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INTRODUCTION
Chapter: 1
INTRODUCTION
CUMENE 1.
INTRODUCTION
Chapter: 1
Introduction
Cumene (isopropyl benzene) is an organic compound that is based on an aromatic
hydrocarbon with an aliphatic substitution. It is a constituent of crude oil and refined fuels. It is a
flammable colorless liquid that has a boiling point of 152 °C. Nearly all the cumene that is produced as
a pure compound on an industrial scale is converted to cumene hydroperoxide, which is an
intermediate in the synthesis of other industrially important chemicals, primarily phenol and acetone.
• The alkylation of benzene with propylene gives CUMENE a very important petrochemical C3
compound.
• The cumene molecular have can be visualize as straight chain propylene group have benzene
ring attached at the middle carbon form cumene (C6H5CH(CH3)2
• The cumene production capacity of the world is about 7 million Ton/day distribute over 40
plant. • The catalyst for such a process is phosphoric acid supposed. Silica Kieselguhr(skpa).
• Only few plants are based on the MONSANTO TECHNOLOGY, which uses aluminum
trichloride (ALCL3) as catalyst.
• Cumene producers account for approximately 20% of the global demand for benzene.
CUMENE 2.
INTRODUCTION
Structure.
Fig. 1, 2-dimension structure of cumene. Fig. 2, 3-dimension structure of cumene
CUMENE 3.
INTRODUCTION
1.2. PRESENT STATUS AND MARKET ANALYSIS.

Essentially, all world cumene is consumed for the production of phenol and acetone. As a
result, demand for cumene is strongly tied to the phenol market. Trade In cumene accounts for only 4%
of world production. The largest exporter of cumene are the United States & Japan. Taiwan also
import large volume of cumene for phenol production.
As of early 2011, the U.S. cumene market was tight-primarily as a result of a shortage of
feedstock propylene. Schedule plant maintenance by several large cumene manufacturer was also
planned for early to mid 2011. Because of the cumene shortage, phenol and acetone plant operations
rate have been reduced significantly, which in turn has restricted phenol export to Europe and higher
demand region such as Asia & South America.
Fig. 3, world consumption patterns of cumene
Increased demand for bisphenol A and phenolic resin will result in strong Demand for phenol,
particularly in Asia (excluding Japan). As a result, consumption of cumene for phenol is forecast to
grow at approximately 8% per year in the region China alone is expected to add a million metric ton of
CUMENE 4.
INTRODUCTION
cumene capacity during stream in 2013) to supply its phenol/ acetone plants that are slated to come on
stream during that period. Overall, worldwide cumene consumption for the production of
phenol/acetone is forecast to grow at an average annual rate of about 4.5% during 2010–2015.
CUMENE 5.
INTRODUCTION
1.3. LIST PRODUCER OF CUMENE.

Table 1, list global cumene manufacturers.
SR. No List of cumene manufacturing industry Capacity
1 Herdillia chemicals Ltd. 2000 TPA

Air India building,
13thfloor,narimanpoint,
Bombay400021(Maharashtra)
2 Si group India ltd. 1470 TPA
Ballarpur road
Opp. juinagar railway station
Turbhethane,
NaviMumbai(Maharashtra)
3 Hindustan organic chemicals Industry, 40000 TPA
81,Maharishi karvemarg,
Harchandri house,
Mumbai (400002)
4 Global polychem LLC. 10301 TPA
N-2, sector 11,
Noida-201301, Uttar Pradesh.
CUMENE 6.
INTRODUCTION
1.3.2 LIST GLOBAL MANUFACTURER

Table 2, Global manufacturer of cumene and capacity of cumene
1 Hangzhou Tianlong Co., Ltd 300000 TPA
Zhejiang, China.
2 A.M. FOOD chemical co., Ltd 10000 TPA

Shandong, China.
3 TS CHEMICAL PVT. LTD 20000 TPA

Texas, American
4 JLM CHEMICAL .PVT .LTD 1120 TPQ

Blue Island, IL, USA
5 EniChem , ENI. CO.LTD. San 1980 TPQ

Donato Milanese, Italy
CUMENE 7.
INTRODUCTION
1.5 PROPERTIES
 PHYSICAL PROPERTIES OF CUMEN.
• Color :- colorless
• Odor. :- odorless
• Molecular weight. :- 120.19
• Purity :- 99%
• Melting point. :- -96.9°C
• Boiling point. :- 152.5°C
• Density :- 0.862 gm/cc
• Flash point. :- 39°C
• Vapor pressure :- 4.5 mmHg at 25°C
• Ignition point. :- 138°C
• Freezing point :- -96°C
• Thermal conductivity. :- 0.124 w×m/k
• Surface tension. :- 0.791 N/M
• Flammable limit in air. :- lower – 0.9% volume,
:-. Higher – 6.5% volume
• Toxicity limit. :- 200 PPM
• Soluble :- Water, and more solvent.
• Insoluble in. :- Alcohol, Ether, Carbon tetrachloride & etc.
CUMENE 8.
INTRODUCTION
 CHEMICAL PROPERTIES OF CUMENE
• Cumene under goes oxidation to give cumene hydroperoxide by means of air or oxygen.
C6 H5CH(CH2)2 + O2 = C6H5 (CH3)2COOH.
• By catalytic actions of dilute sulphuric acid, cumene hydroperoxide is Split into phenol
& acetone.
C6H5(CH3)2COOH = C6H5OH + CH3COCH3
CUMENE 9.
INTRODUCTION
1.6 USES OF CUMENE
1. Cumene is a natural component of coal tar and crude oil, and also can be used as Blanding
component in gasoline.
2. A building-block chemical, almost all cumene approximately 98% of cumene is consumed as a
chemical intermediate in the production of phenol & acetone, two chemicals that are widely use
plastic .
3. Additional, cumene I’m minor amounts is used as a solvent during the manufacturing of paints,
lacquer & enamel.
4. Cumene is also used as a solvent for fats and raisins.
5. Cumene by itself is not generally sold by producers for consumers used.
6. Cumene in minor amounts is used as a thinner for paints, enamels and lacquers and to produce
acetophenone, the chemical intermediate dicumylperoxide and isopropyl benzene.
CUMENE 10.
INTRODUCTION
1.7 RAW MATERIALS USED.

Raw materials for cumene manufacturing are;
1.Benzene
2.Propane
3.Propylene.
1.8 CATALYST USED.
 QZ-2000™ &
 QZ-2001™
2000catalyst is a solid, regenerable, zeolite catalyst used to produce cumene

((isopropyl benzene) via alkylation of benzene with QZ_2001 catalyst is based on
a proprietary beta zeolite formulation developed by UOP.
CUMENE 11.
MANUFACTURING PROCESS
CHAPTER: 2
MANUFACTURING PROCESSES OF CUMENE WITH FLOW

DIAGRAMS
CUMENE. 12.
MANUFACTURING PROCESSES WITH FLOW DIAGRAM
1. Q-MAX™ CUMENE manufacturing process flow diagram.
Fig. 4, Q-MAX™ cumene manufacturing process.
CUMENE 13.
2 CD-TECH CUMENE manufacturing process flow diagram.
Fig.5 CD-TECH CUMENE manufacturing process.
CUMENE 14.
3. MONSANTO – LUMMUS crest cumene process.
Fig.6, MONSANTO LUMMUS cumene manufacturing process
CUMENE 15.
4. UOP cumene manufacturing process.
Fig.7, UOP cumene manufacturing process.
CUMENE
16.
5. Badger Cumene Manufacturing Process.
Fig.8, MOBILE BADGER cumene manufacturing process.
CUMENE 17.
2.3 SELECTION OF CUMENE MANUFACTURING PROCESS
• Q-MAX ™ Manufacturing process is most convenient process for CUMENE

manufacturing
Justification of selection of cumene:-
• Product yield is 99.7 weight%.
• High activity and selective with minimum by product formation.
• Typical cumene productive yield is 95.5% pure.
• Extremely tolerant to poison.
• Proven run-length of up to 5 years.
• Low catalyst cost .
• Low in investments as compare to other process.
• Reduce in solid waste.
• Corrosion free environment.
CUMENE 18.
2.4 Process description on Q-MAX ™ cumene manufacturing process.
1. Raw material propylene and benzene are used for the production of cumene.
2. These are stored in the respective storage tanks of 500MT capacity in the storage yard pumped to
the unit by the centrifugal pumps.
3. Benzene pumped to the feed vessel which mixes with the recycled benzene. Benzene stream is
pumped through the vaporizer with 25 atmospheric pressure and vaporized to the temperature of
243 , mixed with the propylene which is of same and temperature and pressure of benzene
stream. 4. This reactant mixture passed through a fired super heater where reaction temperature
350 is obtained.
5. The vapor mixture is sent to the reactor tube side which is packed with the solid phosphoric acid
catalyst supported on the exothermal heat is removed by the pressurized water which is used for
steam production and the effluent from the reactor i.e. cumene, p-DIPB, unreacted benzene,
propylene and propane with temperature 350 is used as the heating media in the vaporizer
which used for the benzene vaporizing and cooled to 40 in a water cooler, propylene and
propane are separated from the liquid mixture of cumene, p-DIPB, benzene in a separator
operating slightly above atmospheric and the pressure is controlled by the vapor control value of
the separator, the fuel gas is used as fuel for the furnace also.
6. The liquid mixture is sent to the benzene distillation column which operates at 1 atmospheric
pressure, 98.1% of benzene is obtained as the distillate and used as recycle and the bottom liquid
mixture is pumped at bubble point to the cumene distillation column where distillate 99.9%
cumene and bottom pure p-DIPB is obtained.
CUMENE 19.
7. The heat of bottom product p-DIPB is used for preheating the benzene column feed, All the utility
as cooling water, electricity, steam from the boiler, pneumatic air is supplied from the utility
section.
8. The typical reactor effluent yield contains 94.8 Wt. % cumene and 3.1 Wt. % of diiso propyl
benzene. The remaining 2.1 % is primarily heavy aromatics.
9. This high yield of cumene is achieved without of di-iso propyl benzene and is unique to the solid
phosphoric acid catalyst process.
10. The cumene product is 99.9 Wt. % pure and the heavy aromatics, which have an octane number of
109, can either be used as high-octane gasoline blending components or combined with additional
benzene and sent to a trans alkylation section of the plant where diiso propyl benzene is converted
to cumene.
11. The overall yields of cumene for this process are typically 97-98 Wt. % with trans alkylation and
94-96 Wt. % without trans alkylation.
CUMENE 20.
2.5 Manufacturing process description of Cumene.

