Production of Isopropyl Benzene
Chapter I
Introduction and its Background
A. Introduction
Isopropylbenzene (cumene) is an organic compound with an aromatic hydrocarbon and an
aliphatic substitution. It is found in crude oil and refined fuels. It is a colorless, flammable
liquid with a boiling point of 152 °C. Also, it is an important intermediate product in the
petrochemical industry for the main phenol and acetone routes. Isopropyl benzene are also
used in the manufacture of styrene,a-methylstyrene, acetophenone, di-isopropylbenzene and
detergents; as a catalyst for acrylic and polyester-type resins; as a thinner for paints; as a
solvent for fat and resins; and in the manufacture of rubber. Increasing demand of phenolic
resins & bisphenol-A and rise in the consumption of acetone and its derivatives is the most
important driving factor in the global demand of isopropyl benzene. Another factor that fuels
the market demand for isopropyl benzene is the increase in the use of it in adhesives and
sealant. In addition, the surge in the demand for high octane production fuels and the growing
industry for paints and coatings are anticipated to fuel market growth.
Zeolites are microporous aluminosilicate minerals that are commonly used in industry as
adsorbents and catalysts. Naturally occurring zeolites are rarely pure and are frequently
contaminated to varying degrees by other minerals, metals, quartz, or other zeolites. As a
result, naturally occurring zeolites are excluded from a wide range of important commercial
applications that require uniformity and purity. The open 12-membered ring structure of beta
zeolite, combined with its high acidity, made it an excellent catalyst for aromatic alkylation.
These characteristics can lead to increased benzene-to-cumene selectivity and product purity.
Furthermore, the combination of high activity and porous structure conferred a high level of
tolerance to a wide range of common feed contaminants. Regenerating zeolite catalysts
eliminates waste disposal issues associated with SPA and aluminum chloride catalysis.
The goal of this paper is to produce isopropylbenzene in a dependable and cost-effective
manner with low energy consumption, low capital costs, low environmental impact, and high
yield of large-scale technical plant design using zeolite catalyst in the alkylation process of
benzene and propylene. Using zeolite as a regenerable catalysts, the rate of reaction can be
increased, which can save both fixed and operating costs by reducing energy consumption,
waste disposal, and greenhouse gas emissions, making the process more economical and
sustainable. Among the various zeolite-based processes, this design employs distillation train,
while the others employ two fixed-bed reactors for alkylation and transalkylation reactions.
B. Sources of Raw Material
The primary raw materials used in the production of isopropyl benzene are propylene and
benzene. Both materials will be purchased at Petron Corp. in Limay, Bataan. Petron Corp is
the only company that produces both propylene and benzene in the Philippines, despite the
fact that many plants produce either one or the other. The transportation of raw materials will
not be a problem because the plant location is accessible by land and within the same
province.
Beta zeolite will be used as catalysts in the production of isopropyl benzene. It will be
imported from Pingxiang Naike Chemical Industry Equipment Packing Co., Ltd (also known
as NKCHEM) which is a company specialized in R&D and sales of plastic, metal and ceramic
tower packing products in Jiangxi, China.
C. Products
Cumene is a common name for isopropylbenzene, an organic compound. Cumene is a
colorless liquid with a strong aromatic odor. The flash point is 115°F. It is less dense than
water and is insoluble in it. Vapors that is heavier than air. Inhalation, ingestion, and skin
absorption may be moderately toxic. In humans, acute (short-term) inhalation exposure to
cumene can result in headaches, dizziness, drowsiness, slight incoordination, and
unconsciousness. Cumene has a powerful central nervous system (CNS) depressant action in
animals, with a slow induction period and a long duration of narcotic effects. Cumene is an
irritant to the skin and the eyes. There is no information available on cumene's chronic (long-
term), reproductive, developmental, or carcinogenic effects in humans. Animal studies have
found that inhaling cumene causes increased liver, kidney, and adrenal weights. Cumene has
been classified by the EPA as a Group D substance, meaning it is not carcinogenic to humans.
