Optimization of caustic usage

Abstract

A method for determining the quantity of phenol extracted into an aqueous solution of an alkali metal hydroxide uses a measurement of the pH of the solution, from which the equivalents of phenol relative to alkali metal hydroxide in solution is determined. A method for optimizing the use of an aqueous solution of an alkali metal hydroxide in a phenol recovery process uses pH measured to regulate the feed rate of the aqueous solution.

Description

FIELD OF THE INVENTION

[0001] The present invention relates generally to extractive processes using aqueous solutions of alkali metal hydroxides to recover phenol from organic streams. More particularly, the present invention relates to a method for determining the quantity of phenol that has been extracted into an aqueous solution of an alkali metal hydroxide. The invention also relates to the optimization of an extractive process for the recovery of phenol from various distillation streams by monitoring the pH of an aqueous extraction solvent containing an alkali metal hydroxide.

BACKGROUND OF THE INVENTION

[0002] For a number of years, it has been common practice in phenol manufacturing facilities to use aqueous solutions of alkali metal hydroxides to recover phenol from organic streams, such as distillation overheads or bottoms, by extraction into the aqueous stream. This method operates by reaction of the phenol with the alkali metal hydroxide to form a water soluble alkali metal phenate, such as sodium phenate. The basic process by which phenol is converted into sodium phenate is shown by the equation;

1 PhOH+1 NaOH→1 PhO−Na++1 H2O

[0003] As the free sodium hydroxide is consumed by conversion to sodium phenate, the pH of the aqueous solution decreases.

[0004] Historically, alkali metal hydroxide solutions have been used to extract phenol from an organic stream in an equimolar proportion to the amount of alkali metal hydroxide present in the aqueous stream. That is, as in the example shown, one mole of sodium hydroxide reacts with one mole of phenol to produce one mole of sodium phenate, which is extracted into the aqueous stream.

[0005] It is disclosed in U.S. Pat. Nos. 3,277,185 and 4,973,766 that solutions of alkali metal phenate can act as a solvent for free phenol, causing the phenol to have a greater affinity for the aqueous stream. Thus, it is possible to extract greater than an equimolar amount of phenol into an aqueous stream from an organic stream. This phenol is extracted into the aqueous stream as free solubilized phenol, rather than phenate. U.S. Pat. No. 3,277,185 discloses using an aqueous solution of alkali metal phenate at a concentration of 20 to 40% as an extraction solvent to remove phenol from neutral oils in a process for the gasification of solid fuels. U.S. Pat. No. 4,973,766 discloses the use of aqueous solutions of an alkali metal phenate at concentrations of 5 to 15% to extract phenol from a rectification purge containing 20 to 95% phenol.

[0006] The goal of a phenol recovery unit is to remove the maximum amount of phenol possible from the organic stream being treated at minimum cost. It is therefore desirable to take advantage of the ability of solutions of alkali metal phenate to absorb free phenol, in a phenol recovery system that uses aqueous solutions of alkali metal hydroxides as an extracting solvent. By doing so the quantity of alkali metal hydroxide used in phenol recovery processes can be significantly reduced. However, since free phenol is not infinitely soluble in aqueous solutions of alkali metal phenate, an underage of alkali metal hydroxide would result in undesirable loss of phenol to the organic effluent. Also, since the organic streams treated in this fashion often have value themselves, it is desirable to produce an organic effluent stream that is essentially free of phenol. Therefore, in order to ensure cost efficiency and maximum removal of phenol from the organic stream, care must be taken to ensure that an appropriate quantity of aqueous alkali metal hydroxide is used in the recovery process.

[0007] Accordingly, it is desirable to provide a method for determining the quantity of phenol that has been extracted into an aqueous solution of an alkali metal hydroxide. Further, it is desirable to provide a method for regulating the quantity of aqueous alkali metal hydroxide used in phenol recovery operations to ensure maximum recovery of phenol, acceptable organic effluent and cost effectiveness.

SUMMARY OF THE INVENTION

[0008] It is an object of the present invention to provide a method for determining the quantity of phenol that has been extracted into an aqueous solution of an alkali metal hydroxide.

[0009] It is another object of the present invention to provide a method for optimizing the use of an aqueous solution of an alkali metal hydroxide in a process for recovering phenol from an organic stream, based on the pH of the aqueous stream at, at least, one point in the system.