A representative Q-Max flow diagram is shown. The alkylation reactor is typically
divided into four catalyst beds contained in a single reactor shell.
The fresh benzene is routed through the upper midsection of the depolarizer
column to remove excess water and then sent to the alkylation reactor via a side draw. The
recycle benzene to both the alkylation and trans alkylation reactors comes from the
overhead of the benzene column.
A mixture of fresh and recycle benzene is charged down flow through the alkylation
reactor. The fresh propylene feed is split between the four catalyst beds. An excess of benzene is used
to avoid polyalkylation and to help minimize olefin oligomerization.
Because the reaction is exothermic, the temperature rise in the reactor is controlled by
recycling a portion of the reactor effluent to the reactor inlet, which acts as a heat sink. In addition,
the inlet temperature of each downstream bed is reduced to the same temperature as that of the first
bed inlet by injecting a portion of cooled reactor effluent between the beds.
Effluent from the alkylation reactor is sent to the depolarizer column, which removes any
propane and water that may have entered with the propylene feed.
The bottoms from the depolarizer column are sent to the benzene column, where excess
benzene is collected overhead and recycled. Benzene column bottoms are sent to the cumene column,
where the cumene product is recovered overhead. The Cumene column bottom which contains most
isopropyl benzene is send to the DIPB stream leaves the column by way of a side cut and is recycled
to the Tran alkylation reactor. The DIPB column bottom consist of heavy aromatic by-product, which
are normally blended into fuel oil. Steam or hot oil provide the heat for the product, fractionation
section.
CUMENE 21.
A portion of the recycle benzene from the top of the benzene column is combined with
the recycle DIPB from the side cut of the DIPB column and sent to the trans alkylation reactor.
In the trans alkylation reactor, DIPB and benzene are converted to additional cumene. The effluent
from the trans alkylation reactor is then sent to the benzene column. The QZ-2000 catalyst utilized in
both the alkylation and trans alkylation reactors is regenerable.
At the end of each cycle, the catalyst is typically regenerated ex-situ via a simple carbon burn
by a certified regeneration contractor. However, the unit can also be designed for in-situ catalyst
regeneration.
Mild operating conditions and a corrosion-free process environment permit the use of carbon
steel construction and conventional process equipment.
CUMENE 22.
2.6 PROCESS FLOW DIAGRAM WITH INSTRUMENTATION AND EQUIPMENT OF

QMAX™ PROCESS FOR CUMENE MANUFACTURING
. Fig.9, PFD. of Cumene manufacturing process with all instrumentation and fittings with feed
locations, heat exchanger, pumps, coolers etc
CUMENE 23.
LIST MAJOUR EQUIPMENT AND INSTERUMENT
Chapter: 3
LIST MAJOR EQUIPMENT AND INSTRUMENTATION REQUIRED

IN MANUFACTURING OF CUMENE
CUMENE 24.
3.1 MAJOR EQUIPMENT
Major equipment required in Q-MAX ™ CUMENE MANUFACTURING are follow: -
1. Alkylation reactors.
2.Trans alkylation reactor
3. Depolarizer column.
4. Benzene column.
5. Cumene column.
6. DIPB column.
Other general equipment used in cumene manufacturing process.
1. Feed drum.
2. Feed pump.
3. Feed vaporizer.
4. Feed heater.
5. Effluent coolers.
6. Phase separator.
7. Condenser.
8. Reflux pump.
9. Reboiler.
10. Cumene Reflux drum.
CUMENE 25.
1. Alkylation reactors.
The alkylation reactor is typically divided into four catalyst beds contained in a single reactor
shell. The fresh benzene is routed through the upper midsection of the depropanizer column to remove
excess water and then sent to the alkylation reactor via a side draw. The recycle benzene to both the
alkylation and trans alkylation reactors comes from the overhead of the benzene column.
Fig. 10, Alkylation Reactor of Q-MAX ™ Cumene manufacturing process.
CUMENE 26.
A mixture of fresh and recycle benzene is charged down flow through the alkylation
reactor. The fresh propylene feed is split between the four catalyst beds. An excess of benzene is used
to avoid polyalkylation and to help minimize olefin oligomerization.
Because the reaction is exothermic, the temperature rise in the reactor is controlled by
recycling a portion of the reactor effluent to the reactor inlet, which acts as a heat sink. In addition, the
inlet temperature of each downstream bed is reduced to the same temperature as that of the first bed
inlet by injecting a portion of cooled reactor effluent between the beds.
Effluent from the alkylation reactor is sent to the depolarizer column, which removes any
propane and water that may have entered with the propylene feed.
2. Trans alkylation reactor.

In the trans alkylation reactor, DIPB and benzene are converted to additional cumene. The
effluent from the trans alkylation reactor is then sent to the benzene column. The QZ-2000 catalyst
utilized in both the alkylation and trans alkylation reactors is regenerable. At the end of each cycle,
the catalyst is typically regenerated ex-situ via a simple carbon burn by a certified regeneration
contractor. However, the unit can also be designed for in-situ catalyst regeneration. Mild operating
conditions and a corrosion-free process environment permit the use of carbon-steel construction and
conventional process equipment.
CUMENE 27.
3. Depolarizer Reactors.
Depolarizer Reactors is reactors which removes propane, water, and other impurities
present in the propylene feed. The depolarizer has a total condenser, partial reboiler, 20 equilibrium
stages , and operates at 17 bar. The feed streams, a saturated liquid at 101.6°C, enter at stage 11 at a
flow rate of 100Kmol/hr.
Fig. 11, Depolarizer Reactor.
CUMENE 28.
4. Benzene column.
The bottoms from the depolarizer column are sent to the benzene column, where excess benzene
is collected overhead and recycled. Benzene column bottoms are sent to the cumene column, where the
cumene product is recovered overhead.
Fig. 12, Benzene column.
CUMENE 29.
5. Cumene Column.
Benzene column bottoms are sent to the cumene column, where the cumene product is
recovered overhead. The Cumene column bottom which contains most d-isopropyl benzene is send to
the DIPB stream leaves the column by way of a side cut and is recycled to the Tran alkylation reactor.
The bottom liquid mixture is pumped at bubble point to the cumene distillation column where
distillate 99.9% cumene and bottom pure p-DIPB is obtained.
Fig.13, Cumene Column.
CUMENE 30.
6. DIPB COLUMN.
The Cumene column bottom which contains most d-isopropyl benzene is send to the DIPB
stream leaves the column by way of a side cut and is recycled to the Tran alkylation reactor. The DIPB
column bottom consist of heavy aromatic by-product, which are normally blended into fuel oil. Steam
or hot oil provide the heat for the product, fractionation section.
Fig. 14, DIPB Column.
CUMENE 31.
3.2 Instrumentation Required in Cumene Manufacturing Process.

Major instrumentation required in cumene manufacturing process are: -
1. Pressure measuring instruments.
• Diaphragm pressure valve.

