Integrated process for producing bisphenol a

Abstract

An integrated process for producing bisphenol A, the process including separating a first stream including acetone and phenol to provide a second stream including acetone and a third stream including phenol; and reacting acetone present in the second stream and phenol present in the third stream to produce a product stream including the bisphenol A and a recycle stream.

Description

INTEGRATED PROCESS FOR PRODUCING BISPHENOL ABACKGROUND

[0001] Polycarbonates are used in a wide variety of applications because of their good balance of properties, including moldability, impact and transparency. Polycarbonates can be obtained by reacting a carbonate source with bisphenol A (BP A).

[0002] An interest exists for improved processes and systems for producing BPA.

[0003] Opportunities for improvement are addressed by the processes, methods and systems of the present disclosure.BRIEF DESCRIPTION

[0004] The present disclosure provides advantageous integrated processes and systems for producing BPA.

[0005] Disclosed herein is an integrated process for producing bisphenol A, the process comprising: separating a first stream comprising acetone and phenol to provide a second stream comprising acetone and a third stream comprising phenol; and reacting acetone present in the second stream and phenol present in the third stream to produce a product stream comprising the bisphenol A and a recycle stream.

[0006] Also disclosed herein is an integrated process for producing bisphenol A, the process comprising: reacting benzene and acetone to produce cumene; oxidizing the cumene to produce cumene hydroperoxide; cleaving the cumene hydroperoxide to produce a first stream comprising acetone, phenol, and alpha-methyl styrene; separating the first stream to provide a second stream comprising acetone and a third stream comprising phenol; cracking hydrocarbon compounds present in the third stream to produce a cracked hydrocarbon stream comprising phenol; purifying the second stream to provide a purified second stream comprising a greater proportion of acetone than the second stream; purifying the third stream prior to provide a purified third stream comprising a greater proportion of phenol than the third stream; and reacting acetone present in the purified second stream and phenol present in the purified third stream to produce a product stream comprising the bisphenol A and a recycle stream; wherein the recycle stream comprises acetone, wherein separating the first stream to provide the second stream and the third stream comprises separating the cracked hydrocarbon stream to provide thesecond stream and the third stream, and wherein reacting acetone present in the purified second stream and phenol present in the purified third stream to produce the product stream comprises reacting at least a portion of the acetone present in the recycle stream to produce the product stream.

[0007] Further disclosed herein is an integrated system for producing bisphenol A comprising: a first column for separating a first stream to provide a second stream comprising acetone and a third stream comprising phenol; a reactor for reacting acetone present in the second stream and phenol present in the third stream to produce a product stream comprising the bisphenol A and a recycle stream; and a recycling line for recycling the recycle stream to the first column.

[0008] The above described and other features are exemplified by the following figures and detailed description.

[0009] Any combination or permutation of embodiments is envisioned. Additional advantageous features, functions and applications of the disclosed processes, methods and systems of the present disclosure will be apparent from the description which follows, particularly when read in conjunction with the appended figures. All references listed in this disclosure are hereby incorporated by reference in their entireties.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The following figures are exemplary embodiments wherein the like elements are numbered alike.

[0011] FIG. 1 is a block flow diagram of an embodiment;

[0012] FIG. 2 is a process flow diagram of an embodiment;

[0013] FIG. 3 is a process flow diagram of an embodiment;

[0014] FIG. 4 is a process flow diagram of an embodiment;

[0015] FIG. 5 is a process flow diagram of an embodiment;

[0016] FIG. 6 is a process flow diagram of an embodiment;

[0017] FIG. 7 is a process flow diagram of an embodiment;

[0018] FIG. 8 is a process flow diagram of an embodiment;

[0019] FIG. 9 is a process flow diagram of an embodiment; and

[0020] FIG. 10 is a process flow diagram of an embodiment.DETAILED DESCRIPTION

[0021] The exemplary embodiments disclosed herein are illustrative of advantageous integrated processes for producing bisphenol A and systems thereof. It should be understood, however, that the disclosed embodiments are merely exemplary of the present disclosure, which may be embodied in various forms. Therefore, details disclosed herein with reference to exemplary processes for producing bisphenol A and associated systems are not to be interpreted as limiting, but merely as the basis for teaching one skilled in the art how to make and use the advantageous processes for producing bisphenol A of the present disclosure.

[0022] The present disclosure provides advantageous integrated processes for producing bisphenol A, and improved systems for utilizing the processes.

[0023] More particularly, the present disclosure provides advantageous integrated processes for producing bisphenol A, the processes providing cost efficiencies over separately producing BP A and phenol.

[0024] For example, provided is an integrated process for the production of BPA. Phenol from phenol production can be used in BPA production and unreacted phenol from the BPA production can be recycled to the phenol production. More specifically, phenol separated in a distillation column of the phenol production can be used in the BPA production and unreacted phenol from the BPA production can be recycled to the distillation column of the phenol production.

