Cumene-phenol complex with thermal oxidation system

Abstract

This invention describes a method for treating wastewater, waste air, and hydrocarbon-containing liquid and gas streams from cumene / phenol complexes. The various effluent streams are combined in suitable collection containers, including waste air separators, hydrocarbon buffer containers, fuel gas separators, phenolic water containers, and non-phenolic water containers. The streams from these containers are then fed to a thermal oxidation system.

Description

[0001] Priority Statement

[0002] This application claims the benefit of U.S. Provisional Patent Application Serial No. 63 / 060,804, filed August 4, 2020, and U.S. Provisional Patent Application Serial No. 63 / 153,447, filed February 25, 2021, the entire contents of which are incorporated herein by reference. Background Technology

[0003] Typically, phenol is prepared by air oxidation of cumene and subsequent sulfuric acid cleavage of the resulting cumene hydroperoxide to form a reaction mixture containing phenol, acetone, and unreacted cumene. In addition to the major product, varying amounts of byproducts are formed, such as isopropylidene acetone, α-methylstyrene, hydroxyacetone, 2-methylbenzofuran, p-cumylphenol, phenyldimethylmethanol, acetophenone, and high molecular weight phenol.

[0004] In the process of recovering phenol from an acid pyrolysis reaction mixture, the acidic reaction mixture is first neutralized, for example, directly by adding diamine, ammonia, sodium phenoxide, or a caustic soda, or indirectly by contacting an ion exchange resin. In one embodiment, under conditions that achieve crude separation of substances with boiling points below cumene, the neutralized reaction mixture is fed to a distillation column (commonly referred to as a crude acetone column or crude separator), thereby recovering the overhead fraction containing substantially all acetone and low-boiling byproducts, as well as most of the water and unreacted cumene. Acetone is then recovered by further distillation of the crude acetone column overhead distillate, as is cumene. The resulting recovered cumene is recycled to the oxidation process.

[0005] The bottom fraction recovered from the crude acetone column is typically processed to separate the heavy tail fraction, and then fed into a distillation column (often called a cumene column, α-methylstyrene column, or cumene-α-methylstyrene column). This bottom fraction contains phenol and α-methylstyrene (AMS), along with the remainder water and a significant amount of unreacted cumene. The subsequent column operates under conditions where the overhead fraction is separated from the higher-boiling phenol product. This bottom fraction contains water, cumene, α-methylstyrene, and phenol at an azeotropic concentration. The phenol recovered as the bottom fraction also contains certain impurities, such as isopropylidene acetone, 2-methylbenzofuran, and hydroxyacetone, and these impurities are treated and separated from the bottom fraction to yield a substantially pure phenol product.

[0006] The overhead fraction from the cumene-α-methylstyrene column will always contain significant amounts (e.g., between 2% and 25% by weight) of phenol, as well as cumene and α-methylstyrene. This overhead fraction can be subjected to caustic alkali extraction to recover cumene and α-methylstyrene as a water-immiscible organic phase, which is then reacted and recycled as cumene to the oxidation section. Phenol is recovered as sodium phenolate in the aqueous phase. A phenol recovery unit exists in which the aqueous sodium phenolate solution is acid-treated, and the resulting organic phase buffer is recycled for recovery. The aqueous phase containing dissolved phenol and acidifying agent is extracted with a solvent or stripped with steam to recover phenol, followed by necessary treatment for safe disposal.

[0007] In another embodiment, under conditions that achieve crude separation of substances with boiling points below cumene, the neutralized reaction mixture is fed to a partitioned-wall distillation column (typically referred to as a crude separator), thereby recovering the overhead fraction containing substantially all acetone and low-boiling-point byproducts, as well as most of the water and unreacted cumene. Acetone is then recovered by further distillation of the crude acetone column overhead distillate, and the same applies to cumene. The recovered cumene is recycled to the oxidation process.

[0008] The phenol recovered as the bottom fraction also contains certain impurities, such as isopropylidene acetone, 2-methylbenzofuran, and hydroxyacetone. These impurities are treated and separated from the bottom fraction to obtain a substantially pure phenol product.

[0009] The side fraction from the coarse separator will always contain significant amounts of phenol (e.g., between 2% and 25% by weight), the remainder water, and substantial amounts of unreacted cumene and α-methylstyrene. This side fraction can be subjected to caustic alkali extraction to recover cumene and α-methylstyrene as a water-immiscible organic phase, which is then reacted and recycled as cumene to the oxidation section. Phenol is recovered as sodium phenolate in the aqueous phase. A phenol recovery unit exists in which the aqueous sodium phenolate solution is acid-treated, and the resulting organic phase buffer is recycled for recovery. The aqueous phase containing dissolved phenol and acidifying agent is extracted with a solvent or stripped with steam to recover phenol, followed by necessary treatment for safe disposal.

[0010] The recycled cumene from the various segments of the complex may contain trace amounts of organic acid compounds, which are undesirable in the phenol process unit. These are removed using caustic alkali washing and water washing.

[0011] Cucurbitene / phenol complexes are involved in many process units for producing various effluent streams that must be handled and disposed of.

[0012] Therefore, it is desirable to reduce the number of devices in the complex while providing appropriate treatment for the effluent. It is also desirable to reduce the cost of the chemicals used to treat the effluent. Furthermore, it is desirable to reduce the complexity of processing and treating the effluent. Attached Figure Description

[0013] Figure 1 This is a diagram of a cumene / phenol complex constructed using conventional methods.

[0014] Figures 2 to 3 This is a diagram of the cumene / phenol complex according to the present invention.

[0015] Figure 4 This is a diagram illustrating one embodiment of the thermal oxidation system according to the present invention.

[0016] Figure 5 This is an illustration of another embodiment of the thermal oxidation system according to the present invention.

[0017] Figure 6 This is a diagram of a portion of a conventional phenol recovery section.

[0018] Figure 7 This is an illustration of a portion of the phenol recovery unit segment according to the present invention.

[0019] Figure 8 This is a diagram of one implementation scheme for a conventional oxidation section.

[0020] Figure 9 It is based on the present invention Figure 8 A diagram illustrating the implementation scheme of the oxidation unit segment.

[0021] Figure 10 This is a diagram of another implementation scheme for the conventional oxidation section.

[0022] Figure 11 It is based on the present invention Figure 10 A diagram illustrating the implementation scheme of the oxidation unit segment.

[0023] Figure 12 It has improved energy recovery Figure 4 A diagram illustrating one implementation of a thermal oxidation system.

[0024] Figure 13 This is a diagram illustrating the source of process wastewater flow used in energy recovery systems.

[0025] Figure 14 This is a diagram illustrating the uses of condensate streams formed in an energy recovery system.

[0026] Figure 15 This is another illustration of the use of condensate streams formed in energy recovery systems.

[0027] Figure 16 It has improved energy recovery Figure 4 A diagram illustrating another implementation of the thermal oxidation system.

[0028] Figure 17 It has improved energy recovery Figure 5 A diagram illustrating one implementation of a thermal oxidation system.

[0029] Figure 18 It has improved energy recovery Figure 5 A diagram illustrating one implementation of a thermal oxidation system.

[0030] Figures 19A to 19C These are illustrations of different implementation schemes for the thermal oxidation section.

[0031] Figure 20 yes Figure 4 A diagram illustrating another implementation of the thermal oxidation system.

[0032] Figure 21 yes Figure 5 A diagram illustrating another implementation of the thermal oxidation system. Detailed Implementation

[0033] This invention provides a suitable treatment for wastewater, waste air, and hydrocarbon-containing liquid and gas streams from cumene / phenol complexes. Various effluent streams from different portions of the cumene / phenol complex are combined in suitable collection containers, including, for example, one or more of waste air separators, hydrocarbon buffer containers, fuel gas separators, phenolic water containers, and non-phenolic water containers. The streams from these containers are then fed to a thermal oxidation system. This allows for the removal of many components from conventional processes, including one or more of wastewater treatment equipment, oil extraction towers, solvent caustic soda scrubbing towers, waste air adsorbers, solvent tanks, and associated piping, instrumentation, control devices, and mechanical and structural components, thereby reducing both capital and operating costs. Furthermore, this method reduces the cost of treating chemicals and also reduces the size of certain streams.

[0034] The outflow streams include both gaseous and liquid streams. As used herein, the gaseous waste streams have a calorific value of less than 40 BTU / SCF. Examples of gaseous waste streams include, but are not limited to, the cumene production unit effluent gas stream from the cumene production unit, the oxidizing waste air stream from the oxidation unit section, the decanter effluent stream from the oxidation unit section, and the fractionated hydrocarbon effluent stream from the acetone-phenol fractionation unit section. The low-calorific-value gaseous fuel streams have a calorific value greater than 40 BTU / SCF. Examples of low-calorific-value gaseous fuel streams include, but are not limited to, the propane effluent stream from the cumene production unit, the benzene carryover stream from the cumene production unit, and the AMS hydrogen effluent gas stream from the AMS hydrogenation unit. The liquid waste streams have a calorific value of less than 2500 Btu / lb. Examples of liquid waste streams include, but are not limited to, benzene tower water streams from the cumene production unit, peroxide-containing oxidative wastewater streams from the oxidation unit section, peroxide-free oxidative wastewater streams from the peroxide destruction unit, fractionated wastewater streams from the acetone-phenol fractionation unit section, and phenolic wastewater streams from the phenol recovery unit section. High-calorific-value / low-market-value liquid streams have a calorific value greater than 2500 Btu / lb and will include streams rich in polynuclear aromatic compounds, asphaltenes, carbon residues, etc. Examples of high-calorific-value / low-market-value liquid streams include, but are not limited to, cumene production unit hydrocarbon waste streams from the cumene production unit and fractionated organic product streams from the acetone-phenol fractionation unit section. The specific number of streams to be divided between waste streams and streams with calorific value (low or high) can vary. However, this division allows for process integration based on the calorific value of the streams.

[0035] One aspect of the present invention is a method for producing phenol. In one embodiment, the method includes: oxidizing a fresh cumene feed stream in an oxidation unit section to form an oxidation product stream comprising cumene hydroperoxide (CHP), dimethylphenylmethanol (DMPC), and cumene, and at least one of an oxidation wastewater stream, an oxidation waste air stream, and a decanter effluent stream; concentrating the oxidation product stream in a CHP concentration unit section to form a concentrated CHP stream and a concentrated effluent gas stream; and decomposing the concentrated CHP stream in a decomposition unit section using a decomposition acid to form an acidic crude phenol comprising phenol, acetone, cumene, and α-methylstyrene (AMS). Product stream; neutralizing the acidic crude product with a neutralizing agent in the neutralization unit section to form a neutralized crude product stream; fractionating the neutralized crude product stream into a cumene-AMS-phenol stream, and at least one of a phenolic water stream, a fractionated organic product stream, a fractionated wastewater stream, and a fractionated hydrocarbon effluent gas stream in the acetone-phenol fractionation unit section; separating the fractionated cumene-AMS-phenol stream into a cumene-AMS feed stream, and at least one of a buffered phenol stream and a phenolic wastewater stream containing phenol and cumene in the phenol recovery unit section; hydrogenating cumene-AMS-phenol in the AMS hydrogenation unit section. The AMS feed stream is used to form the MSHP recycle cumene stream; at least one of the following steps is performed: introducing at least one of the fractionated organic product stream from the fractionation unit section, the fuel gas separator hydrocarbon liquid stream from the fuel gas separator, and the waste air separator liquid stream from the waste air separator into the hydrocarbon buffer vessel; introducing at least one of the AMS hydrogen effluent gas stream from the AMS hydrogenation unit section, the hydrocarbon buffer vessel effluent gas stream from the hydrocarbon buffer vessel, the phenolic effluent gas stream from the phenolic water vessel, and the non-phenolic effluent gas stream from the non-phenolic water vessel into the hydrocarbon buffer vessel. In a fuel gas separator, at least one of the following is introduced into a phenolic water container: a fractionation wastewater stream, an acetone-phenol fractionation unit stream, a phenolic wastewater stream from a phenol recovery unit stream, and a degreasing aqueous phase from a hydrocarbon buffer container; at least one of the oxidation wastewater stream from an oxidation unit stream and a benzene tower water stream from a cumene production unit stream is introduced into a non-phenolic water container; in a thermal oxidation system, one or more of the following are thermally oxidized: a mixed hydrocarbon waste stream from a hydrocarbon buffer container, a burner fuel gas stream from a fuel gas separator, a phenolic water stream from a phenolic water container, and a non-phenolic water stream from a non-phenolic water container. By thermally oxidizing a specific stream, we mean that thermally oxidizable hydrocarbon components in the stream are thermally oxidized. For example, using a phenolic water stream or a non-phenolic water stream, the thermally oxidizable hydrocarbon components in the phenolic water stream or the non-phenolic water stream are thermally oxidized; water is evaporated.

[0036] In some embodiments, thermal oxidation of one or more of the following: a mixed hydrocarbon waste stream from a hydrocarbon buffer container, a burner fuel gas stream from a fuel gas separator, an exhaust air stream from an exhaust air separator, a phenolic water stream from a phenolic water container, and a non-phenolic water stream from a non-phenolic water container; comprises thermal oxidation in a thermal oxidation section of one or more of the following: a mixed hydrocarbon waste stream from a hydrocarbon buffer container, a burner fuel gas stream from a fuel gas separator, an exhaust air stream from an exhaust air separator, a phenolic water stream from a phenolic water container, and a non-phenolic water stream from a non-phenolic water container, to form a mixture substantially composed of at least one of H2O, CO2, N2, O2, SOx, NOx, HCl, Na2SO4, Na2CO3, and Cl2. The flue gas; waste heat is recovered from the flue gas in a waste heat recovery section; after waste heat recovery, the flue gas is optionally quenched in a quenching section to form a quenched flue gas consisting essentially of at least one of H2O, CO2, N2, O2, SOx, NOx, HCl, Na2SO4, Na2CO3, and Cl2; in a SOx removal section, at least one of Na2SO4, Na2CO3, SOx, HCl, and Cl2 is optionally removed from the flue gas or the quenched flue gas to form a de-SOx outlet flue gas consisting essentially of at least one of H2O, CO2, N2, O2, and NOx, wherein the removal of at least one of Na2SO4, Na2CO3, SOx, HCl, and Cl2 from the flue gas includes: in a scrubbing section... In one section, a caustic alkali solution or an NH3-based solution is contacted with quenched flue gas to form SOx-removed outlet flue gas and a liquid effluent containing at least one of H2O, Na2SO3, Na2SO4, Na2HSO3, Na2CO3, NaCl, (NH4)2SO4, and NH4Cl; or in another section, the flue gas is reacted with reactants to form a reaction section consisting essentially of at least one of H2O, CO2, N2, O2, NaCl, Na2CO3, Na2SO4, NaNO3, CaCl2, CaSO4, CaCO3, Ca(NO3)2, MgCl2, MgCO3, MgSO4, Mg(NO3)2, Cl2, and NOx. Flue gas, wherein the reactants comprise NaHCO3, NaHCO3·Na2CO3·2(H2O), CaCO3, Ca(OH)2, and Mg(OH)2; and optionally filtering the reaction section flue gas in a filter section to remove at least one of NaCl, Na2CO3, Na2SO4, NaNO3, CaCl2, CaSO4, CaCO3, Ca(NO3)2, MgCl2, MgCO3, MgSO4, and Mg(NO3)2 to form SOx-free outlet flue gas; and optionally removing NOx from the flue gas, quenched flue gas, or SOx-free outlet flue gas to form NOx-free outlet flue gas consisting substantially of at least one of H2O, CO2, N2, and O2.

[0037] In some embodiments, the method further includes providing the recovered waste heat to one or more of the following: an evaporator in the CHP concentration unit, a dehydrator steam heat exchanger in the decomposition unit, and a reboiler in the acetone-phenol fractionation unit.