• Border tube pressure gauge
2. Flow measuring devices.
• Turbine flow meter.
• Vortex flowmeters.
• Coriolis flowmeter.
3. Temperature measuring devices.
• Electro pyrometer.
• Helix bimetallic element thermometer.
4. Level measuring instrument.
• Radar level measuring transmitter.
• Buoyancy level measurement device.
5. Valve control and regulations.
6. Ph measuring instruments.
• Ph meter.
• Ph indicator.
CUMENE 32.
MATERIAL BALANCE
Chapter: 4
MATERIAL BALANCE
CUMENE 33.
MATERIAL BALANCE
4.1 Overall Material Balance.
Reaction’s in the Alkylation Reactor:
C3H6 + C6H6 = C6H5 - C3H7 (Cumene, IPB)
C3H6+C6H5-C3H7 = C3H7 –C6H4-C3H7
(di iso propyl benzene; DIPB; C6H4[CH(CH3)2])
Reaction’s in the Trans-Alkylation Reactor:
C3H7–C6H4-C3H7+C6H6 2(C6H5-C3H7)
Conversion of Propylene in Alkylation reactor: %100
Reactor Conversion for Trans-Alkylation reactor: %50
Basis: Per hour of operation
Amount of cumene to be obtained = 1 M ton of cumene per annum.
=106/330 tons per day of cumene.
= 106/ (330 x 24) tons of cumene per hr.
= 126.26 x 103 kg of cumene per hr.
= (126.26 x 103)/120.19 kmoles of cumene per hr.
= 1050.50 Kgmole/hr.
Assuming 97% conversion and 2% loss.
∴ Cumene required = 1050.50/ .98
=1071.94 Kgmoles/hr.
= 128836.32 Kg/hr.
CUMENE 34.
MATERIAL BALANCE
Hence 128836.32 kg of cumene is required to be produced per hr.
Propylene required =1071.94/.97
= 1105.09 Kgmole
= 1105.09 x 42 Kg/hr. of propylene
= 46413.78 Kg/hr. of propylene
Assuming benzene required is 25% extra
= 1105.09 x 1.25 Kmoles of benzene
= 1381.3625 Kgmole/hr.
= 107746.27 Kg/hr.
Propane acts as an inert in the whole process. It is used for quenching purpose in the reactor. It
does not take part in the chemical reaction. Also, it is inevitably associated with the propylene
as an impurity as their molecular weight is very close.
We assume propylene to propane ratio as 3:1.
Being an inert we are neglecting propane balance in the material balance to avoid complexity.
CUMENE 35.
MATERIAL BALANCE
1.) Material balance around reactor:
Propylene = 46413.78 Kg/hr
Benzene = 107746.27 Kg/hr
Products:
ALKYLATION Cumene = 128836.32 Kg/hr.

Propylene = 1105.09-1071.94
REACTOR
DIPB =33.15 Kmoles/hr. is reacted to give
Benzene required to give DIPB
= 33.15/2 kmoles/hr.
= 16.575 kmoles/hr.
DIPB produced= 16.575 x 162
= 2685.15 Kg/hr.
Benzene in product = 1381.3625 – 1071.94 -16.575
= 292.85 kmoles/hr.
= 22820.85 kg/hr.
Input = 46413.78 + 107746.27 = 154160.05 Kg/hr.
Output = 128836.32 + 2685.15 + 22820.85= 154342 Kg/hr.
Input = output
CUMENE 36.
MATERIAL BALANCE
2) Depropanising column.
Propane column is Depropanising column. Assuming almost all the propane is removed in
depropanising column and sent to reactor for quenching. Hence material balance for depropanasing
column is not considered.
CUMENE 37.
MATERIAL BALANCE
3.) Distillation column 1: (Benzene column)
Feed,
F= Benzene + cumene + DIPB = 154160 Kg/hr
XF= 22820.85/154160 = 0.1480
D = Benzene = 15969.41Kg/hr
Benzene
Column W= Cumene + DIPB = 138190 kJ/KG
F=D+W
154160 = D +W
F XF = DXD +WX w
Taking XF = 0.9999
, XD = 0.05
154160 x 0.1480 = D x 0.9999 +W x 0.05
3023.5 =0.9999 D + (20374 – D) x 0.05
D = 15969.41 Kg/hr.
= Benzene
CUMENE 38.
MATERIAL BALANCE
W = 154160 – 15969.41
= 138190.5 Kg/hr.
= cumene + DIPB
Input = 154160 kg/hr.
Output = 15969.41 + 138190.5
= 154160 kg/hr.
Input = Output
Assuming all the Benzene present in benzene column is recycled to the feed. Hence
considering negligible amount of benzene to be part of residue. This will avoid the complexity of
multicomponent distillation in Cumene column.
Therefore, amount of benzene recycled = 15969.5 Kg/hr.
Therefore, feed actually given to the system = 154160 + 15969.5
= 170129.5 Kg/hr.
CUMENE 39.
MATERIAL BALANCE
4) Distillation column 3: (Cumene column) .
F = Cumene + DIPB = 138190.5 Kg/hr
XF = 128836.3/138190.5 = 0.932
Cumene = D = 17065.2Kg/hr
CUMENE COLUMN
DIPB = W = 371.79Kg/hr = 2%.
F = D +W
138190.6 = D +W
FXF = DXD + WXW
Taking XD = 0.995
XW = 0.01
138190.5 x 0.932 = D x 0 .995 + W x 0.01 128793.54
= 0.995D + (138190.5 – D) 0.01 D = 129051 kg/hr.
W = 138190.5 – 129 = 9139.5 Kg/hr.
Input = 138190.5 Kg/hr. Output
= 129051 + 9139.5
= 138190.5 Kg/hr.
Input = output
CUMENE 40.
MATERIAL BALANCE
Table 4, Overall Material balance of cumene manufacturing flow diagram
Chemical Input Output
Mol.wt. Kmol/hr Kg/hr Kmol/hr Kg/hr

Benzene 78 1382.4 107,746.27 204.74 15,969.42
Propylene 42 1105.09 46413.78 0 0
Propane 44 5.9 259.38 5.9 259.3844
Cumene 120 0 0 1075.43 129,051
DIPB 162 0 0 56.42 9139.5
Total - - 154,160.05 - 145,371.2
CUMENE 41.
DESIGN BASIS FOR NEW PLANT
Chapter: 5
DESIGN BASIS FOR NEW PLANT.
CUMENE 42.
5.1 Design Basis.
Capacity, (kmol/h),110
• Alkylation reactor type catalytic distillation reactor
Catalyst, Zeolite -Y
Catalyst regeneration frequency, years;2
Catalyst life, years; 6
Temperature °C (top-bottom) 198-249
Pressure, bar14
B/P feed ratio, mole/mole1.64
Conversion, %: 99
Propylene%100
Benzene%55
• Trans alkylation reactor type: Single catalyst bed
Catalyst Zeolite-Y
Catalyst life, years6
Temperature °C140-150
Benzene/DIPB feed ratio, mole/mole 5.2
Conversion of DIPB%50
Overall yields, mol% Separations Units:
CUMENE 43.
• Benzene column:
Type: Distillation column
Purity of Top product: %100Benzene
Purity of Bottom Product: %78.5Cumene
Operational Condition: Tin:1030C T bottom :1240C Ttop:45
Operational pressure:0.3bar.
• Cumene column:
Type: Distillation column
Purity of Top Product: %100Cumene
Purity of Bottom Product: %100DIPB,
Operational Conditions: Tin:1240C Tbottom:1720C Ttop:1100C
Operational pressure :0.3
CUMENE 44.
ECONOMIC EVALUTION
Chapter:- 6
ECONOMIC EVALUATION OF PROJECT
CUMENE 45.
ECONOMIC EVALUTION
6.1 Economic Evaluation of Project.

Economic Evaluation Of Project is displayed in four categories following .
1. Total Capital Investment.
a) Fixed capital investment.
b) Working capital investment.
2. Total production cost.
a) Manufacturing cost.
 Variable costs.
 Plant Overhead costs.
 Fixed charges.
b) General expenses.
 Administrative expenses.
 Marketing and sales expenses.
 Research and development.
3. Net gross income .
4. Cash flow.
CUMENE 46.
ECONOMIC EVALUTION
• Equipment purchasing cost investment
Table.8 Equipment purchasing cost investment

Sr. no. Equipment Quantity Cost in INR
MAJOR EQUIPMENT
1 Alkylation Reactor 1 9000035

2 Trans Alkylation Reactor 1 6000322
3 Benzene column 1 7939141
4 Cumene column 1 9201500
5 Depropanizer 1 4500232
6 DIPB column 1 3950023
7 Flash tank 3 2000000
8 Cooler 3 5321500
9 Heater 3 1500000
10 Compressors 1 1200000
11 Reflux drum 3 1500000
12 Reboiler 3 9000000
13 Pumps 6 8736600
14 Valves 8 5488000
15 Storages tanks 4 5000000
INSTRUMENTATION
1 Flow controller 6 500000

2 Flow measuring devices 2 50000
3 Pyrometer 2 15000
4 Level controller 6 70000
5 Level measuring 6 75000
6 Flow measuring device 8 80000
7 Flow controller 8 95600
8 Pressure measuring devices 8 80900
9 Pressure controller 8 120000
10 DCS control system 1 100000
CUMENE 47.
ECONOMIC EVALUTION
COST OF ETP
1 Screen units 1 100000

2 Equalizers 1 100000
3 Sedimentation tank 2 200000
4 Dispersion units 1 100000
5 Aeration unit 1 100000
6 Filters 2 200000
7 Sludge thickening units 2 200000
Other cost of spare equipment used in case of failure 15000000/-
TOTAL COST EQUIPMENT 152800000
CUMENE 48.
ECONOMIC EVALUTION
1.TOTAL CAPITAL INVESTMENT COST.

