Arciete, Jayson Del T.
Production of Bisphenol-A from Phenol and Acetone - Cebu City CIT-U 2013
The design of a 120,000 ton capacity plant in a continuous process to react 1 mole of acetone and 3 moles of phenol as the raw material by condensation reaction using an ion exchange resin catalyst in the form of polystyrene divinyl-benzene or Amberlyst33, to produce bisphenol-A. The products of reaction are BPAand water. Excess phenol favors the forward reaction, reduces the formation of by-products and completely converts acetone. Raw materials and products are shipped to and from China and the economic evaluation and profitability of the design are described in this paper.
The equipment of this design are 2 fixed bed reactor, 3 distillation columns, 3 fractional melt crystallizers, 2 heat exchangers, dryer, condensers, reboiler and pumps.Two fixed bed reactors are placed in parallel to allow regeneration of the catalyst for a reactor to minimize downtime period. Distillation columns were designed specifically for each desired component separation. The first distillation column removes acetone and H2O from the phenol and BPAproduct. The distillate of the first distillation column is then pumped to the second distillation column to completely separate acetone from water. The third distillation column is phenol recovery and the bottom of the third distillation has the large mass percentage of BPAwhich is fed to fractional melt crystallizers to undergo crystallization, partial melting and total melting. It is then dried and BPA solid crystals are suitable for market. Bisphenol-A is a heat sensitive material such that temperature control is necessary. Aside form temperature control, pressure and level control are also used to ensure safety and efficiency of the process. Process control is further discussed in chapter 8 of this paper.
Wastes produced in the production of BPAoffers a wide variety of risks to the environment and safety. Wastes such as unreacted products, by-products of reaction, cooling water are treated accordingly to be recycled or disposed to the environment without having a negative effect on it. Chapter 9 shows a detailed list of the wastes produced and how they are utilized and disposed. HAZOP is also provided in chapter 10 to ensure the safety of the workers and the protection of the environment.
Economic study of the design is shown in chapter 11. The study showed that the design is profitable such that the computed rate of return is 42%, which is 12% greater of the minimum rate of return to be considered feasible and profitable.
T D674 2013
Production of Bisphenol-A from Phenol and Acetone - Cebu City CIT-U 2013
The design of a 120,000 ton capacity plant in a continuous process to react 1 mole of acetone and 3 moles of phenol as the raw material by condensation reaction using an ion exchange resin catalyst in the form of polystyrene divinyl-benzene or Amberlyst33, to produce bisphenol-A. The products of reaction are BPAand water. Excess phenol favors the forward reaction, reduces the formation of by-products and completely converts acetone. Raw materials and products are shipped to and from China and the economic evaluation and profitability of the design are described in this paper.
The equipment of this design are 2 fixed bed reactor, 3 distillation columns, 3 fractional melt crystallizers, 2 heat exchangers, dryer, condensers, reboiler and pumps.Two fixed bed reactors are placed in parallel to allow regeneration of the catalyst for a reactor to minimize downtime period. Distillation columns were designed specifically for each desired component separation. The first distillation column removes acetone and H2O from the phenol and BPAproduct. The distillate of the first distillation column is then pumped to the second distillation column to completely separate acetone from water. The third distillation column is phenol recovery and the bottom of the third distillation has the large mass percentage of BPAwhich is fed to fractional melt crystallizers to undergo crystallization, partial melting and total melting. It is then dried and BPA solid crystals are suitable for market. Bisphenol-A is a heat sensitive material such that temperature control is necessary. Aside form temperature control, pressure and level control are also used to ensure safety and efficiency of the process. Process control is further discussed in chapter 8 of this paper.
Wastes produced in the production of BPAoffers a wide variety of risks to the environment and safety. Wastes such as unreacted products, by-products of reaction, cooling water are treated accordingly to be recycled or disposed to the environment without having a negative effect on it. Chapter 9 shows a detailed list of the wastes produced and how they are utilized and disposed. HAZOP is also provided in chapter 10 to ensure the safety of the workers and the protection of the environment.
Economic study of the design is shown in chapter 11. The study showed that the design is profitable such that the computed rate of return is 42%, which is 12% greater of the minimum rate of return to be considered feasible and profitable.
T D674 2013