[0010] It is a further object of the present invention to provide an apparatus for optimizing the use of an aqueous solution of an alkali metal hydroxide in a process for recovering phenol from an organic stream, based on the pH of the aqueous stream at, at least, one point in the system.

[0011] In accordance with one embodiment of the invention, a method for indirectly determining the quantity of phenol that has been extracted into an aqueous solution of an alkali metal hydroxide is provided. In this method, aqueous solutions of an alkali metal hydroxide of known concentration, e.g. 20% sodium hydroxide, are titrated with phenol. The pH data collected is used to develop a curve showing solution pH relative to phenol concentration. The curve thus developed is used to determine phenol concentrations in aqueous solutions of alkali metal hydroxides by simply measuring pH.

[0012] In accordance with another embodiment of the present invention, a method is provided for regulating the rate at which an aqueous solution of alkali metal hydroxide is fed to a phenol recovery unit as an extracting solvent in counter-current flow to a phenol containing organic stream. The pH of the aqueous stream is monitored at, at least one point, in the phenol recovery unit. Based on the pH of the aqueous stream, it is possible to determine the concentration of phenol in the aqueous stream and if any free phenol is present in the aqueous stream. The flow of aqueous alkali metal hydroxide to the unit can then be held constant, increased or decreased accordingly to optimize the recovery of phenol and usage of aqueous extracting solvent. The phenol containing organic stream preferably comprises either cumene or α-methyl styrene.

[0013] In a further embodiment of the current invention, an apparatus is provided, which makes use of the inventive methods herein disclosed. The apparatus is a unit, which uses an aqueous solution of an alkali metal hydroxide for recovering phenol from an organic stream, such as distillation overheads or bottoms. The feed rate of the alkali metal hydroxide to the unit is regulated by measuring the pH at, at least, one point in the unit and adjusting the feed rate accordingly.

[0014] There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described below and which will form the subject matter of the claims appended hereto.

[0015] In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract included below, are for the purpose of description and should not be regarded as limiting.

[0016] As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] FIG. 1 shows curves relating the pH of an aqueous solution of sodium hydroxide to the equivalents of phenol developed using data from Example 1.

[0018] FIG. 2 shows curves relating the pH of an aqueous solution of sodium hydroxide to the equivalents of phenol developed using data from Example 2.

[0019] FIG. 3 shows curves relating the pH of an aqueous solution of sodium hydroxide to the equivalents of phenol developed using data from Example 3.

[0020] FIG. 4 shows curves relating the pH of an aqueous solution of sodium hydroxide to the equivalents of phenol developed using data from Example 4.

[0021] FIG. 5 shows a composite curve relating the pH of an aqueous solution of sodium hydroxide to the equivalents of phenol developed using data from Examples 1-4.

[0022] FIG. 6 is a schematic of a phenol recovery unit using the current inventive method.

DETAILED DESCRIPTION OF THE INVENTION

[0023] An embodiment of the present invention provides a method for determining the quantity of phenol that has been absorbed by an aqueous solution of sodium hydroxide. Relatively concentrated solutions of sodium hydroxide, caustic, typically have a pH in the range of 13 to 14. As phenol is absorbed into these solutions, the sodium hydroxide is consumed as sodium phenate is formed, causing a drop in pH. Once all of the sodium hydroxide is consumed, additional phenol is absorbed as solubilized free phenol, with a continued drop in solution pH as more phenol is absorbed. Therefore, the pH of the aqueous solution at any given time corresponds to an amount of phenol that has been absorbed into the solution.

[0024] In this embodiment, a curve is developed, which relates the pH of an aqueous solution of sodium hydroxide to the quantity of phenol that has been absorbed into the aqueous solution. The curve, as shown in FIG. 5, is developed by titration of aqueous solutions of sodium hydroxide, at various concentrations, with pure liquid phenol. The curve thus developed can be used to determine the quantity of phenol in an aqueous solution of sodium hydroxide by measuring the pH of the aqueous solution and relating that pH to a point on the curve, which corresponds to a concentration of phenol in the solution.