Table 1. Specification of Cumene
Property Specifications ASTM Test Method
Purity, weight %, min 99.92 D3760 or D7057
Alpha-Methylstrene, weight %, max 0.01 D3760 or D7057
Benzene, weight %, max 0.001 D3760 or D7057
Butylbenzenes, weight %, max 0.02 D3760 or D7057
Diisopropylbenzenes, weight %, max 0.002 D3760 or D7057
Ethylbenzene, weight %, max 0.01 D3760 or D7057
Phenols, mg/kg, max 5 D3160 or D3760 or D7057
n-Propylbenzene, weight %, max 0.03 D3760 or D7057
Sulfur, mg/kg, max 1 D7183 or D7359
Bromine index, max 100 D1492 or D2710
Appearance, free of haze, particulates or Pass E2680
suspended matter particles
Color, Pt/Co, max 15 D5386 or D8005
Cumene hydroperoxide, at loading, mg/kg, 100 E298 or E299
max
D. Proposed Plant Location
Figure 1. Proposed Plant Location
The proposed plant will be in Brgy. Lucanin in Mariveles, Bataan and has an area of 20
hectares. The plant location was based on the accessibility of raw materials and demand of the
product. The neighboring petrochemicals plants within the province of Bataan were the main
plant consumers of the product isopropylbenzene. This proposed plant will also supply
isopropylbenzene to different industries, especially petrochemical plants around the country
and potentially around the globe.
D.1 Raw Material Supply
The location of the plant is determined by the availability of raw materials and the demand for
the product. Because the raw materials will be purchased from Petron Corp, which is located 9
kilometers away from the proposed plant, the availability and price of raw materials are
reasonable.
D.2 Market Area
The plant is located near the primary market, which includes chemical industries,
pharmaceuticals, and so on.
D.3 Transport Facility
Interconnected toll roads have reduced travel time between these economic centers, making
logistics and supply chains easier to manage. The transportation of raw materials and finished
products to and from the plant will not be an issue because the plant is accessible via a variety
of modes of transportation, including road, bridge, air transportation and waterway
D.4 Availability of Labor
Construction and operation of the plant will necessarily involve the use of labor. Skilled and
professional workers are typically hired from outside the area, but locals within the site area
should have access to labor.
D.5 Availability of Utilities
The plant will need a large amount of water for general and process use, which is why it is
near a water source, the Lucanin River. Electrical power is also required because the plant will
require a large amount of power. The plant's power source is SMC Limay CFB Powerplant,
which is located 8 kilometers away.
D.6 Environmental Impact and Effluent Disposal
There is a cost for disposing of all waste products generated by industrial processes. The
disposal of hazardous and toxic wastes will be governed by local regulations in Mariveles and
the DENR-EMB’s Non-Combustion Destruction Facility for Persistent Organic Pollutants.
The Environmental Quality Division-Hazardous Waste Management Section's responsibility
is to enforce and assist the EMB Regional Offices in the implementation of Title III
Hazardous Waste Management of DAO 1992-29, the Implementing Rules and Regulations of
RA 6969, and DAO 2013-22, its Procedural Manual. In addition, the Philippine Clean Water
Act (RA 8749), Water Quality Management, Solid Waste Management, Clean Air Program,
Geohazard and Groundwater Assessment Program, and Improved Land Administration and
Management Program are all in place.
D.7 Local Community Considerations
Because there isn't much residential near the proposed site, the proposed plant will blend right
in. In this case, full consideration and strict guidelines must be followed in order to save the
plant's location and avoid putting the community at risk.
D.8 Land Information and Considerations
The available area is a 32 hectares industrial land, but the proposed plant is only 20 hectares in
size, allowing for future growth. This proposed location is the nearest available industrial land
for sale from the Petron Corp., source of raw materials, and it is 1.2 kms away from Seafront,
this is the only FAB ready property nearest to international port with 12 - 20 meters access
road to Roman Super highway.
D.9 Climate Conditions
The wet season in Mariveles is overcast, the dry season is windy and partly cloudy, and it is
hot and oppressive all year. Throughout the year, the temperature typically ranges from 76°F
to 91°F, with temperatures rarely falling below 73°F or rising above 94°F.
