PRESENTATION ON HAZOP ANALYSIS

OF CUMENE PROCESS

Submitted To:
Prof. Bhakti Bapat

Submitted by:
Patel Manankumar Umeshbhai(15BE01030)
Parth J Patel (15BE01034)
Vishal Tapiawala H(15BE01049)
Thakar Krunalbhai Rajeshbhai(15BE01050)
 INTRODUCTION

Name: - Isopropyl benzene (IUPAC)

Cumene (traditional)
𝐶9𝐻12

 Isopropyl benzene, commercially known as Cumene is a colourless, volatile liquid with a gasoline-like odour.

 An aromatic ring with an aliphatic substitution of an isopropyl group.

 Cumene is a key commodity of the petrochemical industry as an intermediate for many important products and as
octane booster in gasoline blending.

 In 2011, the global cumene demand was about 12.4 million tons and in 2022, as the market is growing in the developing
countries, it is expected to reach 25 million tons.
 PROPERTIES OF CUMENE

 Molecular formula : 𝐶9𝐻12  Viscosity: 0.737 𝑚𝑃a 𝑠 𝑎𝑡 25 °𝐶

 Molar weight: 120.19 𝑔/𝑚𝑜𝑙
 Melting point: -96.9℃
 Boiling point: 152.5°C
 Flash point: 39°C
 Auto Ignition point:- 424°C
 Density: 0.862 𝑔/𝑐𝑚3 𝑎𝑡 20 °𝐶
 Volatility: 4.5 𝑚𝑚𝐻𝑔 𝑎𝑡 25 °𝐶
 Color: Colorless
 Odor: Gasoline-like, sharp, penetrating,
aromatic
 Toxic limit concentration: 250 ppm
 Solubility: 61.3 𝑚𝑔/𝐿 𝑎𝑡 25 °𝐶 in water
 Uses

 Cumene producers account for approximately 20% of the global demand for benzene.

 Cumene was first developed as a high-octane addition for engine fuels.

 Phenol and acetone are its two most important derivatives

 The by-products, alpha-methyl styrene and acetophenone, are also produced.

 Cumene in minor amounts is used as a thinner for paints, enamels and lacquers.

 Cumene is also used as a solvent for fats and resins.

 Basic Process Description

 The Friedel-Crafts catalytic alkylation of benzene with propylene is the current production route of cumene.

 Di-isopropyl benzene is the main byproduct, along with traces of higher hydrocarbons.

 Propylene-propane feedstock from refinery off-gases from a naphtha-steam cracking plant is mixed with
benzene and pumped at 25 atms Into the top of a multi-tubular packed bed reactor with H3PO4 impregnated
catalyst beds.

 The temperature is maintained by adding cooling water to absorb the heat of Reaction.

 The reactor effluent is de-propanized and the the de-propanized bottoms are separated into benzene, cumene,
and DIPB in the remaining two columns.
Basic Process Description diagram
 Process Description
Symbol Name Comments

E-1 Vaporizer Liquid feeds are vaporized and heated for reactor.

R-1 Reactor Vapors are reacted over catalyst and effluent having temp
range of 400 – 420C.
C-1 Distillation Tower No. 1 Separating essentially all of the benzene, cumene and
DIPB as a liquid from propylene and propane gases.
C-2 Distillation Tower No. 2 Overhead stream contains 98.1 mole% benzene, balance
cumene; bottoms stream contains cumene and DIPB.
C-3 Distillation Tower No. 3 Overhead stream contains 99.9 mole% cumene; bottoms
stream contains pure DIPB.
R-2 Transalkylator This reactor allows producing additional cumene and the
outlet flow is recycled back to the C2 feed.
Process Reactions
 ENVIRONMENT EFFECT OF
CUMENE PROCESS
Description
 Cumene evaporates when exposed to air. In the air it is reacted quickly into
other chemicals, in the water and soil bacteria break it down.
 It has moderate acute (short-term) toxicity on aquatic life, and high acute
toxicity to birds.
 Insufficient data are available to predict the toxicity of cumene to plants
and land animals.
 It has moderate chronic (long-term) toxicity to aquatic life. Cumene is
expected to minimally bio accumulate.
 ENVIRONMENT EFFECT OF
CUMENE PROCESS
Environmental Occurrence
 Cumene is released to the environment as a result of
its production and processing,
 During its
 transport, from petroleum refining
 the evaporation
 combustion of petroleum products,
 transportation and distribution of motor fuels,
 And by the use of a variety of products containing cumene.
 Cigarette tobacco also releases.
 Cumene releases include operations involving vulcanization of rubber, building
materials, jet engine exhaust, outboard motor operations, solvent uses, paint
manufacture, pharmaceutical production, and textile plants.
 ENVIRONMENT EFFECT OF
CUMENE PROCESS
Source of emission