[0038] In some implementations, the quenched flue gas includes at least one of air, SOx-removed outlet flue gas, NOx-removed outlet flue gas, and water.

[0039] In some implementations, the water includes water flow from a non-phenolic water container or external water flow.

[0040] In some embodiments, the method further includes introducing a water washing waste stream from the phenol recovery unit section and a phenolic wastewater stream from the phenol recovery unit section into a phenolic water container.

[0041] In some embodiments, the method further includes: introducing at least one of an oxidizing waste air stream from an oxidation unit section, a decanter discharge stream from an oxidation unit section, a concentrated discharge gas stream from a CHP concentration unit section, and a fractionated hydrocarbon discharge gas stream from an acetone-phenol fractionation unit section into a waste air separator; optionally preheating the waste air stream from the waste air separator; and thermally oxidizing the waste air stream from the waste air separator in a thermal oxidation system.

[0042] In some embodiments, oxidizing a fresh cumene feed stream in an oxidation unit section to form an oxidation product stream includes: introducing the fresh cumene feed stream and an oxidation air feed stream into at least one oxidation reactor to form an oxidation product stream and an oxidation waste air stream; cooling the oxidation waste air stream in an oxidizer effluent gas cooler before introducing it into a waste air separator to form a condensate stream; passing the condensate stream into a decanter vessel to form a decanter effluent stream, an oxidation wastewater stream, and a decanter cumene recirculation stream; and in a cumene feed scrubbing tower, The decanter cumene recycle stream is washed with a recycle cumene wash water stream and a recycle cumene wash caustic alkali stream to form a washed cumene stream and a recycle cumene wash water waste stream; the washed cumene stream is fed into an oxidation reactor; the recycle cumene wash water waste stream is fed into a non-phenolic water container; and optionally, at least one of the following steps is performed: MSHP recycle cumene from the AMS hydrogenation unit is fed into a cumene feed scrubber, and concentrated recycle cumene from the CHP concentration unit is fed into a cumene feed scrubber.

[0043] In some embodiments, the method further includes at least one of the following steps: recycling a cumene stream from the CHP concentration unit to the oxidation unit; recycling a concentrated effluent gas stream from the CHP concentration unit to the oxidation unit; recycling a buffered phenol stream from the phenol recovery unit to the neutralization unit; and introducing an oxidizing wastewater stream into a peroxide destruction section to convert peroxides in the oxidizing wastewater stream into at least one of alcohols, ketones, aldehydes, organic acids, and water to form a peroxide-free oxidizing wastewater stream, and then introducing the peroxide-free oxidizing wastewater stream into a non-phenolic water container.

[0044] In some embodiments, the method further includes: reacting propylene and benzene in a cumene production area to produce at least one of a cumene feed stream and a cumene production unit hydrocarbon waste stream, a propane discharge stream, a benzene carryover stream, and a cumene production unit exhaust gas stream; and performing at least one of the following steps: introducing the cumene production unit hydrocarbon waste stream into a hydrocarbon buffer container; introducing at least one of the propane discharge stream and the benzene carryover stream into a fuel gas separator; and introducing the cumene production unit exhaust gas stream into a waste air separator.

[0045] In some embodiments, the method further includes preheating at least one of the phenolic water stream from the phenolic water container and the non-phenolic water stream from the non-phenolic water container before using at least one of the recovered waste heat from the thermal oxidation system and the low-pressure steam stream from the cumene production unit to heat and oxidize at least one of the waste air stream, the phenolic water stream, and the non-phenolic water stream.

[0046] In some embodiments, the method further includes: controlling the pressure in at least one of the hydrocarbon buffer container, phenolic water container, and non-phenolic water container in the push-pull system by introducing at least one of the fuel gas, liquefied petroleum gas, and exhaust gas into at least one of the hydrocarbon buffer container, phenolic water container, and non-phenolic water container; and sending excess fuel gas, liquefied petroleum gas, and exhaust gas to a fuel gas separator.

[0047] In some embodiments, phenolic water is atomized and injected into the burner flame in the thermal oxidizer section, and non-phenolic water is injected downstream of the burner flame.

[0048] Another aspect of the invention includes a method for producing phenol. In one embodiment, the method includes: reacting propylene and benzene in a cumene production zone to produce at least one of a fresh cumene feed stream and a cumene production unit hydrocarbon waste stream, a benzene tower water stream, a propane discharge stream, a benzene carry-over stream, and a cumene production unit effluent gas stream; oxidizing the fresh cumene feed stream in an oxidation unit section to form an oxidation product stream comprising cumene hydroperoxide (CHP), dimethylphenylmethanol (DMPC), and cumene, and at least one of an oxidation wastewater stream, an oxidation waste air stream, and a decanter discharge stream; and concentrating the oxidation product stream in a CHP concentration unit section to form a concentrated CHP stream and a concentrated discharge stream. The process includes: an effluent gas stream; decomposition of concentrated CHP stream using a decomposing acid in the decomposition unit to form an acidic crude product stream containing phenol, acetone, cumene, and AMS; neutralization of the acidic crude product stream with a neutralizing agent in the neutralization unit to form a neutralized crude product stream; fractionation of the neutralized crude product stream into a cumene-AMS-phenol stream in the acetone-phenol fractionation unit, as well as at least one of a phenolic water stream, an organic product stream, a wastewater stream, and a hydrocarbon effluent gas stream in the fractionation unit; and separation of the cumene-AMS-phenol stream into a cumene-AMS feed stream in the phenol recovery unit, along with a recycle stream containing phenol and cumene. Buffering at least one of a phenol stream and a phenolic wastewater stream; recycling the buffered phenol stream to a neutralization unit; hydrogenating the cumene-AMS feed stream in an AMS hydrogenation unit to form a MSHP-recycled cumene stream and an AMS hydrogen effluent stream; performing at least one of the following steps: introducing at least one of a fractionated organic product stream from a fractionation unit, a cumene production unit hydrocarbon waste stream from a cumene production unit, a fuel gas separator hydrocarbon liquid stream from a fuel gas separator, and a waste air separator liquid stream from a waste air separator into a hydrocarbon buffer container; introducing AMS hydrogen effluent gas from an AMS hydrogenation unit. At least one of the following streams is introduced into a fuel gas separator: propane discharge stream from the cumene production unit, benzene carry-over stream from the cumene production unit, hydrocarbon buffer container discharge gas stream from the hydrocarbon buffer container, phenolic discharge gas stream from the phenolic water container, and non-phenolic discharge gas stream from the non-phenolic water container; at least one of the following streams is introduced into a phenolic water container: fractionation wastewater stream, acetone-phenol fractionation unit stream, phenolic wastewater stream from the phenol recovery unit stream, and degreasing aqueous phase from the hydrocarbon buffer container; at least one of the following streams is introduced into a non-phenolic water container: oxidation wastewater stream from the oxidation unit stream and benzene tower water stream from the cumene production unit.In a thermal oxidation system, thermal oxidation of one or more of the following includes: thermal oxidation in the thermal oxidation section of the mixed hydrocarbon waste stream from the hydrocarbon buffer container, the burner fuel gas stream from the fuel gas separator, the waste air stream from the waste air separator, the phenolic water stream from the phenolic water container, and the non-phenolic water stream from the non-phenolic water container, to form flue gas substantially composed of at least one of H2O, CO2, N2, O2, SOx, NOx, HCl, Na2SO4, Na2CO3, and Cl2; in waste heat recovery Waste heat is recovered from the flue gas in the first stage; after waste heat recovery, the flue gas is optionally quenched in the quenching stage to form quenched flue gas consisting essentially of at least one of H2O, CO2, N2, O2, SOx, NOx, HCl, Na2SO4, Na2CO3, and Cl2; in the SOx removal stage, at least one of Na2SO4, Na2CO3, SOx, HCl, and Cl2 is optionally removed from the flue gas or the quenched flue gas to form SOx-free outlet flue gas consisting essentially of at least one of H2O, CO2, N2, O2, and NOx, wherein the removal of Na2SO4, Na2CO3, HCl, Cl2, and SOx from the flue gas includes: using a caustic alkali solution in the scrubbing stage. Alternatively, a solution based on NH3 may be contacted with quenched flue gas to form SOx-removed outlet flue gas and a liquid effluent containing at least one of H2O, Na2SO3, Na2SO4, Na2HSO3, Na2CO3, NaCl, (NH4)2SO4, and NH4Cl; or the flue gas may be reacted with reactants in the SOx reaction section to form a reaction mixture substantially composed of at least one of H2O, CO2, N2, O2, NaCl, Na2CO3, Na2SO4, NaNO3, NOx, CaCl2, CaSO4, CaCO3, Ca(NO3)2, MgCl2, MgCO3, MgSO4, Mg(NO3)2, Cl2, and NOx. The reaction section flue gas, wherein the reactants comprise NaHCO3, NaHCO3·Na2CO3·2(H2O), CaCO3, Ca(OH)2, and Mg(OH)2; and optionally, the reaction section flue gas is filtered in a filter section to remove at least one of NaCl, Na2CO3, Na2SO4, NaNO3, CaCl2, CaSO4, CaCO3, Ca(NO3)2, MgCl2, MgCO3, and MgSO4 to form SOx-free outlet flue gas; and optionally, NOx is removed from the flue gas, the quenched flue gas, or the SOx-free outlet flue gas to form NOx-free outlet flue gas consisting substantially of at least one of H2O, CO2, N2, and O2.

[0049] In some embodiments, the method further includes: introducing at least one of the following into a waste air separator: an oxidizing waste air stream from an oxidation unit section, a decanter discharge stream from an oxidation unit section, a concentrated discharge gas stream from a CHP concentration unit section, a fractionated hydrocarbon discharge gas stream from an acetone-phenol fractionation unit section, and a cumene production unit discharge gas stream from a cumene production unit; optionally preheating the waste air stream from the waste air separator; and thermally oxidizing the waste air stream from the waste air separator in a thermal oxidation system.

[0050] In some embodiments, the method further includes providing the recovered waste heat to one or more of the following: an evaporator in the CHP concentration unit, a dehydrator steam heat exchanger in the decomposition unit, and a reboiler in the acetone-phenol fractionation unit.

[0051] In some embodiments, the method further includes at least one of the following steps: introducing a water washing waste stream and a phenolic wastewater stream from the phenol recovery unit into a phenolic water container; and introducing at least one of an oxidation waste air stream from the oxidation unit, a decanter discharge stream from the oxidation unit, a concentrated discharge gas stream from the CHP concentration unit, and a fractionated hydrocarbon discharge gas stream from the acetone-phenol fractionation unit into a waste air separator.

[0052] In some embodiments, the method further includes preheating at least one of the phenolic water stream from the phenolic water container and the non-phenolic water stream from the non-phenolic water container before using at least one of the recovered waste heat from the thermal oxidation system and the low-pressure steam stream from the cumene production unit to heat and oxidize at least one of the waste air stream, the phenolic water stream, and the non-phenolic water stream.

[0053] In some embodiments, the method further includes: controlling the pressure in at least one of the hydrocarbon buffer container, phenolic water container, and non-phenolic water container in the push-pull system by introducing at least one of the fuel gas, liquefied petroleum gas, and exhaust gas into at least one of the hydrocarbon buffer container, phenolic water container, and non-phenolic water container; and sending excess fuel gas, liquefied petroleum gas, and exhaust gas to a fuel gas separator.

[0054] In some implementations, the phenolic water stream is atomized and injected into the burner flame, or directly injected downstream of the calculated flame length in the thermal oxidizer section. The flame length is typically between 5% and 50% of the total thermal oxidizer chamber (combustion chamber) length. The calculated flame length can be calculated using known methods (e.g., Flame Length and its Heat Radiation, Yagi, Bull. Chem. Soc. JP, 1949, Vol. 22, No. 3, pp. 97-104), or determined using known computational fluid dynamics (CFD) modeling (e.g., A Computational Flame Length Methodology for Propane Jet Fires, Cumber and Spearpoint, Fire Safety J., Vol. 3, April 2006, pp. 215-228; Structure & Calculation of a Gas Flame, Kryzhanovsky and Kryzhanovsky, 2012, Ukraine; An Experimental Study of Flame Lengths and Emissions of Fully-Modulated Diffusion Flames, Usowicz, Master's Thesis, Worcester Polytechnic Institute, May, 2001). Inject non-phenolic water downstream of the calculated atomization and evaporation distances for phenolic water. Known CFD modeling methods can be used to calculate the atomization and evaporation distances. Typical atomization and evaporation distances, expressed in time, range from 0.05 seconds to 0.5 seconds or from 0.15 seconds to 0.25 seconds.

[0055] Figure 1 The conventional structure of cumene / phenol complex 100 is shown.

[0056] Propylene feed stream 105 and benzene stream 110 are fed to cumene production unit 115, in which benzene is alkylated with propylene to form cumene. Propylene feed stream 105 contains propylene and propane (e.g., more than 60% propylene and the remainder being propane). Benzene stream 110 typically contains at least 80% by weight benzene, with the balance being C5-C7 non-aromatic compounds.

[0057] Suitable alkylation catalysts include solid acid catalysts, and preferably solid oxide zeolites. Examples include, but are not limited to, zeolite β, zeolite X, zeolite Y, mordenite, octahedral zeolite, zeolite ω, UZM-8, MCM-22, MCM-36, MCM-49, and MCM-56. Typical operating conditions include: temperatures in the alkylation reactor ranging from 100°C to 310°C (212°F to 590°F) or from 120°C to 280°C (248°F to 536°F); and pressures ranging from 800 kPa to 5100 kPa (116 psia to 740 psia) or from 1000 kPa to 3900 kPa (145 psia to 565 psia). Alkylation reactors, operating conditions, and catalysts are known in the art and will not be discussed further herein.

[0058] The effluent from the cumene production unit 115 includes cumene stream 120, benzene tower water stream 125, propane discharge stream 130, benzene carryover stream 135, cumene production unit effluent gas stream 140, and cumene production unit hydrocarbon waste stream 145.

[0059] A stream 120 of cumene, comprising more than 99.9% by weight of cumene and the remainder of other C8-C9 aromatic compounds, is fed to an oxidation unit section 150. Cucurene can be oxidized to cumene hydroperoxide (CHP) by direct liquid-phase oxidation with an oxidizing gas stream 155, which can be oxygen or an oxygen-containing gas such as air. This reaction is typically carried out at elevated temperatures. The temperature range for this oxidation reaction is from room temperature to the boiling point of cumene (152°C (305℉)), and the pressure range is from atmospheric pressure to 3.4 MPa(g) (500 psig).

[0060] Oxidation product stream 160 contains cumene hydroperoxide (CHP), dimethylphenylmethanol (DMPC), and unreacted cumene. Other effluents from oxidation unit section 150 include oxidation waste air stream 165, decanter effluent stream 170, and peroxide-containing oxidation wastewater stream 173.

[0061] The oxidation product stream 160 is transferred to the CHP concentration unit 175, where the CHP concentration is increased to 80% to 85% by weight to form a concentrated CHP stream 190. The cumene stream 180, containing unconverted cumene and a small amount of CHP, is then recycled to the oxidation unit 150. The concentrated exhaust gas stream 185 from the CHP concentration unit 175 can also be recycled to the oxidation unit 150.

[0062] The concentrated CHP stream 190 is fed to the decomposition unit section 195. In the decomposition unit section 195, the concentrated CHP is decomposed into phenol and acetone using decomposition acid 200 and water 205. Decomposition acid 200 can be a liquid acid such as H₂SO₄ or a gas such as H₂S. CHP decomposition is a highly exothermic reaction, typically carried out on a commercial scale in a continuously stirred or reverse-mixed reactor. In such reactors, only a small fraction of the CHP remains unreacted at any given time. The reaction medium consists essentially of the decomposition products of CHP (i.e., phenol and acetone) plus any solvent (e.g., cumene) and other materials added to the reactor along with the CHP. In the presence of the decomposition acid, DMPC formed during cumene oxidation dehydrates to α-methylstyrene (AMS), a useful byproduct.