EXAMPLE 1

[0025] A 19% by weight solution of sodium hydroxide was prepared by dilution of a 46.8% by weight stock solution of sodium hydroxide. A sample of pure phenol was liquefied by heating to the melting point of the solid. The density of the liquid phenol thus prepared was taken as approximately 1.05 gm/mL. A sample of the 19% by weight sodium hydroxide solution was titrated by adding 0.5 mL aliquots to the liquefied phenol to the sodium hydroxide solution with stirring. The pH was measured after each addition and recorded. The data for the trial, which was performed in triplicate, is recorded in TABLE 1. FIG. 1 shows a plot of the pH data from the trials.

EXAMPLE 2

[0026] The procedure described in Example 1 was repeated, with the exception that a 25% by weight solution of sodium hydroxide was used. The data for the trial, which was performed in quadruplicate, is recorded in TABLE 2. FIG. 2 shows a plot of the pH data from the trials.

EXAMPLE 3

[0027] The procedure as described in Example 1 was repeated, with the exception that a 30% by weight solution of sodium hydroxide was used. The data for the trial, which was performed in quadruplicate, is recorded in TABLE 3. FIG. 3 shows a plot of the pH data from the trials.

EXAMPLE 4

[0028] The procedure as described in Example 1 was repeated, with the exception that a 10% by weight solution of sodium hydroxide was used. The data for the trial, which was performed in triplicate, is recorded in TABLE 4. FIG. 4 shows a plot of the pH data from the trials.

[0029] TABLE 5 shows the data for all trials at all concentrations at critical concentrations; 1.0, 1.5, 2.0, 2.5 and 3.0 equivalents of phenol relative to sodium hydroxide. It is clear from the data that the pH relative to the equivalents of phenol does not vary as a function of the concentration of aqueous sodium hydroxide used. The largest standard deviation recorded is 0.49, approximately 4%, at the 1.0 equivalent point. Thus, it is possible to use a single curve to relate pH to concentration of phenol, regardless of the concentration of sodium hydroxide used. A composite curve developed from the data compiled in Examples 1 through 4 is shown in FIG. 5.

[0030] Using a curve thus developed, it is possible to determine the equivalents of phenol in an aqueous solution relative to sodium hydroxide by simply measuring the pH of the solution and relating the pH to a point on the curve. Once the number of equivalents relative to sodium hydroxide has been determined, the actual quantity of phenol can be calculated using the known concentration of sodium hydroxide.

[0031] It will be apparent to those skilled in the art that similar curves can be developed using concentrations of sodium hydroxide other than those reported here. Additionally, it will be apparent that similar curves can be constructed for aqueous bases other than sodium hydroxide, such as potassium hydroxide, lithium hydroxide and calcium hydroxide. Thus, the invention is not limited to the specific embodiment disclosed here.

[0032] In another preferred embodiment, the above method is used to regulate the feed rate of an aqueous solution of sodium hydroxide to a multi-stage phenol recovery unit having at least two tanks. An example of this embodiment of the present inventive method is illustrated in FIG. 6. A three stage phenol recovery unit 10 is provided with tanks 12, 14, 16, 18 and 20. A phenol containing organic stream is fed to tank 12 as either distillation overheads or as distillation bottoms from distillation column 30. The organic stream flows continuously from tank 12 to tank 14, then from tank 14 to tank 16, and finally from tank 16 to tank 18. An aqueous solution of sodium hydroxide is fed to tank 16. The aqueous stream flows continuously from tank 16 to tank 14, then from tank 14 to tank 12, and finally from tank 12 to tank 20. As shown in the figure, the organic and aqueous streams contact each other in counter-current fashion in tanks 12, 14 and 16, such that phenol is extracted from the organic stream into the aqueous stream in each tank. A pH monitor 22 for monitoring the pH of the aqueous stream as it exits tank 14 is provided. The monitor may constitute a sampling port for sampling the aqueous stream for laboratory analysis, or it may constitute an in-line pH measurement device. A regulator 24 is provided for regulating the flow of aqueous sodium hydroxide to tank 16.

[0033] An acceptable pH range is set for the aqueous stream exiting tank 14 such that the pH range corresponds to a desired concentration of phenol relative to the initial concentration of free sodium hydroxide in the aqueous stream fed to the unit. A pH that is above the acceptable range corresponds to an overage of sodium hydroxide. A pH below the acceptable range corresponds to an underage of sodium hydroxide.