Industry sources
 The primary sources are the industries that manufacture it or use it in production.
 Some of the industries that manufacture it or use it in production are oil refiners, chemical industry, rubber
manufacturers, pharmaceutical industry, pulp and paper manufacturing, roofing and paving, plastics
manufacturing, manufacturers of paints, varnishes and lacquers.
 Emissions are to the air, soil and water.

Diffuse sources (included in diffuse emissions data)

 Other possible emitters of cumene are
 vapours and spilling of petrol
 commercial and household painting and paint,
 varnish and lacquer removal.
 These emissions are to the air unless there is a spill.
 ENVIRONMENT EFFECT OF
CUMENE PROCESS
Source of emission
Natural sources
 Natural sources include crude petroleum and coal tar.
 It is also found in the oils of plants, marsh grasses and in some foods.

Transport sources
 Some cumene is found in the exhaust of motor vehicles, jet engines, and outboard motors.

Consumer products
 Some of the consumer products containing cumene are:
 foam plastic insulation
 rubber floor and wall coverings, bathmats,
 wood office desks and furniture (modular)
 thinners for paints, lacquers and enamels.
 OCCUPATIONAL SAFETY AND HEALTH

Health Effect
 Long-term exposures at low levels have caused
effects to the liver and kidneys.
 Short-term exposure to high levels of cumene results in:
 Headache
 Irritation of the eyes
 Nose and throat
 Euphoria followed by dizziness, sleepiness, and unconsciousness.
 May cause Narcotic effects.
 OCCUPATIONAL SAFETY AND HEALTH
Health effects (Animal)
 Animal studies demonstrate that direct eye contact with liquid cumene may cause
slight irritation, but no corneal injury.
 Excessive inhalation of cumene vapours may cause irritation of the nose, throat
and upper respiratory track.
 If ingested or swallowed in small amounts, health effects will likely be minimal
or mild.
 When swallowed in larger amounts, may cause gastrointestinal irritation, and
may be aspirated during vomiting.
 OCCUPATIONAL SAFETY AND HEALTH

Health effect (human)

 Can affect you when inhaled and may be absorbed through the skin.
 Can irritate the skin causing a rash or burning feeling on contact.
 Exposure can irritate the eyes, nose and throat.
 Exposure can cause headache, dizziness, loss of coordination, light headedness,
and passing out.
 Prolonged or repeated exposure can cause drying and cracking of the skin with
redness.
 may damage the liver and kidneys.
 FLAMMABLE liquid & DANGEROUS fire hazard
 OCCUPATIONAL SAFETY AND HEALTH
TYPES OF ACUTE HAZARDS/ PREVENTION/ FIRST AID/
HAZARD/ SYMPTOMS Safety Protection FIRE FIGHTING
EXPOSURE
FIRE Flammable. NO open flames, NO sparks, and Powder,, foam, carbon dioxide.
NO smoking.
EXPLOSION Above 31°C explosive Above 31°C use a closed system, In case of fire: keep drums, etc.
vapour/air mixtures ventilation, and explosion-proof cool by spraying with water.
may be formed. electrical equipment. Prevent
build-up of electrostatic charges
(e.g., by grounding).
EXPOSURE PREVENT GENERATION OF MISTS!
INHALATION Dizziness. Ataxia. Ventilation, local exhaust, or Remove the person from exposure.
Drowsiness. Headache. breathing protection. CPR if heart action has stopped.
Unconsciousness. Transfer promptly to a medical facility.

SKIN Dry skin. Protective gloves. Remove contaminated clothes. Rinse

Protective clothing. and then wash skin with water and
soap.
EYES Redness. Pain. Safety spectacles. First rinse with plenty of water for
several minutes
then take to a doctor.