[0063] An acidic crude product stream 210 containing phenol, acetone, unreacted cumene, and AMS is fed to a neutralization unit 215, in which the acidic crude product stream is contacted with a neutralizing agent 220. Suitable neutralizing agents 220 include, but are not limited to, amines (such as 2-methylpentanediamine (Dytek), hexamethylenediamine, triethylenetetramine, diethylenetriamine), sodium phenolate, ammonia, and sodium hydroxide.

[0064] The neutralized crude product stream 225 is sent to the acetone-phenol fractionation unit section 230. A fractionated cumene-AMS-phenol stream 235 containing cumene, AMS, and phenol is formed. Other streams may also be formed, including a fractionated phenolic water stream 240, a fractionated hydrocarbon effluent gas stream 245, a fractionated organic product stream 250, and a fractionated wastewater stream 255.

[0065] Fractionated cumene-AMS-phenol stream 235 and fractionated phenolic water stream 240 are fed to phenol recovery unit section 260, where further separation occurs. Recycled buffer phenol stream 265, final phenolic wastewater stream 270, and cumene-AMS feed stream 275. The recycled buffer phenol stream 265, containing phenol, unreacted cumene, and water, can be recycled to neutralization unit section 215.

[0066] A cumene-AMS feed stream 275, containing cumene and AMS, is fed to the AMS hydrogenation unit section 280. AMS is reacted with the hydrogen stream 285 to hydrogenate the AMS. A cumene stream 290, containing cumene and 0 to 0.1% by weight of MSHP (methylstyrene hydrogenation process) recycle, is recycled to the oxidation unit section 150. An AMS hydrogen exhaust gas stream 295 is also formed.

[0067] The cumene / phenol complex 100 comprises multiple units to handle various streams from different units in the complex.

[0068] The hydrocarbon waste stream 145 from the cumene production unit 115 contains diphenylpropane and C15+ Aromatic compounds. The hydrocarbon waste stream 145 from the cumene production unit is sent to the organic waste storage container 300.

[0069] The cumene production unit exhaust gas stream 140 from the cumene production unit 115 is sent to the thermal oxidizer 305. The cumene production unit exhaust gas stream contains N2 saturated with cumene at a cooling water temperature (e.g., 3 mol% cumene, 4.5 mol% O2 and the balance being N2 at a cooling temperature of, for example, 35°C).

[0070] The oxidizing waste air stream 165 and the decanter effluent stream 170 from the oxidation unit section 150 are also fed to the thermal oxidizer 305. The oxidizing waste air stream 165 contains N2, O2, and cumene (e.g., 1 mol% to 7 mol% O2 with the balance being N2), and this stream is saturated with cumene (i.e., 0.1 mol%) at a nominal temperature of 5°C (range 2°C–10°C). The decanter effluent stream 170 contains N2, O2, and cumene (e.g., 1 mol% to 7 mol% O2 with the balance being N2), and this stream is saturated with cumene (i.e., 0.1 mol%) at a nominal temperature of 35°C (range 20°C–35°C).

[0071] The fractionated hydrocarbon effluent gas stream 245 from the acetone-phenol fractionation unit section 230 is fed to the thermal oxidizer 305. The fractionated hydrocarbon effluent gas stream 245 contains N2 (e.g., greater than 99 mol% N2 and 0 to 1 mol% phenol and acetone).

[0072] The AMS hydrogen effluent gas stream 295 from the AMS hydrogenation unit section 280 is sent to the thermal oxidizer 305. The AMS hydrogen effluent gas stream 295 contains H2 and methane (e.g., 80 mol% to 100 mol% H2, 0 to 0.1 mol% cumene, and the balance being methane, ethane and N2).

[0073] The cumene / phenol complex has a wastewater treatment device 315 to treat and remove contaminants from industrial water. The wastewater treatment device 315 receives benzene tower water stream 125 from the cumene production unit 115, fractionation wastewater stream 255 from the acetone-phenol fractionation unit 230, final phenolic wastewater stream 270 from the phenol recovery unit 260, and peroxide-containing oxidation wastewater stream 173 from the oxidation unit 150 or peroxide-free oxidation wastewater stream 322 from the peroxide destruction unit 320.

[0074] The fractionated wastewater stream 255 from the acetone-phenol fractionation unit 230 is sent to the wastewater treatment equipment. The fractionated wastewater stream contains water, caustic soda and acetone (e.g., 0 to 30 wppm phenol, 0 to 2 wt% caustic soda, 100 wppm to 1000 wppm acetone and 0 to 500 wppm cumene).

[0075] The final phenolic wastewater stream 270 from the phenol recovery unit section 260 contains water, phenol and salt (e.g., 10 wppm to 100 wppm phenol, 10 wt% to 25 wt% sodium sulfate and the balance being water).

[0076] The peroxide-containing oxidative wastewater stream 173 from oxidation unit section 150 comprises water, CHP, and caustic soda (e.g., 0 to 2000 w ppm total peroxides, 300 w ppm cumene, 0.1 wt% caustic soda, and the remainder being water). The peroxide-containing oxidative wastewater stream 173 can be directly fed to wastewater treatment facility 315 (solid line). In some embodiments, the peroxide-containing oxidative wastewater stream 173 can be fed to an optional peroxide destruction unit section 320, where the peroxides in the peroxide-containing oxidative wastewater stream 173 are converted into alcohols, ketones, aldehydes, organic acids, and water. In this case, the peroxide-free oxidative wastewater stream 322 from the peroxide destruction unit section 320 is fed to wastewater treatment facility 315 (dashed line).

[0077] The benzene tower water stream 125 from the cumene production unit 115 contains water saturated with benzene (e.g., 1100 wppm to 1900 wppm benzene at a cooling temperature of, for example, 35°C).

[0078] The propane discharge stream 130 from the cumene production unit 115 contains propane with saturated benzene (e.g., 45% propane by weight with 25% benzene by weight, 11% non-aromatic compound and 4% ethane by weight at 35°C), and the propane discharge stream is sent to the release manifold.

[0079] The benzene carryover stream contains benzene and C5-C7 non-aromatic compounds (e.g., 40% to 90% by weight of benzene and the balance being C5-C7 non-aromatic compounds). The higher the purity of benzene stream 110, the lower the carryover rate of benzene carryover stream 135. For example, benzene carryover stream 135 can be sent to an aromatic compound complex for benzene recovery, or to a gasoline pool.

[0080] Fractionated organic product stream 250 from acetone-phenol fractionation unit 230 is fed to product storage unit 310. This fractionated organic product stream contains organic residues (e.g., 0 to 5 wt% phenol, 2 wt% to 20 wt% acetophenone, with the balance being unidentified heavy matter). This fractionated organic product stream is typically combusted; in some cases, it is mixed with fuel oil prior to combustion.

[0081] Figures 2 to 3An example of the cumene / phenol complex 325 of the present invention is shown. The portions of the cumene / phenol complex 325 are as described above, including a cumene production unit 115, an oxidation unit section 150, a CHP concentration unit section 175, a decomposition unit section 195, a neutralization unit section 215, an acetone-phenol fractionation unit section 230, a phenol recovery unit section 260, an AMS hydrogenation unit section 280, a peroxide destruction unit section 320, and a product storage unit 310.

[0082] and Figure 1 Compared to other methods, this method requires fewer supplemental chemicals. For example, the amount of sodium hydroxide and sulfuric acid added in the phenol recovery unit 260 is reduced because the first phenolic wastewater stream 271 is sent to the phenolic water container 345 and then to the thermal oxidation system. The first phenolic wastewater stream 271 has a lower concentration of chemicals than other methods. Figure 1 The final phenolic wastewater stream has a higher phenol content than 270, as shown in the following text. Figures 6 to 7 As shown. Furthermore, with Figure 1 Compared to other methods, this method also reduces the amount of first phenolic wastewater flowing through it (271).

[0083] However, as Figure 3 As shown, the method includes an exhaust air separator 330, a hydrocarbon buffer container 335, a fuel gas separator 340, a phenolic water container 345, a non-phenolic water container 350, and a thermal oxidation system 355.

[0084] Waste air separator 330 contains at least one of the following: cumene production unit exhaust gas stream 140 from the cumene production unit, oxidative waste air stream 165 from the oxidation unit section 150, decanter exhaust stream 170 from the oxidation unit section 150, and fractionated hydrocarbon exhaust gas stream 245 from the acetone-phenol fractionation unit section 230. Waste air stream 360 from waste air separator 330 can be sent to thermal oxidation system 355. Cold waste air carry-out stream 361 from waste air stream 360 may be present.

[0085] Hydrocarbon buffer container 335 contains at least one of the following: hydrocarbon waste stream 145 from cumene production unit 115, fractionated organic product stream 250 from acetone-phenol fractionation unit section 230, waste air separator liquid stream 365 from waste air separator 330, and fuel gas separator hydrocarbon liquid stream 370 from fuel gas separator 340. The mixed hydrocarbon waste stream 375 from hydrocarbon buffer container 335 is fed to thermal oxidation system 355.

[0086] The fuel gas separator 340 contains at least one of the following: AMS hydrogen exhaust gas stream 295 from the AMS hydrogenation unit section 280, hydrocarbon buffer container exhaust gas stream 391 from the hydrocarbon buffer container 335, phenolic exhaust gas stream 393 from the phenolic water container 345, and non-phenolic exhaust gas stream 395 from the non-phenolic water container 350. The fuel gas separator may also contain a propane exhaust stream 130 and a benzene carryover stream 135 from the cumene production unit 115. The burner fuel stream 380 from the fuel gas separator 340 is fed to the thermal oxidation system 355.

[0087] The phenolic water container 345 contains at least one of a fractionation wastewater stream 255 from the acetone-phenol fractionation unit section 230 and a first phenolic wastewater stream 271 from the phenol recovery unit section 260. The phenolic water container may also contain a degreased aqueous phase 382 from the hydrocarbon buffer container 335. The phenolic water stream 385 from the phenolic water container 345 is fed to the thermal oxidation system 355.

[0088] The non-phenolic water container 350 contains at least one of the following: a peroxide-containing oxidative wastewater stream 173 from the oxidation unit section 150, a peroxide-free oxidative wastewater stream 322 from the peroxide destruction unit section 320, and a benzene tower water stream 125 from the cumene production unit 115. The non-phenolic water stream 390 from the non-phenolic water container 350 is fed to the thermal oxidation system 355.

[0089] The temperature of one or more of the waste air stream 360, the phenolic water stream 385, and the non-phenolic water stream 390 can be adjusted as needed (e.g., increased or decreased). The heat used to increase the temperature can come from waste heat recovered from the thermal oxidation system 355, as will be discussed below.

[0090] Hydrocarbon buffer container 335, phenolic water container 345, and non-phenolic water container 350 each maintain a constant pressure by using a push / pull system of liquefied petroleum gas / exhaust gas / fuel gas. There are exhaust gas flows 391, 393, and 395 entering and exiting each of the hydrocarbon buffer container 335, phenolic water container 345, and non-phenolic water container 350. When the pressure is high, gas is pushed out of the hydrocarbon buffer container 335, phenolic water container 345, and non-phenolic water container 350 via line 397 to the fuel gas separator 340, while when the pressure is low, gas is drawn into the hydrocarbon buffer container 335, phenolic water container 345, and non-phenolic water container 350 via the exhaust gas / fuel gas supply line 397.

[0091] One implementation of the thermal oxidation system 355 is in Figure 4 As shown in the figure, the thermal oxidation system 355 includes a thermal oxidation section 400, a waste heat recovery section 415, a quenching section 445, an SOx removal section 460, and an optional NOx removal section 490.

[0092] At least one of the following streams is introduced into the thermal oxidation section 400: waste air stream 360 from waste air separator 330, mixed hydrocarbon waste stream 375 from hydrocarbon buffer container 335, burner fuel stream 380 from fuel gas separator 340, phenolic water stream 385 from phenolic water container 345, and non-phenolic water stream 390 from non-phenolic water container 350, along with supplemental natural gas stream 401, quench stream 403, and combustion air stream 405. Optionally, at least one of the following streams may be preheated and / or pressurized before being introduced into the thermal oxidation section 400: waste air stream 360 from waste air separator 330, phenolic water stream 385 from phenolic water container 345, and non-phenolic water stream 390 from non-phenolic water container 350. Waste air stream 360 typically has a temperature of -30°C to 30°C, and may need to be raised to a temperature of 31°C to 180°C. Phenolic water flow 385 and non-phenolic water flow 390 typically have a temperature range of 1°C to 70°C, and they may require temperatures to be raised to 71°C to 180°C.

[0093] The inlet temperature of the thermal oxidation section 400 is typically in the range of -30°C to 500°C, and the pressure is -1 kPa(g) to 3000 kPa(g). The outlet temperature is typically in the range of 650°C to 1300°C, and the pressure is -1 kPa(g) to 50 kPa(g). The residence time in the thermal oxidation section 400 is between 0.5 seconds and 2 seconds. The thermal oxidation section 400 operates at temperatures in the range of 650°C to 1300°C, with residence times between 0.5 seconds and 2 seconds. Any suitable thermal oxidation section 400 can be used, including but not limited to an adiabatic thermal oxidizer chamber. The thermal oxidation section 400 can be forced ventilation, induced ventilation, or a combination of both. Although a selective non-catalytic reduction (SNCR) section is typically absent, an optional SNCR section may be present. The inlet temperature of the SNCR section is typically in the range of 650°C to 1300°C, and the pressure is -1 kPa(g) to 50 kPa(g). The outlet temperature is typically in the range of 650℃-1040℃, and the pressure is -1 kPa(g) to 50 kPa(g). The residence time in the SNCR section is between 0.2 seconds and 1 second. The thermal oxidation step is separated from the SNCR step via a choke wall in the vessel. Hydrocarbons are converted to H2O and CO2. Sulfides from sulfur compounds (e.g., H2S) present in the feed are converted to oxidized sulfur particles SOx (including but not limited to SO2 and SO3) and H2O. Nitrogen from nitrogen-bound molecules (e.g., NH3) present in the feed is converted to nitrogen gas (N2) and NOx (including but not limited to NO and NO2). HCl and Cl2 are retained (if present). However, in many cases, there will not be significant amounts of nitrogen-containing molecules and / or sulfur-containing molecules and / or chlorine-containing molecules in the feed to the thermal oxidation section 400; therefore, the SNCR section, SOx removal section, and NOx removal section will typically not be present.

[0094] In some embodiments, a stream of phenolic water 385 from a phenolic water container 345 is directly injected into the flame section of the thermal oxidation section 400, while a stream of non-phenolic water 390 is injected downstream of the flame section. This reduces the amount of fuel required to operate the thermal oxidation section 400.

[0095] The flue gas stream 410 from the thermal oxidation section 400 consists essentially of one or more of H2O, CO2, N2, O2, SOx (i.e., SO2 and SO3), NOx (i.e., NO and NO2), HCl, Na2SO4, Na2CO3, and Cl2. "Essentially consists of..." means the presence of one or more of these gases or vapors, and the absence of other gases or vapors that require treatment before release into the atmosphere. The flue gas stream 410 is then sent to the waste heat recovery section 415. A quenching stream 412 cools the flue gas stream 410 to a temperature below 720°C, and preferably below 705°C, to prevent liquid salt contamination of the boiler in the waste heat recovery section 415. The inlet temperature of the waste heat recovery section 415 is typically in the range of 500°C to 720°C, and the pressure is -2 kPa(g) to 50 kPa(g). The outlet temperature is typically in the range of 200°C to 400°C, and the pressure is -2 kPa(g) to 50 kPa(g). Suitable waste heat recovery equipment and methods include, but are not limited to, waste heat recovery boilers, including, but not limited to, fire-tube boilers or water-tube boilers. Boiler feedwater or oil flow 420 enters the waste heat recovery section 415, where a portion is converted into steam or hot oil flow 430 as recovered waste heat, and the remainder leaves as effluent water or oil flow 425. In some cases, if desired, a steam turbine may be used, for example, to convert the steam into electricity.