[0034] The regulator 24 is adjusted in response to the pH measured at the monitor 22 such that a detected overage of sodium hydroxide will cause a decrease in the feed rate of sodium hydroxide to tank 16. Conversely, a detected underage of sodium hydroxide will cause an increase the feed rate of sodium hydroxide to tank 16.

[0035] In a more preferred embodiment, a three stage phenol recovery unit 10 as shown in FIG. 6 and described above is provided. The acceptable pH range for the aqueous stream exiting tank 14 is set such that it corresponds to approximately 1 equivalent of phenol relative to sodium hydroxide in the aqueous stream. In this case, all or nearly all of the sodium hydroxide in the aqueous phase exiting tank 14 has been consumed. In this embodiment, all phenol extracted from the organic stream in tank 12 is extracted as solubilized free phenol.

[0036] In an even more preferred embodiment, a three stage phenol recovery unit 10 as shown in FIG. 6 and described above is provided. An additional pH monitor 26 is provided for monitoring the pH of the aqueous stream as it exits tank 12. The acceptable pH range for the aqueous stream exiting tank 14 is set such that it corresponds to approximately 1 equivalent of phenol relative to sodium hydroxide in the aqueous stream. A second acceptable pH range is set for the aqueous stream as it exits tank 12, which corresponds to a phenol content in the aqueous stream of greater than 1 equivalent. In this embodiment, the pH measurements at both monitors are used jointly to adjust the feed rate of the sodium hydroxide such that a detected overage of sodium hydroxide will cause a decrease in the feed rate of sodium hydroxide to tank 16. Conversely, a detected underage of sodium hydroxide will cause an increase in the feed rate of sodium hydroxide to tank 16.

[0037] In a most preferred embodiment of the invention as described above, the concentration of aqueous sodium hydroxide fed to tank 16 is 20% and the organic stream composed primarily of either alpha-methylstyrene or cumene containing from 0.1 to 25% and preferably 0.1 to 12% phenol. The acceptable pH range for the aqueous stream exiting tank 14 is set 11.0 to 12.0 and the acceptable pH range for the aqueous stream exiting tank 12 is 9.7 to 10.7. In this embodiment, all phenol extracted from the organic stream in tank 12 is extracted as solubilized free phenol.

[0038] It will be recognized by those skilled in the art that the operation of the inventive method herein disclosed does not depend on the use of aqueous sodium hydroxide as an extracting solvent. Other bases capable of forming water soluble phenates may also be used in conjunction with the current inventive method. It will further be recognized that the current invention is not limited to the specific pH ranges recited. Acceptable pH ranges for operation of the method are determined based on the quantities of phenol to be extracted, the aqueous base used, the locations of the pH monitoring means and the number of stages in the phenol recovery unit.

[0039] The many features and advantages of the invention are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirits and scope of the invention. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.

TABLE 1
19% Sodium Hydroxide
Titration #1	Titration #2	Titration #3
6.32 g caustic	6.66 g caustic	7.33 g caustic
	mL			mL			mL
	phe-	equiv.		phe-	equiv.		phe-	equiv.
pH	nol	phenol	pH	nol	phenol	pH	nol	phenol
13.33	0.00	0.000	13.29	0.00	0.00	13.16	0.00	0.000
13.26	0.50	0.186	13.22	0.50	0.176	13.10	0.50	0.160
13.27	1.00	0.372	13.17	1.00	0.353	13.06	1.00	0.320
13.22	1.50	0.557	13.14	1.50	0.529	13.02	1.50	0.481
13.16	2.00	0.743	13.11	2.00	0.705	13.00	2.00	0.641
12.92	2.50	0.929	12.94	2.50	0.882	12.89	2.50	0.801
11.65	3.00	1.115	11.71	3.00	1.058	12.40	3.00	0.961
11.30	3.50	1.301	11.29	3.50	1.234	11.40	3.50	1.122
11.14	4.00	1.487	11.10	4.00	1.411	11.14	4.00	1.282
11.02	4.50	1.672	10.97	4.50	1.587	11.00	4.50	1.442
10.92	5.00	1.858	10.87	5.00	1.763	10.90	5.00	1.602
10.83	5.50	2.044	10.79	5.50	1.940	10.81	5.50	1.762
10.75	6.00	2.230	10.71	6.00	2.116	10.73	6.00	1.923
10.68	6.50	2.416	10.64	6.50	2.292	10.66	6.50	2.083
10.62	7.00	2.602	10.58	7.00	2.469	10.61	7.00	2.243
10.55	7.50	2.787	10.52	7.50	2.645	10.55	7.50	2.403