Total Capital Investment is sum of fixed capital investment and working capital investment.
Fixed Capital Investment.
Fixed capital investment in a sum of Direct cost and Indirect cost.
I. Direct Costs: material and labor involved in actual installation of complete facility (70-
85% of
fixed-capital investment)
A. Equipment + installation + instrumentation + piping + electrical + insulation +

painting
(5060% of Fixed-capital investment).
1. Purchased equipment cost (PEC): (15-40% of Fixed-capital investment)
Consider purchased equipment cost = Rs. 1.528×10^8
2. Installation, including insulation and painting: (25-55% of purchased equipment cost.)
Consider the Installation cost = 40% of Purchased equipment cost
= 40% of 1.528×10^8
= 0.40 ×1.528×10^8
= Rs.0.6112×10^8
3. Instrumentation and controls installed: (6-30% of Purchased equipment cost.) Consider
the installation cost = 20% of Purchased equipment cost
= 20% of ×1.528x10^8
= 0.20 ×1.528×10^8
= Rs. 0.3056×10^8
CUMENE 49.
ECONOMIC EVALUTION
4. Piping installed: (10-80% of Purchased equipment cost) Consider the piping cost = 40%
Purchased equipment cost
= 0.40 ×1.528×10^8
= Rs. 0.6112×10^8
5. Electrical, installed: (10-40% of Purchased equipment cost) Consider Electrical cost =
25% of Purchased equipment cost
= 25% of 1.528 ×10^8
= 0.25 ×1.528×10^8
= Rs.0.382×10^8
B. Buildings, process and Auxiliary: (10-70% of Purchased equipment cost
Consider Buildings, process and auxiliary cost,
= 40% of PEC
= 40% of 1.528 ×10^8
= 0.40 ×1.528×10^8
= Rs. 0.6112×10^8
C. Service facilities and yard improvements: (40-100% of Purchased equipment
cost) Consider the cost of service facilities and yard improvement,
= 60% of PEC
= 60% of 1.528 ×10^8
= 0.60 ×1.528×10^8
= Rs. 0.9168×10^8
CUMENE 50.
ECONOMIC EVALUTION
D. Land: (1-2% of fixed capital investment or 4-8% of Purchased equipment cost)
Consider the cost of land = 6% PEC
= 6% of 1.528 ×10^8
= 0.06 ×1.528×10^8
= Rs. 0.09168×108
Thus, Direct cost = Rs. 5.058×10^8----- (82.74% of FCI)
II. Indirect costs: expenses which are not directly involved with material and labor of
actual
installation of complete facility (15-30% of Fixed-capital investment)
A. Engineering and Supervision: (5-30% of direct costs) Consider the cost of engineering
and supervision,
= 10% of Direct costs
= 10% of 5.058 ×10^8
= 0.1× 5.058 ×10^8
= Rs.0.5058×10^8
B. Construction Expense and Contractor’s fee: (6-30% of direct costs)
Consider the construction expense and contractor’s fee,
= 10% of Direct costs
= 10% of 5.058×10^8
CUMENE 51.
ECONOMIC EVALUTION
= 0.1× 5.058 ×10^8
= 0.5058×10^8
C. Contingency: (5-15% of Fixed-capital investment)
Consider the contingency cost = 10% of Fixed-capital investment
= 12% of 6.113×10^8
= 0.12 × 6.113×10^8
= Rs. 0.7336×10^8 Thus, Indirect Costs = Rs.
1.7452×10^8--- (28.55% of FCI)
I. Fixed Capital Investment:
Fixed capital investment = Direct costs + Indirect costs
= (5.058×108) + (1.7452×108)
= Rs. 6.803×108
1) Working Capital: (10-20% of Fixed-capital investment)
Consider the Working Capital = 15% of Fixed-capital investment.
= 15% of 6.803×10^8
= 0.15 × 6.803×10^8
= Rs. 1.0205×10^8
CUMENE 52.
ECONOMIC EVALUTION
2) Total Capital Investment (TCI):
Total capital investment = Fixed capital investment + Working capital
= (6.803×10^8) + (1.0205×10^8)
= Rs. 7.8235×10^8
Table. 9 Total capacity cost investment

