Cosmos Report CLL371 Major
Cosmos Report CLL371 Major
Cosmos Report CLL371 Major
INTRODUCTION
Cumene or more commonly known as isopropyl benzene is an organic
compound, more specifically an aromatic hydrocarbon and is one of the
constituents in refined fuels and also crude oil. Cumene is a colorless
liquid with gasoline-like odour. Cumene is insoluble in water and is only
soluble in alcohol, ether, benzene and CCl4. Cumene was first prepared
by Gerhardt and Cahours in 1841 by distilling cumic acid with lime. Now
there are more advanced methods which we will discuss later. Cumene is
a very important chemical because it is used in industries to produce
commercially valuable chemicals such as phenol and acetone, this is
done by first making the intermediate, cumene hydroperoxide and then
this is selectively cleaved to get phenol and acetone.
Earlier, when it was not discovered that cumene can be converted to phenol and acetone, it was
widely utilised as a fuel additive during Worldin the aviation gasoline War 2 to boost the
performance of the aircraft piston engine. Other than this, cumene is also used for increasing
the octane in gasoline and used as a solvent for fats and resins. Products such as bisfenol-A,
polycarbonate and nylon 6, are among many others which require cumene in their
manufacturing process. Cumene because of its flammable nature can cause undesirable health
issues in humans and has detrimental effects on the environment, especially marine life. The
Cumene market has been growing steadily over the years, and because acetone has become
very essential during these Covid-19 times demand for cumene has increased rapidly. Cumene
is also in the top 5 biggest productions in the world, which also includes benzene, ethylbenzene,
propylene and ethylene. Over 46% of the world revenue of cumene comes from the Asia-Pacific
region.
The process goes as follows: Benzene is mixed with some recycled benzene as well as
propylene-propane feedstock from refinery off gases of a naphtha steam cracking plant, after
mixing it is charged up flow into a fixed bed reactor which is operating at a temperature of
200-260°C and pressure of 3-4MPa. This is then pumped into the top of the reactor at 25 atms
where the catalyst infused with phosphoric acid is packed in a stage wise manner. The
propylene is completely converted in one pass with the help of the catalyst.
The effluent from the reactor is then depropanized and the propane is split into quench or
product streams. The effluent from the reactor typically contains 94.8 wt% cumene, 3.1 wt%
diisopropylbenzene and the 2.1 wt% remaining are the heavy aromatics. We get a very high
yield of cumene even before the transalkylation of diisopropylbenzene and this is the main
advantage of using solid phosphoric acid as the catalyst. The heavy aromatics that we got can
either be used as a blending component for high octane gasoline or is sent with benzene for the
transalkylation of diisopropylbenzene into cumene. The cumene that we get as a product is 99.9
wt% pure. We get around 97-98 wt% overall yield for this process if transalkylation takes place
otherwise the yield is around 94-96 wt%. The removal of the by-products is very simple but in
this the catalyst is not regenerable which is one major disadvantage of this process. There is
also a need for a high benzene/propylene molar feed ratio of about 7/1 to get the best possible
yield of cumene.
3. Q-Max Process
This method of cumene production helps in producing almost an equilibrium level of cumene of
about 85-95 mole% with 5-15 mole% of diisopropylbenzene. This is based on the liquid phase
process and uses beta zeolites as the catalyst. The process unit of this method consists of two
reactors, one alkylation and a transalkylation reactor as well as a distillation section. There are
four catalyst beds present in the alkylation reactor, these four beds are placed inside a single
vessel. The reactor is fed with the feed of propylene and a mixture of fresh and recycled
benzene, propylene reacts completely and forms cumene. Propane which may have entered the
reactor along with propylene is removed from the products leaving the reactor by feeding them
to a depropanizer column, also any extra water is also removed.
The products at the bottom of the depropanizer column are sent into another column where
benzene is collected in the overhead and is then recycled. Products enter the cumene column,
where cumene is collected and the bottom products which mainly contain diisopropylbenzene
and other heavy aromatics are send to DIPB column, where the diisopropylbenzene is
recovered and is sent for transalkylation to form cumene. Heavy aromatics left at the end are
used as a high-octane gasoline blending component. Catalyst used is regenerable in both
alkylation and transalkylation processes. The cycle length is about 2-4 years after that the
catalyst needs to be regenerated and it can last for about 3 cycles. In this process there is
minimum pre-treatment of feeds, so it minimizes the capital costs.
4. CD Cumene process
This process for manufacturing of cumene uses proprietary zeolite catalysts which are
environment friendly as well as non corrosive in nature and the cumene obtained is of very high
purity. With this method we get a much higher yield of the product and the capital used is also
less when compared to typical acid-based methods.