The perceived humidity level in Mariveles, as measured by the percentage of time when the
humidity comfort level is muggy, oppressive, or miserable, does not vary significantly
throughout the year, remaining within 2% of 98 percent.
E. Demand Outlook
The cumene market is projected to register a CAGR of over 4% during the forecast
period (2021-2026). The COVID-19 pandemic has affected various chemical and other
industrial activities, which has negatively affected the demand for cumene. The automotive
industry also faced a decline in production and sales due to the pandemic situation and thus
affected the cumene market. According to the OICA, automobile production declined by
around 23% in the first nine months of 2020 compared to the same period in 2019.
In the medium term, the major factors driving the market studied include increasing
demand for phenol from the plastic industry and increasing use of acetone as a solvent.
On the flip side, harmful effect, due to extended exposure, is expected to significantly
hinder the growth of the market studied.
Asia-Pacific is expected to dominate the global market during the forecast period.
Also, it is expected to register the highest CAGR during the forecast period.
Key Market Trends
Figure X. Global Cumene Market Trend by Application (2020)
Growing Usage in Acetone Application
More than 95% of the global acetone production is used as a by-product of phenol
production, which involves cumene use. The demand for acetone is primarily driven
by its use as a solvent in products, such as nail polish removers, lacquers and finishes,
and adhesives.
Acetone is used in a wide range of applications, such as manufacturing methyl
methacrylate (MMA) and BPA, and as a solvent in the pharmaceutical and cosmetics
industries.
MMA is widely used for the production of PMMA resins, which are increasingly
being used to produce acrylic sheets in the construction industry. Automotive parts and
medical devices are other applications of MMA.
The pharmaceutical industry is continuously expanding, increasing the demand for
acetone, thus, and driving the cumene market. As of the end of 2019, the global
pharmaceutical market was valued at USD 1,250.4 billion. The pharmaceutical market
grew at a rapid pace in 2020 due to the COVID-19 outbreak.
Additionally, the growing cosmetic industry is increasing the demand for acetone for
use as a solvent. According to the Statista market forecast, the revenue generated by
cosmetics reached USD 87 billion in 2020, witnessing a decline of 3% compared to
2019. It is estimated to reach USD 118.5 billion by 2025.
Due to the increase in demand for acetone globally and the setting up of new
phenol/acetone production facilities, the cumene market is expected to witness a high
growth rate during the forecast period.
China to Dominate the Asia-Pacific Market
Figure X. Cumene Market Growth Rate by Region (2021-2026)
In Asia-Pacific, China is the largest economy in terms of GDP. In 2019, the country
witnessed about ~6.1% growth in its GDP, despite facing trade disturbances due to its
trade war with the United States. Currently, the Chinese economy has been severely hit
by the COVID-19 pandemic. According to the International Monetary Fund (IMF)
projections, the Chinese GDP growth has registered a 1.9% in 2020, due to the
COVID-19 pandemic. It is expected to recover and reach 8.2% by the end of 2021.
With the investments from various chemical manufacturers, the production facilities of
bisphenol-A, phenol, and acetone have been increasing in the country. This, in turn, is
projected to drive the demand for cumene in the country in the coming years.
o In 2019, Shandong Lihuayi Weiyuan put its 120,000-metric ton/year new
bisphenol A (BPA) unit into production, with products coming out. Its two
BPA units are running at an average rate of 90% at present, according to
company sources. Thus, all cargo from its 220,000-metric ton/year phenol plant
will be for captive use.
o Zhejiang Petrochemical planned to build new 400,000 metric ton/year phenol
and 250,000 metric ton/year of acetone plant in 2020.
Additionally, cumene is also used as a thinner for paints, enamels, and lacquers. This
is further increasing the demand for cumene in the region.
China is the leading producer and consumer of paints and coatings across the world.
Currently, China produces more than half of the coatings from Asia-Pacific and is
home to more than 10,000 paint companies. Local producers occupy more than half of
the share in the domestic paints market.
However, the country's steps toward recovery from COVID-19, along with fruitful
investments expected to be witnessed in the near future, are likely to act as driving
factors for the cumene market during the forecast period.