Sr.no Types of costs Factors of equipment cost Total cost in ₹ 10
Million
Fixed Capital Investment
I. Direct cost
A. Purchased Equipment cost (PEC) - 1.528
Equipment installation cost 40% of (PEC) 0.6112
Installation & control 20% of (PEC) 0.3056
Piping costs 40% of (PEC) 0.6112
Electrical costs 25% of (PEC) 0.382
B. Buildings, Process & Auxiliary cost 40% of (PEC) 0.6112
C. Service facility &yard improvement. 60% of (PEC) 0.9168
D. Land 6% of (PEC) 0.09168
Total Direct cost 5.058
II Indirect costs
A. Engineering & supervision 10% of (Direct cost) 0.5058
B. Construction expenses 10% of (Direct cost) 0.5058
C. Contingency 12% of (Direct cost) 0.7336
CUMENE 53.
ECONOMIC EVALUTION
Total indirect costs 1.7452
Total fixed capital investment 6.803
Working capital investment
1. Working capital investment 15% of fixed capital investment 1.0205
Total Capital Investment
1. Fixed Capital Investment + (6.803×10^8) + 7.8235
Working capital investment (1.0205×10^8)
CUMENE 54.
ECONOMIC EVALUTION
2. ESTIMATION OF TOTAL PRODUCT COST:
I. Manufacturing Cost = Direct production cost + Fixed charges + Plant overhead cost.
A. Fixed Charges: (10-20% total product cost)
i. Depreciation: (13% of FCI for machinery and equipment and 2-3% for Building Value
for)
Consider depreciation = 13% of FCI
Depreciation = (0.13×6.803×108) + (0.03×0.6112×108)
= Rs. 0.9027×108
ii. Local Taxes: (1-4% of fixed capital investment)
Consider the local taxes = 3% of fixed capital investment
= 0.03×6.803×108
= Rs. 0.2041×108
iii. Insurances: (0.4-1% of fixed capital investment)
Consider the Insurance = 0.7% of fixed capital investment
= 0.007×6.803×108
= Rs. 0.0476×108
iv. Rent: (8-12% of value of rented land and buildings)
Consider rent = 10% of value of rented land and buildings
= 10% of ((0.09168×108) + (0.6112×108))
= Rs. 0.0703x108
Thus, Fixed Charges = Rs. 1.2247×108
CUMENE 55.
ECONOMIC EVALUTION
B. Direct Production Cost: (about 60% of total product cost)
Now we have Fixed charges = 10-20% of total product charges – (given)
Consider the Fixed charges = 15% of total product cost
Total product charge = fixed charges/15%
= 1.2247×108/15%
= 1.2247×108/0.15 = Rs. 8.1647×108
i. Raw Materials: (10-50% of total product cost)
Consider the cost of raw materials, = 25% of total product cost
Raw material cost = 25% of 8.1647×108
= 0.25×8.1647×108 = Rs. 2.0412×108
ii. Operating Labor (OL): (10-20% of total product cost)
Consider the cost of operating labor,
= 12% of total product cost
= 12% of 8.1647×108
= 0.12×8.1647×108 = Rs. 0.9797×108
iii. Direct Supervisory and Clerical Labour (DS & CL): (10-25% of OL)
Consider the cost for Direct supervisory and clerical labour,
= 12% of OL
= 12% of 0.9797×108
= 0.12×0.9797×108 = Rs.
0.1176×108
CUMENE 56.
ECONOMIC EVALUTION
iv. Utilities: (10-20% of total product cost)
Consider the cost of Utilities,
= 12% of 8.1647×108
= 0.12×8.1647×108 = Rs. 0.9797×108
v. Maintenance and repairs (M & R): (2-10% of fixed capital investment)
Consider the maintenance and repair cost,
= 5% of fixed capital investment
= 0.05×6.803×108
= Rs. 0.3402×108
vi. Operating Supplies: (10-20% of M & R or 0.5-1% of FCI)
Consider the cost of Operating supplies,
= 15% of M & R
= 15% of 0.3402×108
= 0.15 ×0.3402×108 = Rs. 0.05103×108
vii. Laboratory Charges: (10-20% of OL)
Consider the Laboratory charges,
= 15% of OL
= 15% of 0.9797×108
0.15×0.9797×
CUMENE 57.
ECONOMIC EVALUTION
108 = Rs.
0.1469×108
viii. Patent and Royalties: (0-6% of total product cost)
Consider the cost of Patent and royalties,
= 4% of 8.1647×108
= 0.04×8.1647×108
= Rs. 0.3266×108
Direct Production Cost = Rs. 4.983×108 ----- (61% of TPC)
C. Plant overhead Costs (50-70% of Operating labour, supervision, and maintenance or 5-
15% of total product cost); includes for the following: general plant upkeep and overhead,
payroll overhead, packaging, medical services, safety and protection, restaurants, recreation,
salvage, laboratories, and storage facilities.
Consider the plant overhead cost,
= 60% of OL, DS & CL, and M & R
= 60% of ((0.9797×108) + (0.1176×108) + (0.3402×108))
= Rs. 0.8625×108
Thus, Manufacture cost = Direct production cost + Fixed charges + Plant overhead costs.
Manufacture cost = (4.983×108) + (6.803×108) + (0.8625×108)
Manufacture cost = Rs. 12.6485×108
II. General Expenses = Administrative costs + distribution and selling costs + research
and
CUMENE 58.
ECONOMIC EVALUTION
development costs
A. Administrative costs:(2-6% of total product cost)
Consider the Administrative costs,
= 0.05 ×8.1647×108
= Rs. 0.4082×108
B. Distribution and Selling costs: (2-20% of total product cost); includes costs for sales
offices, salesmen, shipping, and advertising.
Consider the Distribution and selling costs,
= 15% of 8.1647×108
= 0.15 ×8.1647×108
= Rs. 1.2247×108
C. Research and Development costs: (about 5% of total product cost)
Consider the Research and development costs,
= 5% of 8.1647×108
= 0.05 × 8.1647×108
= Rs. 0.4082×108
D. Financing (interest): (0-10% of total capital investment) Consider interest = 5% of total
capital investment
CUMENE 59.
ECONOMIC EVALUTION
= 5% of 7.8235×108
= 0.05×7.8235×108
= Rs. 0.3912×108
= Rs. 2.4323×108
2. Total Product cost = Manufacture cost + General Expenses
= (12.6485×10^8) + (2.4323×108)
= Rs. 15.0808×108
CUMENE 60.
ECONOMIC EVALUTION
Table.10 Total Production costs of Cumene plant
Sr.no Designation Factors Total ₹ in 10 Million
Manufacturing cost
A. Fixed Charges 13% of (TPC)
1. Depreciation 13%of (FCI) 0.9027
2. Local taxes 3% of (FCI) 0.2042
3. Insurance 0.7% of (FCI) 0.0476
4. Rents 10% of (FCI) 0.0703
Total Fixed cost 1.2247
B. Direct production costs 60% of (TPC)
1. Operating labour 12% of (TPC) 0.9797
2. Raw materials 25% of (TPC) 2.0412
3. Direct supervisor & Clerical Labour 12% of (OL) 0.1172
4. Utilities 12% of (TPC) 0.9797
5. Maintenance & Repairs 5% of (TPC) 0.3402
6. Operating supply 15% of (mfg.) 0.05103
7. Labour charges 15% of(OL) 0.1469
8. Patent & royalty 4%of (TPC) 0.3266
Total Direct production costs 4.983
C. Plant Overhead cost 60%of OL, DS, mfg. 0.8625
CUMENE 61.
ECONOMIC EVALUTION
Total plant Over head cost 0.862
Total Manufacturing cost 12.6485
General Expenses
A Administrative cost 5% of (TPC) 0.4082
B Distribution & selling cost 15% of (TPC) 1.2247
C Research & Development 15% of (TPC) 0.4082
D Finance 5%of (TPC) 0.3912
Total General expenses 2.4323
Total Production costs 15.0808
CUMENE 62.
ECONOMIC EVALUTION
3. Gross Earnings/Income:
Wholesale Selling Price of cumene per kg = Rs.53
Total Income = Selling price × Quantity of product manufactured
= 53 x 30000000
= Rs. 15.9×108
Gross income = Total Income – Total capital investment
= (15.9×108) – (8.1647×108) = Rs. 7.7353×108
Let the Tax rate be 45% (common)
Net Profit = Gross income - Taxes
= Gross income× (1- Tax rate)
= 7.7353 x 108 (1-0.45)
= Rs. 4.2544×108
Net profit margin = (net profit/ annual income) *100
= (4.2544*108/15.9*108)/100
=26.756%
Payback period = FCI/(net profit)
= 6.803*10^8/4.2544*108
= 1.6.
Rate of return = net profit* 100/ (total capital investment)
= 4.2544*108*100 / 7.8235*108 = 54.38 %
CUMENE 63.
ECONOMIC EVALUTION
4. Cash Flow :
Fig. 15, Discounted cash flow of project.
CUMENE 64.
UTILITY REQIIRED IN CUMENE MANUFACTURING
Chapter. 7
UTILITY REQUIRED IN CUMENE MANUFACTURING
CUMENE 65.
7.1 Utilities.
The word utilities are not generally used for the ancillary services needed in the operation of
any production process. These services will normally be supplied from a central site facility, and will
include:
(1) Electricity.
(2) Steam for process heating.
(3) Cooling water.
(4) Water for general use.
(5) Demineralized water.
(6) Compressed air.
(7) Inert gas supplies.
(8) Refrigeration.
(9) Effluent disposal facilities.
Electricity:
. The power required for electrochemical processes, motor drives, lighting, and general use
maybe generated on site, but will more usually be purchased from the local supply company. The
voltage at which the supply is taken or generated will depend on the demand. For a large site the
supply will be taken at a very high voltage, typically 11,000 or 33,000 V. Transformers will be used to
step down the supply voltage to the voltages used on the site. In the United Kingdom a three phase
415V system is used for general industrial purposes, and 240V single phase for lighting and other low
power requirements. If several large motors is used, a supply at an intermediate high voltage will also
be provided, typically 6000 or 11,000V.
CUMENE 66.
Steam:
The steam for heating is usually generated in water tube boilers using the most economical
fuel level available. The process temperatures required can usually be obtained with low temperature
steam typically 2.5 bar and steam distributed at a relatively low pressure, typically around 8 bar (100
psig). Higher steam pressures, or proprietary heat transfer fluids, such as dowtherm will be needed for
high process temperatures.
Combined Heat and Power (Co-generation):
The energy costs on a large site can be reduced if the electrical power required is generated on
the site and the exhaust steam from the turbines used for process heating. The overall thermal
efficiency of such systems can be in the range 70-80 %, compared with the 30-40 % obtained from a
conventional power station, where the heat in the exhaust steam is wasted in the condenser. Whether a
combined heat and power system scheme is worth considering for a particular site will depend on the
size of the site, the cost of fuel, the balance between the power and heating demands, and particularly
on the availability of and cost of, stand by supplies and the price paid for any surplus power electricity
generated.
Cooling Water:
Natural and forced draft cooling towers are generally used to provide the cooling water required
in a site; unless water can be drawn from a convenient river or lake in sufficient quantity.
Water for General Use:
CUMENE 67.
The water required for general purposes on a site will usually be taken from the local mains
supply, unless a cheaper source of suitable quantity water is available from a river, lake or well.
Demineralized Water:
Demineralized water from which all the minerals have been removed by ion exchange, is used
where pure water is needed for process use, and as boiler feed water. Mixed and multiple bed ion
exchange units are used, one resin converting the cations to hydrogen and the other removing the acid
radicals. Water with less than one ppm of dissolved solids can be produced.
Refrigeration:
It will be needed for processes that require temperatures below those that can be economically
obtained with cooling water. For temperatures down to around 10 o C chilled water can be used. For
lower temperatures, down to -30oC, salt brines are used to distribute the “refrigeration” round the site
from a central refrigeration machine.
Compressed Air:
It will be needed for general use, and for the pneumatic controllers that are usually used for
chemical process plant control.
Inert Gases:
Where large quantities of inert gas are required for the inert blanketing of tanks and for purging
is usually supplied from a central facility. Nitrogen is normally used and is manufactured on site in an
air liquefaction plant, or purchased as liquid in tankers.
CUMENE 68.
PLANT LOCATION AND SITE SELECTION
Chapter:8
Plant locations, Plant layout & site selection.
CUMENE 69.
8.1 Plant location and site selection.
The location of the plant can have a crucial effect on the profitability of a project and the
scope for future expansion. Many factors must be considered when selecting a suitable site. The
factors to be considered are:
1. Location with respect to the marketing area
2. Raw material supply.
3. Transport facilities.
4. Availability of labor.
5. Availability of utilities: water, fuel, power.
6. Availability of suitable land.
7. Environmental impact, and effluent disposal.
8. Local community considerations.
9. Climate.
10. Political and strategic considerations.
1. Marketing Area:
For materials that are produced in bulk quantities such as cement, mineral acids and
fertilizers where the cost of the product per ton is relatively low and the cost of transport a
significant fraction of the sales price, the plant should be located close to the primary market. This
consideration will be less important for low volume production, high-priced products, such as
pharmaceuticals.
CUMENE 70.
2. Raw Materials:
The availability and price of suitable raw materials will often determine the plant location. Plant producing
bulk chemicals are best located close to the source of the major raw material: where this is also close to
the marketing area.
3. Transport:
The transport of materials & products to & from the plant will be an overriding consideration in site
selection. If practicable, site should be selected that is close to at least two major forms of transport road,
rail, waterway (canal or river) or a sea port. Road transport is being increasingly efficient for the
movement of personnel &essential equipment & supplies & the proximity of the site airport should be
considered.
4.Availability of labor:
Labour will be needed for construction of the plant & its operation. Skilled construction workers will
usually be brought in from outside the site area, but there should be an adequate pool of unskilled labour
available locally; & labour suitable for training to operate the plant. Skilled tradesmen will be needed for
plant maintenance. Local trade union customs & restrictive practices will have to be considered when
assessing the availability & suitability of the local labour for recruitment & training.
5.Utilities (Services)
Chemical processes invariably require large quantities of water for cooling & general process use, & the
plant must be located near a source of water of suitable quantity. Process water may be drawn from a
river, from wells, or purchased from a local authority. At some sites the cooling water required can be
taken from a river or lake, or from the sea; at other locations cooling tower will be needed. Electrical
CUMENE 71.
power will be needed at all sites. Electrochemical processes that require large quantities of power; for
example, aluminum smelters need to be located close to a cheap source of power. A competitive priced
fuel must be available on site for steam & power generation.
6.Environment impact, & disposal:
All industrial processes produce waste products & full consideration must be given to the difficulties &
cost of their disposal. The disposal of toxic & harmful effluents will be .
covered by local regulations & the appropriate authorities must be consulted during the initial site survey
to determine the standards that must be met. An environmental impact assessment should be made for
each new project or major modification or addition to an existing process.
7.Local community considerations:
The proposed plant must fit in with & be acceptable to the local community. Full consideration must be
given to the safe location of the plant so that it does not impose a significant additional risk to the
community. On a new site, the local community must be able to provide adequate facilities for the plant
personnel: school, banks, housing & recreational & cultural facilities
8.Land (site selection)
Sufficient suitable land must be available for the proposed plant & for future expansion. The land should
ideally be flat, well drained & have suitable load bearing characteristics. A full site evaluation should be
made to determine the need of piling or other special formations.
CUMENE 72.
9.Climate:
Adverse climate conditions at a site will increase cost. Abnormally low temperatures will require the
provision of additional insulation & special heating for equipment & pipe runs. Stronger structures
will be needed at locations subject to high winds (cyclone hurricane areas) or earthquakes.
10.Political & Strategic Considerations:
Capital grants tax concessions & other inducements are often given by the government to direct
renew investments to preferred locations, such as areas of high unemployment. The availability of
such grants can be the overriding consideration in site selection.
CUMENE
8.2 plant layout

