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Cleavage

The Distinctive Feature of ILLA's FAN2000TM Process, differentiating it from other CHP cleavage processes licensed in the world, is the highest achievable selectivity and safety level. In terms of said values, FAN2000TM has no competitors in the world.

FAN2000TM achieved its success due to ILLA's unprecedented Safety Concept and unique solutions of the selectivity issue.

Safety concept:

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automatic computerized start-up of the process;

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three-level process protection;

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on-line computer monitoring and control over the CHP conversion in the reactors;

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protection against process disturbing factors;

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flexibility at variable feed-rates;

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safe and stable performance under overdesign feed-rates;

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automatic balancing of heat generation and heat removal processes;

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completely resolved "hot spots" problem typical of all other technologies.

Selectivity:

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world’s unique selectivity value - AMS yield of more than 90 mole%;

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world’s lowest by-product (phenol tar) yield of 25-30 kg/t;

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stabilization of maximum target products yield at variable feed-rates;

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world&rss lowest yield of undesired minor impurities such as mesityl oxide (less than 50 ppm) and hydroxyacetone (1300 ppm);

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cresol formation issue has been resolved.

Cooling water flow-rate is by 20-40% relat less than in all other technologies. Flexibility towards cooling water temperature.

Brief process description:

FAN2000TM is a two-stage process. At the first stage, the chemical reactions of CHP cleavage and DCP synthesis are simultaneously conducted, and at the second stage - the chemical reactions of DCP cleavage to process target products and DMBA conversion to a valuable side-product AMS are carried out. Both process stages are carried out in the reaction medium of phenol and acetone containing acetone excess with respect to phenol (mole ratio>1).

The mole acetone-to-phenol ratio varies from stage to stage, making the process more selective and safer for operation. A traditional H2SO4 catalyst is employed at the first process stage, and the second stage is operated at mild acidic catalyst NH4HSO4. Such an approach in combination with additional acetone fed to the process enables FAN2000TM Process to be the most selective (actual AMS yield is above 90 mol%) and provides minimum formation of such undesirable by-products as AMS dimers and cumyl phenols.

An important feature of FAN2000TM process is the employment of internal acetone recycle stream, i.e. elimination of adding required amount of additional acetone at this stage from acetone columns, which reduces the load of the fractionation columns. Therefore, there is a significant utilities cost saving and decrease in column size. Additionally, higher acetone product quality is achieved compared to the technologies using external acetone recycle allowing capacity expansion without deterioration of finished products quality.

FAN2000TM Process incorporates the latest state-of-the-art developments for the control system, including automated startup and shutdown as well as unique system of a three-level cleavage process protection which provides the process stability to the effect of external disturbing factors. Unlike outdated one-level system employed in all other CHP cleavage processes, FAN2000TM Process control and three-level protection system provides the process with a multilevel protection and enables the producer to receive stable maximum yield of valuable products regardless of the various disturbing factors.

The process control system is based on the kinetic models developed by ILLA International. A dynamic model developed by ILLA enables a client to see the operation of the future process within the actual time run. The process features a high yield of desired products and a low yield of undesired products at a low cost of auxiliary resources, and also offers flexible operation and the lowest impact on the environment, as compared to competitive processes.

Effluent from Cleavage contains un-neutralized sulfuric acid and minor quantities of formic and acetic acids as well as organic impurities. In ILLA’s process, the composition of cleavage product effluent differs from the competitors' processes by a lower amount of impurities such as mesithyl oxide (less than 50 ppm), hydroxyacetone (1300 ppm), 2-methylbenzofuran (none), cresol (minimum), which give an adverse impact on the quality of phenol product.

In ILLA’s process, unlike conventional technologies, hydroxyacetone and a part of carbonyls are removed from CHP cleavage product prior to Fractionation to provide the guaranteed quality of finished product and save the utilities.

 

 


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