[0096] The recovered waste heat in steam or hot oil stream 430 may be in the form of low-pressure (e.g., less than 350 kPa(g)), medium-pressure (e.g., 350 kPa(g) to 1750 kPa(g)), or high-pressure (e.g., greater than 1750 kPa(g)) saturated or superheated steam, hot oil, and / or electricity. The recovered heat can be used to provide heat to one or more equipment or process streams in the phenol / cumene complex, or to other parts of the equipment. For example, the recovered waste heat in steam or hot oil stream 430 can be used to heat one or more of the evaporator in the CHP concentration unit section 175, the dehydrator steam heat exchanger in the decomposition unit section 195, and the reboiler in the acetone-phenol fractionation unit section 230, or for other heat needs.

[0097] If the removal of Na2SO4, Na2CO3, SOx, NOx, HCl and Cl2 is not required, then exhaust stream 435, which is essentially composed of one or more of H2O, CO2, N2, O2, Na2SO4, Na2CO3, SOx, NOx, HCl and Cl2, leaves the waste heat recovery section 415.

[0098] Additionally, flue gas flow 440 flows from waste heat recovery section 415 to quench section 445, where quenching flow 450 is used to reduce the flue gas temperature to saturation temperature. The inlet temperature of quenching section 445 is typically in the range of 200°C to 400°C, and the pressure is -3 kPa(g) to 50 kPa(g). The outlet temperature is typically in the range of 45°C to 150°C, and the pressure is -3 kPa(g) to 50 kPa(g). Quenching flow 450 includes, but is not limited to, air, SOx-removed outlet flue gas, NOx-removed outlet flue gas, water, or combinations thereof. Water may include a flow from non-phenolic water container 350 (not shown) or an external water flow.

[0099] A quenched flue gas stream 455 from the quenching section 445 is fed to the SOx removal section 460 to remove at least one of Na₂SO₄, Na₂CO₃, SOx, HCl, and Cl₂. The inlet temperature of the SOx removal section 460 is typically in the range of 45°C to 150°C, and the pressure is -4 kPa(g) to 50 kPa(g). The outlet temperature is typically in the range of 45°C to 150°C, and the pressure is -4 kPa(g) to 50 kPa(g). For example, the SOx removal section may be a scrubbing section, in which a feed stream 465 containing a caustic alkali (aqueous NaOH) is introduced into the SOx removal section 460, where the feed stream reacts with SOx, HCl, and Cl₂ (if present) in the flue gas. An aqueous feed stream 470 containing at least one of Na₂SO₃, NaHSO₃, Na₂SO₄, and NaCl exits the SOx removal section 460. If desired, a reducing agent such as NaHSO4 or H2O2 may be included to react with Cl2 to form HCl, which in turn reacts to form NaCl. Alternatively, stream 465 may be a solution based on NH3 (e.g., aqueous or anhydrous NH3). NH3 reacts with SOx to form (NH4)2SO4. NH3 reacts with Cl2 to form N2 and HCl, which then reacts with NH3 to form NH4Cl. When using NH3, a separate reducing agent is not required. In this case, the aqueous stream 470 will be H2O, (NH4)2SO4, and NH4Cl.

[0100] If NOx removal is not required, exhaust stream 475, which consists essentially of one or more of H2O, CO2, N2, O2, and NOx, exits the SOx removal section 460.

[0101] Compared to the incoming quenched flue gas stream 455, the SOx-removed outlet flue gas stream 480 from the SOx removal section 460 has reduced levels of Na2SO4, Na2CO3, HCl, Cl2, SOx, and NOx. The SOx-removed outlet flue gas stream 480 contains one or more of H2O, CO2, N2, O2, and NOx.

[0102] If NOx exceeding the permissible emission limit is present in the SOx removal outlet flue gas stream 480, the SOx removal outlet flue gas stream 480 is sent to an optional NOx removal section 490 to remove NOx. The inlet temperature of the NOx removal section 490 is typically in the range of 150°C to 300°C, and the pressure is -5 kPa(g) to 50 kPa(g). The outlet temperature is typically in the range of 200°C to 350°C, and the pressure is -5 kPa(g) to 50 kPa(g). The SOx removal outlet flue gas stream 480 may need to be heated to obtain the desired inlet temperature of the NOx removal section 490. For example, the NOx removal section 490 may be a selective catalytic reduction (SCR) section, in which an ammonia and / or urea stream 485 is introduced into the SCR section, where the ammonia and / or urea stream reacts with NOx to form N2 and H2O. Any suitable SCR catalyst can be used, including but not limited to ceramic support materials, such as titanium oxide with active catalytic components (such as oxides of base metals (including vanadium, molybdenum, and tungsten)), or activated carbon-based catalysts. The NOx removal outlet flue gas 495 contains one or more of H2O, CO2, N2, and O2.

[0103] Another implementation of the thermal oxidation system 355' is in Figure 5 As shown in the figure, the thermal oxidation system 355' includes a thermal oxidation section 500, a waste heat recovery section 515, an SOx removal section, and a NOx removal section 600, the SOx removal section including an SOx reaction section 550 and a filtration section 570.

[0104] At least one of the following is introduced into the thermal oxidation section 500: waste air stream 360 from waste air separator 330, mixed hydrocarbon waste stream 375 from hydrocarbon buffer container 335, burner fuel stream 380 from fuel gas separator 340, phenolic water stream 385 from phenolic water container 345, and non-phenolic water stream 390 from non-phenolic water container 350, together with supplemental natural gas stream 501, quench stream 503, and combustion air stream 505.

[0105] Optionally, at least one of the waste air stream 360 from the waste air separator 330, the phenolic water stream 385 from the phenolic water container 345, and the non-phenolic water stream 390 from the non-phenolic water container 350 may be preheated before being introduced into the thermal oxidation section 500, as described above.

[0106] The inlet temperature of the thermal oxidizer section 500 is typically in the range of -30°C to 500°C, and the pressure is -1 kPa(g) to 3000 kPa(g). The outlet temperature is typically in the range of 650°C to 1300°C, and the pressure is -1 kPa(g) to 50 kPa(g). The residence time in the thermal oxidizer section 500 is between 0.5 seconds and 2 seconds. Any suitable thermal oxidizer section 500 can be used, including but not limited to adiabatic thermal oxidizer chambers or non-adiabatic direct-fired boilers. The thermal oxidizer section 500 can be forced ventilation, induced ventilation, or a combination of both. The optional non-suspension non-renewal (SNCR) section typically has an inlet temperature in the range of 650°C to 1300°C, and a pressure of -1 kPa(g) to 50 kPa(g). The outlet temperature is typically in the range of 650°C to 1040°C, and the pressure is -1 kPa(g) to 50 kPa(g). The residence time in the SNCR section is between 0.2 seconds and 1 second. The thermal oxidation step is separated from the SNCR step by a choke wall in the container.

[0107] The flue gas stream 510 from the thermal oxidation section 500 contains one or more of H2O, CO2, N2, O2, SOx, Na2SO4, Na2CO3, NOx, HCl, and Cl2. The flue gas stream 510 is then sent to the waste heat recovery section 515. A quenching stream 512 cools the flue gas stream 510 to a temperature below 720°C, and preferably below 705°C, to prevent liquid salt contamination of the boiler in the waste heat recovery section 515. Boiler feedwater or oil stream 520 enters the waste heat recovery section 515, a portion of which is converted into steam or hot oil stream 530, and the remainder leaves as effluent or oil 525. Suitable waste heat recovery equipment and methods are described above. The inlet temperature of the waste heat recovery section 515 is typically in the range of 500°C–720°C, and the pressure is -2 kPa(g) to 50 kPa(g). The outlet temperature is typically in the range of 200°C–400°C, and the pressure is -2 kPa(g) to 50 kPa(g). The recovered waste heat in steam or hot oil stream 530 may be in the form of low-pressure, medium-pressure, or high-pressure saturated or superheated steam, hot oil, and / or electricity, as described above. The recovered waste heat in steam or hot oil stream 530 may be used for one or more of the evaporator in the CHP concentration unit section 175, the dehydrator steam heat exchanger in the decomposition unit section 195, and the reboiler in the acetone-phenol fractionation unit section 230, or for other heat needs.

[0108] If the removal of Na2SO4, Na2CO3, SOx, NOx, HCl and Cl2 is not required, then exhaust stream 535, which is essentially composed of one or more of H2O, CO2, N2, O2, Na2SO4, Na2CO3, SOx, NOx, HCl and Cl2, leaves the waste heat recovery section 515.

[0109] Flue gas stream 540 from waste heat recovery section 515 is fed to SOx reaction section 550 to convert at least one of SOx, HCl, and Cl2. The inlet temperature of SOx reaction section 550 is typically in the range of 200°C–400°C, and the pressure is -3 kPa(g) to 50 kPa(g). The outlet temperature is typically in the range of 200°C–400°C, and the pressure is -3 kPa(g) to 50 kPa(g). Fresh adsorbent 545 and optional recycle adsorbent 555 (comprising one or more of NaCl, Na2CO3, Na2SO4, NaNO3, CaCl2, CaSO4, CaCO3, Ca(NO3)2, MgCl2, MgCO3, MgSO4, and Mg(NO3)2, depending on the compounds used in the reactants, as described below) can be added to flue gas stream 540. For example, the SOx reaction section 550 may contain reactants such as NaHCO3, NaHCO3·Na2CO3·2(H2O), CaCO3, Ca(OH)2, and Mg(OH)2. These reactants react with SOx, NOx, HCl, and Cl2 to form NaCl, Na2CO3, Na2SO4, NaNO3, CaCl2, CaSO4, CaCO3, Ca(NO3)2, MgCl2, MgCO3, MgSO4, Mg(NO3)2, and NOx. Compared to the incoming flue gas stream 540, the SOx removal outlet flue gas stream 560 contains less Na2SO4, Na2CO3, HCl, Cl2, SOx, and NOx. The SOx removal outlet flue gas stream 560 is composed of one or more of the following: H2O, CO2, N2, O2, NaCl, Na2CO3, Na2SO4, NaNO3, CaCl2, CaSO4, CaCO3, Ca(NO3)2, MgCl2, MgCO3, MgSO4, Mg(NO3)2, NOx, and Cl2.

[0110] The SOx-removed outlet flue gas flow 560 is combined with a quenched flow 565 containing air and / or water and / or quenched flue gas. The temperature of the SOx-removed outlet flue gas flow 560 is typically reduced from 200°C-400°C (pressure -3 kPa(g) to 50 kPa(g)) to 150°C-250°C (pressure -4 kPa(g) to 50 kPa(g)). The quenched SOx-removed outlet flue gas flow 560 is then fed to a filter section 570. The inlet temperature of the filter section 570 is typically in the range of 150°C-350°C, and the pressure is -5 kPa(g) to 50 kPa(g). The outlet temperature is typically in the range of 150°C-350°C, and the pressure is -5 kPa(g) to 50 kPa(g). Suitable filter sections 570 may include, but are not limited to, bag filters, ceramic filters, electrostatic precipitators, or combinations thereof. Instrument air purging or a high-pressure DC 575 is introduced into the filter section 570. In the case of instrument air purging, the instrument air purging removes the substances retained in the filter. In the case of high-pressure flow, the high-pressure flow charges the negative electrode of the ESP. Particles are removed from the ESP by vibration. A dry slag stream 580 containing at least one of NaCl, Na2CO3, Na2SO4, NaNO3, CaCl2, CaSO4, CaCO3, Ca(NO3)2, MgCl2, MgCO3, MgSO4, and Mg(NO3)2 exits the filter section 570. The filtered flue gas stream 590 contains one or more of H2O, CO2, N2, O2, and NOx.

[0111] If NOx removal is not required, exhaust stream 585, which consists essentially of one or more of H2O, CO2, N2, NOx, and O2, exits the filter section 570.

[0112] If NOx is present in the filtered flue gas stream 590, the filtered flue gas stream 590 is sent to an optional NOx removal section 600 to remove the NOx as described above. The inlet temperature of the NOx removal section 600 is typically in the range of 150°C to 300°C, and the pressure is -6 kPa(g) to 50 kPa(g). The outlet temperature is typically in the range of 200°C to 350°C, and the pressure is -6 kPa(g) to 50 kPa(g). For example, the NOx removal section 600 may be a selective catalytic reduction (SCR) section, in which an ammonia and / or urea stream 595 is introduced into the SCR section, where the ammonia and / or urea stream reacts with NOx to form N2 and H2O. Any suitable SCR catalyst may be used, including but not limited to ceramic support materials such as titanium oxide (such as oxides of base metals (including vanadium, molybdenum, and tungsten)) with active catalytic components, or activated carbon-based catalysts. The NOx removal outlet flue gas stream 605 contains one or more of H2O, CO2, N2 and O2.

[0113] Figure 6 A portion 645 of the phenol recovery unit section 260 for conventional complexes is shown. Fractionated cumene-AMS-phenol stream 235 and fractionated phenolic water stream 240 are fed to the phenol recovery unit section 260 along with water stream 650, supplemental caustic alkali stream 655, fresh cumene stream 660, and acid injection stream 665. The cumene-AMS feed stream 275 is fed to the AMS hydrogenation unit section 280. The recycled buffered phenol stream 265 is fed to the neutralization unit section 215. The washed waste stream 680 exits from portion 645 of the phenol recovery unit section 260. The first phenolic wastewater stream 271 is fed to an oil extraction tower 690, where it is separated into a phenol-rich cumene solvent stream 695 and a final phenolic wastewater stream 270. This phenol-rich cumene solvent stream contains cumene and phenol (e.g., 50 W ppm to 1000 W ppm phenol, with the balance being cumene). The phenol-rich cumene solvent stream 695 is fed to a solvent caustic alkali scrubbing tower 700. A supplemental caustic alkali stream 705 is introduced into the solvent caustic alkali scrubbing tower 700 to remove phenol from the phenol-rich cumene solvent stream 695. The recirculated sodium phenolate stream 715 is returned to a portion 645 of the phenol recovery unit section 260. The phenol portion of this stream exits together with the recirculated buffer phenol stream 265. A lean solvent stream 710 containing cumene (e.g., 0 to 50 wppm phenol) and a fresh cumene feed 120 are fed to a solvent tank 720. The cumene recycle stream 725 is split into an oil extraction column cumene recycle stream 730 and a PRU cumene recycle stream 735. The oil extraction column cumene recycle stream 730 is returned to the oil extraction column 690. The PRU cumene recycle stream 735 is returned to a portion 645 of the phenol recovery unit section 260.

[0114] Figure 7 A portion 645' of a phenol recovery unit section 260 according to one embodiment of the invention is shown. In this arrangement, the oil extraction tower 690 and the solvent caustic alkali washing tower 700 are eliminated, thereby significantly reducing equipment costs. The water washing waste stream 680 and the first phenolic wastewater stream 271 are sent to a phenolic water container 345. The phenolic water stream 385 from the phenolic water container 345 is sent to a thermal oxidation system 355. This arrangement reduces the amount of caustic alkali (NaOH) and H2SO4 because the phenolic water is sent to the thermal oxidation system 355.

[0115] Figure 8 An embodiment of a conventional oxidation unit section 150 is shown. A cumene stream 120 and an oxidizing gas stream 155 are fed to an oxidation reactor 750, where cumene is oxidized to CHP. An oxidation product stream 160 is fed to a CHP concentration unit section 175, as described above.