The economic construction & efficient operation of a process unit will depend on how well he
plant & equipment specified on the process flow-sheet is laid out. The principal factors to be
considered are:
1. Economic consideration: construction & operating cost
2. The process requirements
3. Convenience of operation
4. Convenience of maintenance
5. Safety
6. Modular construction
1. Costs:
The cost of construction can be minimized by adopting a layout that gives the shortest run of connecting
pipe between equipment & the least amount of structural steel work. However, this will not necessarily
be the best arrangement for operation & maintenance.
Process Requirements:
An example of the need to consider process considerations is the need to clavate the base of columns to
provide the necessary net positive suction head to a pump or the operating head for a thermosyphon
reboiler.
2. Process Requirements:
Equipment that needs to have frequent operator attention should be located convenient to the control
room. Valves, sample points, and instruments should be located at convenient positions and heights.
Enough working space and head room must be provided to allow easy access to equipment.
CUMENE
3.Maintenance:
Heat exchangers need to be cited so that the tube bundles can be easily withdrawn for cleaning and tube
replacement. Vessels that require frequent replacement of catalyst or packing should be located on the
outside of buildings. Equipment that requires dismantling for maintenance, such as compressors and large
pumps, should be placed under cover.
4.Safety:
Blast walls maybe needed to isolate potentially hazardous equipment and confine the effects of an
explosion. At least two escape routes for operators must be provided from each level in the process
buildings.
5.Plant Expansion:
Equipment’s should be located so that it can be conveniently tied in with any future expansion of the
process. Space should be left on pipe alleys for future needs, and services pipes over-sized to allow for
future requirements.
6.Modular Constructions:
In recent years there has been a move to assemble sections of plant at the plant manufacturers site. These
modules will include the equipment, structural steel, piping and instrumentation. The modules are then
transported to the plant site, by road or sea.
CUMENE
8.3 Plant layout.
Fig. 12, Plant layout.
CUMENE
IMPORTANT ASPACT OF SAFETY & POLLUTION
CHAPTER. 9
IMPORTANT ASPECT OF SAFETY AND POLLUTION
CUMENE
9.1 MSDS of Raw materials and product.
HAZARDS IDENTIFICATION
Inhalation -
Breathing high concentrations may be harmful. Mist or vapor can irritate the throat and lungs.
Breathing this material may cause central nervous system depression with symptoms including nausea,
headache, dizziness, fatigue, drowsiness, or unconsciousness.
Eye Contact -
This material can cause eye irritation with tearing, redness, or a stinging or burning feeling.
Further, it can cause swelling of the eyes with blurred vision. Effects may become more serious with
repeated or prolonged contact.
Skin Contact
May cause mild skin irritation with redness and/or an itching or burning feeling. Effects may
become more serious with repeated or prolonged contact. It is likely that some components of this
material are able to pass into the body through the skin and may cause similar effects as from breathing
or swallowing it.
Ingestion –
Swallowing this material may be harmful. Swallowing this material may cause stomach or
intestinal upset with pain, nausea, and/or diarrhea. This material can get into the lungs during
swallowing or vomiting. Small amounts in the lungs can cause lung damage, possibly leading to
chronic lung dysfunction or death. Swallowing this material may cause effects.
Chronic Health Effects Summary -
Secondary effects of ingestion and subsequent aspiration into the lungs may cause pneumatically
(lung cavity) formation and chronic lung dysfunction.
CUMENE
Conditions Aggravated by Exposure -
Disorders of the following organs or organ systems that may be aggravated by significant
exposure to this material or its components include: Skin, Respiratory System, Central Nervous System
(CNS).
Target Organs –
May cause damage to the following organs: kidneys, liver, mucous membranes, spleen, upper
respiratory tract, skin, adrenal, central nervous system (CNS), eye, lens or cornea.
Carcinogenic Potential –
This product is not known to contain any components at concentrations above 0.1% which are
considered carcinogenic by OSHA, IARC or NTP.
1. FIRST AID MEASURES

Take proper precautions to ensure your own health and safety before attempting rescue or
providing first aid.
Inhalation –
Move victim to fresh air. If victim is not breathing, immediately begin rescue breathing. If
breathing is difficult, 100 percent humidified oxygen should be administered by a qualified individual.
Seek medical attention immediately. Keep the affected individual warm and at rest.
Eye Contact –
Check for and remove contact lenses. Flush eyes with cool, clean, low-pressure water for at least
15 minutes while occasionally lifting and lowering eyelids. Do not use eye ointment unless directed to
by a physician. Seek medical attention if excessive tearing, irritation, or pain persists.
CUMENE
Skin Contact –
Remove contaminated shoes and clothing. Flush affected area with large amounts of water. If
skin surface is damaged, apply a clean dressing and seek medical attention. Do not use ointments. If
skin surface is not damaged, clean affected area thoroughly with mild soap and water. Seek medical
attention if tissue appears damaged or if pain or irritation persists.
Ingestion –
Do not induce vomiting. If spontaneous vomiting is about to occur, place victim’s head below
knees. If victim is drowsy or unconscious, place on the left side with head down. Never give anything by
mouth to a person who is not fully conscious. Do not leave victim unattended. Seek medical attention
immediately.
2. FIRE FIGHTING MEASURES

NFPA Flammability Classification - NFPA Class-IC flammable liquid.
Flash Point - Closed cup: 36°C (96°F). (Pesky-Martens.)
Lower Flammable Limit - AP 0.9 %
Upper Flammable Limit - AP 6.5 %
Auto ignition Temperature - 424°C (795°F)
Hazardous Combustion Products - Carbon dioxide, carbon monoxide, smoke, fumes, and/or
unburned hydrocarbons. Special Properties –
This material releases vapors at or below ambient temperatures. When mixed with air in certain
proportions and exposed to an ignition source, its vapor can cause a flash fire. Use only with adequate
ventilation. Vapors are heavier than air and may travel long distances along the ground to an ignition
CUMENE
source and flash back. A vapor and air mixture can create an explosion hazard in confined spaces such
as sewers. If container is not properly cooled, it can rupture in the heat of a fire.
Extinguishing Media –
SMALL FIRE: Use dry chemicals, carbon dioxide, foam, water fog, or inert gas (nitrogen).
LARGE FIRE: Use foam, water fog, or water spray. Water fog and spray are effective in
cooling containers and adjacent structures. However, water can cause frothing and/or may not
extinguish the fire. Water can be used to cool the external walls of vessels to prevent excessive
pressure, auto ignition or explosion. Do not use a solid stream of water directly on the fire as the water
may spread the fire to a larger area.
Protection of Fire fighters –
Firefighters must use full bunker gear including NIOSH-approved positive pressure
selfcontained breathing apparatus to protect against potential hazardous combustion or decomposition
products and oxygen deficiencies. Evacuate area and fight the fire from a maximum distance or use
unmanned hose holders or monitor nozzles. Cover pooling liquid with foam. Containers can build
pressure if exposed to radiant heat; cool adjacent containers with flooding quantities of water until well
after the fire is out. Withdraw immediately from the area if there is a rising sound from a venting safety
device or discoloration of vessels, tanks, or pipelines. Be aware that burning liquid will float on water.
Notify appropriate authorities of potential fire and explosion hazard if liquid enter sewers or waterways.
CUMENE
3. ACCIDENTAL RELEASE MEASURES

Flammable Liquid! Release causes an immediate fire or explosion hazard. Evacuate all
nonessential personnel from immediate area and establish a "regulated zone" with site control and
security. A vapor-suppressing foam may be used to reduce vapors. Eliminate all ignition sources. All
equipment used when handling this material must be grounded. Stop the leak if it can do without risk.
Do not touch or walk through spilled material. Remove spillage immediately from hard, smooth
walking areas. Prevent spilled material from entering waterways, sewers, basements, or confined areas.
Absorb or cover with dry earth, sand, or other non-combustible material and transfer to appropriate
waste containers. Use clean, non-sparking tools to collect Absorbed material. For large spills, secure the
area and control access. Prevent spilled material from entering sewers, storm drains, other drainage
systems, and natural waterways. Dike far ahead of a liquid spill to ensure complete collection. Water
mist or spray may be used to reduce or disperse vapors; but, it may not prevent ignition in closed
spaces. This material will float on water and its run-off may create an explosion or fire hazard. Verify
that responders are properly
HAZWOPER-trained and wearing appropriate respiratory equipment and fire-resistant
protective clothing during cleanup operations. In an urban area, cleanup spill as soon as possible; in
natural environments, cleanup on advice from specialists. Pick up freeliquid for recycle and/or disposal
if it can be accomplished safely with explosion-proof equipment. Collect any excess material with
absorbent pads, sand, or other inert non-combustible absorbent materials. Place into appropriate waste
containers for later disposal. Comply with all applicable local, state and federal laws and regulations.
CUMENE
4. HANDLING AND STORAGE