Competitive Landscape
Figure X. Cumene Market Competitive Concentration and Major Players
The cumene market is partially fragmented in nature. Some of the major players of the
market studied include Exxon Mobil Corporation, Royal Dutch Shell PLC, Braskem, Cepsa,
and INEOS, among others.
Recent Developments
In October 2019, INEOS announced that it breaks ground at its world-scale cumene
investment at Marl, Germany. The plant has a capacity of 750,000 metric ton per year of
cumene, which is expected to be completed in 2021.
F. Market Share
F.1 Propylene
The propylene market is expected to witness market growth at a rate of 4.43% in the forecast
period of 2021 to 2028. Data Bridge Market Research report on propylene market provides
analysis and insights regarding the various factors expected to be prevalent throughout the
forecast period while providing their impacts on the market’s growth. The increase in demand
for the product from end user industries is escalating the growth of propylene market.
Propylene or propene alludes to a dreary and combustible gas determined by breaking
petroleum hydrocarbons. They are the side-effect of gaseous petrol handling and oil refining
and a portion of the subsidiaries of the propylene incorporate acrylic and acrylates, propylene
oxide, alcohols and cumene. This is used as fuel.
The increase in the demand of propylene from construction industry across the globe acts as
one of the major factors driving the growth of propylene market. The rise in the usage of
propylene in various industries such as packaging, textile, construction, automotive and others
and increase in demand for polymer produced from the propylene monomer in the automobile
sector accelerate the market growth. The rise in demand for polypropylene products that are
utilized in the manufacturing of interior trim, instrumental panels, door trims, battery cases
and trays, fender liners, bumpers and other components and continuous expansion of the e-
commerce sector further influence the market. Additionally, expansion of end user industries,
urbanization and industrialization and surge in investment for infrastructural developments
positively affect the propylene market. Furthermore, research and development activities
fermentation and emerging economies extend profitable opportunities to the market players in
the forecast period of 2021 to 2028.
F.2 Benzene
The benzene market size was estimated at over 50 million ton in 2020, and the market is
projected to register a CAGR of over 3% during the forecast period (2021-2026). The market
was negatively impacted by COVID-19 in 2020. Automotive manufacturing units were on a
temporary halt owing to the pandemic scenario, which minimized the demand for products
like nylon tires, injection-molded vehicle parts, foam seatings, and paints, which are made
from benzene-derived intermediates like nylon, styrene, and phenol resins, thus, creating a
negative impact on the market demand. However, demand for the drugs like paracetamol,
which consumes benzene-derived intermediates such as chlorobenzene, has increased in the
current situation, thus, stimulating the market demand in the pharmaceutical sector.
F.3 Zeolite
The zeolites market is expected to record a CAGR of over 2% during the forecast period. The
major factors driving the market studied are increasing demand from the water treatment
industry and increasing the use of zeolite as refrigeration adsorbents. Asia-Pacific region
dominated the global market share. In terms of GDP, China is one of the largest economies in
the world. The zeolites market is consolidated in nature. The major companies include BASF
SE, Arkema Group, Honeywell International Inc, Tosoh Corporation and W. R. Grace & Co.,
among others.
F.4 Cumene
Companies in the cumene market are investing in order to meet the future demand. For
instance, in Germany, in 2019, INEOS Phenol, the world’s largest producer of acetone and
phenol has done new cumene investment at the Evonik Chemiepark in Marl. The fully
integrated unit will use existing pipeline connections between the production of INEOS
phenol and acetone in Gladbeck, the Marl site of Evonik Chemiepark and the Gelsenkirchen
refinery and cracker complex of BP.
G. Design Objectives
The researchers aim to design a cumene production via alkylation process by the use of zeolite
catalyst.
This aims to address the following particular:
To evaluate the large-scale technical feasibility of the proposed process as a more cost-
effective means for producing cumene via alkylation of benzene and propylene using
zeolite catalyst.
To determine the profitability and sustainability of the proposed process in terms of the
supply and demand of cumene, raw materials to be used and major equipment costs.