The unique aspect of this process is that it combines the catalytic reactor as well as the
distillation into a single unit operation. There are fixed bed reactors inside the column where the
alkylation reaction takes place at temperatures which are typically lower than those used in solid
phosphoric acid processes. We can even use refinery grade propylene for the feedstock, so
when it is used, the effluents that we form from the alkylation reaction are sent to the
depropanizer which removes propane in the overhead. We have a separate transalkylation
reactor where benzene and PIPB (polyisopropylbenzene) which have been recycled are
converted to get additional cumene. The effluents from this transalkylation reactor is mixed with
the bottom products from the depropanizer and are sent through 3 distillation columns where
benzene, cumene and PIBP are collected in the overhead of respective columns. Benzene and
PIBP are recycled for previous processes and cumene is removed as products. Heavy
aromatics are separated from the PIBP column.
The cumene we get is of very high purity and can be as high as 99.97% and is typically
obtained when the ratio of feed for Benzene/Propylene is maintained between 3 and 5. Zeolites
used are regenerable and can be used for several cycles before becoming useless. So there is
very little waste to be disposed of in this manufacturing process and even when waste is
generated that is a zeolite catalyst, because of its environment friendly nature it does not pose a
threat to the safety of the environment. But there can be poisoning of the catalyst because of
the contaminant in the feed and that is one the few disadvantages of this process. The reaction
is carried out at low temperature so energy requirement is also less and there are corrosive
elements used therefore carbon steel could be used for the process design of the plant. There is
some need for pretreatment required depending upon the feed, like controlling sulfur content of
refinery grade propylene.
Out of the above two zeolite catalyst processes, CD cumene is said to be more effective
because the time period before regeneration for CD cumene is higher and we get much better
conversion as well as the selectivity if higher. The safety and operability is better in the CD
cumene process because of the absence of any corrosive product, and the temperature for
alkylation is lower, which reduces the investment capital for this type of plant. Overall the plant
design is very customizable in CD cumene because of less rigorous operating conditions with
the choice of using any feedstock, which we discussed above. These reasons make the
CD-cumene process to be much more effective than the Q-max method for manufacturing
cumene.
(NOTE: process flow diagrams for some processes given at the end, could not be added because of
constraint on the number of pages)
INDUSTRIAL ASPECTS
Cumene is used in the production of acetophenones, methyl styrene, phenols and acetones in
industries as feed-stock. It is used as lacquer thinners for paints. The growth in the cumene
market is expected due to a strong increase in demand for phenols and acetones in industries.
Phenols and acetones are used in many applications leading to an increase in their demand. In
the cosmetics and pharmaceutical industries, as a solvent, acetone is used. In household
products, production of paints, and as an intermediate in many industries, phenols are used.
And this makes phenols and acetones to get in more demand increasing the demand for
cumene.
The Cumene Process :-
The process by R. Ūdris and P. Sergeyev, given in 1942. It uses raw materials as
benzene and propylene, and gives the final products as phenols and acetones. It also uses
oxygen, which is taken from the air. Small number of radical initiators is also used.
Using propylene cumene is formed by Friedel-Crafts Alkylation of benzene. At 30 ATM,
250 0C, in the presence of catalytic lewis acid propylene and benzene are compressed together.
In air from O2,, cumene is oxidized. Tertiary benzylic hydrogen is removed and cumene radical is
formed. This cumene radical bonds with oxygen to form it’s peroxide radical. Then from getting
a benzylic hydrogen from a cumene molecule it forms cumene hydroperoxide. Enough pressure
is maintained to make sure that unstable peroxide remains in a liquid state. This cumene radical
formed again goes through the same chain to form it’s peroxide.
In an acidic medium, this hydroperoxide is hydrolyzed to give phenols and acetone. Below is
the mechanism of the process.
TECHNICAL ASPECTS
Cumene’s producution is one of the most large-scale production worldwide, this is among the
top five industries, which includes ethylene, propylene, benzene, ethylbenzene and cumene.
90% of the cumene then is used in the production of phenols and acetones, remaining in the
production of a-methyl styrene as a valuable component of rubbers. These chemicals which are
produced from cumene themselves are used to produce many other chemicals which find their
use in the daily life of humans. All over around 44.0 % of phenol is used in the production of
diphenyl carbonate and bisphenol-A for the production of polyacrylates,
polysulfones,polycarbonates epoxy resins and polyamides.