Handling
A spill or leak can cause an immediate fire or explosion hazard. Keep containers closed and do
not handle or store near heat, sparks, or any other potential ignition sources. Avoid contact with
oxidizing agents. Do not breathe vapor. Use only with adequate ventilation and personal protection.
Never siphon by mouth. Avoid contact with eyes, skin, and clothing. Prevent contact with food and
tobacco products. Do not take internally. When performing repairs and maintenance on contaminated
equipment, keep unnecessary persons away from the area. Eliminate all potential ignition sources.
Drain and purge equipment, as necessary, to remove material residues. Follow proper entry procedures,
including compliance with 29 CFR 1910.146 prior to entering confined spaces such as tanks or pits.
Use gloves constructed of impervious materials and protective clothing if direct contact is anticipated.
Use appropriate respiratory protection when concentrations exceed any established occupational
exposure level Promptly remove contaminated clothing. Wash exposed skin thoroughly with soap and
water after handling. Non-equilibrium conditions may increase the fire hazard associated with this
product. A static electrical charge can accumulate when this material is flowing through pipes, nozzles
or filters and when it is agitated. A static spark discharge can ignite accumulated vapors particularly
during dry weather conditions. Always bond receiving containers to the fill pipe before and during
loading. Always confirm that receiving container is properly grounded.
Bonding and grounding alone may be inadequate to eliminate fire and explosion hazards associated
with electrostatic charges. Carefully review operations that may increase the risks associated with static
electricity such as tank and container filling, tank cleaning, sampling, gauging, loading, filtering,
mixing, agitation, etc. In addition to bonding and grounding, efforts to mitigate the hazards of an
electrostatic discharge may include, but are not limited to, ventilation, inserting and/or reduction of
transfer velocities. Dissipation of electrostatic charges may be improved with the use of conductivity
CUMENE
additives when used with other mitigation efforts, including bonding and grounding. Always keep
nozzle in contact with the container throughout the loading process. Do not fill any portable container
in or on a vehicle. Do not use compressed air for filling, discharging or other handling operations.
Product container is not designed for elevated pressure. Do not pressurize, cut, weld, braze solder, drill,
or grind on containers. Do not expose product containers to flames, sparks, heat or other potential
ignition sources. Empty containers may contain material residues which can ignite with explosive force.
Observe label precautions.
Storage
Keep container tightly closed. Store in a cool, dry, well-ventilated area. Store only in approved
containers. Do not store with oxidizing agents. Do not store at elevated temperatures or in direct
sunlight. Protect containers against physical damage. Head spaces in tanks and other containers may
contain a mixture of air and vapor in the flammable range. Vapor may be ignited by static discharge.
Storage area must meet OSHA requirements and applicable fire codes. Additional information
regarding the design and control of hazards associated with the handling and storage of flammable and
combustible liquids may be found in professional and industrial documents including, but not limited
to, the National Fire Protection Association (NFPA) publications NFPA 30 ("Flammable and
Combustible Liquid Code"), NFPA 77 ("Recommended Practice on Static Electricity") and the
American Petroleum
Institute (API) Recommended Practice 2003, (“Protection Against Ignitions Arising Out of Static,
Lightning, and Stray Currents"). Consult appropriate federal, state and local authorities before reusing,
reconditioning, reclaiming, recycling or disposing of empty containers or waste residues of this product.
CUMENE
5. EXPOSURE CONTROLS AND PERSONAL PROTECTION

Engineering Controls
Provide ventilation or other engineering controls to keep the airborne concentrations of vapor or
mists below the applicable workplace exposure limits indicated below. All electrical equipment should
comply with the National Electrical Code. An emergency eye wash station and safety shower should be
located near the work-station.
Personal Protective Equipment
Personal protective equipment should be selected based upon the conditions under which this
material is used. A hazard assessment of the work area for PPE requirements should be conducted by a
qualified professional pursuant to OSHA regulations. The following pictograms represent the minimum
requirements for personal protective equipment. For certain operations, additional PPE may be required.
Eye Protection
Safety glasses equipped with side shields are recommended as minimum protection in industrial
settings. Chemical goggles should be worn during transfer operations or when there is a likelihood of
misting, splashing, or spraying of this material. A suitable emergency eye wash water and safety shower
should be located near the work station.
Hand Protection
Avoid skin contact. Use heavy duty gloves constructed of chemical resistant materials such as
Viton® or heavy nitrile rubber. Wash hands with plenty of mild soap and water before eating, drinking,
smoking, use of toilet facilities or leaving work. Do not use gasoline, kerosene, solvents or harsh abrasives
as skin cleaners.
Body Protection
Avoid skin contact. Wear long-sleeved fire-retardant garments (e.g., Nomex®) while working
with flammable and combustible liquids. Additional chemical-resistant protective gear may be required
CUMENE
if splashing or spraying conditions exist. This may include an apron, boots and additional facial
protection. If product meets clothing, immediately remove soaked clothing and shower.
Promptly remove and discard contaminated leather goods.
Respiratory Protection
For known vapor concentrations above the occupational exposure guidelines (see below), use a
NIOSH-approved organic vapor respirator if adequate protection is provided. Protection factors vary
depending upon the type of respirator used. Respirators should be used in accordance with OSHA
requirements (29 CFR 1910.134). General Comments
Use of this material in spaces without adequate ventilation may result in generation of hazardous levels
of combustion products and/or inadequate oxygen levels for breathing. Odor is an inadequate warning
for hazardous conditions
6. STABILITY AND REACTIVITY

Chemical Stability - Normally stable but may form peroxides when stored for prolonged time
periods in contact with air.
Conditions to Avoid - Keep away from heat, sparks and flame. Forms peroxides with
prolonged storage.
Materials Incompatibility -Strong acids, alkalis, and oxidizers.
CUMENE
7. TOXICOLOGICAL INFORMATION
Toxicity Data –
Effects from Acute Exposure:
Overexposure to cumene may cause upper respiratory tract irritation and severe CNS
depression.
Effects from Prolonged or Repeated Exposure:
High-level exposure to cumene vapors significantly increases renal tubule adenoma in male rats.
Furthermore, this exposure is associated with increased alveolar/bronchiolar adenoma and carcinoma in
mice and with increased hepatocellular carcinoma in female mice. Currently the relevance of these finds
to human health are not clear.
8. ECOLOGICAL INFORMATION
Eco toxicity - LC50 (fish): 1- 10 mg/l. This product is potentially toxic to freshwater and salt
water ecosystems.
Environmental Fate - This product will normally float on water. Components will evaporate
rapidly. Aquatic toxicity values are expected to be in the range of 1 - 10 mg/l based upon data from
components and similar products. This material may be harmful to aquatic organisms and may cause
long term adverse effects in the aquatic environment. The log Kow value for this product is 3.66.
CUMENE
9. DISPOSAL CONSIDERATIONS
Hazard characteristic and regulatory waste stream classification can change with product use.
Accordingly, it is the responsibility of the user to determine the proper storage, transportation, treatment
and/or disposal methodologies for spent materials and residues at the time of disposition. If discarded,
Cumene is regulated by US EPA as a listed hazardous waste (U055). Transportation, Treatment storage
and disposal of waste materials must be conducted in accordance with RCRA regulations (see 40 CFR
260 through 40 CFR 271). State and/or local regulations may be more restrictive. Contact the
RCRA/Superfund Hotline at your regional US EPA office for guidance concerning case specific
disposal issue.
CUMENE
9.2 Gaseous/Liquid/Solid Waste Treatment.

