Method for producing phenol and acetone

1. A method for producing phenol and acetone in a multi-state process at an elevated temperature from a cumene hydroperoxide mixture comprising cumene, the method comprising the steps of:

(a) reacting the cumene hydroperoxide mixture with a 2-hydroxybenzenesulfonic acid catalyst having a concentration of 0.1 to 1 mmol/L acid catalyst to form a second mixture comprising phenol, acetone and dicumyl peroxide in a first state, wherein the 2-hydroxybenzenesulfonic acid catalyst is selected from the group consisting of 2-hydroxy-5-cumyl-benzenesulfonic acid, 3,3′-propane-2,2-diyl-bis-(6-hydroxybenzenesulfonic) acid, 2-hydroxy-5-chlorobenzenesulfonic acid, 2-hydroxy-5-methoxybenzenesulfonic acid, 2-hydroxy-5-methylbenzenesulfonic acid, 2-hydroxy-4-t-butyl-benzenesulfonic acid and 2-hydroxybenzenesulfonic acid, and

(b) decomposing the second mixture in a second stage to produce a third mixture comprising phenol and acetone.

2. The method of claim 1 , wherein the reacting in the first stage is at a temperature of from 40 to 75° C., and the decomposing in the second state is at a temperature of from 110 to 140° C.

3. The method of claim 1 , wherein the step of reacting the cumene hydroperoxide is in at least two serially connected reactors.

4. The method of claim 1 , wherein the cumene hydroperoxide concentration is from about 50 to 92 mass %.

5. The method of claim 1 , wherein the cumene hydroperoxide concentration is from about 80 to 84 mass %.

6. The method of claim 1 , wherein the second mixture is not quenched with an alkaline material prior to step b).

7. The method of claim 1 , wherein the third mixture has a hydroxyacetone concentration of less than 0.10 mass %, based on the total mass % of the third mixture.

8. The method of claim 1 , wherein the third mixture has a hydroxyacetone concentration of less than 0.05 mass %, based on the total mass % of the third mixture.

9. A method for producing phenol and acetone in a multi-stage process at an elevated temperature from a cumene hydroperoxide mixture comprising cumene, the method comprising the steps of:

(a) reacting the cumene hydroperoxide mixture with a 2-hydroxybenzenesulfonic acid catalyst having a concentration of 0.1 to 1 mmol/L acid catalyst to form a second mixture comprising phenol, acetone and dicumyl peroxide in a first stage, wherein the 2-hydroxybenzenesulfonic acid catalyst is selected from the group consisting of 2-hydroxy-5-cumyl-benzenesulfonic acid, 3,3′-propane-2,2-diyl-bis-(6-hydroxybenzenesulfonic) acid, 2-hydroxy-5-chlorobenzenesulfonic acid, 2-hydroxy-5-methoxybenzenesulfonic acid, 2-hydroxy-5-methylbenzenesulfonic acid and 2-hydroxybenzenesulfonic acid, and

(b) decomposing the second mixture in a second stage to produce a third mixture comprising phenol and acetone.

10. The method of claim 9 , wherein the third mixture has a hydroxyacetone concentration of less than 0.10 mass %, based on the total mass % of the third mixture.

11. The method of claim 9 , wherein the second mixture is not quenched with an alkaline material prior to step b).

12. A method for producing phenol and acetone in a multi-stage process at an elevated temperature from a cumene hydroperoxide mixture comprising cumene, the method comprising the steps of:

(a) reacting the cumene hydroperoxide mixture with a 2-hydroxybenzenesulfonic acid catalyst having a concentration of 0.1 to 1 mmol/L acid catalyst to form a second mixture comprising phenol, acetone and dicumyl peroxide in a first stage, wherein the 2-hydroxybenzenesulfonic acid catalyst is selected from the group consisting of 2-hydroxy-5-cumyl-benzenesulfonic acid, 3,3′-propane-2,2-diyl-bis-(6-hydroxybenzenesulfonic) acid, 2-hydroxy-5-chlorobenzenesulfonic acid, 2-hydroxy-5-methoxybenzenesulfonic acid and 2-hydroxy-5-methylbenzenesulfonic acid, and

(b) decomposing the second mixture in a second stage to produce a third mixture comprising phenol and acetone.

13. The method of claim 12 , wherein the third mixture has a hydroxyacetone concentration of less than 0.10 mass %, based on the total mass % of the third mixture.

14. The method of claim 12 , wherein the third mixture has a hydroxyacetone concentration of less than 0.05 mass %, based on the total mass % of the third mixture.

15. The method of claim 12 , wherein the second mixture is not quenched with an alkaline material prior to step b).