H. Discussion of the Plant Process
This production of cumene plant design is based on zeolite based process. Cumene is created
by alkylating benzene with propylene, resulting in a mixture of alkylated and polyalkylated
benzenes. To improve catalyst specificity, activity, and reliability, propylene is pumped before
each catalyst bed. The alkylation as well as transalkylation discharges are routed to the
benzene column, in which the excess benzene is collected and recycled to the reactors. Excess
benzene is used to ensure that propylene entirely reacts. The combination of alkylated as well
as polyalkylated benzenes is routed through a distillation train composed of benzene columns,
cumene columns, and poly-isopropylbenzene (PIPB) columns. To maximize cumene yield, the
polyalkylated benzenes retrieved in the PIPB column are transalkylated with benzene.
I. Definition of terms
1. Alkylation - is a chemical process by which an alkyl group is attached to an organic
substrate molecule via addition or substitution
2. Benzene - is a clear, colorless, highly flammable and volatile, liquid aromatic
hydrocarbon with a gasoline-like odor.
3. Beta Zeolite - is the only one structured with three-dimensional 12-membered ring
channels among zeolite family. It is of high activity in hydrocracking and
hydroisomerization catalyzing. It is capable of linear paraffin adsorption and anti-poison
with sulfur and nitrogen. It is used in petrochemical industrial for preparation of cumene
by benzene and propylene alkylation, diisopropylbenzene by cumin disproportionation,
methylbenzene isopropylation, arene alkylation, diisopropylbenzene transalkylation,
propylene etherification, carbinol aromatization, propylene epoxide and alcohol
etherification, phenol methylation, aminobenzene methylation, cumene and
methylbenzene transalkylation, methylbenzene disproportionate, etc. The application of
Beta Zeolite and USY Zeolite brings octane number increase. In fine chemical industrial,
Beta Zeolite is good with activity and selectivity in dewatering and deminizating.
4. Catalyst - a substance that accelerates a chemical reaction without undergoing
permanent chemical change
5. Cumene - is an alkylbenzene that is benzene carrying an isopropyl group.
6. Isomerization - is the process in which a molecule, ion or molecular fragment is
transformed into an isomer with a different chemical structure.
7. Optimization - used in many areas of study to find solutions that maximize or minimize
some study parameters, such as minimize costs in the production of a good or service,
maximize profits, minimize raw material in the development of a good, or maximize
production.
8. Propylene - is an alkene that is propane with a double bond at position 1. It has a role as
a refrigerant and a xenobiotic. It is an alkene and a gas molecular entity.
9. Transalkylation - is a chemical reaction involving the transfer of an alkyl group from one
organic compound to another. The reaction is used for the transfer of methyl and ethyl
groups between benzene rings.
10. Zeolite - Zeolites are microporous aluminosilicate minerals that are commonly used in
industry as adsorbents and catalysts.
Chapter II
PROCESS DESIGN LAYOUT
A. Process Flow Diagram
B. Piping and Instrumentation Diagram
C. Plant Layout
Chapter III
TECHNICAL ASPECTS
A. Sources of Raw Materials
Raw Materials Sources
Benzene Petron Corp.
Propylene (Limay, Bataan)
FCC Catalyst Beta Zeolite (pellet) NKCHEM (Jiangxi, China.)
The primary raw materials used in the production of isopropyl benzene are propylene and
benzene. Both materials will be purchased at Petron Corp. in Limay, Bataan. Petron Corp is
the only company that produces both propylene and benzene in the Philippines, despite the
fact that many plants produce either one or the other. The transportation of raw materials will
not be a problem because the plant location is accessible by land and within the same
province.
Beta zeolite will be used as catalysts in the production of isopropyl benzene. It will be
imported from Pingxiang Naike Chemical Industry Equipment Packing Co., Ltd (also known
as NKCHEM) which is a company specialized in R&D and sales of plastic, metal and ceramic
tower packing products in Jiangxi, China.
B. Equipment Functions – in equipment function, include the functions and also the
specification of the equipment. Enumerate the equipment base on its process flow.
See example below(desalter).