Gaseous, liquid and solid waste is treated in Effluent treatment plant..
EFFLUENT TREATMENT PROCESS.
Fig.15, Cumene Effluent treatment process.
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1. Screen chamber:
Remove relatively large solids to avoid abrasion of mechanical equipment’s and clogging of hydraulic
system.
• Screening is the filtration process for the separation of coarse particles from influent.
• Stainless steel net with varying pore size can be utilized.
• Screens are cleaned regularly to avoid clogging.
2. Collection tank:
The collection tank collects the effluent water from the screening chamber, stores and then pumps it to
the equalization tank.
3. Equalization tank:
• The effluents do not have similar concentrations at all the time; the pH will vary
• time to timetan Effluents are stored from 8 to 12 hours in the equalization tank resulting in a
homogenous mixing of effluents and helping in neutralization.
• It eliminates shock loading on the subsequent treatment system.
• Continuous mixing also eliminates settling of solids within the equalization tank.
• Reduces SS, TSS.
• Equalization makes the waste water homogenous.
• Retention time depends upon the capacity of treatment plant. (Generally 8-16 hours)
CUMENE
4. Flash mixer:
Coagulants were added to the effluents:
1. Lime: (800-1000 ppm) To correct the pH up to 8-9
2. Alum: (200-300 ppm) To remove color
3. Poly electrolyte: (0.2 ppm) To settle the suspended matters & reduce SS, TSS. The addition of the
above chemicals by efficient rapid mixing facilitates homogeneous combination of flocculates to
produce microflows.
5. Clarriflocculator:
In the clarriflocculator the water is circulated continuously by the stirrer.
• Overflowed water is taken out to the aeration tank.
• The solid particles are settled down, and collected separately and dried; this reduces SS, TSS.
• Flocculation provides slow mixing that leads to the formation of macro flocs, which then settles
out in the clarifier zone.
• The settled solids i.e. primary sludge is pumped into sludge drying beds.
6. Aeration tank:
• The water is passed like a thin film over the different arrangements like staircase shape.
• Dosing of Urea and DAP is done.
• Water gets direct contact with the air to dissolve the oxygen into water.
• BOD & COD values of water is reduced up to 90%
• . Function of aeration is oxidation by blowing air.
• Aerobic bacteria are used to stabilize and remove organic material presents in waste.
CUMENE
7. Clarifier:
• The clarifier collects the biological sludge.
• The overflowed water is called as treated effluent and disposed out.
• The outlet water quality is checked to be within the accepted limit as delineated in the norms of
the Bureau of Indian standards.
• Through pipelines, the treated water is disposed into the environment river water barren land,
etc.
8. Sludge thickener:
• The inlet water consists of 60% water + 40% solids.
• The effluent is passed through the centrifuge.
• Due to centrifugal action, the solids and liquids are separated.
• The sludge thickener reduces the water content in the effluent to 40% water + 60% solids.
• The effluent is then reprocessed, and the sludge collected at the bottom.
• Here sludge is dried and discharged.
• Partial amount of sludge is returned to the aeration tank from thickening unit through recycle
tank called return sludge tank and disperse tank.
9. Drying beds:
Primary and secondary sludge is dried on the drying be
CUMENE
REFRENCE & CONCLUSION
Chapter: 10
REFERENCE & CONCLUSION
CUMENE
10.1. Conclusion.
• As the first step preliminary analysis was carried out based on the properties and application of
cumene and various processes used in its manufacture.
• Cumene is used as a feed to produce phenol its co-product acetone.
• Cumene oxidation process for phenol synthesis has been growing in popularity since the 1960
and prominent today.
• The first steeps of this process are the formation of cumene hydroperoxide. The hydroperoxide
is then selectively cleaved to phenol and acetone
• We have focused on alkylation of benzene to produce cumene process in this project and
carried out literature survey.
• The process has many advantages over its alternative processes with benchmarking parameters
of economic consideration i.e. profitable and economically.
• Viable at the same time environment aspect and impact of pollution.
• Machinery equipment and raw material are easily available along with skill and unskilled
labors are available.
• Cumene is nonhazardous material and safety parameters are easily complied with.
• The effluent treatment can be carried out with in pollution control board norms. Hence it is a
and ecofriendly process.
CUMENE
10.2. REFERENCE.
• K. Wisemen, H.-J. Arpe Industrial Organic Chemistry fourth, Completely, Revised Edition
• http//www.cdtech.com/indexset.html.
• http://www.businesswire.com/news/home/20110921005269/en/Badger-
LicensingProvideCumeneBPA-Licenses-LG
• http://www.sbioinformatics.com/design_thesis/Cumene/Cumene_Properties
• http://www.dequi.eel.usp.br/~barcza/Fenol%20UOP.pdf
• http://www.primaryinfo.com/projects/cumene.html
• http://www.icis.com/v2/companies/9146114/polimeri-europa.html)
• Alkylation of aromatics with ethylene and propylene: recent developments in commercial
processes Thomas F. Degnan Jr. , Corrissmithh, Chaya R. Venkat)
• Introduction to Zeolite Science and Practice, page853
• http://ip.com/IPCOM/000217241
• http://www.icis.com/Articles/1994/04/04/35102/kelloggdow-detail-new-route-to-cumene.html
• Chemical process technology Jacob A. Moulijn Michiel Makeee Annelies Van Diepen
page/279-281
• http://www.icis.com/Articles/1997/12/08/51748/mobilbadger-make-the-most-of-
cataystuse.html
• http://www.icis.com/v2/companies/9146114/polimeri-europa.html
• www.Lummus.CBI.com
• Petrochemical Production Processes Nauid Naderpour page/77-78
• Chemical process technology Jacob A. Moulijn Michiel Makeee Annelies Van Diepen
• http://www.surechem.org/index.php?Action=document&docId=267794&db=EPA&tab=desc&
l ang=&db_query=0%3A%3A0%3A%3A0%3A&markupType=all
• “Energy Efficient Catalytic Reaction and Production of Cumene”, Russell L. Jarek, Steven M.
hornbergg, Stacia Barrow, Daniel E. Trudell, and Tina M. Neroff.
• (Ullmans Encyclopedia of Chemical Technology, Wiley-VCH, Weinheim, Germany,2003)
• http://www.cbi.com/images/uploads/tech_sheets/MTBE_Sheet_R-3.pdf
• Advances in process technology through catalytic distillation, Gary R. Gilder, Kerry Rock, Tim
McGuirk, 12141Wick Chester, Houston, TX,USA77079
• Economic Design and Controllability Evaluation of Alternative Processes for Cumene
Manufacture, Vivek Gera, Sankalp Agarwal and Nitin Kaistha, 2010.
• www.encyclopedia.co.in.
• www.wekipedia.org
• www.technicaltopic.com
• www.ask.com
• www.siteselectioncriteria.com
• 6-Peters, M.S. and K.D. Timmer Haus," Plant Design and Economics for Chemical
Engineers", 4thEdition McGraw Hill, NewYork,1991.
CUMENE
• Cumene, Ullman’s encyclopedia of industrial chemistry,2002.

• Agency for toxic substances and disease from petrochemicals. 4770 Buford highway Ne
Atlanta, GA30341888232-6348
• Indian Oil Corporation Ltd. Upendramishra 9896.99503

• Outline of chemical technology, Dryden’s, Gopala rao.
• Pollution control effluent treatments. s. rao.
• Unit operation of chemical engineering McCabe and smith Instrumentation, Kirkand Rimboi.
CUMENE

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INTRODUCTION

Cumene (isopropyl benzene) is an organic compound that is based on an aromatic

a pure compound on an industrial scale is converted to cumene hydroperoxide, which is an

ring attached at the middle carbon form cumene (C6H5CH(CH3)2

trichloride (ALCL3) as catalyst.

Fig. 1, 2-dimension structure of cumene. Fig. 2, 3-dimension structure of cumene

1.2. PRESENT STATUS AND MARKET ANALYSIS.

import large volume of cumene for phenol production.

demand region such as Asia & South America.

Fig. 3, world consumption patterns of cumene

1.3. LIST PRODUCER OF CUMENE.

1 Herdillia chemicals Ltd. 2000 TPA

1.3.2 LIST GLOBAL MANUFACTURER

2 A.M. FOOD chemical co., Ltd 10000 TPA

3 TS CHEMICAL PVT. LTD 20000 TPA

4 JLM CHEMICAL .PVT .LTD 1120 TPQ

5 EniChem , ENI. CO.LTD. San 1980 TPQ

 PHYSICAL PROPERTIES OF CUMEN.

• Molecular weight. :- 120.19

• Melting point. :- -96.9°C

• Boiling point. :- 152.5°C

• Density :- 0.862 gm/cc

• Flash point. :- 39°C

• Vapor pressure :- 4.5 mmHg at 25°C

• Ignition point. :- 138°C

• Freezing point :- -96°C

• Thermal conductivity. :- 0.124 w×m/k

• Surface tension. :- 0.791 N/M

• Flammable limit in air. :- lower – 0.9% volume,

:-. Higher – 6.5% volume

• Toxicity limit. :- 200 PPM

• Soluble :- Water, and more solvent.

• Insoluble in. :- Alcohol, Ether, Carbon tetrachloride & etc.

 CHEMICAL PROPERTIES OF CUMENE

C6 H5CH(CH2)2 + O2 = C6H5 (CH3)2COOH.

C6H5(CH3)2COOH = C6H5OH + CH3COCH3

1.6 USES OF CUMENE

2. A building-block chemical, almost all cumene approximately 98% of cumene is consumed as a

lacquer & enamel.

4. Cumene is also used as a solvent for fats and raisins.

5. Cumene by itself is not generally sold by producers for consumers used.

acetophenone, the chemical intermediate dicumylperoxide and isopropyl benzene.

1.7 RAW MATERIALS USED.

1.8 CATALYST USED.

2000catalyst is a solid, regenerable, zeolite catalyst used to produce cumene

MANUFACTURING PROCESSES OF CUMENE WITH FLOW

1. Q-MAX™ CUMENE manufacturing process flow diagram.

Fig. 4, Q-MAX™ cumene manufacturing process.

Fig.5 CD-TECH CUMENE manufacturing process.

3. MONSANTO – LUMMUS crest cumene process.

Fig.6, MONSANTO LUMMUS cumene manufacturing process

Fig.7, UOP cumene manufacturing process.

5. Badger Cumene Manufacturing Process.

Fig.8, MOBILE BADGER cumene manufacturing process.

2.3 SELECTION OF CUMENE MANUFACTURING PROCESS

• Q-MAX ™ Manufacturing process is most convenient process for CUMENE

Justification of selection of cumene:-

• Product yield is 99.7 weight%.

• High activity and selective with minimum by product formation.

• Typical cumene productive yield is 95.5% pure.

• Extremely tolerant to poison.

• Proven run-length of up to 5 years.

• Low catalyst cost .