[0116] Oxidation waste air stream 755 is cooled in oxidizer exhaust gas cooler 760, where it is separated into cooled exhaust gas stream 775 and oxidizer exhaust gas cooler condensate stream 765. Cooled exhaust gas stream 775 is sent to exhaust gas treatment unit 780 for processing. Oxidation waste air stream 165 from exhaust gas treatment unit 780 is sent to thermal oxidizer 305. Oxidizer exhaust gas cooler condensate stream 765 from oxidizer exhaust gas cooler 760 and exhaust gas treatment unit condensate stream 785 from exhaust gas treatment unit 780 are sent to decanter container 770. Decanter effluent stream 170 is sent to thermal oxidizer 305. Decanter water effluent stream 787 leaves decanter container 770. Decanter cumene recirculation stream 790 is sent to cumene feed scrubber 795. The cumene stream 180 from the CHP concentration unit 175 and the cumene stream 290 from the MSHP recirculation unit 280 can also be fed to the cumene feed scrubber 795. The recirculated cumene wash water stream 800 and the recirculated cumene wash caustic alkali stream 805 are introduced into the cumene feed scrubber 795. The scrubbed cumene stream 815 is fed to the oxidation reactor 750. The recirculated cumene wash water waste stream 810 is discharged from the cumene feed scrubber 795 and combined with the decanter effluent stream 787 to form a peroxide-containing oxidation wastewater stream 173. The peroxide-containing oxidation wastewater stream 173 can be directly fed to the wastewater treatment unit 315, or optionally fed to the peroxide destruction unit 320 to form a peroxide-free oxidation wastewater stream 322 before being fed to the wastewater treatment unit 315.

[0117] Figure 9 A similar oxidation reaction unit segment 150' according to the invention is shown. In this embodiment, the effluent gas treatment unit 780 is eliminated. The oxidizer effluent gas cooler condensate stream 765 from the oxidizer effluent gas cooler 760 is sent to the decanter container 770. The cooled effluent gas stream 775 from the oxidizer effluent gas cooler 760 is sent to the waste air separator 330. The decanter effluent stream 170 from the decanter container 770 is sent to the waste air separator 330. The decanter water effluent stream 787 is combined with the recirculated cumene wash water waste stream 810 from the cumene feed scrubber 795 to form a peroxide-containing oxidation wastewater stream 173. The peroxide-containing oxidation wastewater stream 173 can be sent directly to the phenolic water container 345, or optionally to the peroxide destruction unit segment 320 to form a peroxide-free oxidation wastewater stream 322 before being sent to the phenolic water container 345.

[0118] Figure 10Another embodiment of the conventional oxidation unit section 150 is shown. In this case, there is no effluent gas treatment unit 780. In this embodiment, the oxidizing waste air stream 755 is cooled in an oxidizer effluent gas cooler 760, in which the oxidizing waste air stream is separated into a cooled effluent gas stream 775 and an oxidizer effluent gas cooler condensate stream 765. The cooled effluent gas stream 775 is sent to the thermal oxidizer 305. The oxidizer effluent gas cooler condensate stream 765 from the oxidizer effluent gas cooler 760 is sent to a decanter container 770. The decanter effluent stream 170 is sent to the thermal oxidizer 305. The decanter water effluent stream 787 is sent to a wastewater treatment facility 315. The decanter cumene recycle stream 790 is sent to a cumene feed scrubber 795. The remainder of the method is as described above. Figure 8 same.

[0119] Figure 11 A similar oxidation reaction unit segment 150”' according to the invention is shown. In this embodiment, a cooled exhaust gas stream 775 from an oxidizer exhaust gas cooler 760 is sent to a waste air separator 330. A decanter effluent stream 170 from a decanter container 770 is sent to a waste air separator 330. A decanter water effluent stream 787 is sent to a phenolic water container 345. A recirculated cumene wash water waste stream 810 from a cumene feed scrubber 795 is sent to a phenolic water container 345.

[0120] Figure 12 It shows an improved energy recovery Figure 4 An embodiment of the thermal oxidation system 355. In this embodiment, energy can be recovered from the exhaust steam stream 900 by cooling the steam and condensing the water in the exhaust steam stream 900. In some cases, after treatment such as neutralization and / or degassing and / or filtration, the condensate stream can be used as process water for other parts of the process.

[0121] The exhaust steam stream 900 can be sent to an optional secondary heat exchanger 905. The exhaust steam stream 900 can be either a NOx removal outlet flue gas stream 495 or an exhaust stream 475. The exhaust steam stream 900 is sent to the second side of the secondary heat exchanger 905.

[0122] The process flow is fed to the first side of the secondary heat exchanger 905. Depending on the temperature of the exhaust steam flow 900 and the amount of process flow to be heated, there may be one or more secondary heat exchangers 905.

[0123] The process flow can be all or part of the waste air flow 360 from the waste air separator 330, such as Figure 13As shown. Other options for the process flow include all or part of the combustion air flow 405, and all or part of the boiler feedwater or oil flow 420.

[0124] The process flow is heated by heat exchange with the exhaust steam flow 900, which is then cooled to form a first cooled exhaust steam flow 910.

[0125] The heated waste air stream 360 is sent to the thermal oxidation section 400 of the thermal oxidation system 355. The heated combustion air stream 405 is also sent to the thermal oxidation section 400, while the heated boiler feedwater or oil stream 420 is sent to the waste heat recovery section 415, thereby improving the efficiency of steam generation or hot oil generation.

[0126] The process wastewater flows through the first side of the main heat exchanger 915. Depending on the temperature of the exhaust steam flow 900 or the first cooled exhaust steam flow 910 and the amount of process wastewater to be heated, there may be one or more main heat exchangers 915.

[0127] The process wastewater stream can be compressed from a pressure of 0 psig to 75 psig to a pressure of 100 psig to 400 psig in a pump and / or compressor 920, for example, and then the process wastewater stream is introduced into the main heat exchanger 915 to avoid flashing and / or boiling in the main heat exchanger 915.

[0128] The process wastewater stream can be all or part of at least one of the phenolic water stream 385 from the phenolic water container 345 and the non-phenolic water stream 390 from the non-phenolic water container 350.

[0129] The first cooled exhaust steam stream 910 is sent to the main heat exchanger 915, wherein the first cooled exhaust steam stream passes through a second side of the main heat exchanger 915. Alternatively, in the absence of a secondary heat exchanger 905, the exhaust steam stream 900 is sent to the main heat exchanger 915.

[0130] The first cooled exhaust steam stream 910 entering the main heat exchanger 915 has a temperature above the dew point. Heat exchange with the process wastewater stream lowers the temperature of the first cooled exhaust steam stream 910. In some cases, this temperature will drop to or below the dew point, causing water to condense from the first cooled exhaust steam stream 910. The resulting second cooled exhaust steam stream 925 can be sent to the exhaust stack and released into the atmosphere.

[0131] In other cases, the temperature will not drop sufficiently to condense any, most, or all of the water from the first cooled exhaust steam stream 910. In this case, an optional third heat exchanger 930 may be used to lower the temperature of the second cooled exhaust steam stream 925 to at or below the dew point, resulting in the formation of water condensate. The cooling medium used for the third heat exchanger may be, for example, cold / ambient air or chilled water.

[0132] The condensate is recovered and exits the main heat exchanger 915 and / or the third heat exchanger as condensate stream 935. In some cases, after neutralization and / or degassing and / or filtration, condensate stream 935 can be sent to, for example, Figure 14 The decomposition unit segment 195 shown and / or as shown Figure 15 The phenol recovery unit segment 260 shown, and / or used as such Figure 12 The quench flow shown is 450.

[0133] The heated process wastewater stream 940 from the primary heat exchanger 915 is then delivered to a flash tank 950 via a throttling valve or a pressure relief valve 945. This flash tank operates at a lower pressure than the primary heat exchanger 915 (e.g., between 1 psig and 20 psig). As the higher-pressure heated process wastewater stream 940 enters the lower-pressure flash tank 950, it is flashed into a steam stream 955 and a liquid stream 960. The steam stream 955 and the liquid stream 960 are then delivered to the thermal oxidation section 400 of the thermal oxidation system 355. An optional pump and / or compressor 965 may be present on the line supplying the liquid stream 960.

[0134] Figure 16 Showing the use of Figure 4 An alternative energy recovery system for the thermal oxidation system 355. In this arrangement, the process wastewater stream (optionally compressed in a pump and / or compressor 920) is fed to a flash tank 950 for initial flash separation. A portion 970 of the liquid from the flash tank 950 may be compressed in an optional pump and / or compressor 975 and sent to the first side of the main heat exchanger 915. The heated process wastewater stream 940 is depressurized by passing through a throttle valve or pressure relief valve 945 and returned to the flash tank 950, where further separation occurs.

[0135] Water is recirculated from the flash tank to the main heat exchanger and then returned. The ratio of process wastewater fed into the flash vessel to the recirculation rate (i.e., the flow rate from the flash tank to the main heat exchanger and back) is 1:2 to 1:10.

[0136] The process is designed to minimize the time that process wastewater spends in the main heat exchanger 915 in order to avoid the formation of steam in the main heat exchanger 915.

[0137] Figure 17It shows the use of Figure 5 A similar energy recovery system to the thermal oxidation system. In this embodiment, the exhaust steam stream 900 can be either the NOx removal outlet flue gas stream 605 or the exhaust stream 585.

[0138] The exhaust steam stream 900 can be sent to the second side of an optional secondary heat exchanger 905. The process stream can be sent to the first side of the secondary heat exchanger 905. Depending on the temperature of the exhaust steam stream and the amount of process stream to be heated, there can be one or more secondary heat exchangers 905.

[0139] The process flow can be all or part of the waste air flow 360 from the waste air separator 330, such as Figure 13 As shown. Other options for the process flow include all or part of the combustion air flow 505, and all or part of the boiler feedwater or oil flow 520.

[0140] The process stream is heated by heat exchange with the exhaust steam stream 900, which is thus cooled. The heated exhaust air stream 360 is sent to the thermal oxidation section 500 of the thermal oxidation system 355. The heated combustion air stream 505 is also sent to the thermal oxidation section 500, while the heated boiler feedwater or oil stream 520 is sent to the waste heat recovery section 515, thereby improving the efficiency of steam generation or hot oil generation.

[0141] The process wastewater flows through the first side of the main heat exchanger 915. There may be one or more main heat exchangers 915. The process wastewater flow may optionally be compressed in a pump and / or compressor 920 and then introduced into the main heat exchanger 915.

[0142] The process wastewater stream can be all or part of at least one of the phenolic water stream 385 from the phenolic water container 345 and the non-phenolic water stream 390 from the non-phenolic water container 350.

[0143] The exhaust steam flow 910 from the first cooling is passed through the second side of the main heat exchanger 915. Alternatively, in the absence of a secondary heat exchanger 905, the exhaust steam flow 900 is sent to the main heat exchanger 915.

[0144] The first cooled exhaust steam stream 910 entering the main heat exchanger 915 has a temperature above the dew point. Heat exchange with the process wastewater stream lowers the temperature of the first cooled exhaust steam stream 910. In some cases, this temperature will drop to or below the dew point, causing moisture to condense from the first cooled exhaust steam stream 910. The resulting second cooled exhaust steam stream 925 can be sent to the exhaust stack and released into the atmosphere.

[0145] In other cases, the temperature will not drop sufficiently to condense any, most, or all of the water from the first cooled exhaust steam stream 910. In this case, an optional third heat exchanger 930 may be used to lower the temperature of the second cooled exhaust steam stream 925 to at or below the dew point, thereby causing condensation to form. The cooling medium used for the third heat exchanger may be, for example, cold / ambient air or chilled water.

[0146] The condensate is recovered and exits the main heat exchanger 915 and / or the third heat exchanger as condensate stream 935. Condensate stream 935 can be sent to the decomposition unit section 195. Figure 14 ) and / or phenol recovery unit segment 260 ( Figure 15 ).

[0147] Heated process wastewater stream 940 is fed through throttle valve 945 to flash tank 950, which is at a lower pressure than the main heat exchanger 915 (e.g., 1 psig to 20 psig). As the higher-pressure heated process wastewater stream 940 enters the lower-pressure flash tank 950, it is flashed into a vapor stream 955 and a liquid stream 960. The vapor stream 955 and liquid stream 960 are then fed to the thermal oxidation section 500 of the thermal oxidation system 355. An optional pump and / or compressor 965 may be present on the line for the liquid stream 960.

[0148] Figure 18 An alternative arrangement is shown, in which process wastewater is first fed to flash tank 950, as described above. Figure 16 As described.

[0149] Figure 19A , Figure 19B and Figure 19C This illustrates the thermal oxidation section and downstream regulation, waste heat recovery, and applications only in [specific applications]. Figure 19C Different implementations of the catalytic oxidation section are shown. Other sections of the thermal oxidation system (including SOx recovery sections and optional NOx recovery sections) are not shown, as the purpose is to illustrate the different temperature distributions of the thermal oxidation system and how this can lead to reduced efficiency requirements.

[0150] exist Figure 19AIn this configuration, the thermal oxidation section 1000 includes a single high-temperature section 1005, which has the minimum temperature (e.g., 980°C) required to burn compounds in the various streams. Gaseous waste streams (e.g., waste air stream 360 from waste air separator 330), hydrocarbon liquid streams (e.g., mixed hydrocarbon waste stream 375 from hydrocarbon buffer container 335 and / or burner fuel stream 380 from fuel gas separator 340), phenolic wastewater streams (e.g., phenolic water stream 385 from phenolic water container 350), and non-phenolic wastewater streams (e.g., non-phenolic water stream 390 from non-phenolic water container 345) are all introduced at the first end of the high-temperature section 1005. As previously discussed, these streams have different inlet temperatures, and some or all of the streams may require preheating.

[0151] The temperature in the high-temperature section 1005 is maintained at or above the minimum temperature required to burn compounds in the various waste streams. These conditions are determined by the auto-ignition temperature (AIT) of the components. For example, cumene hydroperoxide has an AIT of 148°C, cumene has an AIT of 424°C, phenol has an AIT of 715°C, and benzene has an AIT of 560°C. The temperature used for effective oxidation is typically 93°C to 260°C higher than the AIT of the most difficult organic compounds to oxidize in the waste stream. The destruction efficiency of volatile organic compounds (VOCs) is a function of temperature, (turbulence), and residence time. For example, at 149°C above the AIT and a residence time of 0.5 s, the destruction efficiency is 95%. At 204°C above the AIT and a residence time of 0.5 s, the destruction efficiency is 98%. At 246°C above the AIT and a residence time of 0.75 s, the destruction efficiency is 99%. At 288°C above the AIT and a residence time of 1.0 s, the destruction efficiency is 99.9%. At 343℃ and a residence time of 2.0s, the destruction efficiency was 99.99%.

[0152] The flue gas stream 1010 leaving the high-temperature section 1005 is at or above the minimum temperature. If the sulfides are at excessively high temperatures (above the viscosity point and / or melting point), these sulfides may contaminate the waste heat recovery section 1025 due to condensation, in the presence of cold points below the viscosity point and / or melting point. Therefore, a quenching stream 1015 of water, air, and / or recirculated flue gas is used to reduce the temperature of the flue gas stream 1010 to a temperature below the condensation temperature of the salts in the flue gas (e.g., less than 704°C to 720°C). The cooled flue gas stream 1020 is then sent to the waste heat recovery section 1025 and continues to the rest of the thermal oxidation system.

[0153] exist Figure 19B In the middle, the thermal oxidation section 1000' includes a high temperature section 1005, a medium temperature section 1030, and a low temperature section 1035.