Around 40% of phenol from Russia is exported to Latvia, China and finland. In russian phenol
plant cumene preparation, which uses complex compounds of aluminum chloride which act as
catalyst, it has changed slightly compared to the original,this also has the same technical level,
engineering design. This technology has a one-step character, it is sufficient and efficient , its
propylene conversion is 99% and in this case, its differential selectivity reaches about 91% and
the benzene conversion is around 30-40% per pass. Currently, Russian companies are
producing about 10 kg of the residue which includes aluminum hydroxide as wet slurry which
contains significant amounts of organic impurities per ton of cumene. A challenge is to improve
quality and reduce the cumene production waste in the industry which has been successfully
achieved by the production optimization and by using advanced technologies which includes
computer modeling systems with high prognostic potential.
ECONOMIC ASPECTS
Cumene is mainly used as a raw material in the production of organic compounds like phenol,
bisphenol A, acetone, methyl methacrylate and phenolic resins. Out of all these organic
compounds, acetone and phenol synthesis is where cumene is mostly utilized. Globally, more
than 95% of cumene is consumed in the production of these two compounds.
Over 46% of the world revenue of cumene comes from the Asia-Pacific region, while Europe
and North America followed, each with global cumene demand of around 19%. Mainland China
and indian subcontinent are going to be the fastest growing regions in the upcoming years with
two digit annual growth rates.
The Cumene market has been growing steadily over the years, and because acetone has
become very essential during these Covid-19 times, demand for cumene has increased rapidly.
Cumene is also in the top 5 biggest productions in the world, which also includes benzene,
ethylbenzene, propylene and ethylene.
The following bar graph shows the cumene global demand by volume in million tons from
2000-2025.
COMMERCIAL ASPECTS
The global cumene market was $15.9 billion in 2020, and by 2021 it is expected to reach
$18.34 billion with a compound annual growth rate of 14%. Covid in 2020 affected the market
and in that year there was a decline in demands of many chemicals which led to decrease in
demand for cumene. After 2020 the companies will try to get out from the decline in the
production that they faced in 2020 due to the pandemic. There were many restrictions imposed
due to COVID-19 which resulted in change in operations, demand and other things which
affected the market adversely and resulted in decline in demand in the pandemic era.
The end user industry of cumene includes chemical plastic automotive and many other
industries. Geographically the market of cumene is segmented in Asia-Pacific (29%), North
America (26%), South America (10%), Europe (19%) ,and Middle East and Africa (16%). The
main demand of cumene is due to an increase in demand for phenols and acetones, the
production of phenols and acetones using cumene is explained below in the industrial aspects
section. More than 90% acetone is used from the by-product of phenol production from cumene.
Acetone and phenols have a wide range of applications. For example, MMA and BPA. It is also
used as a solvent in pharmaceutical and cosmetic industries.
Phenols and acetones themselves are used in many industries for other important chemicals.
The increase in those products which are formed from phenols and acetones drives the demand
of cumene and hence it’s market. Due to covid pandemic, the pharmaceutical companies grew
with a very high slope and hence the increase in demand for phenols and acetones in this
industry led to an increase in cumene market. There are many new acetones and phenols
plants set up recently all over the world which will lead to an increase in cumene demand. The
Cumene market is expected to show a very high growth rate in the coming years. It has been
increasing continuously from past years but the slope is not high enough, but in the coming
years the slope is expected to increase.
Cumene Market Analysis :- Application wise, In the cumene market, phenol shares the
largest market in recent years. Among the industries, Plastic industry shares the largest market
in recent years. The increase in demand for plastic products caused the increase in cumene
demand. For metal packaging applications, phenolic resins have increasing demands, this is
due to their characteristics as mechanical strength and their ability to blend with polymers.
Bisphenol-A's production which is used in plastic synthesis involves the use of phenols and
acetones. Plastic based BPA finds many applications in the plastic industry. In food beverages
and storage containers polycarbonate plastic is used.
The increase in use and demands of plastic products leads to the growth of the cumene market
in the coming period. Region Wise Asia-pacific holds the largest share of the cumene market,
which was around 46% in 2019. Countries like India, china, japan, korea are witnessing an
increase in demand for cumene due to increase in use of plastic and rubber products. Acetone
is an intermediate in the production of PMMA which finds many applications, so the increase in
use of PMMA increases the demand for acetone which in turn increases the demand for
cumene. In 2018 2019 this market in this region witnessed a whopping increase of 24%.
**Chart above is made by taking data from various online sources for each year
Effects on humans
No information has been found on the toxicity of cumene in humans following acute, subchronic,
or chronic exposure. Due to the volatile nature of cumene, the major cause of potential
exposure is inhalation. Cumene is a flammable compound, it’s exposure may cause central
nervous system effects and a short term inhalation exposure at high concentrations may cause
headaches, dizziness, drowsiness, slight incoordination, and unconsciousness in humans.