[0025] The integrated process avoids the need for separate systems for purifying phenol in each of the phenol production and BPA production. In an embodiment, phenol from phenol production can be used in more than one BPA production reactor.

[0026] FIG. l is a block flow diagram of an embodiment. Energy integration, for example, in the form of steam, can be provided between cumene production 1000 and phenol production 2000. A stream 3000 including purified phenol and a stream 4000 including purified acetone can be provided from phenol production 2000 to BPA production 5000. A stream 6000 including unreacted phenol and a stream 7000 including by-products from the BPA production 5000 such as heavies can be recycled to phenol production 2000. A product stream 8000 including BPA 8000 from BPA production 5000 can be used in polycarbonate production 9000.

[0027] Recycling a stream including unreacted phenol from BPA production to phenolproduction can provide high purity BPA product, increased process yield, efficient treatment of the unreacted phenol, or a combination thereof. While a larger recycle can provide higher purity BPA product, increasing the amount of recycle may not be desirable from a financially. For example, extra energy may be used (steam) for distillation (purification) of the recycle stream to provide higher purity BPA product.

[0028] The stream including unreacted phenol recovered from BPA production can be of a lower quality, e.g., have a lower BPA purity, than a stream including phenol introduced to the BPA production Raw materials, for example, phenol for BPA production, can be utilized efficiently, as unreacted phenol recovered from BPA production can be utilized for BPA production. Separation of phenol and by-products from BPA production in phenol production and for BPA production can be achieved in a single step or unit, e.g., distillation column.

[0029] With reference to FIG. 2, an integrated process for producing bisphenol A includes separating a first stream 10 including acetone and phenol in a column 100 to provide a second stream 20 including acetone and a third stream 30 including phenol; and reacting acetone present in the second stream 20 and phenol present in the third stream 30 in a BPA production reactor 200 to produce a product stream 40 including the bisphenol A and a recycle stream 50. The recycle stream 50 can include acetone and reacting acetone present in the second stream 20 and phenol present in the third stream 30 to produce the product stream 40 can include reacting at least a portion of the acetone present in the recycle stream 50 to produce the product stream. Whether the recycle stream 50 includes acetone or the amount of acetone in the recycle stream 50 can depend, for example, on the production rate, freshness of catalyst, or a combination thereof.

[0030] In an embodiment, the first stream 10 can include 8 to 12 weight percent (wt%) water, 25 to 28.5 wt% acetone, 8 to 12 wt% cumene, 46 to 49 wt% phenol, and 0.35 to 0.65 wt% alkylated heavies, for example, 9.5 to 10.5 wt% water, 26 to 26.5 wt% acetone, 9 to 9.5 wt% cumene, 46.7 to 47.4 wt% phenol, and 0.45 to 0.55 wt% alkylated heavies. The amount of water can be set by equilibrium; when the amount of cumene is higher, the amount of water can be lower, and conversely, when the amount of cumene is lower, the amount of water can be higher. As used herein, “alkylated heavies” refers to products of side reactions with phenol and can include, for example, p-cumyl phenol, o-cumyl phenol, 2-methylbenzofuran, alpha-methylstyrene dimer 1, alpha-methylstyrene dimer 2, and cyclic alpha-methylstyrenedimer, and para-para-bisphenol A.

[0031] Processing conditions for the column 100 can include a temperature of 180 to 410 °F (82 to 210 °C), a gauge pressure of 2 to 12.5 pounds per square inch (psi) (13,790 to 86,184 pascals (Pa)), and a flow rate of 350 to 470 gallons per minute (GPM) (1,325 to 1,779 liters per minute (LPM)), for example, 190 to 397 °F (88 to 203 °C), 3 to 11.5 psi (20,684 to 79,290 Pa), and 380 to 420 GPM (1,438 to 1,590 LPM).

[0032] In an embodiment, the second stream 20 can include 0.25 to 0.50 wt% water, 99.5 to 99.75 wt% acetone, 0 to 10 parts per million by weight (ppm) cumene, 0 ppm phenol, and 0 ppm alkylated heavies, for example, 0.35 to 0.40 wt% water, 99.55 to 99.65 wt% acetone, 0 to 2 ppm cumene, 0 ppm phenol, and 0 ppm alkylated heavies.

[0033] In an embodiment, the third stream 30 can include 0 to 300 ppm water, 0 to 0.35 ppm acetone, 0 to 0.2 ppm cumene, 99.5 to 99.95 wt% phenol, and 0 to 0.1 ppm alkylated heavies, for example, 50 to 150 ppm water, 0.20 to 0.25 wt% acetone, 0.15 to 0.20 wt% cumene, 99.6 to 99.65 wt% phenol, and 0 ppm alkylated heavies.