[0040]

TABLE 2
25% Sodium Hydroxide
Titration #4	Titration #5	Titration #6	Titration #7
5.93 g caustic	5.66 g caustic	6.16 g caustic	8.02 g caustic
	mL	equiv.		mL	equiv.		mL	equiv.		mL	equiv.
pH	phenol	phenol	pH	phenol	phenol	pH	phenol	phenol	pH	phenol	phenol
13.27	0.00	0.000	13.07	0.00	0.000	12.88	0.00	0.000	12.88	0.00	0.000
13.25	0.50	0.151	13.03	0.50	0.158	12.80	0.50	0.145	12.80	0.50	0.111
13.21	1.00	0.301	12.99	1.00	0.315	12.74	1.00	0.290	12.75	1.00	0.223
13.18	1.50	0.452	12.97	1.50	0.473	12.71	1.50	0.435	12.68	1.50	0.334
13.15	2.00	0.602	12.92	2.00	0.631	12.67	2.00	0.580	12.64	2.00	0.445
13.09	2.50	0.753	12.86	2.50	0.788	12.63	2.50	0.724	12.58	2.50	0.556
12.87	3.00	0.903	12.37	3.00	0.946	12.49	3.00	0.869	12.54	3.00	0.668
11.88	3.50	1.054	11.46	3.50	1.104	11.70	3.50	1.014	12.50	3.50	0.779
11.51	4.00	1.204	11.21	4.00	1.262	11.19	4.00	1.159	12.37	4.00	0.890
11.35	4.50	1.355	11.08	4.50	1.419	11.02	4.50	1.304	11.69	4.50	1.002
11.24	5.00	1.505	10.95	5.00	1.577	10.91	5.00	1.449	11.25	5.00	1.113
11.15	5.50	1.656	10.77	5.50	1.735	10.81	5.50	1.594	11.07	5.50	1.224
11.07	6.00	1.806	10.68	6.00	1.892	10.75	6.00	1.739	10.96	6.00	1.336
11.00	6.50	1.957	10.61	6.50	2.050	10.70	6.50	1.884	10.88	6.50	1.447
10.93	7.00	2.107	10.53	7.00	2.208	10.65	7.00	2.029	10.82	7.00	1.558
10.87	7.50	2.258	10.45	7.50	2.365	10.59	7.50	2.173	10.77	7.50	1.669
10.81	8.00	2.408	10.38	8.00	2.523	10.53	8.00	2.318	10.71	8.00	1.781
10.75	8.50	2.559	10.33	8.50	2.681	10.48	8.50	2.463	10.67	8.50	1.892
10.69	9.00	2.709	10.28	9.00	2.839	10.44	9.00	2.608	10.62	9.00	2.003
10.64	9.50	2.860				10.39	9.50	2.753	10.59	9.50	2.115
10.59	10.00	3.010				10.36	10.00	2.898	10.54	10.00	2.226
10.53	10.50	3.161				10.32	10.50	3.043	10.50	10.50	2.337
10.48	11.00	3.311				10.29	11.00	3.188	10.47	11.00	2.448
10.44	11.50	3.462				10.25	11.50	3.333	10.43	11.50	2.560
10.39	12.00	3.612				10.22	12.00	3.478	10.40	12.00	2.671

[0041]