Design Specification
Equipment Category Treatment
Requirement 1
Capacity 21MT/day
Size 140 sq.m
Manufacturer/Model Number (Look in google)
C. Material Balance and Energy Balance (see example below for assumptions of
operations)
Equipment Assumptions
Desalter Operates @ 92% efficiency
Furnace and Preheater Operates @ 98% efficiency
a. Mass Balance (figure and computation per equipment)
b. Energy Balance
Chapter IV – Economic Analysis
A. Timeline of Construction of the Plant – it includes the design, construction
and procurement (EPC), it should be in graph.
B. Building Cost
C. Vehicles (if any)
D. Pipeline Construction
E. Equipment
F. Installation/ Commissioning
G. Engineering Cost
H. Fire and Safety Cost
I. Labor Cost (Operating Labor, Deductions, Direct Supervisory and Clerical
Labor, Administration Cost)
J. Maintenance and Repair
K. Other Utilities
L. Product Prices
M. Expected Annual Cash Inflow
Chapter V – ENVIRONMENT AND SAFETY ASPECTS
A. Environmental Management System
B. Prevention of Soil Contamination
C. Prevention of Water Contamination
D. Hazardous Chemical Control Activities
E. Recycling of Waste Materials
F. Environmental Cleaning Activities
Safety
A. Process Safety Management
B. Emergency Response System
C. Protection of Marine Environment
D. Oil Spill Prevention
E. Inhouse clinic
F. Health and Safety Considerations (per equipment)
a. Fire Prevention and Protection –covers the potential cause of fire(reason)
b. Safety – prevention
c. Health – exposures
Chapter VI – PROJECT MANAGEMENT
I. Preliminaries
a. Planning Stage
b. Basis of Design Stage
c. Design Stage Layout
/SAPAK/
II. Construction Management
a. Complete Design Stage
b. Procurement and Construction Stage
III. Quality Assurance and Control
a. Quality Assurance
b. Quality Control
Chapter VII – SUMMARY OF FINDINGS, CONCLUSION AND
RECOMMENDATION
/SAPAK/
References
Mordor Intelligence. Cumene Market - Growth, Trends, Covid-19 Impact, and Forecasts
(2021 - 2026). https://www.mordorintelligence.com/industry-reports/cumene-market
Nikfar, S. (2014). Encyclopedia of Toxicology || Cumene, 1082–1085. doi:10.1016/b978-0-
12-386454-3.00599-6
Avenue Market Research. Cumene Market by Application (Phenol/Acetone and Others) -
Global Opportunity Analysis and Industry Forecast 2014-2022.
https://www.alliedmarketresearch.com/cumene-market
ASTM International Designation: D4077 – 17. Standard Specification for Cumene
(Isopropylbenzene). http://106.38.59.21:8080
Dotproperty. Moving Asia. 122-Hectare Shoreline Consolidated Titled Parcels, Bry. Alas-
Asin, Mariveles, Bataan, Philippines. https://www.dotproperty.com.ph/land-for-sale-in-alas-
asin-bataan_7682880
National Center for Biotechnology Information (2021). PubChem Compound Summary for
CID 7406, Cumene. Retrieved October 24, 2021 from
https://pubchem.ncbi.nlm.nih.gov/compound/Cumene.
Weather Spark (2021). Climate and Average Weather Year Round in Mariveles Philippines.
https://weatherspark.com/y/134584/Average-Weather-in-Mariveles-Philippines-Year-
Round#Sections-BestTime
Republic of the Philippines - Department of Environment and Natural Resources
Environmental Management Bureau. https://emb.gov.ph/
MyPropertyPh. (2021) For Sale 32 Hectares Mariveles Bataan, Industrial Land - ready for
AFAB. https://www.myproperty.ph/for-sale-32-hectares-mariveles-bataan-industrial-land-
ready-for-afab.html
Independent Commodity Intelligence Services (1999). Cumene Production Via Zeolites
Gaining https://www.icis.com/explore/resources/news/1999/09/13/94700/cumene-production-
via-zeolites-gaining/
FCC Catalyst Beta Zeolite With Si/Al Ratio of 25, 40, 60 https://www.alibaba.com/product-
detail/FCC-Catalyst-Beta-Zeolite-With-
Si_60716003245.html?spm=a2700.galleryofferlist.normal_offer.d_image.195a41b8BAzvkd