[0034] In an embodiment, the recycle stream 50 can include 0 to 0.5 wt% water, 0 to 0.4 wt% acetone, 0 to 10 ppm cumene, 75 to 90 wt% phenol, and 10 to 25 wt% alkylated heavies, for example, 0 to 0.3 wt% water, 0 to 0.3 wt% acetone, 3 to 5 ppm cumene, 80 to 90 wt% phenol, and 15 to 20 wt% alkylated heavies.

[0035] Processing conditions for the BPA production reactor 200 can include a temperature of 130 to 185°F (54 to 85 °C), a gauge pressure of 0 to 25 psi (0 to 172,369 Pa), and a flow rate of 100 to 200 GPM (379 to 757 LPM), for example, 135 to 175 °F (57 to 79 °C), 0 to 10 psi (0 to 68,948 Pa), and 110 to 140 GPM (416 to 530 LPM).

[0036] In an embodiment, the product stream 40 can include 99.5 to 99.98 wt% BPA, for example, 99.8 to wt% BPA. In an embodiment, the product stream 40 can have an American Public Health Association (APHA) solution color of less than 20 to less than 2 parts per million of platinum cobalt to water. Purity of the product stream 40 can be affected by factors such as number of trays in column 100, flow rate, and reflux in the column 100 and flow rate, freshness of catalyst, and reflux in the BPA production reactor 200.

[0037] With reference to FIG. 3, the process can further include combining the first stream 10 and the recycle stream 50 to provide a combined stream 60, and separating the first stream 10 to provide the second stream 20 and the third stream 30 can include separating thecombined stream 60 to provide the second stream 20 and the third stream 30. In an embodiment, the combined stream 60 can be fed to a tank prior to feeding to the column 100. Water can be decanted from the combined stream 50 in the tank. In an embodiment, first stream 10 can be fed to a tank from which water can be decanted and the recycle stream 50 can be combined with a stream exiting the tank to provide the combined stream 60, which is fed to the column 100.

[0038] In an embodiment, the combined stream 60 can include 8 to 12 wt% water, 26 to 28.5 wt% acetone, 8 to 12 wt% cumene, 26 to 48 wt% phenol, and 0.45 to 0.66 wt% alkylated heavies, for example, 9.5 to 10.5 wt% water, 26 to 26.5 wt% acetone, 9 to 9.5 wt% cumene, 46.7 to 47.4 wt% phenol, and 0.45 to 0.65 wt% alkylated heavies.

[0039] The process can further include adjusting a composition of the combined stream 60 prior to separating the combined stream 60 to provide the second stream 20 and the third stream 30. Adjusting the composition of the combined stream 60 can include, for example, adjusting an amount, e.g., flow rate, of the recycle stream 50. Purity of the product stream 40 can increase with an increased flow rate of the recycle stream 50. Increasing flow rate of the recycle stream can be accompanied by an increase in cost of more steam for distillation of the combined stream.

[0040] With reference to FIG. 4, the process can further include mixing the recycle stream 50 with the second stream 20. With reference to FIG. 5, the process can further include purifying the second stream 20 in a first purifier 300 to produce a purified second stream 25 prior to reacting acetone present in the second stream 20 and phenol present in the third stream 30 to produce the product stream 40 including the bisphenol A.

[0041] Processing conditions for the first purifier 300 can include a temperature of 130 to 170 °F (54 to 77 °C), a gauge pressure of 0 to 21.2 psi (0 to 146,169 Pa), and a flow rate of 150 to 300 GPM (568 to 1,136 LPM), for example, 130 to 170 °F (54 to 77 °C), 0 to 21.2 psi (0 to 146,169 Pa), and 250 to 275 GPM (946 to 1,041 LPM).

[0042] In an embodiment, the purified second stream 25 can include 15 to 20 wt% water, 53 to 56 wt% acetone, 22 to 25 wt% cumene, 0.1 to 1.5 wt% phenol, and 0 to 0.01 wt% alkylated heavies, for example, 17 to 15.2 wt% water, 54 to 55.2 wt% acetone, 23 to 24 wt% cumene, 0.2 to 0.5 wt% phenol, and 0 to 0.1 wt% alkylated heavies.

[0043] With reference to FIG. 6, the process can further include purifying the third stream 30 in a second purifier 400 to produce a purified third stream 35 prior to reacting acetone present in the second stream 20 and phenol present in the third stream 30 to produce the productstream 40 including the bisphenol A.

[0044] Processing conditions for the second purifier 400 can include a temperature of 290 to 425 °F (143 to 218 °C), a gauge pressure of 0 to 1,260 millimeters of mercury (mm Hg) (0 to 167,986 Pa), and a flow rate of 130 to 250 GPM (492 to 946 LPM), for example, 290 to 425 °F (143 to 218 °C), 0 to 1,260 mm Hg (0 to 167,986 Pa), and 200 to 225 GPM (757 to 852 LPM).