TABLE 3
30% Sodium Hydroxide
Titration #8	Titration #9	Titration #10	Titration #11
6.67 g caustic	6.33 g caustic	6.52 g caustic	7.42 g caustic
	mL	equiv.		mL	equiv.		mL	equiv.		mL	equiv.
pH	phenol	phenol	pH	phenol	phenol	pH	phenol	phenol	pH	phenol	phenol
12.68	0.00	0.000	12.18	0.00	0.000	12.51	0.00	0.000	12.86	0.00	0.000
12.62	0.50	0.112	12.14	0.50	0.118	12.42	0.50	0.114	12.77	0.50	0.100
12.55	1.00	0.223	12.10	1.00	0.235	12.35	1.00	0.228	12.66	1.00	0.200
12.48	1.50	0.335	12.06	1.50	0.353	12.29	1.50	0.342	12.58	1.50	0.301
12.44	2.00	0.446	12.05	2.00	0.470	12.27	2.00	0.456	12.51	2.00	0.401
12.42	2.50	0.558	12.03	2.50	0.588	12.25	2.50	0.570	12.47	2.50	0.501
12.38	3.00	0.669	12.07	3.00	0.705	12.25	3.00	0.684	12.43	3.00	0.601
12.31	3.50	0.781	12.15	3.50	0.823	12.25	3.50	0.799	12.40	3.50	0.702
12.20	4.00	0.892	12.14	4.00	0.940	12.17	4.00	0.913	12.34	4.00	0.802
11.54	4.50	1.004	11.42	4.50	1.058	11.57	4.50	1.027	12.17	4.50	0.902
11.19	5.00	1.115	11.16	5.00	1.175	11.38	5.00	1.141	11.49	5.00	1.002
11.05	5.50	1.227	11.04	5.50	1.293	11.24	5.50	1.255	11.21	5.50	1.103
10.97	6.00	1.338	10.96	6.00	1.410	11.15	6.00	1.369	11.11	6.00	1.203
10.87	6.50	1.450	10.91	6.50	1.528	11.03	6.50	1.483	11.02	6.50	1.303
10.81	7.00	1.561	10.84	7.00	1.645	10.96	7.00	1.597	10.97	7.00	1.403
10.76	7.50	1.673	10.79	7.50	1.763	10.91	7.50	1.711	10.92	7.50	1.504
10.72	8.00	1.784	10.74	8.00	1.880	10.86	8.00	1.825	10.87	8.00	1.604
10.68	8.50	1.896	10.70	8.50	1.998	10.81	8.50	1.939	10.82	8.50	1.704
10.63	9.00	2.007	10.68	9.00	2.115	10.76	9.00	2.053	10.77	9.00	1.804
10.59	9.50	2.119	10.66	9.50	2.233	10.73	9.50	2.168	10.73	9.50	1.905
10.55	10.00	2.230	10.61	10.00	2.350	10.69	10.00	2.828	10.70	10.00	2.005
10.52	10.50	2.342	10.57	10.50	2.468	10.64	10.50	2.396	10.66	10.50	2.105
10.48	11.00	2.453	10.53	11.00	2.585	10.60	11.00	2.510	10.63	11.00	2.205
10.44	11.50	2.565	10.49	11.50	2.703	10.57	11.50	2.624	10.59	11.50	2.306
10.41	12.00	2.676	10.45	12.00	2.820	10.53	12.00	2.738	10.57	12.00	2.406
			10.41	12.50	2.938	10.49	12.50	2.852	10.54	12.50	2.506
			10.38	13.00	3.055	10.46	13.00	2.966	10.51	13.00	2.606
						10.42	13.50	3.080	10.49	13.50	2.707
									10.46	14.00	2.807
									10.44	14.50	2.907
									10.41	15.00	3.007

[0042]

TABLE 4
10% Sodium Hydroxide
Titration #12	Titration #13	Titration #14
12.40 g caustic	16.10 g cautic	17.49 g caustic
	mL			mL			mL
	phe-	equiv.		phe-	equiv.		phe-	equiv.
pH	nol	phenol	pH	nol	phenol	pH	nol	phenol
13.73	0.00	0.000	13.57	0.00	0.000	12.96	0.00	0.000
13.53	0.50	0.180	13.54	0.50	0.139	12.94	0.50	0.128
13.48	1.00	0.360	13.51	1.00	0.277	12.95	1.00	0.255
13.48	1.50	0.540	13.49	1.50	0.416	13.13	1.50	0.383
13.42	2.00	0.720	13.46	2.00	0.554	13.14	2.00	0.510
13.19	2.50	0.900	13.41	2.50	0.693	13.14	2.50	0.638
11.8	3.00	1.080	13.29	3.00	0.832	13.07	3.00	0.765
11.38	3.50	1.260	12.79	3.50	0.970	12.35	3.50	0.893
11.21	4.00	1.440	11.79	4.00	1.109	11.71	4.00	1.021
11.1	4.50	1.620	11.56	4.50	1.247	11.42	4.50	1.148
11.01	5.00	1.800	11.35	5.00	1.386	11.26	5.00	1.276
10.93	5.50	1.979	11.20	5.50	1.525	11.15	5.50	1.403
10.87	6.00	2.159	11.10	6.00	1.663	11.08	6.00	1.531
10.80	6.50	2.339	11.03	6.50	1.802	11.01	6.50	1.659
10.75	7.00	2.519	10.97	7.00	1.940	10.96	7.00	1.786
10.70	7.50	2.699	10.91	7.50	2.079	10.88	7.50	1.914
10.65	8.00	2.879	10.86	8.00	2.218	10.83	8.00	2.041
10.60	8.50	3.059	10.82	8.50	2.356	10.80	8.50	2.169
10.56	9.00	3.239	10.77	9.00	2.495	10.78	9.00	2.296
10.52	9.50	3.419	10.73	9.50	2.633	10.74	9.50	2.424
10.48	10.00	3.599	10.68	10.00	2.772	10.71	10.00	2.552
10.44	10.50	3.779	10.65	10.50	2.911	10.67	10.50	2.679
10.41	11.00	3.959	10.53	11.00	3.049	10.64	11.00	2.807
10.38	11.50	4.139	10.52	11.50	3.188	10.61	11.50	2.934
10.38	12.00	4.319	10.50	12.00	3.326	10.58	12.00	3.062
10.33	12.50	4.499	10.49	12.50	3.465	10.55	12.50	3.190
10.29	13.00	4.679				10.52	13.00	3.317
						10.50	13.50	3.445
						10.47	14.00	3.572
						10.45	14.50	3.700
						10.42	15.00	3.827

[0043]

TABLE 5
Composite Data for Examples 1-4
Titration #	pH 1.0 eq.	pH 1.5 eq.	pH 2.0 eq.	pH 2.5 eq.	pH 3.0 eq.
1	12.92	11.14	10.83	10.68
2	11.71	10.97	10.79	10.58
3	12.40	11.00	10.66	10.55
4	11.88	11.24	11.00	10.75	10.59
5	11.70	10.91	10.65	10.48	10.32
6	12.37	10.95	10.61	10.38
7	11.69	10.88	10.62	10.47
8	11.54	10.87	10.63	10.48
9	11.42	10.70	10.57	10.53	10.38
10	11.57	11.03	10.76	10.60	10.46
11	11.49	10.92	10.70	10.54	10.41
12	11.80	11.21	10.93	10.75	10.60
13	12.79	11.20	10.91	10.77	10.53
14	11.71	11.08	10.83	10.71	10.58
Average	11.92	11.00	10.75	10.59	10.48
Std. Dev.	0.49	0.15	0.13	0.12	0.11

Claims

1. A method for optimizing the use of an aqueous stream in a process for extracting phenol from a phenol containing organic stream, wherein the aqueous stream fed to the process comprises an alkali metal hydroxide, the method comprising the steps of; establishing an acceptable pH range for the aqueous stream in a process for extracting phenol from a phenol containing organic stream, measuring the pH of the aqueous stream at an at least one point in the process, and controlling a feed rate of the aqueous stream to the process, based on the pH of the aqueous stream.

2. The method of claim 1, further comprising the step of setting the acceptable pH range to correspond to a quantity of phenol extracted into the aqueous stream relative to alkali metal hydroxide in the aqueous stream fed to the process.

3. The method of claim 2, wherein, the acceptable pH range corresponds to approximately 1 equivalent of phenol having been extracted into the aqueous stream, relative to alkali metal hydroxide in the aqueous stream fed to the process.

4. The method of claim 1, further comprising the steps of; increasing the feed rate of the aqueous stream if the pH is below the acceptable range, decreasing the feed rate of the aqueous stream if the pH is above the acceptable range, and holding constant the feed rate of the aqueous stream if the pH is within the acceptable range.

5. The method of claim 4, wherein the aqueous stream fed to the process comprises sodium hydroxide.

6. The method of claim 5, wherein the concentration of sodium hydroxide in the aqueous stream is about 10% to about 30%.

7. The method of claim 6, wherein the concentration of sodium hydroxide in the aqueous stream is about 20%.

8. The method of claim 7, wherein the acceptable pH range at the at least one point is about 11 to about 12.

9. The method of claim 8, wherein the aqueous stream is fed to a phenol recovery system including a multi-stage scrubber unit comprising a plurality of tanks, wherein the aqueous stream and phenol containing organic stream are contacted in counter-current flow.

10. The method of claim 2 wherein the aqueous stream is fed to a phenol recovery system including a multi-stage scrubber unit comprising a plurality of tanks, wherein the aqueous stream and phenol containing organic stream are contacted in counter-current flow, the method further comprising; increasing the feed rate of the aqueous stream if the pH is below the acceptable range, decreasing the feed rate of the aqueous stream if the pH is above the acceptable range, and holding constant the feed rate of the aqueous stream if the pH is within the acceptable range.

11. The method of claim 10, wherein, at the acceptable pH range, approximately 1 equivalent of phenol has been extracted into the aqueous stream, relative to alkali metal hydroxide in the aqueous stream.

12. The method of claim 11, wherein the aqueous stream fed to the phenol recovery unit comprises sodium hydroxide.

13. The method of claim 12, wherein the concentration of sodium hydroxide in the aqueous stream is about 10% to about 30%.

14. The method of claim 13, wherein the concentration of sodium hydroxide in the aqueous stream is about 20%.

15. The method of claim 14 where the acceptable pH range is from about 11 to about 12.

16. The method of claim 15 wherein; the multi-stage scrubber unit has three tanks, and the pH of the aqueous stream is measured as it exits the second tank.

17. The method of claim 1, wherein the pH of the aqueous stream is measured at a first point and a second point, and the feed rate of the aqueous stream is controlled based on the pH at the first point and the second point.

18. The method of claim 17, further comprising the steps of establishing a first acceptable pH range for the first point, and establishing a second acceptable pH range for the second point.

19. The method of claim 18, wherein the first acceptable pH range and the second acceptable pH range are not the same.

20. The method according to claim 19, wherein the first acceptable pH range corresponds to approximately 1 equivalent of phenol having been extracted into the aqueous stream, relative to alkali metal hydroxide in the aqueous stream fed to the process, and the second acceptable pH range corresponds to greater than 1 equivalent of phenol having been extracted into the aqueous stream, relative to alkali metal hydroxide in the aqueous stream fed to the process.

21. The method of claim 20, wherein the aqueous stream fed to the process comprises sodium hydroxide.

22. The method of claim 21, wherein the concentration of sodium hydroxide in the aqueous stream is about 10% to about 30%.

23. The method of claim 22, wherein the concentration of sodium hydroxide in the aqueous stream is about 20%.

24. The method of claim 23, wherein the first acceptable pH range is from about 11 to about 12, and the second acceptable pH range is about 9.7 to about 10.7.

25. The method of claim 24, wherein the aqueous stream is fed to a phenol recovery system including a multi-stage scrubber unit comprising a plurality of tanks wherein the aqueous stream and phenol containing organic stream are contacted in counter-current flow.

26. The method of claim 25, wherein; the multi-stage scrubber unit has three tanks, and the pH of the aqueous stream is measured at the first point as it exits the second tank, and the pH is measured at the second point as it exits the third tank.

27. The method of claim 26, wherein; the phenol content in the phenol containing organic stream is reduced to less than 100 ppm.

28. The method of claim 27, wherein; the phenol content in the phenol containing organic stream is reduced to less than 25 ppm.

29. The method of claim 1 where the phenol containing organic stream comprises alpha-methylstyrene.

30. The method of claim 1 where the phenol containing organic stream comprises cumene.

31. A method for determining the quantity of phenol that has been extracted into an aqueous stream containing an alkali metal hydroxide, the method comprising the steps of; developing a curve relating the pH of an aqueous solution containing an alkali metal hydroxide to the equivalents of phenol extracted into the solution, determining the initial concentration of alkali metal hydroxide in an aqueous stream, exposing the aqueous stream to a phenol containing organic stream, such that phenol is extracted into the aqueous stream, determining the pH of the aqueous stream having extracted phenol from the phenol containing organic stream, relating the pH of the aqueous stream to a point on the curve, corresponding to a number of equivalents of phenol extracted into the aqueous stream, and calculating the concentration of phenol in the aqueous stream from the number of equivalents of phenol and the initial concentration of alkali metal hydroxide.

32. The method of claim 31, wherein the alkali metal hydroxide is sodium hydroxide.