INGESTION (See Inhalation). Do not eat, drink, or smoke during Rinse mouth.
work. Do NOT induce vomiting.
Refer for medical attention.
 OCCUPATIONAL SAFETY AND HEALTH

Control measures
Include:
(1) enclosing chemical processes for severely irritating and corrosive chemicals,
(2) using local exhaust ventilation for chemicals that may be harmful with a single
exposure,
(3) using general ventilation to control exposures to skin and eye irritants.
 Personal Protective Equipment

Gloves and Clothing

 All protective clothing (suits, gloves, footwear, headgear) should
be clean, available each day, and put on before work.
Eye Protection
 Wear indirect-vent, impact and splash resistant goggles when
working with liquids.
 Wear a face shield along with goggles when working with
corrosive, highly irritating or toxic substances.
 Do not wear contact lenses when working with this substance.
 Personal Protective Equipment
Respiratory Protection
 Leave the area immediately if
(1) while wearing a filter or cartridge respirator you can smell, taste,
or otherwise detect Cumene,
(2) while wearing particulate filters abnormal resistance to breathing is experienced
(3) eye irritation occurs while wearing a full face piece respirator.

 Where the potential exists for exposure over 500 ppm, use a NIOSH approved supplied-air
respirator with a full face piece operated in a pressure-demand or other positive-pressure mode.
 For increased protection use in combination with an auxiliary self-contained breathing apparatus
operated in a pressure-demand or other positive-pressure mode.
 Exposure to 900 ppm is immediately dangerous to life and health. use a NIOSH approved self-
contained breathing apparatus with a full face piece operated in a pressure-demand or other positive-
pressure mode equipped with an emergency escape air cylinder.
 HAZOP STUDY

MAJOR EQUIPMENTS AND THEIR

HAZOPE STUDY

( Double click on below icon)

 DESIGN ALTERNATIVES

 1) PACKED BED REACTOR INSTEAD OF MULTITUBULER PACKED BED REACTOR.

 DESIGN ALTERNATIVES
Packed or Fixed Bed Reactor
A fixed bed reactor usually consists of a cylindrical vessel packed with catalyst pellets and easy to design and
operate. The metal support grid and screen is placed near the bottom to support the catalyst.

1. Ideal plug flow behavior

2. lower maintenance cost
3. Reduced losses due to attrition and wear

Major engineering problems with packed bed reactor

** Poor heat distribution **
 non-uniform reaction rates
 low reactant conversion.
 generation of hot spots and thermal degradation of catalyst.
 can cause explosion and runaway reaction due to exothermicity of reaction.
 Regeneration or replacement of catalyst is also difficult in fixed bed reactors and process needs to
be shutdown
 High pressure drop is also observed for small beads or pellets of catalysts
 DESIGN ALTERNATIVES

2) REACTIVE DISTILLATION IN PLACE OF SIMPLE DISTILLATION COLUMNS

 conventional process and a Reactive distillation process for manufacturing cumene are
evaluated for cost/ energy savings and controllability.

 Conventional processes for cumene manufacture consist of

 Packed bed reactor (liquid or vapor phase) followed by a separation
 Recycles the unreacted benzene and separates the cumene product
from heavies generated by further alkylation of cumene to di/polyisoprenyl benzene.

 Industrial scale processes utilizing Reactive distillation (RD) have been commercialized.
 The tasks of reaction, benzene recovery / recycle as well as separation of light
inerts are combined and performed in a single reactive distillation column.
 A downstream simple distillation column recovers the cumene product in the RD column
bottoms as the distillate and recycles the bottoms heavies to the RD column.
 DESIGN ALTERNATIVES
Comparison of two processes

 Results show that the capital cost for the RD process is significantly lower at less than
half the conventional process cost. The operating costs for both processes are
comparable.

 All these factors thereby affect the energy consumption.

 DESIGN ALTERNATIVES
Safety comparison
 The use of a series of equipments which not only increase the capital cost but also provide
room for maximum exposure to hazards due to chances of improper handling.

 Temperature inferential control of the RD column is found to be effective for handling the
disturbances.

 The production by this method does not assure a high yield of the products thereby resulting in
the
 loss of unreacted hazardous reactants.

 RD method also solved problems of a recovery or treatment Method as safe recovery treatment

 All these factors have led us to tread the path of the Highly efficient Reactive Distillation
method as a solution.