[0045] Product specifications for the purified third stream 35 can include, for example, maximum 30 ppm 2-mthylbenzofurane, 5 ppm hydroxyacetone, 0.1 ppm iron, 5 ppm mesityl oxide, 20 ppm carbonyls, >80 ppm organic impurities such as cresols, 0.03 wt% water, 5 ppm alpha-methyl styrene, 20 ppm m- and p-cresol, 75 ppm o-cresol, or a combination thereof. Purity of the purified third stream 35 can be affected by factors such as number of trays in the column 100, flow rate, and reflux in the column 100 and flow rate, freshness of catalyst, and reflux in the second purifier 400.

[0046] The process can further include reacting benzene and acetone to produce cumene; oxidizing the cumene to produce cumene hydroperoxide; and cleaving the cumene hydroperoxide to produce the first stream 10, and the first stream 10 can further include alpha-methyl styrene.

[0047] With reference to FIG. 7, the process can further include cracking hydrocarbon compounds present in the third stream 30 in a cracker 500 to produce a cracked hydrocarbon stream, at least a portion of which is recycled to the process as stream 70. The cracked hydrocarbon stream 70 can include phenol. Separating the first stream 10 to provide the second stream 20 and the third stream 30 can include separating stream 70 to provide the second stream 20 and the third stream 30.

[0048] The third stream 30 can include impurities associated with both the BPA production and the phenol production. Purification of the third stream 30 can produce not only a purified third stream 35 but also a stream including impurities such as hydrocarbon compounds. Cracking such hydrocarbon compounds can increase yield at high purity.

[0049] Processing conditions for the cracker 500 can include a temperature of 400 to 630 °F (204 to 332 °C), a gauge pressure of 0 to 15 psi (0 to 103,421 Pa), and a flow rate of 5 to 25 GPM (19 to 95 LPM), for example, 500 to 600 °F (260 to 316 °C), 7.5 to 15 psi (51,711 to 103,421 Pa), and 18 to 23 GPM (68 to 87 LPM).

[0050] In an embodiment, stream 70 can include 0 wt% water, 0 wt% acetone, 20 to 25 wt% cumene, 30 to 36 wt% phenol, and 0 to 0.1 wt% alkylated heavies, for example, 0 wt% water, 0 wt% acetone, 22.5 to 23 wt% cumene, 33.2 to 34.2 wt% phenol, and 0 to 0.1 wt% alkylated heavies.

[0051] In an embodiment, the stream sent to the cracker 500 can include 0 wt% water, 0 wt% acetone, 0 wt% cumene, 0.5 to 3.0 wt% phenol, and 60 to 70 wt% alkylated heavies, for example, 0 wt% water, 0 wt% acetone, 0 wt% cumene, 0.8 to 1.2 wt% phenol, and 63 to 67 wt% alkylated heavies.

[0052] With reference to FIG. 8, in an embodiment, the process can include purifying the second stream 20 in a first purifier 300 to produce a purified second stream 25 prior to reacting acetone present in the second stream 20 and phenol present in the third stream 30 to produce the product stream 40 including the bisphenol A, and purifying the third stream 30 in a second purifier 400 to produce a purified third stream 35 prior to reacting acetone present in the second stream 20 and phenol present in the third stream 30 to produce the product stream 40 including the bisphenol A.

[0053] With reference to FIG. 9, in an embodiment, an integrated process for producing bisphenol A includes reacting benzene and acetone in cumene production reactor 800 to produce cumene; oxidizing the cumene in cumene oxidation reactor 900 to produce cumene hydroperoxide; cleaving the cumene hydroperoxide in cleavage reactor 950 to produce a first stream 10 including acetone, phenol, and alpha-methyl styrene; separating the first stream 10 to provide a second stream 20 including acetone and a third stream 30 including phenol; cracking hydrocarbon compounds present in the third stream 30 in cracker 500 to produce a cracked hydrocarbon stream 70 including phenol; purifying the second stream 20 to provide a purified second stream 25 including a greater proportion of acetone than the second stream 20; purifying the third stream 30 prior to provide a purified third stream 35 including a greater proportion of phenol than the third stream 30; and reacting acetone present in the purified second stream 25 and phenol present in the purified third stream 35 to produce a product stream 40 including the bisphenol A and a recycle stream 50 including acetone. Separating the first stream 10 to provide the second stream 20 and the third stream 30 can include separating the cracked hydrocarbon stream 70 to provide the second stream 20 and the third stream 30. Reacting acetone present in the purified second stream 25 and phenol present in the purified third stream 35 to produce theproduct stream 40 can include reacting at least a portion of the acetone present in the recycle stream 50 to produce the product stream.

[0054] Purification of the third stream 30 can produce not only the purified third stream 35 but also a stream including hydrocarbon compounds impurities. Such hydrocarbon compounds are cracked in cracker 500 to produce the cracked hydrocarbon stream 70 including phenol.

[0055] Processing conditions for the cumene oxidation reactor 900 can include a temperature of 175 to 220 °F (79 to 104 °C), a gauge pressure of 70 to 85 psi (482,633 to 586,054 Pa), and a flow rate of 1,000 to 1,400 GPM (3,785 to 5,300 LPM), for example, 175 to 220 °F (79 to 104 °C), 70 to 85 psi (482,633 to 586,054 Pa), and 1,100 to 1,200 GPM (4,164 to 4,542 LPM).

[0056] Processing conditions for the cleavage reactor 950 can include a temperature of 80 to 110 °F (27 to 43 °C), a gauge pressure of 0 to 19.7 psi (0 to 135,827 Pa), and a flow rate of 225 to 400 GPM (852 to 1,514 LPM), for example, 85 to 105 °F (29 to 41 °C), 0 to 19.7 psi (0 to 135,827 Pa), and 350 to 380 GPM (1,325 to 1,438 LPM).

[0057] With reference to FIG. 10, reacting acetone present in the second stream 20 and phenol present in the third stream 30 to produce the product stream 40 can includes reacting acetone present in the second stream 20 and phenol present in the third stream 30 in a first BPA production reactor 600 to produce a first product stream 80 including bisphenol A and a first recycle stream 85, and reacting acetone present in the second stream 20 and phenol present in the third stream 30 in a second BPA production reactor 700 to produce a second product stream 90 including bisphenol A and a second recycle stream 95. Reacting at least a portion of the acetone present in the recycle stream 50 to produce the product stream 40 can include reacting acetone present in the first recycle stream 85 to produce the product stream, and reacting acetone present in the second recycle stream 95 to produce the product stream.

[0058] Processing conditions for the first BPA production reactor 600 can include a temperature of 130 to 185 °F (54 to 85 °C), a gauge pressure of 0 to 25 psi (0 to 172,369 Pa), and a flow rate of 100 to 200 GPM (379 to 757 LPM), for example, 135 to 175 °F (57 to 79 °C), 0 to 10 psi (0 to 68,948 Pa), and 110 to 140 GPM (416 to 530 LPM).

[0059] Processing conditions for the second BPA production reactor 700 can include a temperature of 130 to 185 °F (54 to 85 °C), a gauge pressure of 0 to 25 psi (0 to 172,369 Pa), anda flow rate of 100 to 200 GPM (379 to 757 LPM), for example, 135 to 175 °F (57 to 79 °C), 0 to 10 psi (0 to 68,948 Pa), and 110 to 140 GPM (416 to 530 LPM).

[0060] In an embodiment, the first product stream 80 can include 99.7 to 99.98 wt% BP A, 0 to 250 ppm phenol, and 0.02 to 0.3 wt% heavies, for example, 99.8 to 99.9 wt% BP A, 100 to 200 ppm phenol, and 0.09 to 0.18 wt% heavies.

[0061] In an embodiment, the first recycle stream 85 can include 0 to 0.5 wt% water, 0 to 0.4 wt% acetone, 0 to 10 ppm cumene, 75 to 90 wt% phenol, and 5 to 20 wt% alkylated heavies, for example, 0 to 0.3 wt% water, 0 to 0.3 wt% acetone, 3 to 5 ppm cumene, 80 to 90 wt% phenol, and 10 to 15 wt% alkylated heavies. In an embodiment, the first recycle stream 85 has less heavies than recycle stream 50

[0062] In an embodiment, the second product stream 90 can include 99.5 wt% to 99.98 wt% BPA, for example 99.8 wt% BPA.

[0063] In an embodiment, the second recycle stream 95 can include 0 to 0.5 wt% water, 0 to 0.4 wt% acetone, 0 to 10 ppm cumene, 75 to 90 wt% phenol, and 10 to 25 wt% alkylated heavies, for example, 0 to 0.3 wt% water, 0 to 0.3 wt% acetone, 3 to 5 ppm cumene, 80 to 90 wt% phenol, and 15 to 20 wt% alkylated heavies. In an embodiment, the second recycle stream 95 can have a same composition as recycle stream 50.

[0064] Reacting acetone present in the second stream 20 and phenol present in the third stream 30 to produce the product stream 40 can include reacting acetone present in the second stream 20 and phenol present in the third stream 30 in a first BPA production reactor 600 to produce a first product stream 80 including bisphenol A and a first recycle stream 85, and reacting acetone present in the second stream 20 and phenol present in the third stream 30 in a second BPA production reactor 700 to produce a second product stream 90 including bisphenol A and a second recycle stream 95. The process can further include reacting phenol present in the first recycle stream 85 (represented by the dotted line) with the acetone present in the second stream 20 and the phenol present in the third stream 30 in the second BPA production reactor 700 to produce the second product stream 90 including bisphenol A and the second recycle stream 95. A weight percentage of bisphenol A present in the first product stream 80, based on a total weight of the first product stream 80, can be greater than a weight percentage of bisphenol A present in the second product stream 90, based on a total weight of the second product stream

[0065] In an embodiment, an integrated system for producing bisphenol A includes a column 100 for separating a first stream 10 to provide a second stream 20 including acetone and a third stream 30 including phenol; a reactor 200 for reacting acetone present in the second stream 20 and phenol present in the third stream 30 to produce a product stream 40 including the bisphenol A and a recycle stream 50; and a recycling line for recycling the recycle stream 50 to the column 100.

[0066] The reactor 200 for reacting acetone present in the second stream 20 and phenol present in the third stream 30 to produce the product stream 40 can include a first reactor 600 for reacting acetone present in the second stream 20 and phenol present in the third stream 30 to produce a first product stream 80 including bisphenol A and a first recycle stream 85; and a second reactor 700 for reacting acetone present in the second stream 20 and phenol present in the third stream 30 to produce a second product stream 90 including bisphenol A and a second recycle stream 95.

[0067] This disclosure is further illustrated by the following examples, which are non-limiting.EXAMPLES

[0068] Simulation of the BP A plant was performed using Aspen VI 0 simulation software in accordance with the process shown in FIG. 9. Recycle stream 50 was set at 5% based on total dry mother liquid flow. Details are provided in Tables 1 and 2. Table 1Table 2

[0069] This disclosure further encompasses the following aspects.

[0070] Aspect 1. An integrated process for producing bisphenol A, the processcomprising: separating a first stream comprising acetone and phenol to provide a second stream comprising acetone and a third stream comprising phenol; and reacting acetone present in the second stream and phenol present in the third stream to produce a product stream comprising the bisphenol A and a recycle stream.

[0071] Aspect 2. The process of Aspect 1, wherein: the recycle stream comprises acetone; and reacting acetone present in the second stream and phenol present in the third stream to produce the product stream comprises reacting at least a portion of the acetone present in the recycle stream to produce the product stream.

[0072] Aspect 3. The process of Aspect 1 or 2, further comprising combining the first stream and the recycle stream to provide a combined stream, wherein separating the first stream to provide the second stream and the third stream comprises separating the combined stream to provide the second stream and the third stream.

[0073] Aspect 4. The process of Aspect 3, further comprising adjusting a composition of the combined stream prior to separating the combined stream to provide the second stream and the third stream.

[0074] Aspect 5. The process of any of the preceding aspects, further comprising purifying the second stream prior to reacting acetone present in the second stream and phenol present in the third stream to produce the product stream comprising the bisphenol A.

[0075] Aspect 6. The process of any of the preceding aspects, further comprising purifying the third stream prior to reacting acetone present in the second stream and phenol present in the third stream to produce the product stream comprising the bisphenol A.

[0076] Aspect 7. The process of any of the preceding aspects, further comprising: reacting benzene and acetone to produce cumene; oxidizing the cumene to produce cumene hydroperoxide; and cleaving the cumene hydroperoxide to produce the first stream, wherein the first stream further comprises alpha-methyl styrene.

[0077] Aspect 8. The process of any of the preceding aspects, further comprising cracking hydrocarbon compounds present in the third stream.

[0078] Aspect 9. The process of Aspect 8, wherein cracking hydrocarbon compounds present in the third stream produces a cracked hydrocarbon stream comprising phenol.

[0079] Aspect 10. The process of Aspect 9, wherein separating the first stream to provide the second stream and the third stream comprises separating the cracked hydrocarbon stream toprovide the second stream and the third stream.

[0080] Aspect 11. The process of Aspect 2, wherein: reacting acetone present in the second stream and phenol present in the third stream to produce the product stream comprises reacting acetone present in the second stream and phenol present in the third stream in a first reactor to produce a first product stream comprising bisphenol A and a first recycle stream, and reacting acetone present in the second stream and phenol present in the third stream in a second reactor to produce a second product stream comprising bisphenol A and a second recycle stream; and reacting acetone present in the recycle stream to produce the product stream comprises reacting acetone present in the first recycle stream to produce the product stream, and reacting acetone present in the second recycle stream to produce the product stream.

[0081] Aspect 12. The process of any of Aspects 1 to 10, wherein reacting acetone present in the second stream and phenol present in the third stream to produce the product stream comprises reacting acetone present in the second stream and phenol present in the third stream in a first reactor to produce a first product stream comprising bisphenol A and a first recycle stream, and reacting acetone present in the second stream and phenol present in the third stream in a second reactor to produce a second product stream comprising bisphenol A and a second recycle stream; and the process further comprises reacting phenol present in the first recycle stream with the acetone present in the second stream and the phenol present in the third stream in the second reactor to produce the second product stream comprising bisphenol A and the second recycle stream, wherein a weight percentage of bisphenol A present in the first product stream, based on a total weight of the first product stream, is greater than a weight percentage of bisphenol A present in the second product stream, based on a total weight of the second product stream.

[0082] Aspect 13. An integrated process for producing bisphenol A, the process comprising: reacting benzene and acetone to produce cumene; oxidizing the cumene to produce cumene hydroperoxide; cleaving the cumene hydroperoxide to produce a first stream comprising acetone, phenol, and alpha-methyl styrene; separating the first stream to provide a second stream comprising acetone and a third stream comprising phenol; cracking hydrocarbon compounds present in the third stream to produce a cracked hydrocarbon stream comprising phenol; purifying the second stream to provide a purified second stream comprising a greater proportion of acetone than the second stream; purifying the third stream prior to provide a purified thirdstream comprising a greater proportion of phenol than the third stream; and reacting acetone present in the purified second stream and phenol present in the purified third stream to produce a product stream comprising the bisphenol A and a recycle stream; wherein the recycle stream comprises acetone, wherein separating the first stream to provide the second stream and the third stream comprises separating the cracked hydrocarbon stream to provide the second stream and the third stream, and wherein reacting acetone present in the purified second stream and phenol present in the purified third stream to produce the product stream comprises reacting at least a portion of the acetone present in the recycle stream to produce the product stream.

[0083] Aspect 14. An integrated system for producing bisphenol A comprising: a first column for separating a first stream to provide a second stream comprising acetone and a third stream comprising phenol; a reactor for reacting acetone present in the second stream and phenol present in the third stream to produce a product stream comprising the bisphenol A and a recycle stream; and a recycling line for recycling the recycle stream to the first column.

[0084] Aspect 15. The integrated system of Aspect 14, wherein the reactor for reacting acetone present in the second stream and phenol present in the third stream to produce the product stream comprises: a first reactor for reacting acetone present in the second stream and phenol present in the third stream to produce a first product stream comprising bisphenol A and a first recycle stream; and a second reactor for reacting acetone present in the second stream and phenol present in the third stream to produce a second product stream comprising bisphenol A and a second recycle stream.

[0085] The methods and systems can alternatively comprise, consist of, or consist essentially of, any appropriate materials, steps, or components herein disclosed. The methods and systems can additionally, or alternatively, be formulated so as to be devoid, or substantially free, of any materials (or species), steps, or components, that are otherwise not necessary to the achievement of the function or objectives of the methods and systems.

[0086] All ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other (e.g., ranges of “up to 25 wt%, or, more specifically, 5 wt% to 20 wt%”, is inclusive of the endpoints and all intermediate values of the ranges of “5 wt% to 25 wt%,” etc.). “Combinations” is inclusive of blends, mixtures, alloys, reaction products, and the like. The terms “first,” “second,” and the like, do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The terms“a” and “an” and “the” do not denote a limitation of quantity and are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. “Or” means “and / or” unless clearly stated otherwise. Reference throughout the specification to “some embodiments”, “an embodiment”, and so forth, means that a particular element described in connection with the embodiment is included in at least one embodiment described herein, and may or may not be present in other embodiments. In addition, it is to be understood that the described elements may be combined in any suitable manner in the various embodiments. A “combination thereof’ is open and includes any combination comprising at least one of the listed components or properties optionally together with a like or equivalent component or property not listed.

[0087] Unless defined otherwise, technical and scientific terms used herein have the same meaning as is commonly understood by one of skill in the art to which this application belongs. All cited patents, patent applications, and other references are incorporated herein by reference in their entirety. However, if a term in the present application contradicts or conflicts with a term in the incorporated reference, the term from the present application takes precedence over the conflicting term from the incorporated reference.

[0088] While particular embodiments have been described, alternatives, modifications, variations, improvements, and substantial equivalents that are or may be presently unforeseen may arise to applicants or others skilled in the art. Accordingly, the appended claims as filed and as they may be amended are intended to embrace all such alternatives, modifications variations, improvements, and substantial equivalents.

[0089] Although the processes, methods and systems of the present disclosure have been described with reference to exemplary embodiments thereof, the present disclosure is not limited to such exemplary embodiments and / or implementations. Rather, the processes, methods and systems of the present disclosure are susceptible to many implementations and applications, as will be readily apparent to persons skilled in the art from the disclosure hereof. The present disclosure expressly encompasses such modifications, enhancements and / or variations of the disclosed embodiments. Since many changes could be made in the above construction and many widely different embodiments of this disclosure could be made without departing from the scope thereof, it is intended that all matter contained in the drawings and specification shall be interpreted as illustrative and not in a limiting sense. Additional modifications, changes, andsubstitutions are intended in the foregoing disclosure. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the disclosure.

Claims

CLAIMS1. An integrated process for producing bisphenol A, the process comprising: separating a first stream comprising acetone and phenol to provide a second stream comprising acetone and a third stream comprising phenol; and reacting acetone present in the second stream and phenol present in the third stream to produce a product stream comprising the bisphenol A and a recycle stream.

2. The process of Claim 1, wherein: the recycle stream comprises acetone; and reacting acetone present in the second stream and phenol present in the third stream to produce the product stream comprises reacting at least a portion of the acetone present in the recycle stream to produce the product stream.

3. The process of Claim 1 or 2, further comprising combining the first stream and the recycle stream to provide a combined stream, wherein separating the first stream to provide the second stream and the third stream comprises separating the combined stream to provide the second stream and the third stream.

4. The process of Claim 3, further comprising adjusting a composition of the combined stream prior to separating the combined stream to provide the second stream and the third stream.

5. The process of any of the preceding claims, further comprising purifying the second stream prior to reacting acetone present in the second stream and phenol present in the third stream to produce the product stream comprising the bisphenol A.

6. The process of any of the preceding claims, further comprising purifying the third stream prior to reacting acetone present in the second stream and phenol present in the third stream to produce the product stream comprising the bisphenol A.

7. The process of any of the preceding claims, further comprising: reacting benzene and acetone to produce cumene; oxidizing the cumene to produce cumene hydroperoxide; and cleaving the cumene hydroperoxide to produce the first stream, wherein the first stream further comprises alpha-methyl styrene.

8. The process of any of the preceding claims, further comprising cracking hydrocarbon compounds present in the third stream.

9. The process of Claim 8, wherein cracking hydrocarbon compounds present in the third stream produces a cracked hydrocarbon stream comprising phenol.

10. The process of Claim 9, wherein separating the first stream to provide the second stream and the third stream comprises separating the cracked hydrocarbon stream to provide the second stream and the third stream.

11. The process of Claim 2, wherein: reacting acetone present in the second stream and phenol present in the third stream to produce the product stream comprises reacting acetone present in the second stream and phenol present in the third stream in a first reactor to produce a first product stream comprising bisphenol A and a first recycle stream, and reacting acetone present in the second stream and phenol present in the third stream in a second reactor to produce a second product stream comprising bisphenol A and a second recycle stream; and reacting acetone present in the recycle stream to produce the product stream comprises reacting acetone present in the first recycle stream to produce the product stream, and reacting acetone present in the second recycle stream to produce the product stream.

12. The process of any of Claims 1 to 10, wherein reacting acetone present in the second stream and phenol present in the third stream to produce the product stream comprises reacting acetone present in the second stream and phenol present in the third stream in a first reactor to produce a first product stream comprising bisphenol A and a first recycle stream, and reacting acetone present in the second stream and phenol present in the third stream in a second reactor to produce a second product stream comprising bisphenol A and a second recycle stream; and the process further comprises reacting phenol present in the first recycle stream with the acetone present in the second stream and the phenol present in the third stream in the second reactor to produce the second product stream comprising bisphenol A and the second recycle stream, wherein a weight percentage of bisphenol A present in the first product stream, based on a total weight of the first product stream, is greater than a weight percentage of bisphenol A present in the second product stream, based on a total weight of the second product stream.

13. An integrated process for producing bisphenol A, the process comprising: reacting benzene and acetone to produce cumene; oxidizing the cumene to produce cumene hydroperoxide; cleaving the cumene hydroperoxide to produce a first stream comprising acetone, phenol, and alpha-methyl styrene; separating the first stream to provide a second stream comprising acetone and a third stream comprising phenol; cracking hydrocarbon compounds present in the third stream to produce a cracked hydrocarbon stream comprising phenol; purifying the second stream to provide a purified second stream comprising a greater proportion of acetone than the second stream; purifying the third stream prior to provide a purified third stream comprising a greater proportion of phenol than the third stream; and reacting acetone present in the purified second stream and phenol present in the purified third stream to produce a product stream comprising the bisphenol A and a recycle stream; wherein the recycle stream comprises acetone, wherein separating the first stream to provide the second stream and the third stream comprises separating the cracked hydrocarbon stream to provide the second stream and the third stream, and wherein reacting acetone present in the purified second stream and phenol present in the purified third stream to produce the product stream comprises reacting at least a portion of the acetone present in the recycle stream to produce the product stream.

14. An integrated system for producing bisphenol A comprising: a first column for separating a first stream to provide a second stream comprising acetone and a third stream comprising phenol; a reactor for reacting acetone present in the second stream and phenol present in the third stream to produce a product stream comprising the bisphenol A and a recycle stream; and a recycling line for recycling the recycle stream to the first column.

15. The integrated system of Claim 14, wherein the reactor for reacting acetone present in the second stream and phenol present in the third stream to produce the product stream comprises: a first reactor for reacting acetone present in the second stream and phenol present in the third stream to produce a first product stream comprising bisphenol A and a first recycle stream; and a second reactor for reacting acetone present in the second stream and phenol present in the third stream to produce a second product stream comprising bisphenol A and a second recycle stream.

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