[0154] A gaseous waste stream (e.g., waste air stream 360 from waste air separator 330) and a hydrocarbon liquid stream (e.g., mixed hydrocarbon waste stream 375 from hydrocarbon buffer container 335 and / or burner fuel stream 380 from fuel gas separator 340) are introduced at the first end of a high-temperature section 1005. The high-temperature section 1005 has the lowest temperature (e.g., 980°C) required to burn compounds in the gaseous waste stream and hydrocarbon liquid stream.

[0155] A phenolic wastewater stream (e.g., phenolic water stream 385 from phenolic water container 345) is introduced at the second end of the high-temperature section 1005. The phenolic wastewater stream lowers the temperature of the flue gas, and the intermediate-temperature section 1030 has a lower temperature than the high-temperature section 1005. The intermediate-temperature section 1030 has a minimum temperature (e.g., 900°C) that ensures the destruction of phenolic compounds. The intermediate-temperature section 1030 is maintained at or above the minimum temperature.

[0156] A non-phenolic wastewater stream (e.g., non-phenolic water stream 390 from non-phenolic water container 350) is introduced at the second end of an intermediate temperature section 1030, which further reduces the temperature of the flue gas. A low-temperature section 1040 has a minimum temperature (e.g., 788°C) for burning non-phenolic compounds. A low-temperature section 1035 is maintained at or above the minimum temperature.

[0157] The flue gas stream 1010 exiting the cryogenic section 1035 is at the lowest temperature of the cryogenic section 1035 (e.g., 788°C). A quenching stream 1015 of water, air, and / or recirculated flue gas is used to reduce the temperature of the flue gas stream 1010 to a temperature below the condensation temperature of the salts in the flue gas (e.g., less than 704°C to 720°C). The cooled flue gas stream 1020 is then sent to the waste heat recovery section 1025 and continues to the rest of the thermal oxidation system.

[0158] exist Figure 19C In this embodiment, the thermal oxidation section 1000 includes a high-temperature section 1005 and a low-temperature section 1040. In this embodiment, a gaseous waste stream (e.g., waste air stream 360 from waste air separator 330), a hydrocarbon liquid stream (e.g., mixed hydrocarbon waste stream 375 from hydrocarbon buffer container 335 and / or burner fuel stream 380 from fuel gas separator 340) is introduced at the first end of the high-temperature section 1005, which is maintained at a temperature higher than the minimum temperature required to burn the components in the gaseous waste stream and liquid hydrocarbon stream (e.g., 980°C).

[0159] A phenolic wastewater stream (e.g., phenolic water stream 385 from phenolic water container 345) and a non-phenolic wastewater stream (e.g., non-phenolic water stream 390 from non-phenolic water container 350) are introduced at the second end of the high-temperature section 1005. The temperature of the low-temperature section 1040 is lower than that of the high-temperature section 1005, and the temperature of this low-temperature section depends on the amounts of the phenolic and non-phenolic streams. The low-temperature section 1040 is not designed to sufficiently destroy phenolic compounds and / or benzene compounds to comply with most environmental restrictions.

[0160] If necessary, a quenching flow of water or air 1015 is used to reduce the temperature of the flue gas stream 1010 to a temperature below the condensation temperature of the salts in the flue gas (e.g., less than 704°C to 720°C). In some embodiments, the temperature of the cryogenic section 1040 will be below the condensation temperature of the salts in the flue gas, and quenching will not be required. The cooled flue gas stream 1020 is then sent to the waste heat recovery section 1025.

[0161] The catalytic oxidation stage 1045 completes the destruction of phenolic compounds and / or benzene compounds. For example... Figures 20 to 21 As shown, the catalytic oxidizer is located after the SOx removal section and before the NOx removal section (if present). The catalytic oxidizer operates at a temperature ranging from 200°C to 400°C.

[0162] Figure 20 The catalytic oxidation section 1045 is shown. Figure 4 Another embodiment of the thermal oxidation system. The catalytic oxidation section 1045 is located between the SOx removal section 460 and the NOx removal section 490. Combustion air 1050 and fuel 1055 are introduced into the catalytic oxidation section 1045 if necessary. A quenching flow 1015 at the outlet of the thermal oxidation section is also shown.

[0163] Figure 21 The catalytic oxidation section 1045 is shown. Figure 5 Another embodiment of the thermal oxidation system. The catalytic oxidation section 1045 is located after the SOx removal section, which includes the SOx reaction section 550 and the filtration section 570, and before the optional NOx removal section 600. The catalyst used in the catalytic oxidation section is a base metal oxide (e.g., Ti, V, Cr, etc.) and / or a noble metal (e.g., Pt, Pd, etc.) on a support material (e.g., alumina, silica, etc.). For example, the substrate may be in the form of spheres or a honeycomb structure. The average lifetime of the catalyst is 30,000 to 40,000 hours.

[0164] Combustion air 1050 and fuel 1055 are introduced into catalytic oxidation 1045 as needed. A quenching flow 101 at the outlet of the thermal oxidation section is also shown.

[0165] Example

[0166] Table 1 shows the... Figures 19A to 19C Computer simulations of the effects of the different thermal oxidation and catalytic oxidation stages are shown. All three implementations produced 10 mg / Nm³. 3 Non-methane hydrocarbons, 1 mg / Nm 3 Benzene and 5 mg / Nm 3 The required emission targets for phenol are as follows. However, the required amounts of make-up fuel gas, combustion air, and quench water vary significantly. Arrangements with staged introduction components and a catalytic oxidation section require half the amount of fuel gas and combustion air as those without a staged section, while staged arrangements without a catalytic oxidation section fall somewhere in between. Furthermore, the use of staged introduction components significantly reduces the amount of quench water required. Less steam is generated in both arrangements with staged introduction components.

[0167] Figure 19A The arrangement resulted in the removal of 99.99% of benzene and 99.9% of phenol from the gaseous and liquid waste streams in the high-temperature section 1005.

[0168] Figure 19B The arrangement resulted in the removal of 99.99% of benzene and 99.9% of phenol from the gaseous waste stream in the high-temperature section 1005. In the intermediate-temperature section 1030, 99.99% of benzene and 96% of phenol from the liquid waste stream were removed.

[0169] Figure 19C The arrangement results in the removal of 99.99% of benzene and 99.9% of phenol from the gaseous waste stream in the high-temperature section 1005. In the low-temperature section 1040, 30% of benzene and 10% of phenol from the liquid waste stream are removed. The catalytic oxidation section 1045 removes 90% of residual benzene and 90% of residual phenol from the flue gas.

[0170] Table 1

[0171]

[0172]

[0173] *220psi(g) MP vapor

[0174] **NMHC = Non-methane hydrocarbons**

[0175] ***% Residual phenol and benzene removal rate

[0176] Any of the aforementioned pipelines, conduits, units, equipment, containers, surrounding environment, areas, or the like may be equipped with one or more monitoring components, including sensors, measuring devices, data acquisition devices, or data transmission devices. Signal, method, or condition measurements, as well as data from the monitoring components, can be used to monitor conditions within, around, and in connection with the method or equipment. Signals, measurements, and / or data generated or recorded by the monitoring components may be collected, processed, and / or transmitted through one or more networks or connections, which may be private or public, general or dedicated, direct or indirect, wired or wireless, encrypted or unencrypted, and / or combinations thereof; this specification is not intended to be limiting in this respect.

[0177] Signals, measurements, and / or data generated or recorded by monitoring components may be transmitted to one or more computing devices or systems. The computing devices or systems may include at least one processor and a memory storing computer-readable instructions that, when executed by the at least one processor, cause the one or more computing devices to perform a method that may include one or more steps. For example, one or more computing devices may be configured to receive data from one or more monitoring components related to at least one device associated with the method. One or more computing devices or systems may be configured to analyze the data. Based on the data analysis, one or more computing devices or systems may be configured to determine one or more recommended adjustments to one or more parameters of one or more methods described herein. One or more computing devices or systems may be configured to transmit encrypted or unencrypted data comprising one or more recommended adjustments to one or more parameters of one or more methods described herein.

[0178] Those skilled in the art should recognize and understand that various other components, such as valves, pumps, filters, coolers, etc., are not shown in the accompanying drawings because it is believed that their specific details are entirely within the knowledge of those skilled in the art and their description is not necessary for the implementation or understanding of the embodiments of the present invention.

[0179] While at least one exemplary embodiment has been presented in the foregoing detailed description of the invention, it should be understood that numerous variations exist. It should also be understood that one or more exemplary embodiments are merely examples and are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient roadmap for implementing exemplary embodiments of the invention, and it should be understood that various changes may be made to the function and arrangement of the elements described in the exemplary embodiments without departing from the scope of the invention as set forth in the appended claims and their legal equivalents.

[0180] As used herein, the terms “unit,” “area,” and “segment” can refer to one or more equipment items and / or one or more sub-areas or sub-segments of a type applicable to a unit, area, or segment. Equipment items may include, but are not limited to, one or more reactors or reactor vessels, separation vessels, one or more adsorption chambers, distillation columns, heaters, exchangers, piping, pumps, compressors, and controllers. Additionally, equipment items such as reactors, dryers, adsorption chambers, or vessels may also include one or more segments, sub-segments, areas, or sub-areas.

[0181] Specific implementation plan

[0182] While the following description is presented in conjunction with specific embodiments, it should be understood that the description is intended to illustrate, and not limit, the scope of the foregoing description and the appended claims.

