦 24ℎ𝑟𝑠 𝑡𝑜𝑛
Vo Cumene = 𝑘𝑔 =
862 3
𝑚
0.184143 m3/h
1000𝑘𝑔
2.58626 𝑥
24ℎ
Vo Phenol = 𝑘𝑔 =
1.03 3
𝑚
𝑚3
104.6221683 ℎ
1000𝑘𝑔
0.1777 𝑥
24ℎ
Vo Acetophenone = 𝑘𝑔 =
1.07 3
𝑚
𝑚3
6.919781931 ℎ
1000𝑘𝑔
1.40106673 𝑥
24ℎ
Vo Acetone = 𝑘𝑔 =
784 3
𝑚
𝑚3
0.07446148491
ℎ
1000𝑘𝑔
0.4343 𝑥
24ℎ
Vo AMS = 𝑘𝑔 =
910 3
𝑚
𝑚3
0.01988553114
ℎ
114
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118
CURICCULUM VITAE
NINA THERESE C. BALILI, was born on the 13th

of December 1998 in Lapu-Lapu City, Cebu. She
is the only girl among four children of Mr. Florante
O. Balili and Mrs. Rita Alita C. Balili. She finished
her elementary education and her secondary
education at St. Alphonsus Catholic School Inc. in
Lapu-Lapu City. She is currently a fifth year
student in the course Bachelor of Science in
Chemical Engineering.
ELAINE JULES V. DAQUIADO was born in

Bacay, Tulay Minglanilla, Cebu. She is the
youngest among three children of Mr. Johnny
Cabarse Daquiado and Mrs. Eleonor Vicada
Daquiado. She finished her elementary education
at Minglanilla Central School, Poblacion Ward II,
Minglanilla and also finished her secondary
education at University of the Visayas –
Minglanilla Campus, Tiber, Minglanilla. She is
currently a Bachelor of Science in Chemical
Engineering fifth year student at Cebu Institute of Technology – University.
LUNAR KAYE A. LAVIDES was born on April 15,

1999 and raised in a small city of Cebu by her
parents namely Froilan R. Lavides and Baby A.
Lavides. She graduated her elementary education
with high honors and studied secondary education
in Abellana National School where she developed
an early interest in both chemistry and
mathematics. She also discovered that being an
engineer could help her achieve the goals she
wanted for her family. Due to this, she decided to
take up Bachelor of Science in Chemical Engineering at Cebu Institute of
Technology-University. She is a scholar of Cebu City Government and currently
a fifth year student and a member of Junior Philippine Institute of Chemical
Engineers- Cebu chapter. For her, studying engineering was never been an
easy path to take, as she quoted, “You got to have that strong determination
and passion built as an armor to survive this deranged yet beautiful course”.
119
CORNELIO E. OBRERO III was born in Cebu
City, Cebu. He graduated Elementary education
at Cherubs Academy Inc., Laray, Talisay City. He
finished his secondary education at Talisay City
National High School. Currently, he is a fifth year
student taking up Bachelor of Science in Chemical
Engineering at Cebu Institute of Technology-
University.
PATRICE ALYX O. PINATIL, was born in Sangat,

San Fernando, Cebu. She is the eldest among five
children of Mr. Rommel Lazarte Pinatil and Mrs.
Lolita Omamalin Pinatil. She graduated
elementary education as salutatorian at San
Fernando Central School. Finished secondary
education at St. Catherine’s College, Carcar City,
Cebu as fourth honorable mention. Currently, she
is a fifth year student taking up Bachelor of
Science in Chemical Engineering at Cebu Institute
of Technology – University, a CHED scholar. She is also a member of the
school’s official publication and was the former Literary Editor for the Editorial
Year 2017-2018.
120

Production of Phenol

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Production of Phenol

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Cebu Institute of Technology – University

College of Engineering and Architecture

Department of Chemical Engineering

In Partial Fulfillment of Requirements for the course

Production Phenol – Acetone through

Balili, Nina Therese

Daquiado, Elaine Jules

Pinatil, Patrice Alyx

Engr. Vera Lanaria

This project design entitled “Production of Activated Carbon from Coconut ”,

Engr. Vera Marie Lanaria

Engr.Vera Marie Lanaria Engr. Amis Pacamalan

Date: ____________ Date: ____________

Dr. Evangeline C. Evangelista Dean

College of Engineering and Architecture

This project is design for an integrated process of the production of

1.1. Market Study 7

PROCESS AND OPTION SELECTION

2.1. Process Selection 10

BASIS OF THE DESIGN

3.1. Description of Design 21

3.2. Process Definition 21

3.3. Overall Input and Output Block Scheme 22

3.4. Basic Assumptions 22

3.5. Battery Limit 26

4.1. Thermodynamic Properties of Chemicals 28

4.2. Thermodynamc Properties of Stainless Steel 29

PROCESS STRUCTURE AND DESCRIPTION

5.3. Separation –Settling 32

5.4. Distillation Unit 33

5.6. Distillation Units 33

MASS AND HEAT BALANCES

6.1. Mass Balance 36

6.2. Heat Balance 36

7.1. Continuous Stirred Tank Reactor 37

7.2 Tray Distillation 42

7.5. Plug Flow Reactor 62

8.1 Oxidation Reactor 66

8.2. Cleavage Reactor 67

8.5 Tray Distillation 70

8.6 Pre-purification Reactor 71

8.8 Piping and Instrumentation Diagram 73

9.1 Wastewater Management 74

9.2 Air Pollution Management 77

10.1 Plant Safety –Definition 78

10.2 Hazard and Operability Study 79

10.3 Process and Safety Documentation 84

11.1 Estimation for Economics 87

11.2 Calculation for Economics 89

CONCLUSION AND RECCOMENDATIONS 91

CURRICULUM VITAE 199

One of the most important intermediates of chemical industries are

Phenol is an aromatic organic compound that consists of phenyl group

Phenol and acetone belongs to the class of bulk commodities or bulk

There are several processes technology associated to Phenol

The applicability of Phenol and Acetone is rapidly expanding, companies

Criteria for Selection Ratings

Process Advantages Disadvantages

Batch (+4) Lower initial setup cost (-4)Overall cost Processing is

(+4) Easier to scale up from

(+4) Quality output kept

Selected : Continuous Process

2.2 Equipment Selection

Since, the process chosen is continuous, the following equipment to be

Date: Date: