Processes for making cyclohexanone

1. A process for producing cyclohexanone from a first feed mixture comprising cyclohexylbenzene, cyclohexanone, phenol, and 3-cyclohexenone, the process comprising:

feeding the first feed mixture into a first distillation column at a first feeding location on the first distillation column;

obtaining a cyclohexylbenzene-rich lower effluent from the first distillation column;

obtaining a first upper effluent from a first upper effluent location on the first distillation column above the first feeding location, the first upper effluent comprising phenol, cyclohexanone, and 3-cyclohexenone;

feeding at least a portion of the first upper effluent to a hydrogenation reactor, where the first upper effluent contacts with hydrogen in the presence of a hydrogenation catalyst under hydrogenation conditions to produce a hydrogenation reactor effluent substantially free of 3-cyclohexenone;

feeding at least a portion of the hydrogenation reactor effluent to a second distillation column, and

obtaining an cyclohexanone-rich upper effluent and a phenol-rich lower effluent from the second distillation column.

2. The process of claim 1 , wherein the concentration of 3-cyclohexenone in the first feed mixture is in the range from 30 ppm by weight to 1 wt %, based on the total weight of the first feed mixture.

3. The process of claim 1 , wherein in the hydrogenation reactor, the conversion of 3-cyclohexenone is at least 95%.

4. The process of claim 1 , wherein the first feed mixture further comprises 2-cyclohexenone at a concentration in the range from 30 ppm by weight to 1 wt %, based on the total weight of the first feed mixture, the conversion of 2-cyclohexenone in the hydrogenation reactor is at least 95%, and the hydrogenation reactor effluent is substantially free of 2-cyclohexenone.

5. The process of claim 1 , wherein in the hydrogenation reactor, the conversion of phenol is in the range from 30% to 99%.

6. The process of claim 1 , further comprising feeding at least a portion of the phenol-rich lower effluent to the first distillation column at a second feeding location.

7. The process of claim 6 , wherein the second feeding location is higher than the first feeding location and lower than the first upper effluent location.

8. The process of claim 6 , wherein at least a portion of the phenol-rich lower effluent is recycled to the hydrogenation reactor.

9. The process of claim 1 , further comprising:

injecting a first stream of hydrogen into the second distillation column at a location in the vicinity of the bottom of the second distillation column;

separating at least a portion of the hydrogen from the cyclohexanone-rich upper effluent from the second distillation column to obtain a second stream of hydrogen; and

feeding at least a portion of the second stream of hydrogen into the hydrogenation reactor.

10. The process of claim 1 , wherein the first feed mixture further comprises water and light acids, the first upper effluent comprises water and light acids, and the first upper effluent is stripped of water and/or light acids before being fed into the hydrogenation reactor.

11. The process of claim 1 , wherein the first feed mixture comprises water and light acids, and the process further comprises obtaining a second upper effluent from the first distillation column at a second upper effluent location on the first distillation column above the first upper effluent location, wherein the second upper effluent comprises water and light acids, and is substantially free of phenol.

12. The process of claim 1 , further comprising:

feeding at least a portion of the cyclohexanone-rich upper effluent from the second distillation column into a third distillation column;

obtaining a light-components-rich upper effluent from the third distillation column;

obtaining a light-components-depleted lower effluent from the third distillation column;

feeding at least a portion of the light-components-depleted effluent into a fourth distillation column; and

obtaining a cyclohexanone upper effluent and a lower effluent from the fourth distillation column.

13. The process of claim 12 , wherein the cyclohexanone upper effluent from the fourth distillation column comprises 3-cyclohexenone and/or 2-cyclohexenone each at a concentration no greater than 20 ppm by weight, based on the total weight of the cyclohexanone effluent.

14. The process of claim 1 , wherein the first feed mixture comprises cyclohexylbenzene at a concentration in the range from 20 to 70 wt %, cyclohexanone at a concentration in the range from 10 to 40 wt %, phenol at a concentration in the range from 10 to 40 wt %, and 3-cyclohexenone at a concentration in the range from 30 ppm by weight to 1 wt %, based on the total weight of the first feed mixture.

15. The process of claim 1 , wherein the hydrogenation catalyst comprises one or more of the following elements: Fe, Co, Ni, Ru, Rh, Pd, Re, Os, Ir, and Pt, and the hydrogenation conditions comprise a temperature in the range from 25 to 300° C. and a hydrogen partial pressure in the range from 50 to 2000 kPa.

16. The process of claim 1 , wherein the first feed mixture is produced by a process comprising:

contacting benzene with hydrogen in a hydroalkylation reactor under hydrogenation conditions to produce a hydroalkylation effluent comprising cyclohexylbenzene;

oxidizing at least a portion of the cyclohexylbenzene to obtain an oxidized stream comprising cyclohexylbenzene hydroperoxide and cyclohexylbenzene;

contacting at least a portion of the oxidized stream with an acid in a cleavage reactor to obtain a cleavage effluent comprising phenol, cyclohexanone, and 3-cyclohexenone; and

obtaining the feed mixture from the cleavage mixture.

17. A process for producing cyclohexanone from a first feed mixture comprising cyclohexylbenzene, cyclohexanone, phenol, and 3-cyclohexenone, the process comprising:

feeding the first feed mixture into a first distillation column at a first feeding location;

providing a reactive hydrogenation zone loaded with a hydrogenation catalyst in the first distillation column above the first feeding location;

supplying hydrogen into the first distillation column at a location lower than the hydrogenation zone;

converting at least a portion of the 3-cyclohexenone in the hydrogenation zone under hydrogenation conditions;

obtaining a cyclohexylbenzene-rich lower effluent from the first distillation column; and

obtaining a first upper effluent from a first upper effluent location on the first distillation column above the reactive hydrogenation zone, the first upper effluent comprising cyclohexanone and is substantially free of 3-cyclohexenone and phenol.

18. The process of claim 17 , wherein in the concentration of 3-cyclohexenone in the first feed mixture is in the range from 30 ppm by weight to 1 wt %, based on the total weight of the first feed mixture, and in the hydrogenation zone, the conversion of 3-cyclohexenone is at least 95%.

19. The process of claim 17 , wherein the first feed mixture further comprises 2-cyclohexenone at a concentration in the range from 30 ppm by weight to 1 wt %, based on the total weight of the first feed mixture, the conversion of 2-cyclohexenone in the hydrogenation zone is at least 95%, and the first upper effluent is substantially free of 2-cyclohexenone.

20. The process of claim 17 , wherein the first feed mixture comprises water and light acids, and the process further comprises obtaining a second upper effluent from the first distillation column at a second upper effluent location above the first upper effluent location, wherein the second upper effluent comprises water and light acids.

21. The process of claim 17 , further comprising:

feeding at least a portion of the first upper effluent into a second distillation column;

obtaining a light-components-rich upper effluent from the second distillation column;

obtaining a light-components-depleted lower effluent from the third distillation column;

feeding at least a portion of the light-components-depleted lower effluent into a fourth distillation column; and

obtaining an cyclohexanone upper effluent and a lower effluent from the fourth distillation column.

22. The process of claim 21 , wherein the cyclohexanone upper effluent comprises 2-cyclohexenone and/or 3-cyclohexenone each at a concentration no greater than 10 ppm by weight, based on the total weight of the cyclohexanone upper effluent.

23. The process of claim 17 , wherein the first feed mixture comprises cyclohexylbenzene at a concentration in the range from 20 to 70 wt %, cyclohexanone at a concentration in the range from 10 to 40 wt %, phenol in the range from 10 to 40 wt %, and 2-cyclohexenone and/or 3-cyclohexenone each at a concentration in the range from 30 ppm by weight to 1 wt %, based on the total weight of the first feed mixture.

24. The process of claim 17 , wherein the hydrogenation catalyst comprises one or more of the following elements: Fe, Co, Ni, Ru, Rh, Pd, Re, Os, Ir, and Pt, and the hydrogenation conditions comprise a temperature in the range from 25 to 300° C. and a hydrogen partial pressure in the range from 50 to 2000 kPa.

25. The process of claim 17 , wherein the first feed mixture is produced by a process comprising:

contacting benzene with hydrogen in a hydroalkylation reactor under hydroalkylation conditions to produce a hydroalkylation effluent comprising cyclohexylbenzene;

oxidizing at least a portion of the cyclohexylbenzene to obtain an oxidized stream comprising cyclohexylbenzene peroxide and cyclohexylbenzene;

contacting at least a portion of the oxidized stream with an acid in a cleavage reactor to obtain a cleavage effluent comprising phenol, cyclohexanone, and 3-cyclohexenone; and

obtaining the feed mixture from the cleavage mixture.