[0183] A first embodiment of the present invention is a method for producing phenol, the method comprising: oxidizing a fresh cumene feed stream in an oxidation unit section to form an oxidation product stream comprising cumene hydroperoxide (CHP), dimethylphenylmethanol (DMPC), and cumene, and at least one of an oxidation wastewater stream, an oxidation waste air stream, and a decanter effluent stream; concentrating the oxidation product stream in a CHP concentration unit section to form a concentrated CHP stream and a concentrated effluent gas stream; and decomposing the concentrated CHP stream in a decomposition unit section using a decomposition acid to form a product comprising phenol, acetone, cumene, and AMS. The process involves: a crude acid product stream; neutralizing the crude acid product with a neutralizing agent in a neutralization unit to form a neutralized crude product stream; fractionating the neutralized crude product stream into a cumene-AMS-phenol stream in an acetone-phenol fractionation unit, and at least one of a phenolic water stream, an organic product stream, a wastewater stream, and a hydrocarbon effluent gas stream; separating the cumene-AMS-phenol stream into a cumene-AMS feed stream in a phenol recovery unit, and at least one of a buffered phenol stream containing phenol and cumene, and a phenolic wastewater stream; and hydrogenating cumene in an AMS hydrogenation unit. An olefin-AMS feed stream is used to form a cumene stream for MSHP recycling; at least one of the following steps is performed: introducing at least one of the fractionated organic product stream from the fractionation unit section, the fuel gas separator hydrocarbon liquid stream from the fuel gas separator, and the waste air separator liquid stream from the waste air separator into the hydrocarbon buffer vessel; introducing at least one of the AMS hydrogen effluent gas stream from the AMS hydrogenation unit section, the hydrocarbon buffer vessel effluent gas stream from the hydrocarbon buffer vessel, the phenolic effluent gas stream from the phenolic water vessel, and the non-phenolic effluent gas stream from the non-phenolic water vessel into the hydrocarbon buffer vessel. In a fuel gas separator, at least one of the following is introduced into a phenolic water container: a fractionation wastewater stream, an acetone-phenol fractionation unit stream, a phenolic wastewater stream from a phenol recovery unit stream, and a degreasing aqueous phase from a hydrocarbon buffer container; at least one of the oxidation wastewater stream from an oxidation unit stream and a benzene tower water stream from a cumene production unit stream is introduced into a non-phenolic water container; and in a thermal oxidation system, one or more of the following are thermally oxidized: a mixed hydrocarbon waste stream from a hydrocarbon buffer container, a burner fuel gas stream from a fuel gas separator, a phenolic water stream from a phenolic water container, and a non-phenolic water stream from a non-phenolic water container. One embodiment of the present invention is one, any one, or all of the embodiments described in the preceding embodiments to the first embodiment of this paragraph, wherein thermal oxidation of one or more of the following includes: thermal oxidation in a thermal oxidation section of the mixed hydrocarbon waste stream from the hydrocarbon buffer container, the burner fuel gas stream from the fuel gas separator, the waste air stream from the waste air separator, the phenolic water stream from the phenolic water container, and the non-phenolic water stream from the non-phenolic water container.The process involves forming a flue gas substantially composed of at least one of H2O, CO2, N2, O2, HCl, Cl2, Na2SO4, Na2CO3, SOx, and NOx; recovering waste heat from the flue gas in a waste heat recovery section; optionally quenching the flue gas in a quenching section after waste heat recovery to form a quenched flue gas substantially composed of at least one of H2O, CO2, N2, O2, HCl, Cl2, Na2SO4, Na2CO3, SOx, and NOx; and optionally removing Na2SO4 and Na2O from the flue gas or the quenched flue gas in a SOx removal section. At least one of CO3, SOx, HCl, and Cl2 is used to form a SOx-removed outlet flue gas substantially composed of at least one of H2O, CO2, N2, O2, and NOx, wherein SOx removal from the flue gas comprises: contacting a caustic alkali solution or an NH3-based solution with the quenched flue gas in a scrubbing section to form a SOx-removed outlet flue gas and a liquid effluent containing at least one of H2O, Na2SO3, Na2SO4, NaHSO3, Na2CO3, NaCl, (NH4)2SO4, and NH4Cl; or in a SOx reaction section... The flue gas is reacted with reactants to form a reaction section flue gas substantially composed of at least one of H2O, CO2, N2, O2, NaCl, Na2CO3, Na2SO4, NaNO3, CaCl2, CaSO4, CaCO3, Ca(NO3)2, MgCl2, MgCO3, MgSO4, Mg(NO3)2, Cl2, and NOx, wherein the reactants include NaHCO3, NaHCO3·Na2CO3·2(H2O), CaCO3, Ca(OH)2, and Mg(OH)2; and optionally... The flue gas from the reaction section is optionally filtered in the filter section to remove at least one of NaCl, Na2CO3, Na2SO4, NaNO3, CaCl2, CaSO4, CaCO3, Ca(NO3)2, MgCl2, MgCO3, MgSO4, and Mg(NO3)2 to form a de-SOx outlet flue gas; and NOx is optionally removed from the flue gas in the optional NOx removal section, the quenched flue gas, or the de-SOx outlet flue gas to form a de-NOx outlet flue gas consisting substantially of at least one of H2O, CO2, N2, and O2. One embodiment of the invention is one, any, or all of the embodiments described in the preceding embodiments to the first embodiment of this section, which further includes providing recovered waste heat to one or more of the evaporator in the CHP concentration unit section, the dehydrator steam heat exchanger in the decomposition unit section, and the reboiler in the acetone-phenol fractionation unit section. One embodiment of the invention is one, any, or all of the embodiments described in the preceding embodiments to the first embodiment of this section.The quenched flue gas includes at least one of air, SOx removal outlet flue gas, NOx removal outlet flue gas, and water. One embodiment of the invention is one, any, or all of the embodiments described in the preceding embodiments to the first embodiment of this paragraph, wherein the water includes a water stream from a non-phenolic water container or an external water stream. One embodiment of the invention is one, any, or all of the embodiments described in the preceding embodiments to the first embodiment of this paragraph, further comprising introducing a water washing waste stream and a phenolic wastewater stream from the phenol recovery unit into a phenolic water container. One embodiment of the invention is one, any, or all of the embodiments described in the preceding embodiments to the first embodiment of this paragraph, further comprising introducing at least one of an oxidation waste air stream from an oxidation unit, a decanter discharge stream from an oxidation unit, and a fractionated hydrocarbon discharge gas stream from an acetone-phenol fractionation unit into a waste air separator; optionally preheating the waste air stream from the waste air separator; and thermally oxidizing the waste air stream from the waste air separator in a thermal oxidation system. One embodiment of the present invention is one, any, or all of the embodiments described in the preceding embodiments to the first embodiment of this paragraph, wherein oxidizing a fresh cumene feed stream to form an oxidation product stream in an oxidation unit section comprises: introducing the fresh cumene feed stream and an oxidation air feed stream into at least one oxidation reactor to form an oxidation product stream and an oxidation waste air stream; cooling the oxidation waste air stream in an oxidizer effluent gas cooler before introducing it into a waste air separator to form a condensate stream; and introducing the condensate stream into a decanter container to form a decanter effluent stream, an oxidation wastewater stream, and a decanter discharge stream. The decanter cumene recirculation stream; in the cumene feed scrubber, the decanter cumene recirculation stream is scrubbed with a recirculated cumene scrubbing water stream and a recirculated cumene scrubbing caustic alkali stream to form a scrubbed cumene stream and a recirculated cumene scrubbing water waste stream; the scrubbed cumene stream is fed into an oxidation reactor; the recirculated cumene scrubbing water waste stream is fed into a non-phenolic water container; and optionally, at least one of the following steps is performed: MSHP recirculated cumene from the AMS hydrogenation unit is fed into the cumene feed scrubber, and concentrated recirculated cumene from the CHP concentration unit is fed into the cumene feed scrubber. One embodiment of the invention is one, any, or all of the embodiments described in the preceding embodiments to the first embodiment of this paragraph, which further includes performing at least one of the following steps: recycling the cumene stream from the concentration section of the CHP concentration unit to the oxidation unit; recycling the concentrated effluent gas stream from the CHP concentration unit to the oxidation unit; recycling the buffered phenol stream from the phenol recovery unit to the neutralization unit; and introducing the oxidation wastewater stream into the peroxide destruction section for converting the peroxides in the oxidation wastewater stream into at least one of alcohols, ketones, aldehydes, organic acids, and water.To form a peroxide-free oxidative wastewater stream, the peroxide-free oxidative wastewater stream is then introduced into a non-phenolic water container. One embodiment of the invention is one, any, or all of the embodiments described in the preceding embodiments to the first embodiment of this paragraph, which further includes reacting propylene and benzene in a cumene production area to produce at least one of a cumene production unit hydrocarbon waste stream, a propane discharge stream, a benzene carryover stream, and a cumene production unit exhaust gas stream; and performing at least one of the following steps: introducing the cumene production unit hydrocarbon waste stream into a hydrocarbon buffer container; introducing at least one of the propane discharge stream and the benzene carryover stream into a fuel gas separator; and introducing the cumene production unit exhaust gas stream into a waste air separator. One embodiment of the invention is one, any, or all of the embodiments described in the preceding embodiments to the first embodiment of this paragraph, which further includes preheating at least one of the phenolic water stream from the phenolic water container and the non-phenolic water stream from the non-phenolic water container before using at least one of the recovered waste heat from the thermal oxidation system and the low-pressure steam stream from the cumene production unit to heat and oxidize at least one of the phenolic water stream and the non-phenolic water stream. Another embodiment of the invention is one, any, or all of the embodiments described in the preceding embodiments to the first embodiment of this paragraph, which further includes controlling the pressure in the at least one of the hydrocarbon buffer container, phenolic water container, and non-phenolic water container in the push-pull system by introducing at least one of the fuel gas, liquefied petroleum gas, and exhaust gas into the hydrocarbon buffer container, the phenolic water container, and the non-phenolic water container; and sending excess fuel gas, liquefied petroleum gas, and exhaust gas to a fuel gas separator. One embodiment of the invention is one, any, or all of the embodiments from the previous embodiments to the first embodiment of this paragraph, wherein the phenolic water stream is atomized and injected into the burner flame or directly injected downstream of the calculated flame length in the thermal oxidizer section, and wherein non-phenolic water is injected downstream of the calculated atomization and evaporation distance of the phenolic water stream. One embodiment of the invention is one, any, or all of the embodiments described in the preceding embodiments to the first embodiment of this paragraph, further comprising: passing a process wastewater stream through a first side of a main heat exchanger, wherein the process wastewater stream comprises all or a portion of at least one of a phenolic water stream and a non-phenolic water stream; passing an exhaust steam stream from a thermal oxidation system through a second side of the main heat exchanger, wherein the exhaust steam stream comprises an exhaust stream or a NOx removal outlet flue gas stream; transferring heat from the exhaust steam stream to the process water stream, cooling the exhaust steam stream to form a cooled exhaust stream, and heating the process wastewater stream to form a heated process wastewater stream; reducing the pressure of the heated process wastewater stream; and introducing the depressurized and heated process wastewater stream into a flash tank having a pressure lower than that in the main heat exchanger.To form a steam flow and a liquid flow; to introduce the steam flow and liquid flow into the thermal oxidation section of the thermal oxidation system; and to introduce the cooled exhaust flow into the exhaust chimney. One embodiment of the invention is one, any, or all of the embodiments described in the preceding embodiments to the first embodiment of this paragraph, the embodiment further comprising passing a process flow through a first side of a secondary heat exchanger, wherein the process flow comprises at least one of a waste air flow, a combustion air flow, and a boiler feedwater or oil flow from a waste air separator; passing exhaust steam through a second side of the secondary heat exchanger before passing exhaust steam through the main heat exchanger to reduce the temperature of the exhaust steam flow, and to heat at least one process flow and form a second cooled exhaust steam flow and at least one of a heated waste air flow, a heated combustion air flow, and a heated boiler feedwater or oil flow; passing the second cooled exhaust steam through the main heat exchanger, wherein passing exhaust steam from the thermal oxidation system through the second side of the main heat exchanger comprises passing the second cooled exhaust steam through the second side of the main heat exchanger; and performing at least one of the following steps: passing heated waste air through the thermal oxidation section of the thermal oxidation system; passing heated combustion air through the thermal oxidation section of the thermal oxidation system; and passing heated boiler feedwater or oil through the waste heat recovery section. One embodiment of the invention is one, any, or all of the embodiments described in the preceding embodiments to the first embodiment of this paragraph, which further includes introducing a process wastewater stream into a flash tank to form liquid and vapor before the process wastewater stream is introduced into a main heat exchanger; and compressing at least a portion of the liquid; wherein passing the process wastewater stream through a first side of the main heat exchanger includes introducing a portion of the compressed liquid from the flash tank into the main heat exchanger; wherein reducing the pressure of the heated process wastewater stream includes reducing the pressure of the heated compressed liquid from the main heat exchanger; and wherein introducing the depressurized heated process wastewater into the flash tank includes introducing the depressurized heated compressed liquid into the flash tank. Another embodiment of the invention is one, any, or all of the embodiments described in the preceding embodiments to the first embodiment of this paragraph, wherein the exhaust steam stream is cooled in the main heat exchanger to a temperature at or below the dew point to cause water from the exhaust steam stream to condense, forming a first condensate stream. One embodiment of the invention is one, any, or all of the embodiments described in the preceding embodiments to the first embodiment of this paragraph, which further includes passing a first condensate stream into at least one of a phenol recovery unit and a decomposition unit. Another embodiment of the invention is one, any, or all of the embodiments described in the preceding embodiments to the first embodiment of this paragraph, wherein a cooled exhaust vapor stream is passed into a third heat exchanger before being passed into an exhaust stack, and wherein the cooled exhaust vapor stream is further cooled in the third heat exchanger to a temperature at or below the dew point, so that water from the cooled exhaust vapor stream condenses.A second condensate stream is formed. One embodiment of the invention is one, any, or all of the embodiments described in the preceding embodiments to the first embodiment of this paragraph, further comprising passing the second condensate stream into at least one of the phenol recovery unit section and the decomposition unit section. One embodiment of the invention is one, any, or all of the embodiments described in the preceding embodiments to the first embodiment of this paragraph, further comprising compressing the process wastewater stream before it is passed into the main heat exchanger. One embodiment of the invention is one, any, or all of the embodiments described in the preceding embodiments to the first embodiment of this paragraph, wherein the thermal oxidation section includes a high-temperature section, and wherein, when present, a mixed hydrocarbon waste stream from a hydrocarbon buffer container, a burner fuel gas stream from a fuel gas separator, a phenolic water stream from a phenolic water container, and a non-phenolic water stream from a non-phenolic water container are introduced into the high-temperature section, and wherein the high-temperature section has a minimum temperature for burning the mixed hydrocarbon waste stream from the hydrocarbon buffer container and the burner fuel gas stream from the fuel gas separator. One embodiment of the invention is one, any, or all of the embodiments described in the preceding embodiments to the first embodiment of this paragraph, wherein the thermal oxidation section includes a high-temperature section, an intermediate-temperature section, and a low-temperature section, and wherein, when present, a mixed hydrocarbon waste stream from a hydrocarbon buffer container and a burner fuel gas stream from a fuel gas separator are introduced into a first end of the high-temperature section, and wherein, when present, a phenolic water stream from a phenolic water container is introduced at a second end of the high-temperature section, and wherein, when present, a non-phenolic water stream from a non-phenolic water container is introduced at the low-temperature section, and wherein the high-temperature section has a minimum temperature for burning the mixed hydrocarbon waste stream from the hydrocarbon buffer container and the burner fuel gas stream from the fuel gas separator, wherein the intermediate-temperature section has a minimum temperature for burning phenolic compounds, and wherein the low-temperature section has a temperature for burning non-phenolic compounds. One embodiment of the invention is one, any, or all of the embodiments described in the preceding embodiments to the first embodiment of this paragraph, wherein the thermal oxidation section includes a high-temperature section and a low-temperature section, and wherein, when present, a mixed hydrocarbon waste stream from a hydrocarbon buffer container and a burner fuel gas stream from a fuel gas separator are introduced into the high-temperature section, and wherein, when present, a phenolic water stream from a phenolic water container and a non-phenolic water stream from a non-phenolic water container are introduced into the low-temperature section, and wherein the high-temperature section has a minimum temperature for burning the mixed hydrocarbon waste stream from the hydrocarbon buffer container and the burner fuel gas stream from the fuel gas separator, and wherein the low-temperature section has a temperature for burning non-phenolic compounds and a portion of phenolic compounds, and; and further includes: oxidizing additional phenolic compounds and benzene in the presence of a catalyst in a catalytic oxidation section located after the SOx removal section and before an optional NOx removal section. One embodiment of the invention is one, any, or all of the embodiments described in the preceding embodiments to the first embodiment of this paragraph.The SOx removal section includes an SOx reaction section and an optional filter section.

[0184] A second embodiment of the present invention is a method for producing phenol, the method comprising reacting propylene and benzene in a cumene production zone to produce at least one of a fresh cumene feed stream and a cumene production unit hydrocarbon waste stream, a benzene tower water stream, a propane discharge stream, a benzene carry-over stream, and a cumene production unit effluent gas stream; oxidizing the fresh cumene feed stream in an oxidation unit section to form an oxidation product stream comprising cumene hydroperoxide (CHP), dimethylphenylmethanol (DMPC), and cumene, and at least one of an oxidation wastewater stream, an oxidation waste air stream, and a decanter discharge stream; and concentrating the oxidation product stream in a CHP concentration unit section to form a concentrated... The system comprises: a CHP stream and a concentrated effluent gas stream; in the decomposition unit, the concentrated CHP stream is decomposed using a decomposing acid to form an acidic crude product stream containing phenol, acetone, cumene, and AMS; in the neutralization unit, the acidic crude product is neutralized with a neutralizing agent to form a neutralized crude product stream; in the acetone-phenol fractionation unit, the neutralized crude product stream is fractionated into a cumene-AMS-phenol stream, and at least one of a phenolic water stream, an organic product stream, a wastewater stream, and a hydrocarbon effluent gas stream; in the phenol recovery unit, the fractionated cumene-AMS-phenol stream is separated into a cumene-AMS feed stream, and a stream containing phenol and cumene... At least one of a phenol stream and a phenolic wastewater stream from a phenol recycling unit; recycling the phenol stream to a neutralization unit; hydrogenating the cumene-AMS feed stream in an AMS hydrogenation unit to form a MSHP-recycled cumene stream and an AMS hydrogen effluent stream; performing at least one of the following steps: introducing at least one of a fractionated organic product stream from a fractionation unit, a cumene production unit hydrocarbon waste stream from a cumene production unit, a fuel gas separator hydrocarbon liquid stream from a fuel gas separator, and a waste air separator liquid stream from a waste air separator into a hydrocarbon buffer vessel; effluent AMS hydrogen from the AMS hydrogenation unit. At least one of the following is introduced into a fuel gas separator: a propane discharge stream from the cumene production unit, a benzene carryover stream from the cumene production unit, a hydrocarbon buffer container discharge stream from a hydrocarbon buffer container, a phenolic discharge stream from a phenolic water container, and a non-phenolic discharge stream from a non-phenolic water container; at least one of the following is introduced into a phenolic water container: a fractionation wastewater stream, an acetone-phenol fractionation unit stream, a phenolic wastewater stream from a phenol recovery unit, and a degreasing aqueous phase from a hydrocarbon buffer container; at least one of the following is introduced into a non-phenolic water container: an oxidation wastewater stream from an oxidation unit and a benzene tower water stream from the cumene production unit.In a thermal oxidation system, thermal oxidation of one or more of the following includes: thermal oxidation in the thermal oxidation section of a mixed hydrocarbon waste stream from a hydrocarbon buffer container, a burner fuel gas stream from a fuel gas separator, a phenolic water stream from a phenolic water container, and a non-phenolic water stream from a non-phenolic water container, to form a mixture substantially composed of at least one of H2O, CO2, N2, O2, Na2SO4, Na2CO3, HCl, Cl2, SOx, and NOx. The process involves: preparing flue gas; recovering waste heat from the flue gas in a waste heat recovery section; optionally quenching the flue gas in a quenching section after waste heat recovery to form a quenched flue gas consisting substantially of at least one of H2O, CO2, N2, O2, Na2SO4, Na2CO3, HCl, Cl2, SOx, and NOx; and optionally removing at least one of Na2SO4, Na2CO3, SOx, HCl, and Cl2 from the flue gas or the quenched flue gas in a SOx removal section to form a de-SOx outlet flue gas consisting substantially of at least one of H2O, CO2, N2, O2, and NOx, wherein SOx is removed from the flue gas... This includes: contacting a caustic alkali solution or an NH3-based solution with quenched flue gas in the scrubbing section to form SOx-removed outlet flue gas and a liquid effluent containing at least one of H2O, Na2SO3, Na2SO4, NaHSO3, Na2CO3, NaCl, (NH4)2SO4, and NH4Cl; or reacting flue gas with reactants in the SOx reaction section to form essentially H2O, CO2, N2, O2, NaCl, Na2CO3, Na2SO4, NaNO3, CaCl2, CaSO4, CaCO3, Ca(NO3)2, MgCl2, and MgCO3. The flue gas in the reaction section consists of at least one of NaCl, Na2CO3, Na2SO4, NaNO3, CaCl2, CaSO4, CaCO3, Ca(NO3)2, MgCl2, MgCO3, MgSO4, and Mg(NO3)2, wherein the reactants include NaHCO3, NaHCO3·Na2CO3·2(H2O), CaCO3, Ca(OH)2, and Mg(OH)2; and the flue gas in the reaction section is optionally filtered in the filter section to remove at least one of NaCl, Na2CO3, Na2SO4, NaNO3, CaCl2, CaSO4, CaCO3, Ca(NO3)2, MgCl2, MgCO3, MgSO4, and Mg(NO3)2 to form SOx-free outlet flue gas;And optionally remove NOx from flue gas, quenched flue gas, or SOx-removed outlet flue gas to form NOx-removed outlet flue gas substantially composed of at least one of H2O, CO2, N2, and O2. One embodiment of the invention is one, any, or all of the embodiments described in the preceding to the second embodiments of this paragraph, which further includes introducing at least one of the following into a waste air separator: an oxidizing waste air stream from an oxidation unit section, a decanter discharge stream from an oxidation unit section, a fractionated hydrocarbon discharge gas stream from an acetone-phenol fractionation unit section, and a cumene production unit discharge gas stream from a cumene production unit; optionally preheating the waste air stream from the waste air separator; and thermally oxidizing the waste air stream from the waste air separator in a thermal oxidation system. One embodiment of the invention is one, any, or all of the embodiments described in the preceding to the second embodiments of this paragraph, which further includes providing recovered waste heat to one or more of the following: an evaporator in the CHP concentration unit, a dehydrator steam heat exchanger in the decomposition unit, and a reboiler in the acetone-phenol fractionation unit. Another embodiment of the invention is one, any, or all of the following embodiments described in the preceding to the second embodiments of this paragraph, which further includes at least one of the following steps: introducing a water washing waste stream and a phenolic wastewater stream from the phenol recovery unit into a phenolic water container; and introducing at least one of the following: an oxidation waste air stream from the oxidation unit, a decanter effluent stream from the oxidation unit, a concentrated effluent gas stream from the CHP concentration unit, and a fractionated hydrocarbon effluent gas stream from the acetone-phenol fractionation unit into a waste air separator. One embodiment of the invention is one, any, or all of the embodiments described in the preceding to the second embodiments of this paragraph, which further includes preheating at least one of the phenolic water stream from the phenolic water container and the non-phenolic water stream from the non-phenolic water container before using at least one of the recovered waste heat from the thermal oxidation system and the low-pressure steam stream from the cumene production unit to heat and oxidize at least one of the waste air stream, the phenolic water stream, and the non-phenolic water stream.

[0185] Although no further detailed description has been provided, it is believed that those skilled in the art will be able to make full use of the invention by employing the foregoing description and will be able to readily identify the essential features of the invention without departing from its spirit and scope, and to make various changes and modifications to adapt it to various uses and situations. Therefore, the foregoing preferred embodiments should be understood as illustrative only and not as limiting the remainder of this disclosure in any way, and are intended to cover various modifications and equivalent arrangements included within the scope of the appended claims.

[0186] In the foregoing, all temperatures are expressed in degrees Celsius, and all portions and percentages are by weight unless otherwise specified.

Claims

1. A method for producing phenol, comprising: In the oxidation unit section (150), the fresh cumene feed stream (120) is oxidized to form an oxidation product stream (160) comprising cumene hydroperoxide (CHP), dimethylphenylmethanol (DMPC) and cumene, and at least one of an oxidation wastewater stream (173), an oxidation waste air stream (165), and a decanter discharge stream (170). The oxidation product stream (160) is concentrated in the CHP concentration unit section (175) to form a concentrated CHP stream (190) and a concentrated effluent gas stream (185). In the decomposition unit segment (195), the concentrated CHP stream (190) is decomposed using a decomposition acid (200) to form an acidic crude product stream (210) containing phenol, acetone, cumene and α-methylstyrene (AMS). The acidic crude product (210) is neutralized with a neutralizing agent (220) in the neutralization unit segment (210) to form a neutralized crude product stream (225). In the acetone-phenol fractionation unit section (230), the neutralized crude product stream (225) is fractionated into a cumene-AMS-phenol stream (235), and at least one of a phenolic water stream (240), an organic product stream (250), a wastewater stream (255), and a hydrocarbon effluent gas stream (245). In the phenol recovery unit section (260), the fractionated cumene-AMS-phenol stream (235) is separated into a cumene-AMS feed stream (275), and at least one of a buffered phenol stream (265) containing phenol and cumene and a phenolic wastewater stream (270). The cumene-AMS feed stream (275) is hydrogenated in the AMS hydrogenation unit section (280) to form a cumene stream (290) recycled from the methylstyrene hydrogenation process. Perform at least one of the following steps: At least one of the fractionated organic product stream (250) from the fractionation unit section (230), the fuel gas separator hydrocarbon liquid stream (370) from the fuel gas separator (340), and the waste air separator liquid stream (365) from the waste air separator (330) is introduced into the hydrocarbon buffer container (335). At least one of the following is introduced into the fuel gas separator (340): the AMS hydrogen exhaust gas stream (295) from the AMS hydrogenation unit section (280), the hydrocarbon buffer container exhaust gas stream (391) from the hydrocarbon buffer container (335), the phenolic exhaust gas stream (393) from the phenolic water container (345), and the non-phenolic exhaust gas stream (395) from the non-phenolic water container (350); At least one of the fractionation wastewater stream (255), the acetone-phenol fractionation unit (230), the phenolic wastewater stream (271) from the phenol recovery unit (260), and the degreased aqueous phase (382) from the hydrocarbon buffer vessel (335) is introduced into the phenolic water vessel (345). At least one of the oxidation wastewater stream (173) from the oxidation unit section (150) and the benzene tower water stream (125) from the cumene production unit (115) is introduced into the non-phenolic water container (350). as well as In the thermal oxidation system (355), one or more of the following are thermally oxidized: a mixed hydrocarbon waste stream (375) from the hydrocarbon buffer container (335), a burner fuel gas stream (380) from the fuel gas separator (340), a phenolic water stream (385) from the phenolic water container (345), and a non-phenolic water stream (390) from the non-phenolic water container (350). The thermal oxidation of one or more of the mixed hydrocarbon waste stream (375) from the hydrocarbon buffer container (335), the burner fuel gas stream (380) from the fuel gas separator (340), the phenolic water stream (385) from the phenolic water container (345), and the non-phenolic water stream (390) from the non-phenolic water container (350) includes: In the thermal oxidation section (400), one or more of the following are thermally oxidized: the mixed hydrocarbon waste stream (375) from the hydrocarbon buffer container (335), the burner fuel gas stream (380) from the fuel gas separator (340), the phenolic water stream (385) from the phenolic water container (345), and the non-phenolic water stream (390) from the non-phenolic water container (350) to form flue gas (410) consisting substantially of at least one of H2O, CO2, N2, O2, HCl, Cl2, Na2SO4, Na2CO3, SOx, and NOx. Waste heat is recovered from the flue gas (410) in the waste heat recovery section (415); After recovering the waste heat, the flue gas (440) is optionally quenched in the quenching section (445) to form a quenched flue gas (455) consisting essentially of at least one of H2O, CO2, N2, O2, HCl, Cl2, Na2SO4, Na2CO3, SOx and NOx. In the SOx removal section (460), at least one of Na2SO4, Na2CO3, SOx, HCl, and Cl2 is optionally removed from the flue gas (440) or the quenched flue gas (455) to form a de-SOx outlet flue gas (480) consisting substantially of at least one of H2O, CO2, N2, O2, and NOx, wherein removing SOx from the flue gas comprises: In the washing section, a caustic alkali solution or an NH3-based solution (465) is contacted with the quenched flue gas (455) to form the SOx-removed outlet flue gas (480) and a liquid effluent (470) containing at least one of H2O, Na2SO3, Na2SO4, NaHSO3, Na2CO3, NaCl, (NH4)2SO4 and NH4Cl. or In the SOx reaction section (550), the flue gas (540) is reacted with reactants to form a reaction section flue gas (560) substantially composed of at least one of H2O, CO2, N2, O2, NaCl, Na2CO3, Na2SO4, NaNO3, CaCl2, CaSO4, CaCO3, Ca(NO3)2, MgCl2, MgCO3, MgSO4, Mg(NO3)2, Cl2, and NOx, wherein the reactants include NaHCO3, NaHCO32- ... Na2CO3 2(H2O), CaCO3, Ca(OH)2 and Mg(OH)2; and The reaction section flue gas (560) is optionally filtered in an optional filter section (570) to remove at least one of NaCl, Na2CO3, Na2SO4, NaNO3, CaCl2, CaSO4, CaCO3, Ca(NO3)2, MgCl2, MgCO3, MgSO4, and Mg(NO3)2 to form the SOx-removed outlet flue gas (590); and NOx is optionally removed from the flue gas (590) in an optional NOx removal section (600), the quenched flue gas (560), or the de-SOx outlet flue gas (590) to form a de-NOx outlet flue gas (605) consisting substantially of at least one of H2O, CO2, N2, and O2.

2. The method according to claim 1, further comprising: At least one of the oxidized waste air stream (165) from the oxidation unit section (150), the decanter discharge stream (170) from the oxidation unit section (150), and the fractionated hydrocarbon discharge gas stream (245) from the acetone-phenol fractionation unit section (230) is introduced into the waste air separator (330). Optionally preheat the waste air stream (360) from the waste air separator (330); and In the thermal oxidation system (355), the waste air stream (360) from the waste air separator (330) is thermally oxidized.

3. The method according to claim 1, further comprising: Propylene (105) and benzene (110) are reacted in the cumene production unit (115) to produce at least one of the cumene feed stream (120) and the cumene production unit hydrocarbon waste stream (145), propane discharge stream (130), benzene carry-over stream (135), and cumene production unit effluent gas stream (140); and Perform at least one of the following steps: The hydrocarbon waste stream (145) from the cumene production unit is introduced into the hydrocarbon buffer container (335); At least one of the propane discharge stream (130) and the benzene carryover stream (135) is introduced into the fuel gas separator (340); and The exhaust gas stream (140) from the cumene production unit is introduced into the waste air separator (330).

4. The method according to claim 1, further comprising: The pressure in at least one of the hydrocarbon buffer container (335), the phenolic water container (345), and the non-phenolic water container (350) in the push-pull system is controlled by introducing at least one of the fuel gas, liquefied petroleum gas, and exhaust gas into at least one of the hydrocarbon buffer container (335), the phenolic water container (345), and the non-phenolic water container (350); and An excess of at least one of the fuel gas, liquefied petroleum gas and exhaust gas is sent to the fuel gas separator (340).

5. The method according to claim 1, further comprising: The process wastewater is passed through the first side of the main heat exchanger (915), wherein the process wastewater includes all or part of at least one of the phenolic water flow (385) and the non-phenolic water flow (390); The exhaust steam flow (900) from the thermal oxidation system is passed through the second side of the main heat exchanger (915), wherein the exhaust steam flow (900) comprises an exhaust flow (475) or a NOx removal outlet flue gas flow (495). Heat is transferred from the exhaust steam stream (900) to the process water stream, the exhaust steam stream (900) is cooled to form a cooled exhaust stream (925), and the process wastewater stream is heated to form a heated process wastewater stream (940). Reduce the pressure of the heated process wastewater flow (940); The depressurized heated process wastewater is fed into a flash tank (950), which has a lower pressure than that in the main heat exchanger (915) to form a steam flow (955) and a liquid flow (960). The steam flow (955) and the liquid flow (960) are introduced into the thermal oxidation section (400) of the thermal oxidation system; and The cooled exhaust stream (925) is introduced into the exhaust chimney.

6. The method according to claim 5, further comprising: The process flow is passed through the first side of the secondary heat exchanger (905), wherein the process flow is at least one of the waste air flow (360), combustion air flow (405), and boiler feedwater or oil flow (420) from the waste air separator (330); Before the exhaust steam stream (900) is introduced into the main heat exchanger (915), the exhaust steam stream (900) is introduced into the second side of the secondary heat exchanger (905) to reduce the temperature of the exhaust steam stream (900) and to heat at least one of the following: exhaust steam stream (910) that forms a second cooled process stream and a heated waste air stream (360), a heated combustion air stream (360), and a heated boiler feedwater or oil stream (420); The second cooled exhaust steam flow (910) is introduced into the main heat exchanger (915), and wherein allowing the exhaust steam flow (900) from the thermal oxidation system to pass through the second side of the main heat exchanger (915) includes allowing the second cooled exhaust steam flow (910) to pass through the second side of the main heat exchanger (915); and Perform at least one of the following steps: The heated waste air stream (360) is introduced into the thermal oxidation section (400) of the thermal oxidation system. The heated combustion air stream (405) is introduced into the thermal oxidation section (400) of the thermal oxidation system; and The heated boiler feedwater or oil flow (420) is introduced into the waste heat recovery section (415).

7. The method according to claim 5, further comprising: The process wastewater is introduced into the flash tank (950) to form liquid and steam before the process wastewater is introduced into the main heat exchanger (915); as well as Compress at least a portion of the liquid; The process wastewater flow through the first side of the main heat exchanger (15) includes introducing a portion (970) of the compressed liquid from the flash tank (950) into the main heat exchanger (915). The reduction of pressure in the heated process wastewater flow (940) includes reducing the pressure of the heated compressed liquid from the main heat exchanger (915); and The process wastewater flow (940) heated under reduced pressure is introduced into the flash tank (950), which includes the compressed liquid heated under reduced pressure being introduced into the flash tank (950).

8. The method according to claim 5, wherein the exhaust steam stream (925) is cooled in the main heat exchanger (915) to a temperature at or below the dew point, so that water from the exhaust steam stream condenses to form a first condensate stream (935); and The first condensate stream (935) is fed into at least one of the phenol recovery unit (260) and the decomposition unit (195).

9. The method according to claim 1: The thermal oxidation section (1000) includes a high-temperature section (1005), wherein, when present, the mixed hydrocarbon waste stream (375) from the hydrocarbon buffer container (335), the burner fuel gas stream (380) from the fuel gas separator (340), the phenolic water stream (385) from the phenolic water container (345), and the non-phenolic water stream (390) from the non-phenolic water container (350) are introduced into the high-temperature section (1005), and wherein the high-temperature section (1005) has a minimum temperature for burning the mixed hydrocarbon waste stream (375) from the hydrocarbon buffer container (335) and the burner fuel gas stream (380) from the fuel gas separator (340); or The thermal oxidation section (10001) comprises a high-temperature section (1005), a medium-temperature section (1030), and a low-temperature section (1035), wherein, when present, the mixed hydrocarbon waste stream (375) from the hydrocarbon buffer container (335) and the burner fuel gas stream (380) from the fuel gas separator (340) are introduced into the first end of the high-temperature section (1005), and wherein, when present, the phenolic water stream (385) from the phenolic water container (345) is introduced into the second end of the high-temperature section (1005), and wherein, when present... At that time, the non-phenolic water stream (390) from the non-phenolic water container (350) is introduced into the low-temperature section (1035), wherein the high-temperature section (1005) has a minimum temperature for burning the mixed hydrocarbon waste stream (375) from the hydrocarbon buffer container (335) and the burner fuel gas stream (380) from the fuel gas separator (340), wherein the medium-temperature section (1030) has a minimum temperature for burning phenolic compounds, and wherein the low-temperature section (1035) has a temperature for burning non-phenolic compounds; or The thermal oxidation section (1000'') comprises a high-temperature section (1005) and a low-temperature section (1040), wherein, when present, the mixed hydrocarbon waste stream (375) from the hydrocarbon buffer container (335) and the burner fuel gas stream (380) from the fuel gas separator (340) are introduced into the high-temperature section (1005), and wherein, when present, the phenolic water stream (385) from the phenolic water container (345) and the non-phenolic water stream from the non-phenolic water container are introduced into the high-temperature section (1005). The non-phenolic water stream (390) of (350) is introduced into the low-temperature section (1040), wherein the high-temperature section (1005) has a minimum temperature for burning the mixed hydrocarbon waste stream (345) from the hydrocarbon buffer container (335) and the burner fuel gas stream (380) from the fuel gas separator (340), and wherein the low-temperature section (1040) has a temperature for burning the non-phenolic compound and a portion of the phenolic compound; and further includes: In the catalytic oxidation section (1045), located after the SOx removal section (460) and before the optional NOx removal section (490), additional phenolic compounds and benzene are oxidized in the presence of a catalyst.

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