Cumene oxidation

A process for oxidizing cumene to cumene hydroperoxide using an oxygen containing gas, the process comprising

• conducting a cumene feed and an oxygen containing gas feed to at least the first oxidation reactor in a series of 3-8 reactors, thereby forming an oxidation mixture, and
• conducting the oxidation mixture from the first oxidation reactor directly to at least one subsequent reactor whereby the driving force for conducting the oxidation mixture from the first reactor is gravity,
• wherein
• the reactors are operated with reducing liquid levels;
• the oxidation is operated as a dry oxidation, whereby the only gaseous feeds conducted to the oxidation reactors are the cumene feed and the oxygen containing gas feed;
• the oxygen containing gas feed is washed with caustic and then with water to remove all acidic or caustic traces before conducting it into an oxidation reactor;
• the pressure within each oxidation reactor is in the range of 0-10 barg;
• the off-gases from the top section of each oxidation reactor are separated and cooled, whereby a condensate containing unreacted cumene is formed, and
• washing the condensate and recycling at least a part of the unreacted cumene from condensate of off-gases to at least the first oxidation reactor;
• the non-condensed off-gases are treated in a thermal oxidizer;
• and
• the first reactor in the series of oxidation reactors has a liquid inventory of 30-300% larger than in the remaining reactors, or the first two reactors in the series of oxidation reactors have a liquid inventory of 30-300% larger than in the remaining reactors.