Phenol Aspen process simulation

The diagram below shows the main process of the cumene process. This stage consists mainly of four steps: oxidation, concentration, decomposition, and further concentration. Fresh isopropylbenzene, recycled isopropylbenzene from the concentration process, and recovered isopropylbenzene from the hydrogenation unit are mixed in certain proportions and fed into two series-connected oxidation towers, where they react with the oxygen present in the air entering the towers to produce isopropylbenzene peroxide. The oxidation reaction conditions are a temperature of 90–104°C and a pressure of 0.31–0.35 MPa; simultaneously, 1 mol of reactant releases 31.6 kcal of heat. The reaction temperature is achieved by raising the temperature to the appropriate level through two heating steps before the materials enter the reactor; since the reaction is exothermic, heat is removed via the exhaust gases, and a circulating cooling pump at the bottom of the reactor helps to maintain a stable temperature inside it. The reaction pressure was chosen to be 0.31–0.35 MPa because a lower reaction pressure is favorable for the reaction; however, if the pressure is too low, the volume of the oxidizer will become very large. Therefore, medium-pressure oxidation was selected after considering all factors. Isopropyl hydrogen peroxide (CHP), with a concentration of about 25% resulting from the oxidation reaction, is concentrated to around 79–86% before being fed into the decomposition reactor. The decomposition reaction takes place under the catalysis of acid at a temperature of around 80°C. At the same time, 1 mol of this reaction releases 53.5 kcal of heat. Since the catalyst is prepared by adding sulfuric acid, the amount of sulfuric acid used must be appropriate. An important factor in maintaining a stable temperature is removing the heat generated by the reaction, and propane evaporation is used here for heat removal. By controlling the amounts of sulfuric acid and propylene added, the reaction is kept at an appropriate temperature. The reaction temperature is the boiling point of the mixture in the reactor, usually around 80°C. At this point, isopropylbenzene peroxide decomposes into phenol and propylene; the decomposition mixture containing less than about 1% CHP enters a secondary decomposition reactor for thermal decomposition. In the refining section, the decomposition liquid from the decomposition and neutralization systems, which contains propylene, phenol, water, isopropylbenzene, and various by-products with vaporization ranges ranging from very high (acetaldehyde) to very low (tar), passes successively through the crude propylene tower and the propylene refining tower (under reduced pressure distillation) for propylene refinement. The bottom stream from the crude propylene column, together with the bottom stream from the phenol purification column, serves as the feed for the crude phenol column. A large amount of phenol in the tower, along with the light organic compounds originating from the crude phenol tower, is distilled off at the top of the tower; approximately 80% of the phenol remains in the bottom of the crude phenol tower, which helps to lower the temperature there and reduces the concentration of phenylethyl group at the tower top. The vapor from the phenol recovery tower enters directly the bottom of the crude phenol tower; the tar stream containing less than 10% phenol is sent to the tar storage tank after being cooled in the heavy components cooler. The top stream from the crude phenol column merges with the top cut stream from the phenol purification column to enter the dehydrogenation column, which uses water as an azeotrope to separate hydrocarbons from phenol at the 45 trays in its upper section. The bottom product of the dehydrogenation tower is almost entirely phenol, which is sent to the phenol processor. Acid removal points are provided at trays 51, 53, and 55 of the phenol processor to remove trace amounts of organic acids that may occur in this area. The phenol processor uses CT-151 solid acid ion exchange resin to cause trace amounts of related compounds to react with phenol, thereby producing high-molecular-weight components that help purify the phenol product. The output from the phenol processor enters the phenol purification tower. After being cooled to 60–70°C by the phenol product cooler, it is fed into the phenol product tank at a rate of 4.84 t/h.

My design topic is the process design for an annual production capacity of 100,000 tons of phenol

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