Prolonged skin contacts with cumene may cause mild skin irritation with little redness.
A chronic inhalation exposure of cumene vapors can cause irritation in the respiratory system so
it is suggested that one should avoid inhaling cumene vapors over long periods. There is also a
slight risk of having chemical pneumonitis when cumene is swallowed, which may be fatal. Till
now, no epidemiology and clinical controls of humans were found for cumene. Apart from this, it
is also found that exposure to food and drinking water(lesser extent) is a major source of
exposure via the environment.
The density of cumene vapors are higher than the air so they might travel across the ground
and reach remote ignition sources and can cause a fire danger. Under normal conditions the
compound is stable but oxidises on contact with air to form unstable peroxides.
Cumene is dangerous to aquatic animals with chronic effects. It is a biodegradable compound
which easily degrades in the environment and does not bioaccumulate significantly.
Safety measures
Humans are mainly exposed to cumene at industrial workplaces that use cumene, in industries
the exposure concentration is found to be low because the chemical reactions occur in the
closed system. To enhance employee safety from the exposure of cumene, employers and
workers should practice the guidelines provided on the safety data sheet of the product, which
may include wearing protective gloves and clothes to avoid contact with skin, and wearing
safety spectacles to keep eyes safe. Moreover, there should be proper ventilation, local
exhaust, or breathing protection in workplaces to minimize the potential for worker exposure. To
avoid ingestion of cumene one should not eat, drink, or smoke during work.
In case of spillage, prevent cumene from reaching drains and water courses, in order to keep
marine life safe from hazardous effects. Cumene should be kept away from the reach of acids
and strong oxidants. Long-term storage of cumene may lead to the formation of explosive
peroxides.
A spill or leak of cumene, because of its flammable nature, could lead to generation of fire
immediately. This is the reason why it is very important to handle and store cumene properly. It
has been observed that long term storage of cumene could lead to formation of highly explosive
peroxides so proper rules must be followed. In case of spill, cumene must be dealt with
immediately and should be kept away from water bodies because of its highly hazardous effects
on marine/aquatic life.
FUTURISTIC ASPECTS
The global cumene market has observed a strong demand in recent years and it is anticipated
to rise at a compound annual growth rate (CAGR) of 4.03% till 2030. It is expected that the
cumene market will rise upto USD 28.94 billion by 2026 as the scope and its applications are
rising extremely across the world. The derivative of coal tar and crude oil is cumene, which is
generally used for manufacturing of acetone and phenol. 95% consumption of cumene gives
these two compounds however remaining 5% is utilized as a resin enamels and solvents.
Increasing demands of these two compounds in various end use factories in developing
countries is considered as a major factor for cumene industry growth in the upcoming years.
Due to the outbreak of COVID-19 pandemic, demand for acetone has increased, as it is used to
manufacture Isopropyl Alcohol, which is a main chemical for sanitizers. Furthermore, an
increase in the use of phenol in paint and coating industries as a solvent will boost the demand
for cumene in the years to come. Hence, strong demand for these two compounds has resulted
in an increase in the demand for cumene. However, the hazardous effects of cumene on health
and environment may decrease the market growth in the coming years.
Globally, it is estimated that Asia will lead the overall market share of cumene in the upcoming
years due to the high demand of phenol and acetone in the developing countries like China and
India. Instead, Europe is also estimated to have a positive impact on the growth of the cumene
market in the future followed by North America. In China, the demand for acetone is increasing
rapidly, it is used in the automotive and medical industries as a solvent and an intermediate for
the production of Polymethyl methacrylate.
The main vendors of the cumene market across the globe are Dow Chemical Company, China
Petroleum, Badische Anilin- und Soda-Fabrik (BASF SE) and Chemical Corporation. These
vendors mainly give attention to the mergers and acquisitions in the market to increase the
demand.
References:-
1. Manufacturing
process-https://fdocuments.in/download/cumene-manufacturing-procedure
5. https://www.chemanalyst.com/industry-report/cumene-market-55
6. https://admin.chemanalyst.com:8181/images/New%20Global%20Cumene%20Histogram
%201.png
7. https://en.wikipedia.org/wiki/Cumene_process
8. https://www.mordorintelligence.com/industry-reports/cumene-market
9. https://www.thebusinessresearchcompany.com/report/cumene-global-market-report
10. https://www.industryarc.com/Report/15888/cumene-market.html
11. https://core.ac.uk/download/pdf/53078978.pdf
3. CD Cumene process